Drives and Controls

VLT ® 5300 - 5500 VLT ® 6350 - 6550

Interactive service guide

VLT® is a trademark of Danfoss A/S

 VLT® 5000/6000 Series

Main Menu
Brief introduction:
Please use the Acrobat Reader navigation tools to navigate through this Service Manual.
The manual consist of one main file and three sub-files with additional documentation.
Links to sections:
• How to use this guide and what information is in this Service Guide
• Precautions
• Tools and test equipment
• Diagrams
• Static tests
• Dynamic tests
• Disassembly/assembly

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 VLT® 5000/6000 Series

How to use this guide

• Click on the Main Topic that you want know more about. The blue text links are links that takes you to the
specific topic or sub-topic.

• The icon indicates that the operations involved requires special precautions.

• The icon shows you how to navigate back to the starting point.

• NB! Indicates something to be noted by the reader

• The icon indicates that there is an animation or video that shows you more about the topic.

What information is in this Service Guide

• This Service Guide deals only with the VLT 5300 - 5500 Industrial and AQUA
and the VLT 6300 -6500 HVAC. For more information on general VLT 5000/6000 topics, please refer to the
Service Manual
• Please note that the photos and videos are made by using PROTOTYPE units and may differ slightly from the
final versions.

• IMPORTANT: The static and dynamic test shown on the videos are made under controlled laboratory condi-
tions. When performing these tests you MUST close the cabinet doors!
• All test must be performed with the utmost care as the VLT carries lethal voltages even after removing AC and
DC power. You must read the PRECAUTIONS section before servicing the VLT!

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 VLT® 5000/6000 Series

Precautions
The VLT carries voltage and current even after power is removed, that may lead to lethal injuries.
YOU MUST follow the below precautions:
Click on the icon to 1: Before removing the shielding, make sure
see the LED’s turn on that power is turned off and the DC load/
at power-up and hear capacitor bank is discharged. This is done:
the sound of 1a: By checking the red LED indicator
the VLT start- shown (DC charge indicator):
ing 1b: And by checking the three green
LED indicators shown (±14 and +5volt
indicators):
ALL LED’s must be turned off!
2: Make sure that the VLT can not be switched
on by accident while you work on it!
3: After removing the shielding, check the
DC bus for remaining charge by measuring
the voltage at the DC terminals: The voltage
must be less than 10 Volts. It is possible to
discharge the DC bus faster by using a 10-20
kW variable resistor (start with higher resist-
NB! The shown VLT is without fuses and disconnection
ance and then decrease the resistance at a
moderate pace)
General precautions:
• Always use insulated tools when working in VLT’s that may have voltage applied
• Always wear shoes that provide electric insulation when working in VLT’s that may have voltage applied.
• Be extremely cautious with VLT’s that have failed as the indicators may not work properly!
• Wear anti-static bracelets connected to earth when servicing the VLT.

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 VLT® 5000/6000 Series

Tools and test equipment:

Please read/view the chapter “Precautions” section before starting any tests!

• Signal Board Code No.: 176F1429

• Power Card D.C. supply Code No.: 176L2793
A power supply for the Control card so that test of
signals can be performed without having to apply
power to the Power-parts

• SCR gate Test Cable Code No.: 176F1430

• Tools required

• Instruments required for field service:

- Digital Ohm meter (Multimeter)

with Diode Check facilities

- Analog volt meter (average RMS)

- Analog clamp-on Ampmeter

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 VLT® 5000/6000 Series

Signal Board Card

• The Signal Board Card is placed at the top of the Power
Circuit Board as shown on the photos. Place the Signal
Board wth the components/terminals upwards.

Please refer to the Signal Board Instruction Manual

for further details.

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 VLT® 5000/6000 Series

Power Card DC Supply

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 techni-
cian to make a variety of tests without the risk of damage
or injury due to a fully charged DC bus. One such exam-
ple 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.
Please also refer to the PC Card DC Supply Source
Documentation

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 VLT® 5000/6000 Series

SCR Gate Driver Test Cable:

The SCR Gate Driver Test Cable gives the techni-
cian 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 oscillo-
scope, 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.First and fore-
most the drive must have AC power removed and the DC voltage discharged. This should always be verified by a
meter prior to servicing. 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 The SCR gate current

have a waveform as pulse waveform with a
shown at left with: 112 A load
A1 > 1.1 A
A2 > 0.40 A
T1> 300 ms

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 VLT® 5000/6000 Series

Required Tools:

Sockets Torx’s
19 mm T50
17 mm T40
13 mm T30
10 mm T25
8 mm T20
7 mm T15
T10

Allen wrench/socket Additionals:

6 mm Snap-action Torque wrench
Standard and Phillips screw drivers (wide and narrow)
¼ and 3/8 inch tools
Torx’s and Nut starters
Magnet

Anti-static bracelet.

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 VLT® 5000/6000 Series

Block diagram:
For further details please refer to the following diagrams:
VLT 5300, 5350,6350: 175R5254
VLT 5450, 6400: 175R5255
VLT 5500, 6500: 175R5256
VLT 5600, 6550: 175R5257

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 VLT® 5000/6000 Series

NB!: You must read Static Tests:

the Precautions Click on items for more information or click on icons to see video clips.
section before starting
Please note that the protective shielding and center bracket has been removed from the VLT on the video.
any of the
static tests
• Initial inspection

• DC bus charge

• Soft charge/fuses

• Rectifiers

• Brake IGBT’s

• IGBT’s

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 VLT® 5000/6000 Series

Static Test, Initial inspection:

• After opening the cabinet, visually check for signs of damage like
burnt or exploded components, debris or possible conductive dusts
or fluids. Look for any signs of short-circuits or loose connections.
• Before removing the protective shielding, run through the initial
routine in the Precautions section (Power is removed, all LED’s
are off, especially the DC indicator, and measure the DC bus volt-
age)

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 VLT® 5000/6000 Series

See the DC bus Checking D.C. bus charge

charge check • After removing the shielding, check the DC bus for remaining
procedure. charge by measuring the voltage on the DC terminals:The volt-
Click on the Icon: age must be less than 10 Volt. Use a 100-200 W variable resis-
tor to discharge (start with high Ohm and then decrease the
resistance at a moderate pace)

D.C. bus
terminals

NB! The shown VLT includes

fuses and disconnection

Please also refer to com-

plete diagram

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 VLT® 5000/6000 Series

See the Soft Static Test, Soft Charge circuit/fuses:

Charge circuit • Check the fuses using a digital Ohmmeter.
check proce-
dure. Click on the
Icon:

Please also refer to

complete diagram

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 VLT® 5000/6000 Series

See the diode Static Test, Rectifiers

check proce- • Short-circuit the Capacitors situated above the Main
dure. Click on Capacitor bank
the Icon: • Measure the resistance from the D.C. terminals to
ground. Reading must be above 1 (one) Meg Ohm
• Measure the resistance between the R, S and T power
input terminals and ground. Reading must be above
1 (one) Meg Ohm
• Measure the resistance between the output terminals ( U,V,W) and ground.
The reading must be above 1(one) Meg Ohm as well.
• Set the multimeter to check diodes. Most types of Digital multimeters have a
Diode Check setting. If an analog multimeter is being used, set it to the
R X 100 scale.
• Connect the positive (+) meter lead to the DC minus terminal. Connect
the negative (-) meter lead to the “R” (L1), “S” (L2), and “T” (L3) terminals
in turn. Each reading should show a diode drop (200-500 ohms or .3-.7
Volts, depending upon the type of meter being used).
• Reverse the meter leads connecting the (-) lead to the DC minus terminal
and the (+) lead to terminals “R”, “S”, and “T” in turn. Each reading should
show open.
• Connect the (+) meter lead to the DC Plus terminal. Connect the (-) lead to
the “R”, “S”, and “T” terminals in turn. Each reading should show open.
Note: when an open reading is shown, a capacitor charging effect may be indicated by the multimeter.
• Reverse the meter leads connecting the (-) lead to DC Plus and the (+) lead to “R”, “S”, and “T”. Each reading
should also show open. Note: when an open reading is shown, a capacitor charging effect may be indicated by
the multimeter.
Please also refer to diagram
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 VLT® 5000/6000 Series

Static Test, Rectifiers

Please also refer to text
1: Check DC terminals 3: Check
resistence to ground Output
4: Check Diodes in terminals
rectifier. resistence to
In both directions. ground

2: Check Power Input

terminals resistence to
ground

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 VLT® 5000/6000 Series

See the brake Static Test, Brake IGBT’s

IGBT check The following test must be performed on both Brake IGBT’s:
procedure. • Measure the resistance between R+ (plus) and R- (minus). The resistance must be
Click on the Icon higher than 1 (one) Meg Ohm.
NB! Poor sound qual- • Measure the resistance between R- (minus) and DC- (minus). The resistance must
ity! be higher than 1 (one) Meg Ohm.
• Set the multimeter to check diodes. Most types of Digital multimeters have a
Diode Check setting. If an analog multimeter is being used, set it to the
R X 100 scale.
• Connect the positive (+) meter lead to the R - (minus) terminal. Connect
the negative (-) meter lead to the R + (plus) terminal. The reading should show a
diode drop (200-500 ohms or .3-.7 Volts, depending upon the type of
meter being used).
• Perform the same test on the other Brake IGBT as well

Please also refer to

complete diagram
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 VLT® 5000/6000 Series

See the IGBT Static Test, IGBT circuit

test procedure. Prior to making tests, disconnect the motor from the unit. The low
Click on the resistance of the motor windings can adversely affect the test results.
Icon:
• Start by checking the resistance from U, V, W to Ground. The reading
must exceed 1 (one) Meg Ohm.
• Set the Multimeter to Diode Check.
• Connect the positive (+) meter lead to DC Plus. Connect the
negative (-) meter lead to the “U”, “V”, and “W” terminals in turn.
Each reading should show open.
• Reverse the meter leads connecting the (-) lead to DC Plus and DC bus U,
U, V,
V, W
W
the (+) lead to “U”, “V”, and “W” in turn. Each reading should
show a diode drop.
• Connect the (+) lead to DC Minus. Connect the (-) lead to
“U”, “V”, and “W” in turn. Each reading should show a diode drop.
• Reverse the meter leads connecting the (-) lead to DC Minus and
the (+) lead to “U”, “V”, and “W” in turn.
Each reading should show open. Note: when an open
reading is shown, a capacitor charging effect may be
indicated by the multimeter.

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 VLT® 5000/6000 Series

NB!: You must read Dynamic Tests:

the Precautions Click on items for more informations or click on icons to see video clips.
section before starting NB! The videos are taken under strict protected laboratory conditions and must NOT be regarded as
any test normal testing conditions!
Please note that the protective schielding and central door rail has been removed from the VLT in the video.

• Output Voltage Ballance

• Output Current Ballance

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 VLT® 5000/6000 Series

See the Output Dynamic Tests, Output Voltage Balance:

Voltage • NB! You must read the Precautions section before starting any Dynamic Testing!
Ballance meas- • After repairing the VLT, it is recommended to measure the Output Voltage Balance before connecting the motor.
urement. NB! The This is done by measuring the voltage from output- to output terminal, U, V and W.
video was recorded Due to the high amount of DC components, the reading from a digital volt meter can be erroneous, therefore an
under strict labora- analog voltmeter needs to be used.
tory conditions! • NB! You must close the cabinet doors BEFORE turning the VLT on!
• Ramp the VLT up to approx. 40 Hz , and measure the voltage when it is stable.

• Remove power to the VLT (NB! Let the DC bus discharge before opening the enclosure
doors!)
• Connect the voltmeter to the next two phases.
• When the measurements are completed between all three phases, compare the
three measurements.

NB! Max. imbalance of 0.5% of the average voltage/current reading.

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 VLT® 5000/6000 Series

See the Output Dynamic Tests, Output Current Ballance:

Current • NB! You must read the Precautions section before starting any Dynamic Test!
Ballance meas- • After repairing the VLT, it is recommended to measure the Output Current Ballance:
urement. NB! The This is done by measuring the current through the U, V and W cables after connecting the motor.
video was recorded
under strict labora- There are several ways of measuring the current by using different types of probes and instruments. It is however
tory conditions! recommended to use a clamp-on type of Amp-meter due to the high
amount of transients from the output switch patterns.

The measurement is carried out after connecting the motor, after checking
the output voltage ballance and after closing the enclosure doors.

The clamp-on Amp-meter is clamped around one set of output cable at one
time, recording and comapring each reading.

NB! Max. imballance of 0.5% of the average voltage/current reading.

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 VLT® 5000/6000 Series

Disassembly/assembly:
NB! Before disassembling any part of the VLT please read the Precautions section.
Disconnect the VLT from the Mains supply and insure that the VLT cannot be turned on during servicing. Always
wear a Static Discharge bracelet connected to ground.

• Control Card (cabinet door, fan, etc)

• Soft Charge Circuit Board

• SCR’s

• Power Card

• Gate Driver Card

• DC Capacitor bank

• Snubber board

• IGBT’s torque specifications and patterns

• Brake option

• Cabinet fans
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 VLT® 5000/6000 Series

Disassembly/assembly Control Card (cabinet door, fan etc.):

In order to make servicing easier it may be an advantage to open the enclosure doors wider.

• To remove the Control Card Cassette, disconnect the two ribbon cables and unscrew the two captive screws at
the bottom of the cassette.

• In order to make servicing easier it may be an advantage to remove the central door rail. Remove the four screws
and remove the cable straps in front of the Power Card.

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 VLT® 5000/6000 Series

Disassembly/assembly Soft Charge Board:

To remove the soft charge board, remove the two cables attached at the upper side of the card. Use a Torx 20
screwdriver, to remove the six screws attaching the card to the mounting bracket. Take care not to let the board
fall.
Soft Charge Board:
Screws are marked with
yellow circles, cables with
red rectangles

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 VLT® 5000/6000 Series

See how to Disassembly/assembly SCR’s:

disassemble the
Rectifier SCR • Before gaining access to the SCR’s, the mounting bracket where the Control Card Cassette is attached must be
removed. Remove the 8 screws attaching the mounting bracket to the DC Capacitor
bank and to the enclosure side.

• Remove the three phase (R, S, and T) bus bars attached to the SCR’s.
• Loosen up the screws on the plus and minus DC bus bars on SCR’s that are not defective.
• Remove the screws on the plus and minus DC bus bars on the defective SCR (on the
video it shows the middle SCR being replaced)
• Remove the gate signal cable
• Remove the four screws attaching the SCR to the heatsink.

You can now slide the SCR out from under the bus bars.
NB! Please note that a new thermal pad must be used when replacing the SCR.

Mount the new SCR and reassemble the VLT in the reverse order. Remember to re-attach the gate signal cable.

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 VLT® 5000/6000 Series

Disassembly/assembly Gate Driver Card:

• Remove cables attached to the Gate Driver Card, including the two ribbon cables attached to the Power Card.
• Use a Torx 20 screwdriver to remove the eight screws attaching the card to the mounting bracket.
• When replacing the new Gate Driver Card, note compression washers are used for mounting board to bracket.

Gate Driver Card:

Screws are marked with
yellow circles, cables with
red rectangles

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 VLT® 5000/6000 Series

Disassembly/assembly Power Card:

• Remove all cables attached to the Power Card.

• Use a Torx 20 screwdriver to remove the ten screws attaching the card to the mounting bracket.
• When replacing the new Power Card, note compression washers are used for mounting board to bracket.

Power Card:
Screws are marked with
yellow circles, cables with
red rectangles

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 VLT® 5000/6000 Series

See how to Disassembly/assembly Capacitor Bank:

disassemble the
aluminum cover • Remove the Power Card and the Gate Driver Card.
See how to • Unscrew 12 Torx 20 screws to remove the Power and Gate Driver Card mounting bracket in one piece.
disassemble the • To remove the DC Capacitor bank start by locating the hardware that must be removed. (see video and/or photo).
Capacitor Bank • Due to the weight of the DC Capacitor Bank, two persons my be needed for removal and re-installation.
• When re-installing the Capacitor bank, observe the torque limits of the hardware, failure to do so will result in
See the position a damaged IGBT.
of screws and • Take care that the Torx 40 screws are carefully aligned in the threads of the IGBT’s
nuts of the
Capacitor bank

Unscrew 12 Torx 20 screws to To remove the DC Capacitor bank

remove the Power and Gate Driver start by locating the hardware that
Card mounting bracket in one piece. must be removed. (see video and/
or photo)

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 VLT® 5000/6000 Series

Disassembly of the Snubber Card:

• Remove the Power Card, the Gate Driver Card, the Power and Gate Driver
Card mounting bracket and the DC Capacitor bank attached to the Snubber
Card you are going to replace.
• Unscrew the four screws that attach the Snubber Card to the IGBT’s
• Unscrew the two nuts that hold the Snubber board in place.
• When re-assembling the renewed Snubber Card you should renew the plastic
spacer as the thread may be damaged.
• Tighten the screws that attach the Snubber Card to the IGBT to 13 lb in. or
1.5 Nm.
Over-torque of these four screws will damage the IGBT!

Snubber Card:
Screws are marked with
yellow circles. The
orange circles shows the
nuts fastened to a plastic
spacer.

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 VLT® 5000/6000 Series

Replacing the IGBT:

• Remove the Power Card, the Gate Driver Card, the Power and Gate Driver Card mounting
bracket, the DC Capacitor bank and the Snubber Board in fornt of or above the IGBT you are
going to replace.
• Unscrew the six screws that attach the IGBT to the heatsink by using a Torx 20 screwdriver.
• Please note that a new Thermal pad must be used when replacing the IGBT.
• Please note the proper torque pattern:
1: Initial torque the screws to 11 lb in (inch pounds) or 1.5 Nm
in the order shown on the picture
3 5
2: Final torque the screws to 27 lb in (inch pounds) or 3.1 Nm

1 2

6 4

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 VLT® 5000/6000 Series

Disassembly, Brake IGBT’s:

• Remove the Control Card and mounting bracket above the Brake IGBT’s .
• Remove the cables attached to the Brake Snubber Card ( red circles on the picture. Use a Torx 20 screwdriver)
• Remove the four screws, two Torx 40 and two Medium
Philips/Crosshead screws.
• Remove the four Torx 20 at each corner of the IGBT.
• Please note that a new Thermal pad must be used when
replacing the IGBT.

• 1: Initial torque the screws to 11 lb in (inch pounds) or

1.5 Nm in the order shown on the picture
2: Final torque the screws to 27 lb in (inch pounds)
or 3.1 Nm

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 VLT® 5000/6000 Series

Disassembly, Cabinet fans:

• Remove the top protective cover
• Detatch the Power Connectors from
their sockets on the top of the cabinet.
• Unscrew the central railing with the NB! The top protective cover
defective fan. is removed in the pictures.
• Unscrew the defective fan.
• When re-assembling the screws must be
tightened to the specificed torque

Unscrew the railing.

Connectors on top
of cabinet

Connetors on
Power Card

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