Invertek Drives OPTIDRIVE E3 User manual

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Electrical Test
IP20 & IP66
SERVICE MANUAL
Frame Size 3
240V - 480V

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Contents Page no:
Service Request Form ..........................................................................................................3
Multimeter checks:................................................................................................................3
Control terminal checks:..................................................................................................................3
Input Terminal Checks: ...................................................................................................................4
Output Terminal checks:.................................................................................................................5
IGBT tests (480V).................................................................................................................6
IGBT tests (240V).................................................................................................................7
Brake chopper test 240V & 480V..................................................................................................8
Main components on an ODE-3............................................................................................9
Control PCB......................................................................................................................................9
Power board PCB 240 & 480V.....................................................................................................10
Inrush circuit test (480V & 240V).........................................................................................12
IGBT pin outs......................................................................................................................13
4.0kW, 240V, 5.5 -7.5kW, 480V...................................................................................................13
5.5kW, 220V, 11.0kW, 480V ........................................................................................................13
DC Bus check.....................................................................................................................14
Power board (supply rails)...................................................................................................15
Power board Pin outs..........................................................................................................16
PCB pin outs...................................................................................................................................16
Control board PCB pin outs..........................................................................................................17
Control board (Supply rails).................................................................................................18
Control board (Digital inputs/outputs, Comms & display).....................................................19
Parameter group 0..............................................................................................................20
Fault codes.........................................................................................................................21
Drive test procedure (240 - 480V).......................................................................................22

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IP20 drive & IP66
Service Request Form
The following information can be used to complete a Service Request Form
Multimeter checks:
Without taking the drive apart these initial checks can give a good indication if there
is a fault on the drive.
Readings are based on a general purpose digital multimeter with resistance readings
+/- 10%.
Control terminal checks:
Set your multimeter to read Ohms
Place Black lead on terminal 1 then the red lead on the remaining control
board terminals:
The following reading should be found depending on the drive supply voltage:
480V 240V
T1 to T2 1.22 M +/- 10% 1.23 M +/- 10%
T 1 to T3 1.22 M +/- 10% 1.23 M +/- 10%
T1 to T4 101 K +/- 10% 99 K +/- 10%
T1 to T5 31.41 K +/- 10% 28.80 K +/- 10%
T1 to T6 102 K +/- 10% 99 K +/- 10%
IP66 used control terminal used
as an example

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480V 240V
T1 to T7 15.72 K +/- 10% 13.11 K +/- 10%
T1 to T8 33.35 K +/- 10% 30.72 K +/- 10%
T1 to T9 15.72 K +/- 10% 13.11 K +/- 10%
T1 to T10 Open circuit Open circuit
T1 to T11 Open circuit Open circuit
Input Terminal Checks:
Set your multimeter to read Ohms
Place black lead on L1 terminal phase then the red lead on the following
terminals:
L1 to L2 500K +/- 10% and rising
L2 to L3 500K +/- 10% and rising
L1 to L3 500K +/- 10% and rising
Ensure measurement is balanced/same value across each phase
IP66 used control terminal used
as an example

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Output Terminal checks:
Set your multimeter to read Ohms
Place the multimeter leads on the following terminals:
U to V 400 K +/- 10% and rising
V to W 400 K +/- 10% and rising
U to W 400 K +/- 10% and rising
Ensure measurements is balanced/same value across each phase
IP66 used control terminal used
as an example

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IGBT tests (480V)
Remove cover off drive per the Mechanical Service Manual
In order to carry out the next set of tests the multimeter leads must be placed on the +/- DC
Bus in the following steps. (Ensure Multimeter is set to read/test diode)
Rectifier check (L1, L2 & L3)
Using a multimeter set to read diode
complete the following tests:
1) Black lead on the - DC Bus and measure with the
red lead on L1, L2 & L3 input phases, value should
read open circuit.
2) Black lead to +DC point and measure to L1, L2 &
L3. Values = 0.520V +/- 10%
3) Red lead on –DC and measure with the black lead
to L1, L2 & L3. Values = 0.520V +/- 10%
4) Red lead on +DC and measure with the black lead
to L1, L2 & L3. Value = open circuit.
Output check (U, V & W)
Using a multimeter set to read diode,
complete the following tests:
1) Black lead on the - DC Bus and measure with the
red lead on U, V & W input phases, value should
read open circuit.
2) Black lead on the +DC point and measure to U, V
& W, values = 0.429V +/- 10%
3) Red lead on –DC and measure with the black
lead to L1 U, V & W values = 0.429V +/- 10%
4) Red lead on +DC and measure with the black
lead to U, V & W value should read open circuit.

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IGBT tests (240V)
Remove cover off drive per the Mechanical Service Manual
In order to carry out the next set of tests the multimeter leads must be placed on the0 +/- DC
Bus in the following steps. (Ensure Multimeter is set to read/test diode)
Rectifier check (L1, L2 & L3)
Using a multimeter set to read diode
complete the following tests:
1) Black lead on the - DC Bus and measure with the
red lead on L1 & L2 input phases, value should read
open circuit.
2) Black lead to +DC point and measure to L1 & L2
Values = 0.52V +/- 10%
3) Red lead on –DC and measure with the black lead
to L1, L2 & L3. Values = 0.521V +/- 10%
4) Red lead on +DC and measure with the black lead
to L1, L2 & L3. values = open circuit.
Output check (U, V & W)
Using a multimeter set to read diode,
complete the following tests:
1) Black lead on the - DC Bus and measure with the
red lead on U, V & W input phases, value should
read open circuit.
2) Black lead on the +DC point and measure to U, V
& W, values = 0.433V +/- 10%
3) Red lead on –DC and measure with the black
lead to L1 U, V & W values = 0.433V +/- 10%
4) Red lead on +DC and measure with the black
lead to U, V & W value should read open circuit.

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Brake chopper test 240V & 480V
Picture base on IP66 unit
Picture for reference purposes only
Brake Chopper
The brake chopper circuit is a
means of dumping excess voltage
on the DC Bus.
This excess voltage can be created
when an AC motor is decelerated at
too fast a deceleration ramp time.
The motor will effectively turn into a
generator and will feed a voltage
back into the drive causing the DC
Bus voltage to rise beyond its
nominal value.
To remove excess voltage the drive
can be fitted with a brake resistor
and the voltage can be dissipated in
the form of heat.
Test
As per the diagram opposite the
brake chopper circuit can be tested
using the following multimeter
checks.
Diode test
Set your multimeter to read diode
and carry out the following tests:
Red lead on + terminal/Black
lead on BR terminal = open
circuit
Black lead on + terminal/Red
lead on BR terminal = 0.432V +/-
10%

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Main components on an ODE-3
Control PCB
Display
RJ45 connector
Terminal connector
Microprocessor

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Power board PCB 240 & 480V
IP66 variant used for photographic purposes
Control PCB
Filter PCB
Rectifier built into IGBT
module
SMPs
transformer
Varistors
SMPs
DC caps

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Inrush resistors
Inrush relay
DCCT
Gate drive circuit

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Inrush circuit test (480V & 240V)
Set your multimeter to read Ohms and measure across the Inrush Resistors highlighted
above. Note that each resistor is 100 Ohms and are connected in parallel hence a
reading of 33R +/- 15% should be measured.

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IGBT pin outs
4.0kW, 240V, 5.5 -7.5kW, 480V
34NAB12T4V1M11
5.5kW, 220V, 11.0kW, 480V
35NAB12T4V1M11

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DC Bus check
This test is designed to check a drive which shows no fault during the multimeter checks or
has had a faulty component replaced.
The drive will be powered-up at a safe level, 30V DC only. This will ensure no further
damage is made to the drive if the fault has not been cleared.
Please complete the following tests:
1. Ensure all faulty components have been replaced if applicable.
2. If powering up the PCB’s from a dismantled unit ensure all leads are properly connected
and the boards are rested on an insulated material. Position the control PCB where the
buttons can be accessed without risk of electric shock. DO NOT LEAVE THE PCB’s
EXPOSED - RISK OF ELECTRIC SHOCK.
3. Check voltage setting on drive.
4. Using an appropriate Isolated DC Power Supply (0-500V, 1.0A max) set to 0V, connect
the power to the Input terminals L1, L2.
5. Turn on the power supply. Apply the DC voltage at 10V DC intervals (30V DC MAX
ONLY) and check that the DC Bus voltage rises as the DC voltage is increased on the
supply.
6. If the DC Bus voltage is OK at 30V DC, carry on increasing the voltage slowly at 10V
intervals until the display indicates U-VOLTS.
For 380 - 480V AC drives the U-VOLTS will appear at: 302V DC (+/- 10%).
For 220 - 240V AC drives the U-VOLTS will appear at: 146V DC (+/- 10%).
7. If the U-VOLTS display is present continue increasing the DC Supply voltage until the
inrush relay clicks and display shows STOP.
For 380V - 480V AC drives the STOP will appear at: 490V DC (+/- 10%)
For 220V - 240V AC drives the STOP will appear at: 249V DC (+/- 10%)

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Power board (supply rails)
240V - 480V
= 5V ISO (Control board)
= 26V ISO (Control board)
= 15V ISO
= 5V (Power board)
= 15V (Power board)

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Power board Pin outs
240V - 480V
PCB pin outs

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Control board PCB pin outs
240V - 480V

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Control board (Supply rails)
220V & 480V
= 3V3 ISO
= 10V OUT
= -5V ISO
= 24V OUT

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Control board (Digital inputs/outputs, Comms & display)
220V & 480V
Digital input 1 MODBUS
Digital input 2 User relay 1
Display Analogue output 1
Optibus Analogue output 2

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Parameter group 0