Danfoss VLT FC 103 Service Manual Download Page 45

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130BX500.10

6 10

PCA8

R+

REGEN+

81
R-

REGEN-

TB4

BRAKE IGBT

MODULE

IGBT4

RED

BLK

WHT

RS485

616869

ANALOG INPUTS
394250535455

DIGITAL INPUTS

12131819272932332037

2 1

+ M -

CT1

1 3

RFI PCA6

1 3

HF PCA7

MK1802

K1G1K2G2K3G3

1 4 2 5 3 6

NTC

MK100

1 4 2 5 3 6

IGBT U
MK501

8 4 5 1

IGBT V
MK601

8 4 5 1

IGBT W
MK701

8 4 5 1

BRAKE GATE

MK201

1 6 10 2 7 5

FANS

MK501

CUSTOMER RELAYS

MK500

C NONC C NONC

1 2 3 5 6 7

EMC RELAYS

MK502

4 6 1 3

3 FAN+
4 CTL
1 SENS
2 FAN -

BRAKE TEMP
MK106

1 2 3

CURRENT SENSORS

MK101

1 2

MK300

AUX TEMP

A B

MK901

SPLIT BUS

DC BUS

MK902

1 4

3 FAN+

4 CTL
1 SENS
2 FAN -

1 6 10

PCA8

1 610 5

PCA9

1 2

NTC1

1 610 5

PCA10

1 2

NTC2

1 610 5

PCA11

1 2

NTC3

2 1

+ M -

CT2

+ M -

CT3

A1A2
CONT

TEST CONNECTOR

MK104

30 PIN

3 FAN+

1 SENS
2 FAN -

JUMPER
177G1043

LCP1

DISPLAY

SAFE STOP JUMPER

FC-X02

PCA1

GND

FU1

FU2

FU3

FUSE OPTION

MANUAL

DISCONNECT

CIRCUIT

BREAKER

TB1

CONTACTOR

SCR1

DC INDUCTOR

SCR2

SCR3

CBANK 1

TB2

LS+

LS-

TB3

R+

REGEN+

R-

REGEN-

TB4

A1 RFI

INRUSH PCA4

GATEDRIVE PCA5

BAL/HF

PCA7

POWER CARD PCA2

CBL10

RED

BLK

RED BLK RED BLK RED

WHT BLK

WHT

BLK

WHT BLK

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
BLK

44 PIN

FK102

44 PIN MK102

WHT

BLK

WHT BLK

WHT

BLK

WHT

BLK

RED
BRN

HS FAN

RED

BRN
YEL
BLK

BLK
WHT
RED

SHIELD

RED

WHT

BLK

CURRENT

SCALING

PCA3

WHT

BLK

TOP FAN (IP20)

DOOR FAN

(IP54)

RED
BRN

YEL
BLK

10 PIN

MK1800

BRAKE IGBT

MODULE

IGBT4

RED

BLK

WHT

IGBT1

WHT

BLK

RED

BLK

RED

IGBT2

WHT

BLK

RED

BLK

RED

IGBT3

WHT BLK

BLK

RED

BLK

RED

BLK

RED

BLK

RED

WHT

BLK

RED

WHT

BLK

BLK WHT

GND

HEATER OPTION

CUSTOMER

TERMINAL BLOCK

230VAC 50/60Hz

BLK

WHT

CBL9

CBL8

CBL12

CBL4

CBL3

CBL7

CBL2

CBL1

GND

CUSTOMER

TERMINAL BLOCK

230VAC 50/60Hz

GND

BLK

WHT

GRN/YEL

REC+

REC-

REC+

TB6

TB5

FU4

FU5

FU6

FU7

SW1

SW2

PCA6

BAL. CKT

CBL5

CBL6

CBL11

CBL13

MIXING

FAN

RED

YEL
BLK

RED

CBL14

BLK

WHT

BAL/HF PCA7

T5 130B7184
T7 130B7185

Figure 3.8 Brake Option

Internal Adjustable Frequen...

Service Manual

MG94A222

Summary of Contents for VLT FC 103

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: ...gs 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 2 6 3 Control Power Supply 30 2 7 Control Terminals 30 2 8 Control Terminal Functions 31 2 9 Grounding Shielded Cables 32 3 Internal Adjustable Frequency Drive Operation 33 3 1 General 33 3 2 Descrip...

Page 4: ...ustable 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 61 5 1 4 Programming Problems 61 5 1 5 Motor Load Problems 62 5 2 Internal Adjustable Frequency Drive Problems 62 5 2 1 Overtemperature Faults 62 5 2 2 Current Sensor Faults 62 5 2 3 EMI Signal and Po...

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 Current 82 6 4 10 IGBT Switching Test 83 6 4 11 IGBT Gate Drive Signals Test 83 6 4 12 Current Sensors Test 86 6 4 13 Fan Tests 87 6 4 14 Input Terminal Signal Tests 88 6 5 After Repair Tests 89 7 Disas...

Page 6: ...GBT 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 Fan 102 7 3 21 Door Fan IP21 NEMA 1 or IP54 NEMA 12 Enclosures Only 102 7 3 22 Top Fan IP20 Enclosures Only 102 7 4 D2h D4h Disassembly and Assembly Instructions 103 7 4 1 General Information 103 7 4...

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 Enclosures only 114 7 4 24 Brake IGBT Module 114 7 5 D6h Disassembly and Assembly Instructions 115 7 5 1 Overview 115 7 5 2 Removing the Heatsink Fan with Options Cabinet Present 115 7 5 3 Removing th...

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

Page 9: ...ither 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 IP20 chassis IP21 NEMA 1 and IP54 NEMA 12 enclosures 1 3 For Your Safety 1 3 1 Warnings WARNING Adjustable frequency drives contain dangerous voltages when connected to line power Only a competent tec...

Page 10: ...0 200 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 FC 103 and FC 202 kW 550 V AC HP 575 V AC kW 690 V AC Frame Size N75K 55 75 75 D1h D3h D5h D6h N90K 75 100 90 D1h D3h D5h D6h N110 90 125 110 D1h D3h D5h D6h N132 110 150 132 D1h D3h D5h D6h N160 132 ...

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 0 5 19 Nm Needle nose pliers Magnetic sockets Ratchet Screwdrivers ESD protective mat and wrist strap Introduction Service Manual MG94A222 Danfoss A S Rev 2014 02 10 All rights reserved 9 1 1 ...

Page 12: ...ize 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 Class Bin Nm in lbs M4 T20 2 8 24 2 8 24 M5 T25 5 1 45 4 0 35 Table 1 7 Torque Values for Thread Forming into Plastic Class A Clamping metal Class B Clamping PCA or plastic Optional Equipment Locati...

Page 13: ...ate 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 power input terminals 7 SCR Diode modules 15 Gate drive card 8 IGBT modules 16 optional RFI filter Table 1 9 Legend to Figure 1 1 Introduction Service Manual MG94A222 Danfoss A S Rev 2014 02 10 All right...

Page 14: ...rt 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 input terminals 7 DC inductor 16 Gate drive card 8 SCR Diode modules 17 optional RFI filter 9 IGBT modules Table 1 10 Legend to Figure 1 2 Introduction Service Manual 12 Danfoss A S Rev 2014 02 10 All ri...

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 Max input current Continuous at 400 V A 171 204 204 251 251 304 304 381 381 463 463 567 Continuous at 460 500 V A 154 183 183 231 231 291 291 348 348 427 427 516 Max cable size line power motor brake...

Page 16: ...2719 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 60 s Table 1 12 Line Power Supply 3x380 480 V AC 1 For type of fuse see the Instruction Manual 2 American Wire Gauge 3 Measured using 16 5 ft 5 m shielded motor cables at rated load and rated freque...

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 Continuous at 575 V A 74 85 85 106 106 124 124 151 151 189 189 234 Continuous at 690 V 77 87 87 109 109 128 128 155 155 197 197 240 Max cable size line power motor brake and load share mm2 AWG 2x95 2x...

Page 18: ...2 400 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 690 V W 3123 3851 3771 4614 4258 5155 Weight enclosure IP21 IP54 kg lbs 125 275 Weight enclosure IP20 kg lbs 125 275 Efficiency 0 98 Output frequency 0 590 Hz Heatsink overtemperature trip 230 F 110 ...

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 690 V A 87 109 128 155 197 240 Max cable size line power motor brake and load share mm2 AWG 2x95 2x3 0 2x185 2x350 mcm Max external electrical fuses A 160 315 315 315 350 350 Estimated power loss at...

Page 20: ...and 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 IP54 kg lbs 125 275 Weight enclosure IP20 kg lbs 125 275 Efficiency 0 98 Output frequency 0 590 Hz Heatsink overtemp trip 230 F 110 C Power card ambient trip 167 F 75 C Normal overload 110 current for ...

Page 21: ...90 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 Warning Arms 141 167 209 253 300 372 468 561 666 Overcurrent Alarm1 1 5 s delay Arms 255 255 255 255 330 483 483 585 734 Ground Fault Alarm Arms 11 14 17 21 24 30 38 45 54 Short Circuit Alarm Apk 459 4...

Page 22: ...ble 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 DC 786 821 1099 Overvoltage Warning with brake V DC 810 828 1109 Overvoltage Trip V DC 820 855 1130 Table 1 19 DC Voltage Levels Introduction Service Manual 20 Danfoss A S Rev 2014 02 10 All rights ...

Page 23: ...lp 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 accessed through the LCP 2 2 User Interface 2 2 1 How to Operate the VLT Control Panel LCP 102 The LCP is divided into four functional groups 1 Graphical display with status lines 2 Menu keys and indicator...

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 2 A 105 A Status display I This read out state is standard after start up or initiali zation Press Info to obtain information about the value measurement linked to the displayed operating variables ...

Page 25: ...select 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 adjustable frequency drive The most common functions can be programmed here The Quick Menu consists of My Personal Menu Quick Set up Function Set up Changes Made Loggings The Function set up provides quic...

Page 26: ...ill 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 External stop signals activated with control signals or a serial bus overrides a Start command via the LCP Off Stops the connected motor The key can be selected as 1 Enable or 0 Disable via 0 41 Off Key ...

Page 27: ...nstruction 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 Initialization 4 Press OK 5 Cut off the line power supply and wait until the display turns off 6 Reconnect the line power supply the adjustable frequency drive is now reset 14 22 Operation Mode initializes ...

Page 28: ...o 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 limit for the brake resistor defined in 2 12 Brake Power Limit kW has been reached Coast Coast inverse was selected as a function for a digital input parameter group 5 1 Digital Inputs The corresponding ...

Page 29: ...de 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 frequency drive is removed but the control card is supplied by the external 24 V Protection md Protection mode is active The unit has detected a critical status an overcurrent or overvoltage To avoid tripp...

Page 30: ...tus 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 parameter group 15 Drive Information 130BC283 10 Operating Data 15 04 Over Temp s 0 1 1 15 0 4 2 0 81A Figure 2 14 Parameter Group 15 Menu See the Programming Guide for detailed information on accessing and ...

Page 31: ...Digital 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 1 0 is open 1 is closed Digital inputs to the adjustable frequency drive are switched commands such as start stop reverse coast reset and so on Do not confuse these digital inputs with serial commun...

Page 32: ...that 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 terminal must be receiving a signal Confirm that the control and power sources are wired to the terminal Then check the signal Signals can be checked in two ways To select digital input for display ...

Page 33: ...or indicating values such as frequency reference current and torque The analog signal is 0 4 to 20 mA at a maximum of 500 Ω The digital signal is 24 V DC at a minimum of 500 Ω 50 10 V DC 15 mA maximum analog supply voltage for potentiometer or thermistor 53 54 Selectable for 0 10 V DC voltage input R 10 kΩ or analog signals 0 4 to 20 mA at a maximum of 200 Ω Used for reference or feedback signals ...

Page 34: ...at 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 Hz ground loops may occur that can disturb the entire system Resolve this by connecting one end of the shield with a 100 nF capacitor and keeping the lead short Serial communication control cables Lo...

Page 35: ...he 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 divided into four main sections rectifier intermediate circuit DC bus inverter and control see Figure 3 1 130BX458 11 Power Section Logic to Power Interface Control Logic Figure 3 1 Basic Block Diagram To ...

Page 36: ...rofile 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 operation to prevent undesired program changes With the addition of a remote mounting kit the LCP can be mounted in a remote location of up to 3 m 10 ft away Control terminals with programmable functions a...

Page 37: ...r 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 circuitry for the SCR diode modules in the rectifier the DC bus filter circuitry containing the DC coils often referred to as the intermediate or DC bus circuit and the output IGBT modules which make ...

Page 38: ...ecifications 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 uncontrolled rectifier as a result When the DC bus capacitors are fully charged the voltage on the DC bus equals the peak voltage of the input AC line Theoretically this figure can be calculated by mul...

Page 39: ...R 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 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 BLK 44 PIN FK102 44 PIN MK102 WHT BLK WHT BLK WHT B...

Page 40: ...e 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 currents in the HF range to prevent interference with other sensitive equipment in the area The circuit as with other RFI filter circuitry can be sensitive to unbalanced phase to ground voltages in the t...

Page 41: ...3 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 RED BLK RED BLK RED BLK RED WHT BLK RED 30 PIN MK103 30 PIN MK101 YEL BLK RED BRN YEL BLK 44 PIN FK102 44 PIN MK102 WHT BLK WHT BLK WHT BLK WHT BLK RED BRN HS FAN F2 RED BRN YEL BLK BLK WHT RED BLK WH...

Page 42: ...eform 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 frequency drive delivers a current waveform that nearly replicates a true AC sine wave Hall effect current sensors monitor the output current and deliver proportional signals to the power card where they are...

Page 43: ...TOR 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 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 BLK 44 PIN FK102 44 PIN ...

Page 44: ...y 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 selecting the resistor based on application need dissipating the energy outside of the control panel and protecting the frequency converter from overheating when the brake resistor is overloaded The ...

Page 45: ...1 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 RED BLK RED WHT BLK RED 30 PIN MK103 30 PIN MK101 YEL BLK RED BRN YEL BLK 44 PIN FK102 44 PIN MK102 WHT BLK WHT BLK WHT BLK WHT BLK RED BRN HS FAN F2 RED BRN YEL BLK BLK WHT RED BLK WHT RED BLK WHT ...

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 progress Mixing Fan The mixing fan runs at full speed whenever the adjustable frequency drive has power Heatsink Fan The IGBT temperature and the output current determine the speed of the heatsink fan That...

Page 47: ...ors 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 and DC fuses and line power AC reactors on line power Attempting such a configuration requires detailed considerations Do not attempt without first consulting Danfoss Application Engineering In the ...

Page 48: ...hooting 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 long term installation do not assume that a motor is wired properly possibly overlooking issues such as loose connections improper programming or added equipment It is best to develop a detailed approa...

Page 49: ...e 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 power semiconductors or pieces of broken component housings loose inside the unit EMC considerations Check for proper installation regarding electromagnetic capability Refer to the adjustable frequen...

Page 50: ...not 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 control logic or an incorrectly programmed adjustable frequency drive Such occurrences result in one or more of the following status messages being displayed LCP Stop Action The Off key has been pressed...

Page 51: ...Gate 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 and Current to ensure that the adjustable frequency drive is providing correct output See Motor runs rough Run an AMA to check the motor for open windings and unbalanced resistance Inspect all motor...

Page 52: ...esistor 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 Inrush fault X X 34 Fieldbus communication fault X X 36 Mains failure X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 X 41 Overload of Digital Output Terminal 29...

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 delayed X 98 Clock fault X 104 Mixing Fan Fault X X 100 199 See Instruction Manual for MCO 305 200 Fire mode X 201 Fire mode was active X 202 Fire mode limits exceeded X 243 Brake IGBT X X 244 Heatsink tem...

Page 54: ...ply 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 on the adjustable frequency drive voltage rating The unit is still active WARNING 6 DC link voltage low The intermediate circuit voltage DC is lower than the low voltage warning limit The limit is d...

Page 55: ...l 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 selects terminal 18 or 19 WARNING ALARM 12 Torque limit The torque has exceeded the value in 4 16 Torque Limit Motor Mode or the value in 4 17 Torque Limit Generator Mode 14 25 Trip Delay at Torque Limit ...

Page 56: ...rt 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 can be disabled in 14 53 Fan Monitor 0 Disabled Troubleshooting Check for proper fan operation Cycle power to the adjustable frequency drive and check that the fan operates briefly at start up Check...

Page 57: ...in 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 department Note the code number for further troubleshooting directions No Text 0 Serial port cannot be initialized Contact your Danfoss supplier or Danfoss Service Department 256 258 Power EEPROM data is ...

Page 58: ...the 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 Department ALARM 51 AMA check Unom and Inom The settings for motor voltage motor current and motor power are wrong Check the settings in parameters 1 20 to 1 25 ALARM 52 AMA low Inom The motor curre...

Page 59: ...ion 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 leakage in the system 22 50 End of Curve Function is set for alarm Troubleshoot the system and reset the adjustable frequency drive after the fault has been cleared ALARM 95 Broken belt Torque is below the...

Page 60: ...ual 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 AC power to adjustable frequency drive 5 Give the adjustable frequency drive a run command and slowly increase reference speed command to approximately 40 Hz 6 Using an analog voltmeter or a DVM cap...

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 parameters is crucial Enter the motor data required as listed on the motor nameplate For effective and efficient load control the adjustable frequency drive relies on this information for calculating th...

Page 62: ...ontrol 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 overvoltage control corrects it However with the same inertia if the ramp is set at a larger difference such as three seconds overvoltage control engages initially and then disengages allowing the adjustabl...

Page 63: ...his 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 If the signal is not present the problem is external to the adjustable frequency drive The circuitry providing the signal along with its associated wiring must then be checked 5 1 4 Programming Proble...

Page 64: ...ion 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 the unit to see if the overtemperature condition is still present If not check the temperature sensor with an ohmmeter 5 2 2 Current Sensor Faults An overcurrent alarm that cannot be reset even with...

Page 65: ...omagnetic interference EMI related distur bances to adjustable frequency drive operation are uncommon the following detrimental EMI effects sometimes occur Motor speed fluctuations Serial communication transmission errors Adjustable frequency drive CPU exception faults Unexplained adjustable frequency drive trips A disturbance resulting from other nearby equipment is more common Generally other in...

Page 66: ...I 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 Figure 5 1 Adjustable Frequency Drive Functionality Diagram 5 2 6 EMI Propagation Adjustable frequency drive generated EMI is both conducted to the line power and radiated to nearby conductors See F...

Page 67: ...e 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 adjustable frequency drive grounding or the equipment ground system can cause some of the currents to travel out to the power network 130BX139 11 Motor Cable AC Line VFD Motor Stray capacitance Signal wiri...

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 130BX140 11 Motor Cable AC Line VFD Motor Stray capacitance AC Line Figure 5 4 Alternate Signal Conductor Currents High frequency currents can be coupled into the line power supplying the adjustable freque...

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 cable it can be implemented in the field using the materials on hand Motor Cable Selection The management of the motor conductors has the greatest influence on the EMI characteristics of the system Chec...

Page 70: ...n 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 cables motor and line power 2 Adjustable frequency drive 7 Motor 3 phase and PE 3 Output contactor generally not recommended 8 Line power 3 phase and reinforced PE 4 Ground rail PE 9 Control wiring 5 Ca...

Page 71: ...tatic 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 components before applying power WARNING For dynamic test procedures line input power is required All devices and power supplies connected to line power are energized at rated voltage Use extreme caution ...

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 discharge times Before doing any work ensure the DC bus capacitors have discharged Measure the DC bus using a voltage meter See Figure 6 2 6 3 Static Test Procedures 6 3 1 Pre check Precautions Consider t...

Page 73: ...table 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 depending on the model of ohmmeter Whatever the ohmmeter displays as a typical forward bias diode is defined as a diode drop in these procedures With a typical DVM the voltage drop across most compone...

Page 74: ...2 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 and 2 12 MK102 Control card to power card connection 6 MK501 Heatsink and door top fan control 13 Current scaling 7 MK502 RFI relay control Table 6 2 Legend to Figure 6 3 Test Procedures Service Manu...

Page 75: ...ode 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 it would be possible that the SCR diode modules are shorted Replace the shorted SCR diode module If an open reading occurs replace the open SCR diode module Main rectifier circuit test part IV 1 Rev...

Page 76: ...inity 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 meter lead to the brake resistor terminal 81 R 2 Connect the negative meter lead to the brake resistor terminal 82 R A diode drop indicates a correct reading Brake IGBT test part III 1 Connect the posi...

Page 77: ...ce is approximately 5 k Ohms At 32 F 0 C the resistance is approximately 13 7 kΩ At 140 F 60 C the resistance is approximately 1 5 kΩ The higher the temperature the lower the resistance 6 3 7 Gate Resistor Test Mounted to each IGBT module is an IGBT gate resistor board containing gate resistors for the IGBT transistors In some cases a defective IGBT can still produce good readings in the previous ...

Page 78: ...r 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 contactor coil the contactor is closed When there is no power the contact is open NOTICE Complete testing of the contactor requires an external 230 V AC power supply Contactor Test part I 1 Remove pow...

Page 79: ...y 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 all the necessary safety precautions for system startup Test Procedures Service Manual MG94A222 Danfoss A S Rev 2014 02 10 All rights reserved 77 6 6 ...

Page 80: ...tion 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 static tests chapter 6 3 Static Test Procedures before applying power to the unit Test Procedures Service Manual 78 Danfoss A S Rev 2014 02 10 All rights reserved MG94A222 6 6 ...

Page 81: ...ng 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 incorrect reading here requires further investigation of the main supply Typical items to check would be Open blown input fuses or tripped circuit breakers Open disconnects or line side contactors Prob...

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 75 5 25 V DC Table 6 4 Measured Voltages at Select Terminals In addition the signal test board contains three LED indicators that indicate the presence of voltage as follows Red LED 18 V DC supplies...

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 appears as in Figure 6 5 Figure 6 5 Normal AC Input Voltage Waveform The waveform shown in Figure 6 6 represents the input current waveform for the same phase as Figure 6 5 while the adjustable frequen...

Page 84: ...load 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 clamp on the ammeter An analog device is preferred To achieve an accurate reading run the adjustable frequency drive above 40 Hz which is normally the frequency limitation of such meters A balanced o...

Page 85: ...rive 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 output of the gate drive card just before they are delivered to the IGBTs A simple test to check for the presence of the gate signals can be performed with a voltmeter To check the waveforms more pre...

Page 86: ...egative 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 upper IGBT test point 2 MK101 Gate drive and inrush control signals to the power card 9 MK601 V phase IGBT gate signal 3 MK700 W phase upper IGBT test point 10 MIK602 V phase lower IGBT test point 4 MK7...

Page 87: ...een 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 test board into power card connector MK104 6 With scope probe common connected to terminal 4 common of the signal board measure six gate signals at signal board terminals 25 through 30 7 Place the a...

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 current is greater than 1 2 A and no current producing parameters are active disconnect the motor cables and repeat the test 4 Remove power from the adjustable frequency drive 5 Remove the output mo...

Page 89: ... N75kT7 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 P75kT7 P55kT7 5 9 P90kT7 P75kT7 5 9 P110T7 P90kT7 5 9 P132T7 P110T7 4 5 P160T7 P132T7 3 1 P200T7 P160T7 3 1 P250T7 P200T7 2 6 P315T7 P250T7 5 1 P400T7 P315T7 4 5 P450T7 P355T7 4 5 P500T7 P400T7 3 8 P56...

Page 90: ...sourcing 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 input turns on when the terminal is connected to Signal Common terminal 20 The power for the digital inputs can either come from the 24 V DC built into the adjustable frequency drive or from an exter...

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 configured for voltage the analog input on the control card has failed Replace the control card Check the individual inputs if configured for current Measure the DC voltage as follows 1 Connect the negative m...

Page 92: ...adjustable 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 restart adjustable frequency drive Adjust motor speed to a nominal level 10 Using a clamp on style ammeter measure output current on each output phase All currents must be balanced Test Procedures S...

Page 93: ...Electrostatic 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 can reduce the life affect performance or completely destroy sensitive electronic components CAUTION Use the correct ESD procedures to prevent damage to sensitive components when servicing the adjusta...

Page 94: ...r 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 mounting plate can be removed with the power card still mounted Remove the power card in accordance with chapter 7 3 4 Power Card if necessary 3 To remove the power card mounting plate with the power car...

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 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 See Figure 7 ...

Page 96: ...move 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 Disconnect the customer input power wiring 2 Remove input terminals chapter 7 3 5 AC Input Bus Bars 3 Remove the two screws T25 at the bottom of the terminal block 4 Remove the terminal by sliding it dow...

Page 97: ...of 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 Tightening Values 7 3 9 Current Sensors 1 Remove power terminal mounting plate in accordance with chapter 7 3 8 Power Terminal Mounting Plate 2 Disconnect the wire harness from each current sensor Note w...

Page 98: ...hree 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 according to chapter 1 7 General Torque Tightening Values NOTICE Note the wire cable connections on the UDC and UDC terminals 7 3 12 DC Bus Rails 1 Remove the power card mounting plate in accordance with ch...

Page 99: ...ectors 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 3 15 SCR Input Bus Bars 1 Remove the inrush card in accordance with chapter 7 3 13 Inrush Card 2 Remove three standoffs 0 4 in 11 mm thread forming one on each SCR AC input bus bar 3 Remove the blac...

Page 100: ...oil 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 instructions 7 3 17 Brake IGBT Module 3 4 5 1 2 130BC581 10 Figure 7 8 Brake IGBT module 1 T20 thread forming screws 4 T30 screws 2 T25 thread forming screw 5 Snubber capacitor 3 T25 screws Table 7 8 L...

Page 101: ...e 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 have to be removed to remove the insulator 13 Remove the DC plate by removing Three screws T20 thread forming next to the IGBT modules One standoff 0 3 in 8 mm connecting the plate to the positive ter...

Page 102: ...s 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 removing Three screws T20 thread forming next to the IGBT modules One standoff 0 3 in 8 mm connecting the plate to the negative terminal of capacitor 3 Screws T25 connecting the plate to the negative ...

Page 103: ...rew 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 may have to be removed to remove the insulator 10 Remove the DC plate by removing three screws T20 thread forming next to the IGBT modules and two screws T25 connecting the plate to the positive termin...

Page 104: ...cy 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 connection 2 Remove the door fan by removing four nuts 0 3 in 7 mm using an open ended wrench Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque T...

Page 105: ...en 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 Power card PCA3 7 Plastic standoff 2 Scaling card 8 MK501 3 MK902 9 MK502 4 MK106 10 MK101 5 Power card mounting plate 11 MK103 6 0 3 in 8 mm standoff 12 MK104 Table 7 12 Legend to Figure 7 12 1 Remove...

Page 106: ...is 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 Input Bus Bars 1 4 3 5 6 7 2 8 9 130BX450 10 Figure 7 13 Power Terminals 1 Top 0 5 in 13 mm nut 6 Line power input terminal 2 Brake bus bar optional 7 Fuse spacer 3 Motor terminal bus bar 8 Bottom 0 5 ...

Page 107: ...power 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 captive retaining clips not shown 5 Remove the terminal by sliding it down to disengage it from the metal clips holding it in place Refer to Figure 7 13 Reinstall in reverse order of this procedure and t...

Page 108: ...d 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 place 3 Remove two 0 3 in 8 mm nuts 4 Remove the current sensor signal cables 5 While pulling the plate up unplug the mixing fan located under the mounting plate Reinstall in reverse order of this proced...

Page 109: ...ove 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 procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values NOTICE Note the wire cable connections on the UDC and UDC terminals 2 3 4 5 6 7 8 130BX465 10 1 Figure 7 16 Balanc...

Page 110: ...01 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 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 4 15 Inru...

Page 111: ...Fasten 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 Bus Bars 2 Remove the DC bus bar by removing the three screws T50 one from each SCR module 3 Remove the DC bus bar by removing the one screw T30 and three screws T50 one from each SCR modle 4 Disconne...

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 mm two per bus bar 5 Remove 1 nut 13 mm on the DC bus rail near the center 6 Remove 1 screw T40 from the DC bus rail near the center 7 Remove the IGBT gate drive card in accordance with chapter 7 4 14...

Page 113: ...ce 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 4 18 DC Bus Rails 4 Remove the Mylar cover from the capacitor bank 5 Remove the one screw T20 thread forming from each IGBT output bus bar 6 Remove the IGBT output bus bar by removing two screws T40...

Page 114: ...e 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 connecting DC plate and the DC center plate to the capacitors may have to be removed to remove the insulator 9 Remove the DC plate by removing one standoff 0 3 in 8 mm connecting the plate to the negative te...

Page 115: ...the 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 the plate to the negative terminal of capacitor 2 and screws T25 connecting the plate to the negative terminals of capacitors 1 5 and 6 Number of T25 screws varies based on the size of the frequency co...

Page 116: ...n 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 inline connector not shown Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7 4 24 Brake IGBT Module 1 2 3 4 5 6 7 8 9 130BB817 1...

Page 117: ...us 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 from the top of the bus bars one per bus bar 8 Remove 3 nuts 13 mm from the bottom of the input bus bars one per bus bar 9 Remove the fan access panel by removing 6 nuts 8 mm from the bottom of the ...

Page 118: ...install 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 2 Remove the air baffle by removing two nuts 0 3 in 8 mm 3 Remove the four nuts 0 3 in 8 mm one from each corner to remove the disconnect Reinstall in reverse order of this procedure and tighten hard...

Page 119: ...t 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 reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7 6 3 Removing the Adjustable Frequency Drive from the Options Cabinet NOTICE When removing...

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 the contactor bracket and lift the contactor out Reinstall in reverse order of this procedure and tighten hardware according to chapter 1 7 General Torque Tightening Values 7 6 5 Disconnect 1 Remove ...

Page 121: ...e 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 five or nine screws depending on the size of the adjustable frequency drive Reinstall in reverse order of this procedure and tighten fasteners according to chapter 1 7 General Torque Tightening Values ...

Page 122: ...plit 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 voltage to the adjustable frequency drive when it is wired in split bus mode The power card supply should provide between 610 and 750 V DC of power The Danfoss split bus power supply provides 650 V DC wit...

Page 123: ...re 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 can be used to verify the presence of such signals it cannot be relied upon to verify that the waveform is correct An oscilloscope is the preferred instrument When similar signals are being measured a...

Page 124: ...MMON 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 Not used 9 Not used 10 Not used 11 VPOS 18 V DC regulated supply 16 5 to 19 5 V DC The red LED indicates voltage is present between VPOS and VNEG terminals 18 V DC regulated supply 16 5 to 19 5 V DC...

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 phases TP25 TP30 26 GUN_T IGBT gate signal buffered U phase negative 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 di...

Page 126: ...sitive 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 IGBT gate signal buffered W phase negative 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...

Page 127: ...age 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 No enter the unit P N or T C These are displayed on the product label 7 Select Configure 8 Examine the product description to confirm that it matches the unit as seen in the type code 9 Select Accep...

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 for Details Spare Parts Service Manual 126 Danfoss A S Rev 2014 02 10 All rights reserved MG94A222 9 9 ...

Page 129: ...le 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 Figure 9 2 N110T7 N90kT7 Figure 9 2 N132T7 N110T7 Figure 9 2 N160T7 N132T7 Figure 9 6 N200T7 N160T7 Figure 9 6 N250T7 N200T7 Figure 9 7 N315T7 N250T7 Figure 9 7 N400T7 N315T7 Table 9 2 DC Capacitor Bank...

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 BLK 44 PIN FK102 44 PIN MK102 WHT BLK WHT BLK WHT BLK WHT BLK RED BRN HS FAN F2 RED BRN YEL BLK BLK WHT RED BLK WHT RED BLK WHT RED SHIELD RED WHT BLK CURRENT SCALING PCA3 WHT BLK TOP FAN IP20 DOOR F...

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 Motor power 56 N Navigation keys 26 O Output 46 58 89 Output current 26 53 Output voltage 58 90 Overcurrent 27 Overvoltage 27 P Phase loss 52 Programming 52 Q Quick Menu 23 R Reference 26 27 Remote refer...

Page 133: ...tus 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 131 ...

Page 134: ...time 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 this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved MG94A222 130R0296 MG94A222 Rev 2014 02 10 ...

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