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Danfoss VLT FC 100, Service Manual, Page: 6 / 134

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Summary of Contents for VLT FC 100

Page 1: ...MAKING MODERN LIVING POSSIBLE Service Manual VLT FC Series D Frame VLT HVAC Drive FC 100 VLT AQUA Drive FC 200 VLT Automation Drive FC 300 VLT Refrigeration Drive FC 103 www danfoss com drives...

Page 2: ......

Page 3: ...s with the LCP 25 2 3 Status Messages 26 2 4 Status Message Definitions 26 2 5 Service Functions 28 2 6 Adjustable Frequency Drive Inputs and Outputs 28 2 6 1 Input signals 29 2 6 2 Output signals 29...

Page 4: ...stable Frequency Drive and Motor Applications 59 5 1 Torque Limit Current Limit and Unstable Motor Operation 59 5 1 1 Overvoltage Trips 60 5 1 2 Line Phase Loss Trips 60 5 1 3 Control Logic Problems 6...

Page 5: ...Test 80 6 4 5 Switch Mode Power Supply SMPS Test 80 6 4 6 Input Imbalance of Supply Voltage Test 80 6 4 7 Input Waveform Test 81 6 4 8 Input SCR Test 81 6 4 9 Output Imbalance of Motor Voltage and Cur...

Page 6: ...BT Module 98 7 3 18 IGBTs 99 7 3 18 1 400 V AC Power Size 99 7 3 18 2 690 V AC Power Size 99 7 3 19 DC Capacitors 100 7 3 19 1 400 V AC Power Size 100 7 3 19 2 690 V AC Power Size 101 7 3 20 Heatsink...

Page 7: ...7 4 20 DC Capacitors 112 7 4 20 1 400 V AC Power Size 112 7 4 20 2 690 V AC Power Size 113 7 4 21 Heatsink Fan 114 7 4 22 Door Fan IP21 NEMA 1 or IP54 NEMA 12 Enclosures Only 114 7 4 23 Top Fan IP20 E...

Page 8: ...Signal Test Board p n 176F8437 120 8 1 3 Signal Test Board Extension 121 8 1 4 Signal Test Board Pin Outs 121 9 Spare Parts 125 9 1 Spare Parts 125 9 1 1 General Notes 125 9 1 2 DC Capacitor Bank 125...

Page 9: ...ther constant torque or variable torque industrial applications They operate a variety of applications and incorporate a wide range of control and communication options These models are available in I...

Page 10: ...200 D1h D3h D5h D6h N160 160 200 250 300 200 250 D2h D4h D7h D8h N200 200 250 300 350 250 315 D2h D4h D7h D8h N250 250 315 350 450 315 355 D2h D4h D7h D8h Table 1 2 FC 302 380 500 V AC Model FC 102 F...

Page 11: ...test board p n 176F8437 Signal test board extension p n 130B3147 Metric socket set 0 28 0 75 in 7 19 mm Socket extensions 3 94 5 91 in 100 150 mm Torx driver set T10 T50 Torque wrench 4 4 168 2 in lbs...

Page 12: ...ze Drives Size Torx Hex Class A Nm in lbs Class B Nm in lbs M4 8 T25 5 7 50 3 1 27 M5 T25 1 7 15 Table 1 6 Torque Values for Thread Cutting into Metal Shaft Size Drives Size Torx Hex Class A Nm in lbs...

Page 13: ...te 10 Gate drive support bracket 3 Power card and mounting plate 11 Capacitor bank 4 Inrush card 12 Balance High frequency card 5 Top fan IP20 only 13 Motor output terminals 6 DC inductor 14 Line powe...

Page 14: ...t bracket 3 Power card and mounting plate 12 Capacitor bank 4 Inrush card 13 Balance High frequency card 5 Inrush card mounting bracket 14 Motor output terminals 6 Top fan IP20 only 15 Line power inpu...

Page 15: ...123 147 147 180 180 218 218 274 274 333 333 407 Continuous kVA at 460 V kVA 127 151 151 191 191 241 241 288 288 353 353 426 Continuous kVA at 500 V kVA 139 165 165 208 208 262 262 313 313 384 384 463...

Page 16: ...719 3622 3561 4558 5703 Weight enclosure IP21 IP54 kg lbs 62 135 125 275 Weight enclosure IP20 kg lbs 62 135 125 275 Efficiency4 0 98 Output frequency 0 800 Hz 0 600 Hz Normal overload 110 current for...

Page 17: ...86 108 108 130 130 154 154 191 191 241 Continuous kVA at 690 V kVA 87 103 103 129 129 157 157 185 185 229 229 289 Max input current Continuous at 550 V A 77 89 89 110 110 130 130 158 158 198 198 245 C...

Page 18: ...400 Max cable size line power motor brake and load share mm2 AWG 2x185 2x350 Max external electrical fuses A 550 Estimated power loss at 575 V W 3012 3723 3642 4465 4146 5028 Estimated power loss at...

Page 19: ...kVA 86 108 130 154 191 241 Continuous kVA at 690 V kVA 103 129 157 185 229 289 Max input current Continuous at 550 V A 89 110 130 158 198 245 Continuous at 575 V A 85 106 124 151 189 234 Continuous at...

Page 20: ...nd load share mm2 AWG 2x185 2x350 mcm Max external electrical fuses A 400 500 550 Estimated power loss at 575 V W 3719 4460 5023 Estimated power loss at 690 V W 3848 4610 5150 Weight enclosure IP21 IP...

Page 21: ...0 N110 N132 N160 N200 N250 N315 N400 FC 103 N75 N90 N110 N132 N160 N200 N250 N315 N400 FC 202 N75 N90 N110 N132 N160 N200 N250 N315 N400 FC 302 N55 N75 N90 N110 N132 N160 N200 N250 N315 Overcurrent Wa...

Page 22: ...le warning reset V DC 413 602 380 480 V units 380 500 V units Overvoltage Warning without brake V DC 778 817 1084 Dynamic Brake Turn On V DC 778 810 1099 Inverter Overvoltage Re Enable warning reset V...

Page 23: ...p isolate a fault condition whether in the adjustable frequency drive or elsewhere Familiarity with the information provided on the display is important Additional diagnostic data can be easily access...

Page 24: ...0 24 Display Line 3 Large has its own scale and number of digits after a possible decimal point Larger numeric values are displayed with few digits after the decimal point Ex Current readout 5 25 A 15...

Page 25: ...elect the mode of display or change back to Display mode from Quick Menu mode Main Menu mode or Alarm mode Press Status to toggle between the three readouts Quick Menu Allows quick set up of the adjus...

Page 26: ...ll active when Hand On is activated Hand On Off Auto On Reset Coasting stop inverse Reversing Set up select lsb Set up select msb Stop command from serial communication Quick stop DC brake NOTICE Exte...

Page 27: ...struction manual Initialize the adjustable frequency drive to default settings in two ways Recommended initialization via 14 22 Operation Mode 1 Select 14 22 Operation Mode 2 Press OK 3 Select Initial...

Page 28: ...start AMA running AMA process is in progress Braking The brake chopper is in operation Generative energy is absorbed by the brake resistor Braking max The brake chopper is in operation The power limi...

Page 29: ...e and to prevent the adjustable frequency drive from tripping PowerUnit Off For adjustable frequency drives with an external 24 V power supply installed only Line power supply to the adjustable freque...

Page 30: ...us values during the 20 most recent events that stopped the adjustable frequency drive and adjustable frequency drive nameplate data The service information is accessed by displaying items in paramete...

Page 31: ...igital signals are a simple binary 0 or 1 which act as a switch A 0 24 V DC signal controls the digital signals A voltage signal lower than 5 V DC is a logic 0 A voltage higher than 10 V DC is a logic...

Page 32: ...hat the control terminal is programmed for the correct function See the Programming Guide for details on changing parameters and the functions available for each control terminal In addition the input...

Page 33: ...s for indicating values such as frequency reference current and torque The analog signal is 0 4 to 20 mA at a maximum of 500 The digital signal is 24 V DC at a minimum of 500 50 10 V DC 15 mA maximum...

Page 34: ...t can disturb the entire system Fitting an equalizing cable next to the control cable will resolve this Minimum cable cross section is 8 AWG 50 60 Hz ground loops When using long control cables 50 60...

Page 35: ...e motor changes The adjustable frequency drive can also stop and start a motor without the mechanical stress associated with a line start In its basic form the adjustable frequency drive can be divide...

Page 36: ...ofile and parameter set It can also be used through its download function in programming other adjustable frequency drives or to restore a program to a repaired unit The LCP is removable during operat...

Page 37: ...Section The high voltage power section consists of AC input and motor output terminals fuses wiring harness AC and DC bus bars and optional components The power section see Figure 3 3 also contains c...

Page 38: ...cifications After a short delay an inrush enable signal is sent from the control card to the inrush card SCR gating circuit The SCRs are automatically gated when forward biased acting similar to an un...

Page 39: ...SCR2 S SCR3 T CBANK 1 C2 C3 96 U 97 V 98 W TB2 89 LS 88 LS TB3 82 R REGEN 81 R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK...

Page 40: ...adjustable frequency drive is powered down Also located in the intermediate section is the high frequency HF filter card It contains a high frequency filter circuit to reduce naturally occurring curr...

Page 41: ...82 R REGEN 81 R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK R...

Page 42: ...form takes on the sine wave shape common to an AC system The rate at which the pulses occur determines the frequency of the waveform By employing a sophisticated control scheme the adjustable frequenc...

Page 43: ...OR C1 SCR1 R L1 DC INDUCTOR SCR2 S SCR3 T CBANK 1 C2 C3 96 U 97 V 98 W TB2 89 LS 88 LS TB3 82 R REGEN 81 R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10...

Page 44: ...to be returned to the DC bus This occurs for example when the load drives the motor causing the voltage to return to the DC bus circuit External placement of the brake resistor has the advantages of...

Page 45: ...R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK RED BLK RED BLK...

Page 46: ...Speed Control The following conditions cause the fans to run at full speed Low IGBT temperature Active DC hold Active DC brake Active dynamic brake circuit Pre magnetization of the motor AMA in progre...

Page 47: ...rs while also saving energy Any number of adjustable frequency drives can be connected in this way as long as they are of the same voltage rating In addition it may be necessary to install DC reactors...

Page 48: ...ooting Servicing an adjustable frequency drive that has been operational for an extended period will be slightly different from a new installation When using proper trouble shooting procedures on a lo...

Page 49: ...of dirt metal chips moisture and corrosion Check for burned or damaged power components or carbon deposits resulting from catastrophic component failure Check for cracks or breaks in the housings of...

Page 50: ...ot Run When this symptom occurs first verify that the unit is properly powered up display is lit and that there are no warning or alarm messages displayed The most common cause is either incorrect con...

Page 51: ...ate Drive Signals Test Motor draws high current but cannot start Possible open winding in the motor or open phase in connection to the motor Perform the chapter 6 4 9 Output Imbalance of Motor Voltage...

Page 52: ...sistor power limit X X 27 Brake chopper fault X X 28 Brake check failed X X 29 Heatsink temp X X X 30 Motor phase U missing X X X 31 Motor phase V missing X X X 32 Motor phase W missing X X X 33 Inrus...

Page 53: ...CSIV corrupt X 82 CSIV parameter error X 90 Encoder loss X X 91 Analog input 54 wrong settings X 92 No Flow X X 93 Dry pump X X 94 End of curve X X 95 Broken belt X X 96 Start delayed X 97 Stop delaye...

Page 54: ...y voltage and supply currents to the adjustable frequency drive WARNING 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent...

Page 55: ...53 or 54 When using digital inputs 18 or 19 check that the thermistor is connected correctly between either terminal 18 or 19 digital input PNP only and terminal 50 Check 1 93 Thermistor Source selec...

Page 56: ...t up Check the sensors on the heatsink and control card WARNING 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning...

Page 57: ...n Table 4 4 is displayed Troubleshooting Cycle power Check that the option is properly installed Check for loose or missing wiring It may be necessary to contact your Danfoss supplier or service depar...

Page 58: ...he specified limit in 1 86 Trip Speed Low RPM except when starting or stopping the adjustable frequency drive will trip ALARM 50 AMA calibration failed Contact your Danfoss supplier or Danfoss Service...

Page 59: ...on is set for alarm Troubleshoot the system and reset the adjustable frequency drive after the fault has been cleared ALARM 94 End of curve Feedback is lower than the setpoint This may indicate leakag...

Page 60: ...al Inspection 2 Perform static test procedures to ensure that adjustable frequency drive is safe to start 3 Disconnect motor leads from output terminals U V W of the adjustable frequency drive 4 Apply...

Page 61: ...1 25 Motor Nominal Speed configure the adjustable frequency drive for the connected motor These parameters are motor power voltage frequency current and rated motor speed Accurate setting of these par...

Page 62: ...ntrol corrects minor but not major discrep ancies between ramp rates For example if a deceleration ramp of 100 seconds is required due to the inertia and the ramp rate is set at 70 seconds the overvol...

Page 63: ...is test with a voltmeter or oscilloscope in accordance with the chapter 6 4 14 Input Terminal Signal Tests If the signal is present at the terminal the control card is defective and must be replaced I...

Page 64: ...on is displayed determine whether this condition actually exists within the adjustable frequency drive or whether the thermal sensor is defective This can easily be detected by touching the outside of...

Page 65: ...magnetic interference EMI related distur bances to adjustable frequency drive operation are uncommon the following detrimental EMI effects sometimes occur Motor speed fluctuations Serial communication...

Page 66: ...The high rate of voltage change caused by the IGBT switching creates high frequency EMI 130BX137 10 AC Line Rectifier DC Bus Inverter Motor Filter reactor IGBT Filter capacitor PWM waveform Sine wave...

Page 67: ...with control signals These currents return to the DC bus via the ground circuit and a high frequency HF bypass network within the adjustable frequency drive itself However imperfections in the adjust...

Page 68: ...4 While these currents tend to travel back to the adjustable frequency drive imperfections in the system cause some current to flow in undesirable paths thus exposing other locations to the EMI 130BX1...

Page 69: ...alternative is to twist the existing single conductors to provide a balanced capacitive and inductive coupling cancelling differential mode interference While not as effective as true twisted pair cab...

Page 70: ...recommendation as closely as possible to alleviate such problems 1 2 3 4 5 6 7 8 PE U V W 9 L1 L2 L3 PE 130BB607 10 10 Figure 5 5 Proper EMC Installation 1 PLC 6 Min 200 mm 7 9 in between control cab...

Page 71: ...atic tests are performed with little or no disassembly The purpose of static testing is to check for shorted power components Perform these tests on any unit suspected of containing faulty power compo...

Page 72: ...the power has been removed before touching any internal components to ensure that the capacitors have fully discharged See the label on the front of the adjustable frequency drive door for exact disch...

Page 73: ...able frequency drive configurations NOTICE For best troubleshooting results perform the static test procedures described in this section in the order presented Diode Drop A diode drop reading varies d...

Page 74: ...DC voltage from DC bus to power card SMPS 10 MK104 Signal test board connector 4 MK106 Brake temperature switch input 11 MK100 Current scaling board connector 5 MK500 Customer terminals for relays 1...

Page 75: ...de drop indicates a correct reading Incorrect reading With the Part III test connection the diodes in the SCR diode modules are forward biased The meter reads the diode drops If a short circuit exists...

Page 76: ...nity is a correct reading The meter may start out at a value and climb toward infinity as capacitance is charged within the adjustable frequency drive Brake IGBT test part II 1 Connect the positive me...

Page 77: ...ce is approximately 5 k Ohms At 32 F 0 C the resistance is approximately 13 7 k At 140 F 60 C the resistance is approximately 1 5 k The higher the temperature the lower the resistance 6 3 7 Gate Resis...

Page 78: ...Test The contactor is optional If present it is located in the option cabinet The contactor uses a customer supplied 230 V AC control signal wired to the contactor coil When power is applied to the co...

Page 79: ...WARNING Do not disconnect the input cabling to the adjustable frequency drive with power applied due to danger of severe injury or death WARNING Before starting the adjustable frequency drive take al...

Page 80: ...ion optional Table 6 3 Legend to Figure 6 4 Whenever possible perform these procedures with a split bus power supply For more information see chapter 8 1 1 Split Bus Power Supply NOTICE Always perform...

Page 81: ...g in an imbalance of 3 Although the adjustable frequency drive can operate at higher line imbalances this will shorten the lifetime of some components such as DC bus capacitors Incorrect reading An in...

Page 82: ...of the signal board With a positive meter lead check the following terminals on the signal board Terminal Supply Voltage Range 11 18 V 16 5 19 5 V DC 12 18 V 16 5 19 5 V DC 23 24 V 23 25 V DC 24 5 V 4...

Page 83: ...following measurements require an oscilloscope with voltage and current probes Under normal operating conditions the waveform of a single phase of input AC voltage to the adjustable frequency drive ap...

Page 84: ...ad If suspect readings are recorded disconnect the motor cables to isolate the problem further 1 Monitor three output phases at adjustable frequency drive motor terminals 96 U 97 V and 98 W with the c...

Page 85: ...ive signal test see chapter 6 4 11 IGBT Gate Drive Signals Test to determine if the gate drive signal is correct 6 4 11 IGBT Gate Drive Signals Test This procedure tests the gate drive signals at the...

Page 86: ...gative to 9 V DC Average voltage read by the voltmeter is 2 2 to 2 5 V DC 130BX503 10 14 13 12 11 10 9 8 7 6 5 4 1 2 3 Figure 6 9 Gate Drive Card 1 MK102 Connection to inrush board 8 MK600 V phase upp...

Page 87: ...en lost before arriving at the gate card The gate signals can then be checked with the signal test board to verify their presence from the control card to the power card as follows 5 Insert the signal...

Page 88: ...displayed exceeds 1 2 A 3 Run the adjustable frequency drive with a zero speed reference Note the output current reading in the display The correct reading on the display is approximately 1 2 A If the...

Page 89: ...5kT7 N55kT7 5 9 N90kT7 N75kT7 5 9 N110T7 N90kT7 5 9 N132T7 N110T7 5 0 N160T7 N132T7 4 0 N200T7 N160T7 3 2 N250T7 N200T7 2 7 N315T7 N250T7 5 6 N400T7 N315T7 5 9 P45kT7 P37kT7 5 9 P55kT7 P45kT7 5 9 P75k...

Page 90: ...ourcing output PNP or a sinking output NPN When programmed for PNP factory default the digital input turns on when 24 V DC is applied to the digital input terminal When programmed for NPN the digital...

Page 91: ...minal 53 or 54 For each analog input the measured DC voltage should match the value shown in the display parameter If the display does not correspond with the measured input and the switch is configur...

Page 92: ...djustable frequency drive and remove input power Allow 20 minutes for DC capacitors to discharge fully 8 Reconnect motor cables to adjustable frequency drive output terminals U V W 9 Reapply power and...

Page 93: ...lectrostatic Discharge ESD ELECTROSTATIC DISCHARGE ESD Many electronic components within the adjustable frequency drive are sensitive to static electricity Voltages so low that they are undetectable c...

Page 94: ...4 Power card mounting plate Table 7 2 Legend to Figure 7 2 1 Remove the control card mounting plate in accordance with chapter 7 3 2 Control Card and Control Card Mounting Plate 2 The power card moun...

Page 95: ...this adjustable frequency drive and is not part of the replacement power card NOTICE Keep this scaling card for future reinstallation of any replacement power card Reinstall in reverse order of this p...

Page 96: ...ove the bus bars Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7 3 6 Line Power Input Terminal Block See Figure 7 4 1 Disc...

Page 97: ...f the adjustable frequency drive 4 Unplug the mixing fan located under the mounting plate Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tigh...

Page 98: ...ree nuts 0 3 in 8 mm 5 Remove one screw T20 NOTICE The screw and one of the nuts also hold in place the DC and DC wire harness Reinstall in reverse order of this procedure and tighten hardware accordi...

Page 99: ...ctors MK100 MK501 MK601 MK701 MK102 4 Remove six screws T20 thread forming Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7...

Page 100: ...il following the same procedure as with the DC 6 Disconnect the gate leads one from each SCR module 7 Remove one screw T30 from either side of each SCR module For reassembly use the replacement SCR in...

Page 101: ...of the adjustable frequency drive 12 Remove the Mylar insulator between the DC plate and the DC and DC center capacitor plate The screws connecting the DC and DC center plates to the capacitors may h...

Page 102: ...bar by removing two screws T30 from each IGBT output bus bar one bus bar per IGBT module 7 Remove the snubber capacitor one from each IGBT module by removing two screws T30 8 Remove the DC plate by r...

Page 103: ...ew T25 from negative terminal of capacitor 3 One round plastic alignment cap 9 Remove the Mylar insulator between the DC plate and the DC plate The screws connecting one of the two DC center plates ma...

Page 104: ...y drive see chapter 7 5 2 Removing the Heatsink Fan with Options Cabinet Present for fan removal instructions 7 3 21 Door Fan IP21 NEMA 1 or IP54 NEMA 12 Enclosures Only 1 Unplug the fan electrical co...

Page 105: ...n hardware according to chapter 1 7 General Torque Tightening Values 7 4 3 Power Card Mounting Plate 1 7 3 9 11 2 4 5 6 8 10 12 130BX449 10 12 Figure 7 12 Power Card and Power Card Mounting Plate 1 Po...

Page 106: ...s procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values When installing the power card ensure that the insulator sheet is installed behind the power card 7 4 5 AC In...

Page 107: ...ower wiring 2 Remove the AC input bus bars in accordance with chapter 7 4 5 AC Input Bus Bars 3 Remove the two screws T25 at the bottom of the terminal block 4 Free current sensor wiring from the capt...

Page 108: ...to Figure 7 14 1 Remove the motor terminal in accordance with chapter 7 4 9 Motor Terminal Block 2 Remove the five screws T25 thread cutting from the top of the plate The fan screw may remain in plac...

Page 109: ...ve the one standoff 0 3 in 8 mm from the corner of the card 4 Remove three nuts 0 3 in 8 mm NOTICE Two of the nuts also hold in place the DC and DC wire harness Reinstall in reverse order of this proc...

Page 110: ...1 13 MK1800 7 MK100 Table 7 17 Legend to Figure 7 17 1 Remove the AC input bus bars or RFI option not shown in accordance with the procedure 2 Brake option only Unplug MK201 3 Unplug connections MK100...

Page 111: ...asten all components hand tight and then place the inrush support to align all before tightening the fasteners 7 4 17 SCRs 1 Remove the SCR input bus bars in accordance with chapter 7 4 16 SCR Input B...

Page 112: ...plate in accordance with chapter 7 4 10 Power Terminal Mounting Plate 3 Remove the 2 screws T40 at the top end of the bus bar one per bus bar 4 From the other end of the bus bar remove the 4 nuts 10 m...

Page 113: ...e with chapter 7 4 14 IGBT Gate Drive Card 2 Remove the balance high frequency card in accordance with chapter 7 4 13 Balance High Frequency Card 3 Remove the DC bus rails in accordance with chapter 7...

Page 114: ...terminals of capacitors 1 2 4 9 and 12 Number of T25 screws varies based on the size of the adjustable frequency drive 8 Remove the insulator between the DC plate and the DC plate The screws connecti...

Page 115: ...he DC plate The screws connecting DC plate and the two DC centre plates to the capacitors may have to be removed to remove the insulator 9 Remove the DC plate by removing 1 standoff 8 mm connecting th...

Page 116: ...hardware according to chapter 1 7 General Torque Tightening Values 7 4 23 Top Fan IP20 Enclosures only 1 Remove two screws T25 2 Slide the fan and bracket forward and pull them out 3 Unplug the inlin...

Page 117: ...s bar one per bus bar 6 Remove 3 screws 17 mm at the top of the bus bar one per bus bar 7 Remove the input jumper bus bars between the main enclosure and the options cabinet by removing 3 screws 17 mm...

Page 118: ...nstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7 5 5 Disconnect 1 Remove the fuses in accordance with chapter 7 5 4 Contactor...

Page 119: ...bus bars one per bus bar 10 Remove the fan access panel by removing six nuts 0 3 in 8 mm from the bottom of the panel 11 Remove the fan in accordance with chapter 7 4 21 Heatsink Fan Reinstall in rev...

Page 120: ...17 mm from below the fuses 3 Remove the contactor to fuse bus bars by removing three nuts 0 7 in 17 mm 4 Remove the contactor coil wires from terminals A1 and A2 5 Remove four bolts 0 5 in 13 mm from...

Page 121: ...back of it is otherwise inaccessible reposition it so that the back is fully accessible 3 Remove the screws 0 1 3 mm internal hex connecting the access panel to the back of the enclosure There are fi...

Page 122: ...lit bus power supply to connector MK902 on the power card 4 Connect the DC bus supply cable from the split bus power supply to the cable that was unplugged from MK902 NOTICE Do not apply AC line volta...

Page 123: ...e are provided in chapter 6 Test Procedures of this manual Other than power supply measurements most of the signals being measured are made up of waveforms Although in some cases a digital voltmeter c...

Page 124: ...MON Logic common This common is for all signals 5 Not used 6 Not used 7 INRUSH Control Card signal Signal from the control card to start gating the SCR front end 3 3 V DC Inrush mode 0 V DC Run mode 8...

Page 125: ...buffered U phase positive Signal originates on the control card 8 00 6 00 4 00 2 00 0 00 V 2 00 4 00 6 00 8 00 4 0ms 50Us Div Input A 130BX153 10 2v div 100us div Run 10 Hz 2 2 2 5 V DC Equal on all p...

Page 126: ...itive Signal originates on control card 8 00 6 00 4 00 2 00 0 00 V 2 00 4 00 6 00 8 00 4 0ms 50Us Div Input A 130BX153 10 2v div 100us div Run 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 30 GWN_T...

Page 127: ...ge 5 Under Configurable Products select the type of unit The unit type is displayed on the product label as well as in the first five digits of the type code T C 6 Under Configure by Type Code or Code...

Page 128: ...Figure 9 3 DC Capacitor Bank Layout See Table 9 1 for Details 130BC568 10 Figure 9 4 DC Capacitor Bank Layout See Table 9 1 for Details 130BC569 10 Figure 9 5 DC Capacitor Bank Layout See Table 9 1 fo...

Page 129: ...e 9 2 for Details 130BC570 10 Figure 9 7 DC Capacitor Bank Layout SeeTable 9 2 for Details Graphic Reference Model FC 102 FC 103 and FC 202 FC 302 Figure 9 2 N75kT7 N55kT7 Figure 9 2 N90kT7 N75kT7 Fig...

Page 130: ...10 Block Diagrams Block Diagrams Service Manual 128 Danfoss A S Rev 2014 02 10 All rights reserved MG94A222 10 10...

Page 131: ...S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED WHT BLK RED 30 PIN MK103 30 PIN MK101 YEL BLK RED BRN YEL...

Page 132: ...57 Fuses 55 G Graphical display 21 I Indicator lights 23 Initialization 25 Input terminal 52 L LCP 25 48 LED 48 LEDs 21 Local control 26 Local Control Panel 24 M Motor current 56 Motor data 53 56 Moto...

Page 133: ...us messages 21 Status mode 26 Stop command 27 Supply voltage 55 Switching frequency 27 V Voltage imbalance 52 W Warning 49 Index Service Manual MG94A222 Danfoss A S Rev 2014 02 10 All rights reserved...

Page 134: ...ime without notice provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser All trademarks in thi...

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