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VSD Novomet Troubleshooting Manual. Rev.0.

| September 2013

VSD Novomet
Troubleshooting Manual
Rev.0. | September 2013

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Contents

1. List of abbreviations.............................................................................................................................3

2. Minimum amount of tools and accessories required for repair of VSD......................................................4

3. Safety provisions for work with VSD Novomet..........................................................................................5

4. Composition of NVSD XXXKVA 480V 60HZ 6P NIF-B NSWF-B NSP-B........................................................5

5. Troubleshooting .................................................................................................................................8

Appendix 1. Connection layout of Controller

Appendix 2. Connection layout of VSD Novomet

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

1. List of abbreviations
VSD Variable speed drive;
NIF-B Novomet input filter - built-in;
NSWF-B Novomet sine-wave filter - built-in;
NSP-B Novomet surface panel - built-in;
UPS Uninterruptible power supply;
USB Universal Serial Bus;
ESP Electrical Submersible Pump;
CF Compact Flash memory card

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

2. MiniMUM aMoUnt of tooLs


anD aCCessories reQUireD for rePair of vsD
1. Digital multimeter Fluke 17B or equivalent 5. RS485->USB interface converter

2. Set of screwdrivers with flat and cross-head tips 6. USB programmer-debugger PICkit2

3. Box wrench 7. Card reader with Compact Flash slot

4. Laptop with Windows x32 system and pre-installed


8. Key for VSD
SW (MCT 10, Acronis, PICkit2 Programmer)

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

3. 3. safetY Provisions for WorK


WitH vsD novoMet
1. Never touch energized power components. Wait at least 15 minutes after de-energizing of the power source;
2. Each connection must be performed with the de-energized VSD;
3. Make sure VSD is grounded properly prior to start of work;
4. When using multimeter make sure to use insulating gloves;

4.CoMPosition
of nvsD XXXKva 480v 60HZ 6P nif-b nsWf-b nsP-b

Figure 1

Figure 1

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

4.1 terminal block for external connections

Terminal block for external connections

Figure 2

4.2 Composition power circuit breaker


of nvsD XXXKva 480v 60HZ 6P nif-b nsWf-b nsP-b
QF 2 Control Electricity
circuites meter circuits
HL 1 Indication
power

Power circuits
Electricity meter

RU1 Voltage
suppressors
QF 8 Voltage
suppressors circuits

Socket
220V, 60Hz, 6A

QF3 Socket QF7 Ventilation


circuit circuit
QF4 Controller
circuit QF6 Lighting
QF5 NSP-B circuit
circuit Figure 3

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

4.3 Composition of controller


of nvsD XXXKva 480v 60HZ 6P nif-b nsWf-b nsP-b:

Board PK-01
Industrial
computer

Board PIT-02

Figure 4

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

5. troUbLesHootinG
Description of trouble: Controller not functioning;
Solution:
1. Using multimeter measure voltage at the power supply plug of controller (Figure 5), it should be ~220V:

Power supply plug


of controller

Figure 5

– No voltage:
A) Using multimeter measure line voltage of the supply mains (AB, BC, CA), voltage at the input terminals
of VSD (Figure 6) it should be: ~480V +/- 15%;

measure line voltage


of the supply mains

Figure 6

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

B) Check voltage at the secondary winding of step-down transformer (Figure 7) T1 (~220V);

Measure voltage

Figure 7

C) Check output voltage after filter (Figure 8) FV1 (~220V);

Measure voltage

Figure 8

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

D) Check serviceability of automatic circuit breaker QF4 (Figure 9) located at the bottom part of power
breaker panel (shown in Figure). Breaker should be triggered with no jerks, with no foreign sound and lock on
in ON/OFF positions, if during test the breaker fails to meet at least one of the criteria then this breaker needs
replacement;

Automatic circuit breaker

Figure 9

– Voltage is available:
A) Check integrity of the breaker (Figure 10). Housing of the breaker must not be damaged, when the ohmic
resistance is measured by the multimeter it should not show open circuit, i.e. indefinitely high resistance.
The fuse is located beneath the power socket of the controller in a separate compartment;

Fuse

Figure 10

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

B) Make sure that lamp at PIT-02 circuit board is ON (Figure 11) which indicates live voltage ~220V and using
the multimeter measure the voltage at XP2 socket;

Lamp at PIT-02 circuit board

Measure the voltage ~220V

Figure 11

C) Using multimeter measure the secondary voltage at the points shown in the Figures (Figure 12), the voltage
values should read -5V and -24V;

DC voltage -5V
DC voltage -24V

Figure 12

If one of the items B or C is not complied with, then replace PIT-02 circuit board if it is feasible or replace the
controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: single circuit board industrial computer does not function (i.e. Windows and BIOS
do not boot when starting, while the display is white and ‘WAIT’ lamp is blinking)

Figure 13

1. Measure voltage -5V at PIT-02 circuit board (Figure 14);

DC voltage -5V

Figure 14

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

– No voltage:
A) Check tight connection of the cable (Figure 15) K9 (control of PIT-02 circuit board). Cable contacts should
not slip out of the plug, the plug itself should be in tight contact with the circuit boards. Cable K9 should have no
visible damage as well;

Cable K9

Figure 15

If item A is complied with, then a possible reason is the fault of voltage converter at PIT-02 circuit board. In this
case replace PIT-02 circuit board if it is feasible or replace the controller as a whole item.
– Voltage is available:
A) Check tight connection of K4 cable (Figure 16). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К4 should have no visible damage as well;

Cable K4

Figure 16

If item A is complied with, then a possible reason is the fault of the single circuit board computer. In this case
replace computer circuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: RAM of single circuit board industrial computer does not function (i.e. Windows
and BIOS do not boot when starting, while the display is white and ‘WAIT’ lamp is blinking);

Figure 17

Solution:
1. Measure voltage -5V at PIT-02 circuit board (Figure 18);

DC voltage -5V

Figure 18

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

– No voltage:
A) Check tight connection of the cable (Figure 19) K9 (control of PIT-02 circuit board). Cable contacts should
not slip out of the plug, the plug itself should be in tight contact with the circuit boards. Cable К9 should have no
visible damage as well;

Cable K9

Figure 19

If item A is complied with, then a possible reason is the fault of voltage converter at PIT-02 circuit board. In this
case replace PIT-02 circuit board if it is feasible or replace the controller as a whole item.
– Voltage is available:
A) Check tight connection of K4 cable (Figure 20). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К4 should have no visible damage as well;

Cable K4

Figure 20

B) Clean the contacts of the single circuit board computer RAM;


If item A and B are complied with, then a possible reason is the fault of the single circuit board computer.
In this case replace computer circuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: when booting the controller there is no communication with all the devices;

Figure 21

Solution:
1. Measure voltage -5V at PIT-02 circuit board (Figure 22);

DC voltage -5V

Figure 22

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013
– No voltage:
A) Check tight connection of the cable (Figure 23) K9 (control of PIT-02 circuit board). Cable contacts should
not slip out of the plug, the plug itself should be in tight contact with the circuit boards. Cable К9 should have no
visible damage as well;

Cable K9

Figure 23

If item A is complied with, then a possible reason is the fault of voltage converter at PIT-02 circuit board. In this
case replace PIT-02 circuit board if it is feasible or replace the controller as a whole item.
– Voltage is available:
A) Check tight connection of K5 cable (Figure 24). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К5 should have no visible damage as well;

Cable K5

Figure 24

If item A is complied with, then a possible reason is the fault of PK-01 circuit board. In this case replace PK-01
circuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: in cases of voltage dropdown or shutdown of the supply mains the controller can
not run from UPS;
Solution:
1. Check position of the switch (Figure 25) located at the housing of UPS (it must be ON – respective light
indicators should be ON);

UPS switch

Figure 25

2. Check contact of the cable connecting UPS with the controller (Figure 26). Plugs should be fitted tightly and
have no misalignment;

UPS Plug

Figure 26

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

3. Check contact of K8 cable (Figure 27). Cable contacts should not slip out of the plug, the plug itself should
be in tight contact with the circuit board. Cable К8 should have no visible damage as well;

Cable K8

Figure 27

If all of the items are complied with, then a possible reason is low charged battery of UPS, please wait till it
recharges completely. If UPS does not function after complete recharging, then replace UPS.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: USB port (or both ports) located at the front side of the controller does not function;
Solution:
1. Check tight connection of K15 cable (Figure 28). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К15 should have no visible damage as well;

Cable K15

USB 1 USB 2

Figure 28

2. Reconnect К15 cable to USB2 port located nearby at the single circuit board computer (Figure 28).
If USB ports still do not function after completing item 2, then a possible reason is the fault of USB ports at
the single circuit board computer. In this case replace the computer if it is feasible or replace the controller as a
whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013
Description of trouble: no communication via RS485 channel from terminal box of external connections;
Solution:
1. Check tight connection of K12-1 cable (Figure 29). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К12-1 should have no visible damage as well;

Socket XS3

Cable K12-2

Cable K12-1

Figure 29 Figure 30

2. Check tight connection at the socket (Figure 30) XS3 (inside and outside of the controller). Plugs should be
fitted tightly and have no misalignment;
If both the items are complied with, then a possible reason is the fault of PK-01 circuit board, replace the cir-
cuit board if it is feasible or replace the controller as a whole item.
Description of trouble: no communication with PK-01 and with NSP-B;

Figure 31

Solution:
– no communication with PK-01 and with NSP-B simultaneously;
1. Check tight connection of K12-2 cable (Figure 29). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К12-2 should have no visible damage as well;
If this item is complied with, then a possible reason is the fault of PK-01 circuit board, replace the circuit board
if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

– no communication only with NSP-B:


1. Check tight connection at the socket (Figure 32) XS2 (inside and outside of the controller);

Socket XS2

Figure 32

2. Check tight connection of socket RS485 at the NSP-B;


3. Insert RS485 plug to another socket at the NSP-B (Figure 33);

Backup
connector

Check tight connec-


tion of socket RS485

Figure 33

If all the three items are complied with, then a possible reason is the fault of PK-09 circuit board, replace the
circuit board if it is feasible or replace the NSP-B.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: no communication with Danfoss frequency converter;

Figure 34

Solution:
1. Check tight connection of K12-3 cable (Figure 35). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К12-3 should have no visible damage as well;

Cable K12-3

Figure 35

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

2. Check tight connection at the socket (Figure 36) XS1 (inside and outside of the controller);

Socket XS2

Figure 36

3. Make sure that the control panel at the frequency converter is ON and shows current status;
4. Check settings of communication channel using control panel of the frequency converter (parameter
numbers required to adjust settings of the communication channel: 8-30-[2] ModBUS RTU, 8-31-[131], 8-32-[7]
115200, 8-33-[2] No parity 1 stop bit);
5. Using multimeter measure line voltage of the supply mains (AB, BC, CA), voltage at the output terminal of
VSD (Figure 37) it should be: ~480V +/-15%;

measure line voltage


of the supply mains

Figure 37

If all of the items are complied with, then a possible reason is the fault of PK-01 circuit board, replace the cir-
cuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: no communication with the electricity meter;

Figure 38
Solution:
1. Check tight connection of K13 cable (Figure 39). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К13 should have no visible damage as well;

Cable K13

Figure 39

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

2. Check tight connection at the socket (Figure 40) XP1 (inside and outside of the controller);

Socket XP1

Figure 40

3. Visually check serviceability of interface converter manufactured by ABB (if meter of ABB is used);
4. Make sure that electricity meter shows the parameters which are being measured;
If all of the items are complied with, then a possible reason is the fault of PK-01 circuit board, replace the cir-
cuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: cooling system of controller does not function (no functioning of the fan located at
butt end of the controller);
Solution:
1. Check tight connection of K20 cable (Figure 41). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К20 should have no visible damage as well;

K20 cable

Figure 41

If all of the items are complied with, then a possible reason is the fault of the fan, replace the fan if it is feasible
or replace the controller as a whole item.
Description of trouble: controller heating system does not function;
Solution:
1. Check tight connection of K2 cable at PIT-02 circuit board (Figure 37). Cable contacts should not slip out of
the plug, the plug itself should be in tight contact with the circuit boards. Cable К2 should have no visible damage
as well;
2. Check tight connection of K2 cable at BK1 thermal switch (Figure 42);

Thermal switch

Cable K2

Figure 42

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3. Using multimeter measure voltage at PIT-02 circuit board (Figure 43) (~220V);

Lamp at PIT-02 circuit board

Measure the voltage ~220V

Figure 43

If item 3 is not complied with, then a possible reason is the fault of PIT-02 circuit board, replace the circuit
board if it is feasible or replace the controller as a whole item.
Description of trouble: controller display does not show any information (display is highlighted);
Solution:
1. Check tight connection of K22 cable at the circuit board of the industrial computer (Figure 44). Cable con-
tacts should not slip out of the plug, the plug itself should be in tight contact with the circuit boards. Cable К22
should have no visible damage as well;

Cable K22
Cable plug

Figure 44

2. Check serviceability of the single circuit board computer against item: single circuit board industrial com-
puter does not function;

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: stop/manual/automatic switch does not function;


Solution:
1. Check tight connection of K8 cable at PK-01 circuit board (Figure 45). Cable contacts should not slip out of
the plug, the plug itself should be in tight contact with the circuit boards. Cable К8 should have no visible damage
as well;
2. Check tight connection of K10 cable at PK-01 circuit board (Figure 45). Cable contacts should not slip out of
the plug, the plug itself should be in tight contact with the circuit boards. Cable К10 should have no visible dam-
age as well;

Cable K10

Cable K8

Automatic circuit breaker

Figure 45 Figure 46

If the items are complied with, then a possible reason is the fault of PK-01 circuit board, replace the circuit
board if it is feasible or replace the controller as a whole item.
Description of trouble: no alarm data in case of mains dropdown;
Solution:
1. Check condition of automatic circuit breaker (Figure 46) QF10 (must be ON). Breaker should be triggered
with no jerks, with no foreign sound and lock on in ON/OFF positions, if during test the breaker fails to meet at
least one of the criteria then this breaker needs replacement;
2. Check integrity of voltage divider elements (Figure 47), diodes and resistors should not have traces of
burnout and mechanical damage;

Voltage
divider

Figure 47

If one of the elements of voltage divider is damaged, replace the element if it is feasible or replace the voltage divider.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

3. Check tight connection of the K10 cable (Figure 48). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К10 should have no visible damage as well;

K10 cable

Socket XS1

Figure 48 Figure 49

4. Check tight connection at the socket (Figure 49) XS1 (inside and outside of the controller);
f items 1, 3, 4 are complied with, then a possible reason is the fault of PK-01 circuit board, replace the circuit
board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: stop/wait/run indicators do not function;


Solution:
1. Check tight connection of K11 cable (Figure 50). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К11 should have no visible damage as well;

Cable K11

Cable K14

Socket XP2

Figure 50 Figure 51

Description of trouble: controller keyboard does not function;


Solution:
1. Check tight connection of K14 cable (Figure 51). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К14 should have no visible damage as well;
2. Check tight connection at XP2 socket (Figure 51);
If the items are complied with, then a possible reason is the fault of single circuit board computer, replace the
circuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: backspin detection board does not function (when ESP system is shutdown back-
spin detection is not indicated);
Solution:
1. Check integrity of the fuse at PITV circuit board (Figure 53);
2. Check tight connection at the socket (Figure 52) XS2 (inside and outside of the controller);

Fuse
Socket XS6

Socket XS7

Socket XS2

Figure 52 Figure 53

3. Check tight connection at XS7 socket (Figure 53);


4. Check tight connection at XS6 socket (Figure 53);
If the items are complied with, then a possible reason is the fault of single circuit board computer, replace the
circuit board if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: surface panel does not function (none of the LEDs is ON);
Solution:
1. Measure voltage at the power supply plug of the surface panel (Figure 54) (~220V):

Supply plug

measure line voltage


of the supply mains

Figure 54 Figure 55

– No voltage:
A) Measure voltage of the supply mains (Figure 55);
B) Check voltage at the secondary winding of step-down transformer (Figure 56) T1 (~220V);

Measure voltage

Figure 56

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C) Check output voltage after filter (Figure 57) FV1 (~220V);

Measure voltage

Figure 57

D) Check serviceability of circuit breaker QF5 (Figure 58) located at the bottom part of power breaker panel
(shown in Figure). Breaker should be triggered with no jerks, with no foreign sound and lock on in ON/OFF posi-
tions, if during test the breaker fails to meet at least one of the criteria then this breaker needs replacement;

Automatic circuit breaker QF5

Figure 58

If voltage is available, then a possible reason is the faulty surface panel. Replace the surface panel if it is feasible.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: highlighting of display is not ON (or it is very dull);


Solution:
1. Measure availability of voltage +24V at PIT-02 circuit board (Figure 59) (indicator lamp is ON);

Cable K9

Measure voltage

Figure 59

– No voltage:
A) Check tight connection of K9 cable (Figure 59) (control of PIT-02 circuit board). Cable contacts should not
slip out of the plug, the plug itself should be in tight contact with the circuit boards. Cable К9 should have no vis-
ible damage as well;
If item A is not complied with, then a possible reason is the fault of voltage converter at PIT-02 circuit board. In
this case replace PIT-02 circuit board if it is feasible or replace the controller as a whole item.
– Voltage is available:
A) Check tight connection of K6 cable (Figure 60). Cable contacts should not slip out of the plug, the plug
itself should be in tight contact with the circuit boards. Cable К6 should have no visible damage as well;

Cable K6

Figure 60

If item A is complied with, then a possible reason is the fault of the graphic display. In this case replace the dis-
play if it is feasible or replace the controller as a whole item.

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Description of trouble: cooling system of VSD does not function;


Solution:
1. Measure voltage of the supply mains (Figure 61);

Measure voltage

measure
Measure line voltage
of the supply mains

Figure 61 Figure 62

2. Check voltage at the secondary winding of T1 step-down transformer (Figure 62) (~220V);
3. Check output voltage after FV1 filter (Figure 63) (~220V);

Measure voltage

Figure 63

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

4. Check serviceability of QF7 circuit breaker (Figure 64) located at the bottom part of power breaker panel
(shown in Figure). Breaker should be triggered with no jerks, with no foreign sound and lock on in ON/OFF posi-
tions, if during test the breaker fails to meet at least one of the criteria then this breaker needs replacement;

Automatic circuit breaker QF7

Figure 64

If all of the items are complied with and one of the fans does not function, then a possible reason is the fault of
the fan. Replace the faulty fan if it is feasible.
Description of trouble: when controller is started Windows does not boot (or ProgektSU does not start,
i.e. after booting of Windows the display shows blue screen);

Figure 65

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VSD Novomet Troubleshooting Manual. Rev.0. | September 2013

Solution:
1. Check availability of Industrial CF at the socket of the single circuit board computer (Figure 66);

Check availability
of Industrial CF

Figure 66

If the memory card is fitted in the computer slot and Windows does not boot, then re-write CF (this operation
can be effected without shutdown of the VSD).

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VSD Novomet Troubleshooting Manual | 11.09.2013

APPENDIX 1

Connection layout of Controller


VSD Novomet Troubleshooting Manual | 11.09.2013

APPENDIX 2

Connection layout of VSD Novomet