Pentair FAIRBANKS NIJHUIS INTELLIBOOST 7710 Series User manual

NOTE! To the installer: Please make sure you provide this manual to the owner of the equipment or to the responsible
party who maintains the system.
7710 SERIES
INTELLIBOOST™
WATER BOOSTER SYSTEM
BASIC OPERATION MANUAL
Part # FM-03-554 | © 2012 Pentair Pump Group, Inc. | 11/29/12

Fairbanks Nijhuis™ 11/12/12
2Intelliboost™ Water Booster System
Basic Operation Manual
MULTIPLE PUMP CONTROLLER WITH UP TO 4 DRIVES:
The controller will have a power OFF/ON selector switch to power up system. The normal operation of the controller,
as well as the staging of the pumps, is controlled by an independent processor. The VFD(s) act as “signal follower”
and do not independently control the speed of the pumps in Auto On mode. For initial setup and in the event of a
system failure, the VFD(s) can run the pumps in Hand On control at a user selected fixed speed, ignoring all signals
from the pump controller.
VFD OPERATION:
4-2 drives operate in the same manner. Hand On, Off, Auto On and Reset are the basic operations for the Local
Control Panel. Hand On selection is for independent drive operation. Off will turn off VFD, stopping pump rotation.
Auto On is selected when PLC is ready for testing and operation. Reset, in case of VFD fault, refers to the
operation manual.
VFD PARAMETERS AND COMMUNICATION SETTINGS:
VFD parameters set as described below should be entered when VFD is in the Off position. PLC and VFD are master
slave configured using Mod Bus RTU communication. Loss of communication will stop drive after Timeout. Each drive
shares the same parameter set except where drive name is required (Drive1 = 2, Drive2 = 3, Drive3 = 4, Drive4 = 5).
A Master Local Control Panel, LCP, is used to Copy and Download parameters from VFD to VFD.
Danfoss VLT AQUA FC 200 VFD (Factory Settings)
Parameter Set Designation Default
0-01 Manual Language US English
0-02 Manual Motor Speed Units, RPM or Hz Hz
0-03 Manual Regional Settings North America
1-03 Manual Torque Characteristics Auto EnergyOptim VT
1-23 Manual Motor Frequency Nameplate
1-24 Manual Motor Current Nameplate
1-25 Manual Motor Speed Nameplate
3-03 Manual Maximum Reference 60 Hz
3-41 Manual Ramp-Up Time 5 sec.
3-42 Manual Ramp-Down Time 2 sec.
4-14 Manual Motor High Speed Limit 60 Hz
4-19 Manual Maximum Output Frequency 60.1 Hz
4-12 Manual Motor Speed Low Limit 0 Hz
5-12 Manual Terminal 27 No Operation
8-01 Manual Control Site Control Word Only
8-03 Manual Control Time Out Limit 20 sec.
8-04 Manual Control Time Out Function Stop
8-10 Manual Control Word Profile FC Profile
8-30 Manual Protocol Mod Bus RTU
8-31 Manual Addresses Drive1 = 2, Drive2 = 3, Drive3 = 4, Drive4 = 5
8-32 Manual FC Port Baud Rate 19200
8-33 Manual Parity Even Parity, 1 Stop Bit
8-50 Manual Thru 56 Bus
0-50 Manual LCP Copy All to LCP
0-50 Manual LCP Download Download all to LCP
INTELLIBOOST™ WATER BOOSTER SYSTEM
BASIC OPERATION MANUAL

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Basic Operation Manual
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NORMAL OPERATION (AUTO ON – VFD):
The Pump Controller receives a system pressure signal from the Discharge Pressure Transducer. The signal is
compared to the Setpoint and the pump(s) speed is adjusted.
Setpoint: Desired system pressure in psi.
INPUT TRANSDUCER SETTINGS: Discharge, Suction and Flow. Only Discharge or Flow is required
for operation.
CONTROLLER HMI AND SETTINGS:
HOME SCREEN. Home screen shows real-time system
operation, status, settings and hardware. Alarms, Faults and
Maintenance indicators are active when called for and may be
accessed through this screen. Audio/Visual indication set to
Relay 1. May be enabled or disabled by touching Horn & Lt,
R1. Home screen is the default screen. Period of inactivity will
display a screensaver, if enabled by user.
No entries are accepted on the Home screen; it is an
information screen only.
MENU: Menu is the base of navigation throughout the
program.
Menu may be Password Protected, if Enabled (refer to Basic
Setup 4).
Advanced Settings are used only when engineered changes
are required.
Password Protection Setup on Advanced Menu screen.
Default, Enabled Password/Pin – 999.
If Password Protection for Menu is activated, Password Entry
Basic screen will display when Menu button is touched. When
correct password/pin is entered, Menu screen will display. If
incorrect, returns to screen with message “Incorrect Password”.
Reenter correct Password/Pin or ESC.
Factory Setting – Disabled.

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BASIC SETUPS:
Basic Setup screens need to be completed by factory and/or End User before operation.
To set Time, Date and Year – Touch SET, enter information and hit Accept or Cancel to exit.
Select Discharge or Flow and its corresponding Setpoint. Only one is selected as Control Type. Discharge/Flow
Setpoint is the system PSI/GPM at the output of the Booster that will be maintained. If flow required, presetup at
factory is necessary. Contact factory.
Select number of pumps to be operated by Controller. VFDs not set to Hand On or Off will continue to operate with
VFDs that are left in Auto On. Lost communication between a VFD and Controller will also continue to operate with
VFDs with an established communication and set to Auto On. VFD operation mode and communication are shown on
Home screen.
Pump Control Response to System Changes: Select High, Medium or Low for desired response for system demand.
High system demands (quick flow changes) may be set to High. Low system demands (low flow changes) may be set
to Low. Normal operations should be set to Medium.
STAGING (General description based on pressure or flow related to speed). Lead pump is the first pump in the
system that is turned on. Other pumps that follow are Lag pumps. Lead pump will turn on when minimum PSI is not
met and Lead pump Time Delay is timed out. Staging on of the pumps once Lead pump is established is based on
Speed and PSI. If the Lag On Delay times out, additional pumps are turned on. If the speed is equal to or greater than
Set Start Speed and PSI remains below Setpoint, then next pump will turn on. If the Speed is minimum for greater
than the Lag Off Time Delay, first Lag pump on is turned off.
The minimum Lead pump and Lag pump Starting Speed are entered in the Advanced Settings screen at the factory.
The minimum Lead pump and Lag pump Stopping Speed is determined by pump curves and PLC calculations.
Lead and Lag pump operation and speed are set at recommended settings and should not be adjusted without
proper investigation.
LEAD PUMP SEQUENCE. First Pump On/First Pump Off. In the default controller settings, the Lead pump is
changed during every start-up cycle or when more than one pump has been started in a single stage cycle. This
sequence will be First Pump On/First Pump Off. The first pump on or lead pump will rotate to the next pump in the
sequence if only one pump is cycled on and off. If more than one pump has been started, then the pump that started
second will be the new lead pump. The old lead pump will be the first pump off. The new lead pump will be last pump
on in new start-up cycle. The next lead pump will be the next pump in the sequence.

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Timed Pump Rotation by Hours of Operation. Lead pump changed to next pump when Hours of Operation Timer is
timed out. Lag pump turns on and off as called for. Lag pump sequence is first Lag pump on, first Lag pump off.
Same Lead Pump for All Starts. Same Lead pump turns on for every start. Lag pump turns on and off as needed.
The Lag pump sequence is first Lag pump on, first Lag pump off. Transducer Failure Settings, when in Auto mode:
Select Alarm or Fault. Alarm will allow continued operation when system is in Auto Mode and will run at Speed
entered in the Alarm Speed Setting in Hz. If no flow is
detected, drives will stop. Periodic starts will determine
if flow is established. Fault will stop all drives.
Password Setup Disabled/Enable. When password Enabled,
enter up to (4) numbers and record new password/pin. When
enabled, Password screen will display if Menu button is
pressed on Home screen. Factory Setting – Disabled.
Screensaver: To set Screensaver, select ON and input
minutes of inactivity (minimum 2). Return from Screensaver by
touching screen. Home screen will appear by default. Factory
Setting – OFF.
Review Selections. If selections need adjusting, use Back or
Start Basic Setup Over button. Press Finish when done, Home
screen will display.
Basic Setup finished. Set drives to Auto On, system now
operational.
ADVANCED MENU:
Factory Set: Hardware, Speed Max/Min, Start/Stop, Discharge,
Suction, Flow.
Advanced Menu Password/Pin – Factory Setting Default –
Enabled, Password/Pin: 999.
ADVANCED SETUP:
If Password Protection for Advanced Menu is enabled,
Password Entry Advanced screen will display when Advanced

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Menu button is touched. When correct password/pin is entered, Menu screen will display. If incorrect, returns to
screen with message “Incorrect Password”. Reenter correct password/pin or ESC.
Factory Default Password/Pin: 999.
Bypass Password Protection. Basic and Advanced Passwords may be accessed from Home screen. Record Model
Number, Serial Number and call factory.
Drive Controls – VFD in Auto. Realtime Drive information and Controls. Drive controls remote to HMI allow basic
drive operation without using the Local Control Panel at VFD. Drive screens monitor basic Drive Parameters, Speed
in Hz and VFD On/Off. VFD must be in Auto Mode for this screen operation. In case of transducer failure, Manual
Control will be switched to ON. Fault or Alarm will occur (Basic
Setup 4). Turn Drive ON to manually change speed. Drive Control
screens are created for each Drive in system.
Hardware Connections To Controller. Select device that is
currently connected to Controller. This is a Factory Setting and
should never be adjusted without consulting factory.
Speed Max/Min Settings. HMI Manual Max Speed – The max
speed that can be set on the Drive screens when HMI is used as
Manual Control operation for VFD. VFD must be in Auto On.
Max Speed VFDs – Maximum speed VFD can operate when in
Auto On mode and Controller is in operation.

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Min Speed VFDs – Minimum speed VFD can operate when in Auto On mode and Controller is in operation. Minimum
Speed VFD should be equal to Start Speeds Lead and Lag pumps (see Advanced Setup 2) or consult factory.
Factory settings recommended.
START/STOP SETTINGS
Factory setting is Auto Detect. Stop Setpoint is set to minimum predicted speed when pump is no longer working
efficiently. Stop and Start Delay prevents pumps from starting and stopping until system has stabilized.
Start Speeds are set at factory.
DISCHARGE INPUT TRANSDUCER SETTINGS
Discharge Transducer Range – Enter range marked on Transducer in PSI. Set at factory.
Discharge Alarms to Fault – A number of Alarms activated per Alarm setting in assigned amount of hours will cause
system to Fault and pumps will stop operating.
Discharge Alarms and Faults – Alarms are set values to warn of conditions that may be harmful or undesirable for
system. Alarms Reset when system returns to desired operational values. Alarm is recorded in Number of Alarms.
Faults are set values not to be exceeded. If exceeded, system will stop operating. Fault restart requires Operator
assistance. Fault must be cleared or disabled for continued operation.
SUCTION INPUT TRANSDUCER SETTINGS
Suction Transducer Range – Enter range marked on Transducer in PSI. Set at factory.
Suction Alarms to Fault – A number of Alarms activated per Alarm setting in assigned amount of hours will cause
system to Fault and pumps will stop operating.
Suction Alarms and Faults – Alarms are set values to warn of conditions that may be harmful or undesirable for
system. Alarms Reset when system returns to desired operational values. Alarm is recorded in Number of Alarms.
Faults are set values not to be exceeded. If exceeded, system will stop operating. Fault restart requires Operator
assistance. Fault must be cleared or disabled for continued operation.

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Flow Input Transducer Settings. Must be initialized at factory.
Flow Transducer Range – Enter range marked on Transducer in PSI. Set at factory.
Flow Alarms to Fault – A number of Alarms activated per Alarm setting in assigned amount of hours will cause
system to Fault and pumps will stop operating.
Flow Alarms and Faults – Alarms are set values to warn of conditions that may be harmful or undesirable for
system. Alarms Reset when system returns to desired operational values. Alarm is recorded in Number of Alarms.
Faults are set values not to be exceeded. If exceeded, system will stop operating. Fault restart requires Operator
assistance. Fault must be cleared or disabled for continued operation.
EQUIPMENT MAINTENANCE ALARM (BASED ON HOURS OF OPERATION AND STARTS):
Alarm set to be indicated on Home screen. Disable Alarms, enter -1 at default.
Maintenance indicator will also be an option for Relay Output Alarms as a general Maintenance Alarm.
To reset, enter 0 in Total Hours or # of Starts. The controller will start timing again as equipment is being used.
An alarm is activated when Starts, Pump Hours, Motor Hours, VFD Hours, Discharge Transducer, Suction
Transducer, Flow Transducer, PLC Hours numbers equal or exceed Alarm Default. A marker will appear at the
default when alarm activates on the Maintenance Alarm screen. A maintenance alarm will be flashing on Home
screen. If alarm in Alarm Group is acknowledged, then Maintenance Alarm will stop flashing and number (counts) will
stay active. If alarm is reset, then the number or counts will be reset to zero. Default will stay the same and Total will
still be numbering (counting).

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DIGITAL INPUTS 24VDC:
External dry contacts required for input terminal signal. DC signal supply provided at terminal. Inputs are selectable
as an Unused, Alarm, Fault, For Relay Out or Fault Reset. 4 Inputs is standard configuration for customer’s use.
Additional 4 can be added as an option, 8 total.
If Alarm is selected, press Alarm button to configure. Input Alarm Configuration screen will display for input. See Input
Alarm Configuration screen. Alarm selection from Digital Input Setup screen. After alarm has been pressed, continue
with configuration.
Setup Input 1, 2, 3, 4 Alarm Configuration will allow multiple alarms to cause a fault. Inputs 5–8 Alarm Configuration
allowed, if available.
Alarms are recorded. The number of Alarms is a set value not to be exceeded. If exceeded within a set time period,
a Fault will occur and system will stop operating. Fault restart
requires Operator assistance. Fault must be cleared or
disabled for continued operation.
RELAY OUTPUTS:
The output relays are form C contacts rated 240Vac 6A. 4
Relay Outputs are standard for customer’s use. Additional
4 can be added as an option. Relay Outputs can choose to
indicate:
Relay Outputs can choose to indicate:
System On Auto
System On Manual
Pump Running
VFD Alarm
Discharge Pressure System Alarm Low
Discharge Pressure System Fault Low
Discharge Pressure System Alarm High
Discharge Pressure System Fault High
Suction Pressure System Alarm Low
Suction Pressure System Fault Low
Suction Pressure System Alarm High
Suction Pressure System Fault High
Flow Alarm Low
Flow Low Fault
Flow Alarm High
Flow High Fault
All Alarms
All Faults
Digital In 1
Digital In 2
Digital In 3
Digital In 4
Digital In 5
Digital In 6
Digital In 7
Digital In 8
Maintenance Alarm

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COM – OPTIONAL FUNCTIONS: SD CARD AND
ETHERNET WITH WEB SERVER:
SD Card
When SD Card is available and set up for Controller:
– Copy Current Settings and Values from PLC
to SD Card, TO SD CARD.
– Copy Settings and Values on SD Card to PLC,
TO PLC.
WARNING:
Copy application overwrites existing memory locations
and settings in SD or PLC.
Web Server
Ethernet Card Setup for Web Server (SD Card included and must be in Controller for operation).
CONTROLLER:
Description: 16" h x 12" w x 8" d, NEMA 4 Enclosure
Power: 100–240 VAC 50/60 Hz
Operator Controls:
Power Off/On Switch
Operator Touch Screen – 5.7' Color Touch Panel
Audible/Visual Alarm
Control Connections:
RS485 communication port to VFDs
Discharge Pressure Transducer (4-20 mA)
Suction Pressure Transducer (4-20 mA)
External Fault and Alarm inputs, (4) – User defined
Relay Outputs (6 amp, form ‘C’) Fault and Alarm,
(4) – User defined
Additional I/O Connections:
Optional Flow Meter Input
Optional Flow Indicator
External Fault and Alarm Inputs, maximum (8 total)
– User defined
Additional Relay Outputs (6 amp, form ‘C’), maximum
(8 total) – User defined
Additional Options:
SD Card ID, Defaults and Settings – Must be available for Web Server
Ethernet Interface Web Server and Communication with External RJ45
Datalogs, Trends, Data Tables with SD card – Contact factory for availability

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Troubleshooting Guide
Field Wiring
All wiring connections and wiring sizes must meet National Electrical Code and local requirements.
Motor Protection
See the motor nameplate for electrical connection/wiring diagram. Fairbanks Nijhuis™ pumps must be used with the
proper size and type of motor starter to ensure protection against damage from low voltage, phase failure, current
imbalances, and overloads. The overload should be sized to trip at the full-load current rating of the motor.
OPERATION
Priming
WARNING! Risk of explosion and scalding.
Do not run the pump with the discharge valve closed; the water in the pump may boil, causing risk of
explosion and steam burns to anyone nearby.
WARNING! Risk of electric shock.
Can shock, burn or kill. Disconnect all power to the pump before servicing or working on the pump. Make
sure that the power is locked out and that the pump cannot be accidentally started.
NOTICE: Under no circumstances should the pump be operated without flow through the pump. Never operate the
pump dry.
Operation of closed system or open system with the liquid level above the pump priming plug.
1. Close the discharge isolating valve and loosen the needle valve located in the assembly in the pump head
(figure below). Do not remove the needle valve.
NOTICE: On PVM(X)2/4 models, remove the couple guard for access to the vent plug.
CAUTION! Risk of flooding.
Can cause personal injury and/or property damage. Watch
the direction of the priming plug and make sure that the
liquid escaping from it does not injure persons nearby
or damage the motor or other components. In hot water
installations, pay particular attention to the risk of injury
from scalding hot water.
2. Slowly open the isolation valve in the suction pipe
until a steady stream of liquid runs out the vent in
the priming pot.
3. Tighten needle valve to 25 inch-pounds. Completely
open isolation valves.

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NOTICE: Please see to “Starting” before proceeding any further. Operation of open systems with the liquid
level below the top of the pump:
NOTICE: The suction pipe requires a check valve or isolation valve.
1. Close to discharge isolation valve.
2. Remove the vented priming plug.
3. Pour liquid through the priming port until the suction pipe and the pump are completely filled with liquid.
4. Replace the vented priming plug and tighten it securely.
5. Repeat steps 1 - 4 until the pump is primed.
NOTICE: Please see “Starting” before proceeding any further.
CHECKING DIRECTION OF ROTATION
NOTICE: Do not disconnect the motor from the shaft to check the direction of rotation. If you remove the coupling,
then you must adjust the shaft position when you reinstall it. This must be done before starting the pump.
Arrows on the pump head show the correct direction of rotation. When seen from the motor fan, the pump should
rotate counterclockwise . For pump motors without a fan, remove one of the coupling guards and look at the
coupling to determine the direction of rotation. Turn off the pump and replace coupling guard.
NOTICE: Do not check the directions of rotation until the pump has been filled with liquid. See “Priming” above.
1. Switch power off.
2. Remove the coupling guard and rotate the pump shaft to be certain it can turn freely. Replace the coupling
guard.
3. Verify that the electrical connections are in accordance with the wiring diagram on the motor.
4. If the fan is visible, turn on and off to verify rotation.
5. To reverse the direction of rotation, first switch OFF the power supply.
6. On three phase motors, switch 2 of the 3 power leads on the load side of the starter. On single phase motors,
see the connection diagram on the motor nameplate. Change the wiring as indicated.
WARNING! Risk of electric shock.
Can shock, burn or kill. Ground the pump motor correctly before connecting to power supply per article
250-80 of National Electric Code (NEC) in the U.S., or the Canadian Electrical Code (CEC), as applicable.
7. Switch the power supply and recheck the direction of motor rotation.
STARTING
1. If a suction line isolation valve has been installed, check to be sure that it is completely opened.
2. For initial starting, the isolation valve in the discharge pipe should be almost closed.
3. Start the pump.
4. When the piping system has been filled with liquid, slowly open the discharge isolation until it is completely open.
Opening the valve too fast may result in water hammer in the discharge pipe. If the pump or system starts to
rattle, the pump is cavitating; to avoid damage to the pump, reduce the flow through the discharge isolation
valve until the rattling stops. If this does not give adequate flow for your installation, call your installer or
system designer.
5. Record the voltage and amperage of the motor. Adjust the motor overloads if required
6. If pressure gauges have been installed, check and record operating pressures.
7. Check all controls for proper operation.

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WARNING!
If motor is nameplated for hazardous locations, do not run motor without all of the grease or drain
plugs installed.
Relubrication Time Interval
(For motors with regreasing provisions)
Service
Conditions
NEMA Frame Size
140-180 210-360 400-510
1800 RPM
and less
Over 1800
RPM
1800 RPM
and less
Over 1800
RPM
1800 RPM
and less
Over 1800
RPM
Standard 3 years 6 months 2 years 6 months 1 year 3 months
Severe 1 year 3 months 1 year 3 months 6 months 1 month
Season 1. For Motors nameplated as “belted duty only”, divide the above intervals by 3
2. Lubricate at the beginning of the season. Then follow service schedule above.

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WARNING! Risk of electrical shock and possible unexpected starts.
Disconnect all power to the pump before servicing or working on pump. Make sure that power is locked out
and that pump cannot be accidentally started.
Problem Cause
1. Motor does not run
when started
A. Power failure
B. Fuses blown
C. Motor starter overload has tripped out
D. Main contacts in motor starter are not making contact or the coil is faulty.
F. Motor is defective
2. Motor starter overload
trips out immediately
when power supply is
switched on
A. One fuse has blown
B. Contacts in motor overload relay are faulty
C. Cable connections are loose or faulty
D. Motor winding is defective
E. Pump is mechanically blocked
F. Overload setting is too low
3. Motor starter overload
trips out occasionally
A. Overload setting is too low
B. Low voltage at peak times
4. Motor starter has not
tripped out but the motor
does not run
A. Power failure
B. Fuses blown
C. Main contacts in motor starter are not making contact or the coil faulty
D. Control circuit fuses are defective
5. Pump capacity is not
constant
A. Pump inlet pressure is too low
B. Suction pipe/pump is blocked
C. Pump is sucking air
6. Pump runs but gives
no water.
A. Suction pipe/pump is blocked
B. Foot or nonreturn valve is blocked in closed position
C. Leakage in suction pipe
D. Air in suction pipe or pump
E. Motor rotates in the wrong direction
7. Pumps runs backward
when switched off
A. Leakage in suction pipe
B. Foot or nonreturn valve is defective
C. Foot valve is blocked in open or partly open position
D. Nonreturn valve leaks or is blocked in open or partly open position
E. Discharge valve is defective
8. Leakage from shaft seal A. Pump shaft position is incorrect
B. Shaft seal is defective
9.Noise A. Cavitation is occurring in the pump
B. Pump does not rotate freely (that is, there is increased frictional resistance) because
of incorrect shaft position

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NOTICE: The suction pipe requires a check valve or isolation valve.
1. Close to discharge isolation valve.
NOTICE: Please see “Starting” before proceeding any further.
CHECKING DIRECTION OF ROTATION
NOTICE: Do not disconnect the motor from the shaft to check the direction of rotation. If you remove the coupling,
then you must adjust the shaft position when you reinstall it. This must be done before starting the pump.
Danfoss Drive Preventive Maintenance Instruction
PM Checklist
rVacuum dust and dirt from heat sink fins
rClean or replace as conditions require intake air filters (125 Hp constant torque models, 150 Hp variable torque
models and larger have filters located behind the intake louver panels)
rCheck ventilation fans for proper operation and clean as needed.
rConfirm VFD’s ventilation clearances have not been obstructed
rCheck electrical connections and re-torque as needed. If possible, perform an IR thermal scan of the VFD’s
power input and power output.
rCheck line voltage
rCheck motor & output phase balance
rInspect DC buss capacitors (older drives)
rRecord the VFD’s parameter settings using MCT-10
rConfirm the VFD doors and covers are in place and properly closed
2. Clean the drive’s interior.
a. Dirt coating drive circuit boards and other components can interfere with proper cooling and even provide a path
for electricity to short out along unintended paths. This can cause erratic operation and possibly damage to drive
components.
b. Corroded electrical connections can cause excess heat build-up, short circuits, erratic drive operation, and even
component damage.
c. This should be done after the installation of the drives is complete and before power is applied to the drive. The
main point here is to ensure that no metal filings or other installation-related dirt are inside the drive or its option
enclosure.
d. If the drive is installed in an area where a lot of construction work will be performed, it is best to keep the drive
covered while it is not in operation. Of course, if it is being used, the drive must be uncovered so that cooling air
can be freely supplied to it. After the construction is complete it will be important to clean the interior of the drive.
Low pressure, clean, dry air or similar commercial products can be used to clean dirt off of circuit boards. While
a vacuum cleaner can be used to collect falling dirt, it is important to ensure that circuit boards are not damaged
by the use of a powerful vacuum cleaner on the boards. Inspect drive connectors for dirt or corrosion.
e. In a normal environment, the drive’s interior should be inspected annually and cleaned, if necessary. In dirty
environments, more frequent inspection is required. The level of dirt found inside the drive can be used to dictate
the frequency of inspections and cleanings that is required.
3. Clean air filters (if any).
a. Many VLT drives have no air filters. However, some sizes and enclosure styles do use air filters in conjunction
with their fan cooling systems. For these drives it is important to periodically inspect and clean or replace the
filter element.
b. Because the loading of the air filters can vary dramatically from one installation to another, it is important to
initially check the air filters frequently to establish the required inspection interval

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4. Check the tightness of connections.
a. Loose power connections can cause extra heating and/or arcing. The heating reduces efficiency and can
actually melt down connectors. The arcing can cause intermittent currents and electrical noise. These can
disrupt the operation of the drive.
b. Loose or corroded ground connections can cause electrical noise problems. All of the VLT drives have some
degree of electrical noise filtering. Some of this electrical noise is sunk to earth ground. Without a reliable ground
connection the noise filters cannot operate as designed. In addition, a poor ground connection can become a
safety issue.
c. Loose control wires can cause intermittent operation of equipment. Loose or missing shielding for signal wires
can cause erratic operation of the drive. In a extreme case this can even cause the drive to trip off.
d. The preventive maintenance procedure would involve first turning off power to the drive and waiting until the
DC bus capacitors have discharged to a safe level. Then all of the accessible connections should be inspection
for corrosion and checked for tightness. It should not be necessary to disassemble the drive to perform this
operation.
e. This should be performed once the drive is installed and at least annually afterward. If the drive is subjected to
vibration or wide temperature variations, it should be checked more frequently.
5. Check cooling fans.
a. Cooling fans are used to remove heat from the drive. Proper operation of the cooling fans helps ensure long
drive life by keeping the drive’s components cool. The cooling system should be inspected at least annually,
more frequently when the drive is exposed to extreme conditions.
b. Inspect the heat sinks, air inlets, and air outlets to ensure that there is an open path for air flow.
c. The cooling fans in many VLT drives will turn themselves off when the drive’s temperature is low enough to not
require forced ventilation. To check for proper fan operation if the fans are not running, remove power from the
drive. When power is reapplied the fans should start and run for a few seconds.
d. Listen for unusual noises from the fans when they are running.
e. The VLT drives use a heat sink temperature sensor to help indicate if there is a problem with the cooling system.
If the drive issues a HEAT SINK OVERTEMP. warning or alarm, check the cooling system carefully.
6. Check bus capacitors for voltage balance and/or physical damage.
a. The large DC bus capacitors in the drives are subject to deterioration over an extended period of time. It
generally takes a significant number of years before any problems occur, although high ambient temperatures
and other factors can accelerate this process.
b. Problems with the DC bus capacitors generally first show up as a large “AC ripple voltage” being superimposed
on the DC bus. The VLT 6000 continually monitors for excessive DC bus ripple, so it will generally provide an
early warning of bus capacitor problems. If the drive gives a MAINS PHASE LOSS warning or alarm and a check
of the input AC power line shows it to be balanced under loaded conditions, the DC bus capacitors should be
checked carefully.
c. On drives with an input power line voltage of 380 V AC or larger, the DC bus capacitors are connected as two
banks that are in series with each other. With power applied to the drive, the voltage across the positive half
should be within 10% of the voltage across the negative half.
d. With power removed from the drive, a physical inspection of the capacitors should not show any deformation of
the cases of the capacitors or liquid leaking from them.
e. Low voltage capacitor testers are of no use in checking DC bus capacitors. The main concern is to ensure that
the capacitors don’t have excessive leakage current when the DC bus voltage is applied to it. This cannot be
tested at a low voltage.
f. If one capacitor on the DC bus is found to be weak or damaged, it is important to replace the entire capacitor
bank. A capacitor with an excessive amount of leakage current places excessive stress on other capacitors in
the bank.
g. If it is convenient to access the two halves of the DC bus capacitors, the inspection technique given in “c” and “d”
can be performed annually. Otherwise, it is best to simply let the drive’s internal monitoring circuitry described in
“b” provide an indication of possible problems.

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Basic Operation Manual
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Basic Operation Manual
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Basic Operation Manual
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