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Danfoss VLT FC Series, Service Manual

Discover the Danfoss VLT FC Series, a robust drive solution enhancing system performance across a variety of industries. Need detailed guidance? Access the free Instructions Manual for seamless setup and operation. Dive into extensive features by downloading the manual directly from manualshive.com. Get your comprehensive guide today!

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Block

D

iag

ram

Name

Spar

e

Par

t

Number

Spar

e 

par

t 

name

Commen

ts

380–480/500

 V

A

C

 (T4/T5)

 

E1h/E3h

E2h/E4h

FC

 102

 (T4)

N355

N400

N450

N500

N560

FC

 103

 (T4)

N355

N400

N450

N500

N560

FC

 202

 (T4)

N355

N400

N450

N500

N560

FC

 302

 (T5)

N315

N355

N400

N450

N500

IGB

T7,8

176F6646

IGB

T 

br

ake

 module

 450A

 E2,E4

Br

ake

 IGB

T 

module

, 1

 per

 k

it

 

–

–

–

2

2

SCR1,2,3

176F6647

Rectifier

 SCR/diode

 700A

MP

 1600V

SCR/diode

, 1

 per

 k

it

 

3

3

3

3

3

 

Capacit

ors

CBANK1

176F6634

Capacit

or

 T5

Individual

 DC

 bus

 capacit

or

, 1

 per

 k

it

 

14

16

16

20

20

C1,2,3,4,5,6

176F8323

IGB

T 

snubber

 cap

 1000V

 1.5UF

IGB

T 

snubber

 cap

, moun

ts

 on

 IGB

T 

modules

 

6

6

6

–

–

C1,2,3,4,5,6

176F3162

IGB

T 

snubber

 cap

 1000V

 1.5uF

 wide

 moun

t

IGB

T 

snubber

 cap

, moun

ts

 on

 IGB

T 

modules

 

–

–

–

6

6

 

Fans

F2

176F6637

Fan,

 heat

 sink

, UL

 12

 P4001

Fan,

 heat

 sink

, high

 speed

, 172X51mm,

 48VDC

 

3

3

3

3

3

F1

176F3167

Top

 fan

 IP20

 DC

 80X38

 48VDC

Fan,

 IP20,

 door

, 80x38mm,

 48VDC

 

2

2

2

2

2

F4

176F6636

Fan,

 top/door

 P4001

 E1h–E4h

D

oor

 fan,

 E1h–E4h,

 120X38mm,

 48VDC

 

2

2

2

2

2

 

Fuses

FU1,2,3

176F6639

Fuse

, main,

 1250A,

 700V

M

ains

 fuse

, 1

 per

 k

it

 

3

3

3

3

3

 

Induc

tors

 and

 C

urr

en

t 

Sensors

C

T1,2,3

176F6633

Cur

ren

t 

sensor

 1000A

LEM

 LF1010-S

-SP

A1,

 1

 per

 k

it

 

3

3

3

3

3

L1

176F6730

DC

 link

 c

oil

 47uH

DC

 induc

tor

 

1

–

–

–

–

L1

176F6731

DC

 link

 c

oil

 42uH

DC

 induc

tor

 

–

1

1

–

–

L1

176F6732

DC

 link

 c

oil

 28uH

DC

 induc

tor

 

–

–

–

1

1

 

D

isc

onnec

ts

SW1

176F6315

Swit

ch,

 disc

,800A,690V

M

ain

 disc

onnec

t

 

1

1

1

–

–

SW1

176F6735

Swit

ch,

 disc

,1200A,690V

M

ain

 disc

onnec

t

 

–

–

–

1

1

SW1

176F9189

D

ouble

 disc

, handle

 &

 rod

 E

 fr

m

 LHD/AAF

D

ouble

 disc

 handle

 &

 12x165

 mm

 shaf

t

 

1

1

1

1

1

 

Cables

CBL1

176F3181

Cable

 L

CP

 to

 c

on

tr

ol

 car

d

 D1h

 D3h

DB9

 e

xt

ension

 cable

 assembly

 

1

1

1

1

1

CBL2

176F3183

Cable

 c

on

tr

ol

 car

d

 to

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w

er

 car

d

 D1H

 D3H

Cable

, c

on

tr

ol

 car

d

 to

 po

w

er

 car

d

 

1

1

1

1

1

CBL3

176F6651

A

ssy

, wir

e,

 CBL3,

 P4001

 ,p

wr

-mixing

, E1

W

ire

 har

ness

, po

w

er

 car

d

 to

 mixing

 fans

 

1

1

1

–

–

CBL3

176F6652

A

ssy

, wir

e,

 CBL3,

 P4001,

 p

wr

-mixing

, E2

W

ire

 har

ness

, po

w

er

 car

d

 to

 mixing

 fans

 

–

–

–

1

1

CBL4

176F6653

A

ssy

, wir

e,

 CBL4,

 P4001,

 p

wr

-C

T,

 E1h

W

ire

 har

ness

, po

w

er

 car

d

 to

 cur

ren

t 

sensors

 

1

1

1

–

–

CBL4

176F6654

A

ssy

, wir

e,

 CBL4,

 P4001,

 p

wr

-C

T,

 E2h

W

ire

 har

ness

, po

w

er

 car

d

 to

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ren

t 

sensors

 

–

–

–

1

1

CBL5

176F6693

A

ssy

, wir

e,

 CBL5,

 P4001,

 DC-p

wr

, E1h

W

ire

 har

ness

, DC

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 fan

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w

er

 supply

 

1

1

1

–

–

CBL5

176F6694

A

ssy

, wir

e,

 CBL5,

 P4001,

 DC-p

wr

, E2h

W

ire

 har

ness

, DC

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 fan

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w

er

 supply

 

–

–

–

1

1

CBL6

176F3790

A

ssy

, wir

e,

 CBL6,

 P4001,

 p

wr

-RFI,

 E1h

W

ire

 har

ness

, po

w

er

 car

d

 to

 HF

 and

 RFI

 

1

1

1

–

–

Spare Parts

Service Guide

MG94A502

Danfoss A/S © 02/2019 All rights reserved.

347

15

15

Summary of Contents for VLT FC Series

Page 1: ...e VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 VLT HVAC Drive FC 102 VLT Refrigeration Drive FC 103 VLT AQUA Drive FC 202 VLT AutomationDrive FC 302 VLT AutomationDrive FC 361 VLT Parallel Driv...

Page 2: ......

Page 3: ...ize Definitions 17 3 6 Product Views 22 3 6 1 Exploded View of D1h D3h D5h D6h J8 Drive 22 3 6 2 Exploded View of D2h D4h D7h D8h J9 Drive 23 3 6 3 Exploded View of Multi Drive System 24 3 6 4 View of...

Page 4: ...49 5 3 3 Inverter Section 52 5 3 4 Brake Option 55 5 3 5 Cooling Fans 57 5 3 6 Fan Speed Control 57 5 3 7 Load Sharing and Regen 58 5 3 8 Specific Power Card Connections 59 6 Troubleshooting 60 6 1 T...

Page 5: ...90 8 2 1 Special Test Equipment 90 8 2 2 Signal Test Board 90 8 2 3 Metering Tools 91 8 3 Test Preparations 91 8 3 1 Preparations for Parallel Drive Systems 92 8 3 2 Access to Testing Connection Point...

Page 6: ...epair Tests 118 8 6 1 After repair Tests for D sized and E sized Drives 119 8 6 2 After repair Tests for Parallel Drive Systems 119 9 Special Test Equipment 120 9 1 Split Bus Power Supply 120 9 1 1 Ov...

Page 7: ...20 Standard DC Capacitors 156 10 2 21 Standard DC Capacitor Bank Layouts 162 10 2 22 Twistlock DC Capacitors 164 10 2 23 Twistlock DC Capacitor Bank Layouts 168 10 2 24 Heat Sink Fan 170 10 2 25 Door...

Page 8: ...30 11 2 25 Heat Sink Fan 232 11 2 26 Door Fan 235 11 2 27 Top Fan 237 11 3 D7h D8h Disassembly and Assembly 240 11 3 1 Removing the Drive from the Extended Options Cabinet 240 11 3 2 Accessing the Hea...

Page 9: ...wer Card Mixing Fan 281 13 2 13 Gate Drive Card Mounting Plate 283 13 2 14 Gate Drive Card 285 13 2 15 Current Sensors 287 13 2 16 Motor Busbar Assembly 289 13 2 17 Balance High Frequency Card 291 13...

Page 10: ...Configurator Tool 323 15 1 2 Spare Parts Lists 323 15 1 3 Recommended Current Scaling Cards 324 16 Block Diagrams 356 Index 362 Contents VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 8 Danfoss...

Page 11: ...5h E6h enclosed drive systems However the drive modules within these enclosed drive systems are based on D3h D4h and E3h E4h drives which are documented in the current manual The VLT Parallel Drive Mo...

Page 12: ...CP Local control panel LED Light emitting diode LOP Local operation pad mA Milliamp MCB Miniature circuit breakers MCO Motion control option MCP Motor control processor MCT Motion control tool MDCIC M...

Page 13: ...d Certifications The following list is a selection of possible type approvals and certifications for Danfoss drives 089 NOTICE The specific approvals and certification for the drive can be found on th...

Page 14: ...iar with the instructions and safety measures described in this manual Authorized personnel are qualified personnel trained by Danfoss to service Danfoss products 2 4 Safety Precautions WARNING HIGH V...

Page 15: ...y can result in death or serious injury Ensure the correct grounding of the equipment by a certified electrical installer WARNING LOAD SHARE DISCONNECT Load share is a connection between DC circuits o...

Page 16: ...ature symbol yellow triangle on the drive can result in serious burns Be aware that internal components such as busbars can be extremely hot even after the drive has been powered off Exterior areas ma...

Page 17: ...ders to create 2 module or 4 module systems NOTICE PARALLEL MODULE CONFIGURATION VLT Parallel Drive Modules have specialized software and hardware configurations that differ from standalone D sized un...

Page 18: ...4 291A 160 kW 250 HP Normal Overload VLT P N 134X5584 S N 000201H345 CAUTION Stored charge wait 30 min Charge residuelle attendez 30 See manual for special condition mains fuse Voir manuel de conditio...

Page 19: ...H D2h D4h Table 3 4 200 240 V AC T2 Voltage Rating for FC 102 FC 103 and FC 202 Power rating Drive type Enclosure size Enclosure size with extended options cabinet Number of drive modules N45K H D1h...

Page 20: ...N560 P6 P8 Db4 4 module system N560 H E2h E4h N630 P2 P4 Da4 4 module system N630 P6 P8 Db4 4 module system N710 P2 P4 Da4 4 module system N710 P6 P8 Db4 4 module system N800 P2 P4 Da4 4 module syste...

Page 21: ...8 Db2 2 module system N400 H E1h E3h N450 P2 P4 Da2 2 module system N450 P6 P8 Db2 2 module system N450 H E2h E4h N500 P2 P4 Da4 4 module system N500 P6 P8 Db4 4 module system N500 H E2h E4h N560 P2 P...

Page 22: ...2 2 module system N500 H E1h E3h N560 P6 Db2 2 module system N560 H E1h E3h N630 P6 Db2 2 module system N630 H E1h E3h N710 P2 Da4 4 module system N710 P6 Db4 4 module system N710 H E2h E4h N800 P2 Da...

Page 23: ...em N355 H E1h E3h N400 P6 Db2 2 module system N400 H E1h E3h N500 P6 Db2 2 module system N500 H E1h E3h N560 P6 Db2 2 module system N560 H E1h E3h N630 P2 Da4 4 module system N630 P6 Db4 4 module syst...

Page 24: ...RFI filter optional 13 Regen load share terminals optional 5 Gate drive card 14 SCR diode modules 6 Gate drive card support bracket 15 Brake IGBT module optional 7 Mains input terminals 16 IGBT modul...

Page 25: ...unting plate 12 Top fan IP20 only 4 Inrush card 13 Inrush card bracket 5 RFI filter optional 14 Regen load share terminals optional 6 Gate drive card 15 SCR diode modules 7 Gate drive card support bra...

Page 26: ...connects to the control shelf via a 44 pin ribbon cable This example also includes an optional busbar kit and optional cooling duct kits 130BF896 10 2 3 5 4 6 1 7 9 8 1 MDCIC behind cover plate 6 Enc...

Page 27: ...gnals to the modules The control card communicates with the MDCIC via a cable 130BE597 11 1 2 3 5 7 8 4 9 11 6 10 12 1 LCP cradle 7 Multi drive control interface card MDCIC 2 LCP control card undernea...

Page 28: ...e connector slot 7 AC fuse 13 IGBT modules 2 Blank cover plate no LCP 8 Mains input terminal 14 Brake terminals optional 3 Mounting plate no control card 9 Balance high frequency card 15 Motor output...

Page 29: ...round terminals 2 MDCIC plug 9 Top fan 3 Microswitch to DC fuse connector 10 Drive module label 4 Relay 1 and 2 connector 11 Motor output terminals inside the unit 5 Brake fault jumper and connector 1...

Page 30: ...mounting plate 16 SCR diode modules 6 Upper input plate 17 IGBT modules 7 RFI filter optional 18 DC capacitor bank 8 AC fuses optional 19 Balance high frequency card 9 Lower input plate 20 Heat sink...

Page 31: ...always include fuses These options are not applicable to parallel drive systems 2 AC fuses are the default configuration for VLT Parallel Drive Modules 3 Regeneration terminals are standard in J8 J9...

Page 32: ...Familiarity with the information provided on the LCP display is important More diagnostic data can be accessed easily through the LCP 4 2 Local Control Panel The local control panel LCP is the combine...

Page 33: ...ses parameter groups or enables an option C5 Moves between items in the menu Table 4 3 LCP Navigation Keys D Indicator lights Indicator lights are used to identify the drive status and to provide a vi...

Page 34: ...4 2 2 3 Q2 Quick Set up The parameters in Q2 Quick Set up are the basic parameters that are always necessary for set up This menu provides the most efficient set up for most applications Perform the u...

Page 35: ...tings To create a back up upload data to the LCP before initialization Refer to chapter 4 2 4 Uploading and Downloading Parameter Settings Restore the default parameter settings by initializing the un...

Page 36: ...set reversing DC brake and other signals applied to the control terminals can override local control Table 4 10 Operating Mode Remote The speed reference is given from External signals Serial communic...

Page 37: ...lected When a stop command for example Stop inverse is activated the voltage selected according to the parameter 1 55 V f Characteristic V is applied to the motor Feedback high The sum of all active f...

Page 38: ...on mode can be restricted in parameter 14 26 Trip Delay at Inverter Fault QStop The motor decelerates using parameter 3 81 Quick Stop Ramp Time 4 Quick stop inverse was selected as a function for a di...

Page 39: ...al communication Trip lock An alarm occurs and the motor stops Once the cause of the alarm is cleared cycle power to the drive Reset the drive manually by Pressing Reset Remotely by control terminals...

Page 40: ...increase or decrease output in relation to the amount of current or voltage For example a sensor or external controller can supply a variable current or voltage The drive output in turn regulates the...

Page 41: ...r to Table 4 13 The setting selected in the parameter enables the function of the terminal It is important to confirm that the control terminal is programmed for the correct function In addition the i...

Page 42: ...Off some units 39 Common for analog and digital outputs 42 Analog and digital outputs for indicating values such as frequency reference current and torque The analog signal is 0 4 to 20 mA at a maximu...

Page 43: ...disturb the entire system Fitting an equalizing cable next to the control cable resolves this issue Minimum cable cross section is 8 36 mm2 8 AWG 50 60 Hz ground loops When using long control cables 5...

Page 44: ...rols the motor speed It can also maintain a constant speed as the load on the motor changes The drive can also stop and start a motor without the mechanical stress associated with a line start In its...

Page 45: ...nverter section Converts the DC voltage into a variable controlled PWM AC output voltage to the motor 7 Motor output Sends output to the motor being controlled 8 Control Monitors input and motor curre...

Page 46: ...terminals Control terminals with programmable functions are provided for input commands such as run stop forward reverse and speed reference Extra output terminals are provided to supply signals to r...

Page 47: ...er section Optional components The inrush circuit controls the firing of the SCRs in the rectifier When power is applied the SCRs limit the charging rate of the DC capacitors Once the capacitors are c...

Page 48: ...alarm voltage low for the DC bus See chapter 14 Product Specifications After a short delay an inrush enable signal is sent from the control card to the inrush card SCR gating circuit The SCRs are aut...

Page 49: ...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 WH...

Page 50: ...D INRUSH CARD PCA4 GATEDRIVE CARD PCA5 INRUSH CARD PCA4 Illustration 5 6 Rectifier Circuit in E sized Drives Internal Drive Operation VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 48 Danfoss A S...

Page 51: ...itors when the drive is powered down The intermediate section also includes the high frequency HF filter card This card contains a high frequency filter circuit to reduce naturally occurring currents...

Page 52: ...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...

Page 53: ...ER CARD PCA2 FAN POWER CARD INRUSH CARD PCA4 GATEDRIVE CARD PCA5 Illustration 5 8 Intermediate Section in E sized Drives Internal Drive Operation Service Guide MG94A502 Danfoss A S 02 2019 All rights...

Page 54: ...at the motor detects also varies The resulting current waveform 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 emplo...

Page 55: ...CR1 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...

Page 56: ...OWER CARD INRUSH CARD PCA4 GATEDRIVE CARD PCA5 Illustration 5 11 Inverter Section in E sized Drives Internal Drive Operation VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 54 Danfoss A S 02 2019...

Page 57: ...of the brake resistor offers multiple advantages Selecting the resistor based on application need Dissipating the energy outside of the control panel Protecting the drive from overheating when the br...

Page 58: ...1 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...

Page 59: ...wered by 48 V DC from a dedicated switch mode power supply on the power card E sized drives in IP00 IP20 enclosures include 2 fans mounted on the top of the drive The top fans are powered from the fan...

Page 60: ...re the fan starts and runs at its minimum speed As the control card temperature increases the fan speed increases When the control card temperature reaches the fan maximum speed temperature the fan is...

Page 61: ...e possible If the input state changes the drive trips issuing alarm 27 Brake Chopper Fault If no such input is used or the normally open configuration is selected a jumper must be installed between te...

Page 62: ...If in doubt consult the factory or authorized repair center for assistance 6 2 Exterior Fault Troubleshooting Servicing a drive that has been operational for an extended period is slightly different f...

Page 63: ...onent housings inside the unit EMC considerations Check for proper installation regarding electromagnetic compatibility EMC Refer to the drive operating instructions and chapter 7 3 Electromagnetic Co...

Page 64: ...ive input terminals check the control wiring Also check that the unit is programmed properly to accept the signal Refer to chapter 8 5 14 Input Terminal Signal Tests Off 1 2 or 3 This message indicate...

Page 65: ...ed Warning messages can be critical but are not necessarily so An alarm indicates that the drive tripped The alarm must be reset to restart operation once its problem is fixed Resetting can be done in...

Page 66: ...External fan fault X 25 Brake resistor short circuit X 26 Brake resistor power limit X X 27 Brake chopper fault X X 28 Brake check failed X X 29 Heat sink temp X X X 30 Motor phase U missing X X X 31...

Page 67: ...73 Safe stop auto restart X X 74 PTC thermistor X 75 Illegal profile sel X 76 Power unit setup X 77 Reduced power mode X 78 Tracking error X X 79 Illegal power section configuration X 80 Drive initial...

Page 68: ...perature X X 248 Illegal power section configuration X X 250 New spare part X 251 New type code X X 421 Temperature fault X 422 FPC communication X X 423 FPC updating X 424 FPC update successful X 425...

Page 69: ...w 18 00040000 262144 Brake overload Brake overload 19 00080000 524288 U phase loss Brake resistor 20 00100000 1048576 V phase loss Brake IGBT 21 00200000 2097152 W phase loss Speed limit 22 00400000 4...

Page 70: ...heck the supply voltage and supply currents to the drive WARNING 5 DC link voltage high The DC link voltage DC is higher than the high voltage warning limit The limit depends on the drive voltage rati...

Page 71: ...tor torque limit is exceeded during ramp up extend the ramp up time If the generator torque limit is exceeded during ramp down extend the ramp down time If torque limit occurs while running increase t...

Page 72: ...compressor in an attempt to lower the discharge temperature The alarm indicates that the discharge temperature exceeds the level programmed in parameter 28 26 Emergency Level WARNING ALARM 20 Temp inp...

Page 73: ...ing the drive trips when the dissipated braking power reaches 100 WARNING ALARM 27 Brake chopper fault The brake transistor is monitored during operation and if a short circuit occurs the brake functi...

Page 74: ...the drive Troubleshooting Remove the power from the drive and check motor phase V ALARM 32 Motor phase W missing Motor phase W between the drive and the motor is missing WARNING HIGH VOLTAGE Drives c...

Page 75: ...slot C1 is too old 1315 The option SW in slot A is not supported not allowed Number Text 1316 The option SW in slot B is not supported not allowed 1317 The option SW in slot C0 is not supported not al...

Page 76: ...an WARNING 47 24 V supply low The supply on the power card is out of range There are 4 supplies generated by the switch mode supply SMPS on the power card 48 V 24 V 5 V 18 V Troubleshooting Check for...

Page 77: ...ed on the temperature sensor in the IGBT module Increase the ambient temperature of the unit Also a trickle amount of current can be supplied to the drive whenever the motor is stopped by setting para...

Page 78: ...out is detected Parameter 14 89 Option Detection is set to 0 Frozen config uration and the option layout has been changed To apply the change enable option layout changes in parameter 14 89 Option Det...

Page 79: ...ETR interpol points freq ALARM 166 ATEX ETR freq lim alarm The drive has operated for more than 60 s in a period of 600 s below the allowed minimum frequency parameter 1 98 ATEX ETR interpol points fr...

Page 80: ...indicates which drive module generated the alarm 1 Left drive module 2 Second drive module from left 3 Third drive module from left in 4 module module systems 4 Fourth drive module from left in 4 mod...

Page 81: ...ve must be reset to stop the alarm ALARM 425 FPC update failure This alarm is generated after the control card failed to update the fan power card PUD Troubleshooting Check the fan power card wiring R...

Page 82: ...output waveform in response to the application demands Parameter 1 29 Automatic Motor Adaptation AMA This parameter activates the automatic motor adaptation AMA function When AMA is performed the driv...

Page 83: ...ad is greater than the commanded speed the overvoltage circuit increases the frequency to match The same restriction on the amount of influence applies The drive adds about 10 to the base speed before...

Page 84: ...areas where programming errors can affect drive and motor operation are Motor settings References and limits I O configuration Refer to chapter 4 6 Drive Inputs and Outputs Set up the drive correctly...

Page 85: ...or becomes defective the output voltage level varies by more than the 15 mV The defective current sensor in that phase indicates current flow when there is none This condition results in the sum of th...

Page 86: ...Diagram 7 3 4 EMI Propagation Drive generated EMI is both conducted to the mains and radiated to nearby conductors Refer to Illustration 7 2 Stray capacitance between the motor conductors equipment g...

Page 87: ...ential 1 Potential 2 Potential 3 Illustration 7 2 Ground Currents AC line Frequency converter Motor cable Motor Stray capacitance 130BX139 12 Signal wiring to BMS Illustration 7 3 Signal Conductor Cur...

Page 88: ...ble Motor Stray capacitance AC line 130BX140 12 Illustration 7 4 Alternate Signal Conductor Currents Drive and Motor Application VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 86 Danfoss A S 02 2...

Page 89: ...acitive and inductive coupling This method cancels differential mode interference While not as effective as true twisted pair cable it can be implemented in the field using the available materials Mot...

Page 90: ...bles and mains cables 13 Common ground busbar Follow local and national requirements for cabinet grounding 5 Mains supply 14 Brake resistor 6 Bare unpainted surface 15 Metal box 7 Star washers 16 Conn...

Page 91: ...Da2 Da4 Db2 Db4 parallel drive systems 20 minutes E1h E4h drives 40 minutes E5h E6h enclosed drive systems 40 minutes Table 8 1 Discharge Time This section contains detailed procedures for testing dri...

Page 92: ...ules 8 2 1 Special Test Equipment Special test tools have been developed to aid in testing VLT FC Series drives The tools are required to perform some of the procedures outlined in this chapter See ch...

Page 93: ...y of the drive Connect the drive to the mains only after completion of static tests Complete all necessary precautions for system start up before applying power to the drive WARNING DISCHARGE TIME The...

Page 94: ...on on testing an individual module after repair and before placing it back into the parallel system refer to chapter 8 6 2 After repair Tests for Parallel Drive Systems 8 3 2 Access to Testing Connect...

Page 95: ...sting and servicing Some connectors are optional and not found on all configurations The printed circuit cards shown include Power card Fan power card Multi drive control interface card MDCIC Gate dri...

Page 96: ...MK102 Control card to power card connection 12 MK106 Brake temperature switch input 5 MK100 Scaling card connector not in parallel drive modules 13 MK500 Customer terminals for relays 1 and 2 6 MK104...

Page 97: ...MK102 Ribbon cable to control card 12 MK106 Brake temperature switch input 5 MK100 Current scaling card connector 13 MK500 Customer terminals for relays 1 and 2 6 MK105 CANBUS connection to fan power...

Page 98: ...K114 Connector to module 4 3 MK108 Connector for current scaling card for module 2 8 MK111 Connector to module 1 4 MK107 Connector for current scaling card for module 1 9 MK112 Connector to module 2 5...

Page 99: ...Inrush card MK110 and power card MK105 2 MK803 Power card signals MK902 5 MK602 Door top fan control 3 Fan power card PCA16 6 MK600 Heat sink fan control Illustration 8 7 Fan Power Card in E sized Dri...

Page 100: ...se lower IGBT test point 4 MK701 W phase IGBT signal 11 MK100 IGBT temperature feedback 5 MK702 W phase lower IGBT test point 12 MK500 U phase upper IGBT test point 6 MK200 Brake IGBT test point optio...

Page 101: ...se IGBT gate signal 2 Gate drive card 6 MK201 Brake IGBT gate signal optional 3 MK501 U phase IGBT gate signal 7 MK701 W phase IGBT signal 4 MK100 IGBT temperature feedback 8 Screw T20 Illustration 8...

Page 102: ...diode module Main rectifier circuit test part II 1 Reverse meter leads by connecting the negative meter lead to the positive DC bus 2 Connect the positive meter lead to L1 L2 and L3 in sequence The c...

Page 103: ...ter leads by connecting the negative meter lead to the negative DC bus 2 Connect the positive meter lead to U V and W in sequence Infinity is the correct reading The meter starts at a low value and sl...

Page 104: ...ke perform the brake IGBT test next The only other likely cause for failure would be a defective capacitor There is not an effective test of the capacitor bank when it is fully assembled It is unlikel...

Page 105: ...e defective replace the entire IGBT module assembly See chapter 10 2 19 IGBTs chapter 11 2 19 IGBTs or chapter 13 2 22 IGBTs 8 4 7 Mains Fuse DC Fuse Test In D1h D8h units optional mains fuses are loc...

Page 106: ...power the contact is open NOTICE POWER REQUIREMENTS Complete testing of the contactor requires an external 230 V AC supply Contactor test part I 1 Remove power to the contactor coil 2 To measure acros...

Page 107: ...to the drive Do not touch energized parts of the drive when connected to mains NOTICE TEST ORDER Test procedures in this section are numbered for reference only Perform dynamic tests in any order and...

Page 108: ...nals Illustration 8 11 Power Terminals in E sized Drives Whenever possible perform these procedures with a split bus power supply For more information see chapter 9 1 1 Overview Test Procedures VLT FC...

Page 109: ...h 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...

Page 110: ...age 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 8 5 Measured Voltages at Select Terminals In addition the signal test board contains 3 LED indica...

Page 111: ...pical of any 6 diode bridge It is the same for drives with SCR diode modules The same waveform is seen when measuring a 12 pulse drive between the rectifier and the transformer 0 0 ms 5 ms Div 130BX14...

Page 112: ...er 1 Monitor 3 output phases at 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 drive above 40 Hz which is normall...

Page 113: ...osed drive systems 20 minutes Da2 Da4 Db2 Db4 parallel drive systems 20 minutes E1h E4h drives 40 minutes E5h E6h enclosed drive systems 40 minutes Table 8 6 Discharge Time To determine whether the IG...

Page 114: ...o chapter 9 1 1 Overview In D sized drives there is a 3 pin test connector on the gate drive card near each gate signal lead Refer to Illustration 8 8 These leads are labeled MK500 MK502 MK600 MK602 M...

Page 115: ...then be checked with the signal test board to verify their presence from the control card to the power card as follows 1 Insert the signal test board into power card connector MK104 2 With scope prob...

Page 116: ...he following parameter settings are disabled Motor check Premagnetizing DC hold DC brake Any others that create a holding torque while at 0 speed 3 Run the drive with a 0 speed reference and check the...

Page 117: ...N160 3 2 N250 N200 2 7 N315 N250 5 6 N400 N315 Table 8 9 Scaling Resistance D1h D8h Units 525 690 V Scaling resistance measured in Model Drive modules FC 102 FC 103 and FC 202 FC 302 4 2 N500 N450 2...

Page 118: ...left input plate mixing fan or power card mixing fan Parameter 43 20 FPC Fan A Speed for left heat sink fan Parameter 43 21 FPC Fan B Speed for the middle heat sink fan Parameter 43 22 FPC Fan C Spee...

Page 119: ...ltage A correct reading is 21 27 V DC If the supply voltage is not present perform the basic control card voltage test See chapter 8 5 3 Basic Control Card Voltage Test Check the individual inputs if...

Page 120: ...sistor to create a voltage drop A 4 mA current flow creates approximately a 0 8 V DC voltage reading A 20 mA current flow creates approximately a 4 0 V DC voltage reading The display shows the mA valu...

Page 121: ...input for each module using the test cable 176F8766 Preferably use a Danfoss split bus power supply 5 Apply power to the split bus power supply and check that the LCP lights properly The fans do not...

Page 122: ...C bus is split into 2 parts One part powers the SMPS on the power card allowing the various logic circuits to be tested without the risk of damaging the power components The other part can be used to...

Page 123: ...e Drive SMPS POWER CARD Split Bus Connector MK901 SERVICE KIT CONTROL CARD MDCIC 650 V DC 24 V DC DC Bus Connector MK902 130BF086 10 SPLIT BUS POWER SUPPLY 130B4146 MK 111 MK102 A C 44 Pin Ribbon Cabl...

Page 124: ...ned to provide 650 V DC which is compatible with 400 V AC and 690 V AC drives 6 Reinstall the control card mounting plate 7 Apply the voltage to the unit The LCP indicator lights illuminate as if the...

Page 125: ...ive Control Interface Card SLOT FOR 24 V DC BACKUP 1 2 43 44 CURRENT SCALING CARD INV1 130BF083 10 1 2 MK106 Illustration 9 5 Service Kit Internal Connection Diagram Because the control card and curre...

Page 126: ...ng to EEPROM 12 Power cycle the drive module The module is initialized in standalone mode and is ready for testing as described in chapter 8 Test Procedures Running a parallel drive module in standalo...

Page 127: ...vice Kit Troubleshooting If alarm 240 Illegal PS config error appears verify that the correct current scaling card is placed in the parallel drive module If alarm 14 short circuit appears check that t...

Page 128: ...nsed U phase not conditioned 2000 0 1500 0 1000 0 500 0 0 0 mV 500 0 1000 0 1500 0 2000 0 200 ms 1 ms Div Input A 130BX148 10 Approximately 400 mV RMS at 100 load 0 937 V ACpeak at 165 of CT current r...

Page 129: ...ortional to UDC 0 V switch must be off 1 V DC 250 V DC 23 VDD 24 V DC power supply Yellow LED indicates that voltage is present 24 V DC regulated supply 23 25 V DC 24 VCC 5 0 V DC regulated supply 4 7...

Page 130: ...v Run at 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 29 GWP_T IGBT gate signal buffered W phase positive 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 50U...

Page 131: ...pair work use an appropriate voltage measuring device to make sure that the capacitors are fully discharged For parallel drive modules measure DC bus capacitor voltages before and after the individual...

Page 132: ...te The control card and control terminals can remain attached when the control card mounting plate is removed from the drive To remove or reinstall the control card mounting plate use the following st...

Page 133: ...nel 4 Screw T20 2 LCP cradle 5 Power card 3 Control card mounting plate 6 Power card mounting plate Illustration 10 1 Control Card Mounting Plate D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Dan...

Page 134: ...of the mounting plate 4 Remove 1 screw T25 from the top center of the mounting plate 5 Free the cables from the retaining clips on the plate 6 Lift the power card mounting plate from the drive Reasse...

Page 135: ...ower card PCA3 3 Power card mounting plate 2 Screw T20 4 Cable retaining clip Illustration 10 2 Power Card Mounting Plate D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019 All rig...

Page 136: ...p of the plastic standoff NOTICE PARTS REUSE Replacement power cards do not include a current scaling card Keep the current scaling card for future installation with any replacement power card Reassem...

Page 137: ...4 MK102 Control card to power card connection 12 MK106 Brake temperature switch input 5 MK100 Current scaling card connector not in parallel drive modules 13 MK500 Customer terminals for relays 1 and...

Page 138: ...ener Torque Ratings 10 2 5 2 AC Fuses Only 1 Remove AC fuses by removing 6 nuts 13 mm 1 at each end of 3 fuses 2 Remove 3 nuts 10 mm at the top of the AC input busbars 1 per phase 3 Remove the AC inpu...

Page 139: ...dle 7 Top fan IP20 3 Control terminals 8 Screw T25 4 Nut 10 mm 9 Control card mounting plate 5 AC input busbars 10 Screw T20 Illustration 10 5 AC Input Busbars and Power Terminals D1h D3h D5h D6h J8 D...

Page 140: ...clips on the mounting plate It can be necessary to remove 1 screw T25 from the EMC shield when removing the terminal block Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings...

Page 141: ...17 Screw 6 EMC shield 18 Screw 7 U V W terminal label 19 Cylinder busbar 8 Motor terminal block 20 Nomex tube 9 Power terminal mounting plate 21 Current sensor 10 Nut 22 Thread forming screw 11 Mixin...

Page 142: ...enter of each current sensor Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Position the motor terminal block by sliding it upward under the 2 metal retaining clips 2...

Page 143: ...screw T40 5 Reconnect the brake wiring 10 2 9 Power Terminal Mounting Plate To remove or reinstall the power terminal mounting plate use the following steps Refer to Illustration 10 6 and Illustratio...

Page 144: ...le connector Tape the free end of the fan cable to the mounting plate so that it does not fall back into the drive 3 Remove the mixing fan from the fan housing Reassembly 1 Connect the fan cable to th...

Page 145: ...ease tab 4 Power terminal mounting plate 2 Cable connector 5 Cable access hole 3 Mixing fan 6 Mixing fan slot Illustration 10 7 Mixing Fan D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A...

Page 146: ...outer 2 current sensors at the top of the power terminal mounting plate with the current sensor base against the plate 2 Invert the middle current sensor so that the wider base is at the top 3 Align t...

Page 147: ...3 Thread forming screw T20 2 Outer current sensor upright position 4 Power terminal mounting plate IP20 Chassis Illustration 10 8 Current Sensors in D3h Drive D1h D3h D5h D6h J8 Drive Di Service Guid...

Page 148: ...card 5 Replace the power terminal mounting plate Refer to chapter 10 2 9 Power Terminal Mounting Plate Disassembly in 690 V AC units 1 Remove the power terminal mounting plate Refer to chapter 11 2 11...

Page 149: ...the DC bus rails 1 per bus rail 6 Lift the DC bus rails from the drive Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Position the DC bus rails in the drive 2 Secure 2...

Page 150: ...e inrush card 4 Remove the inrush card from the drive Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Position the inrush card in the drive 2 Fasten 5 screws T20 in the...

Page 151: ...Screw T30 4 Inrush support bracket 10 DC busbar 5 Threaded standoff 11 mm 11 DC busbar DC coil to capacitor bank 6 DC busbar DC coil to capacitor bank Illustration 10 9 DC Bus Rails and Inrush Card D...

Page 152: ...busbar 3 Fasten 2 screws T25 in the black plastic inrush support 4 Secure 3 standoffs 11 mm 1 in each SCR input busbar 5 Replace the inrush card Refer to chapter 10 2 14 Inrush Card 10 2 16 SCRs To r...

Page 153: ...module 1 of 3 4 Screw T30 12 IGBT gate signal connector 5 Screw T30 13 IGBT thermal sensor connector 6 Current sensor cylinder busbar 14 Snubber capacitor 7 Cyclinder busbar support bracket 15 Screw T...

Page 154: ...ake IGBT module use the following steps Refer to Illustration 10 11 Disassembly 1 Remove the gate drive card Refer to chapter 10 2 17 Gate Drive Card 2 Remove the mains input terminal block Refer to c...

Page 155: ...forming screws T20 4 Thread forming screw T25 2 Snubber capacitor 5 Screws T25 3 Screws T30 Illustration 10 11 Brake IGBT Module D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019...

Page 156: ...shown by removing 4 screws T25 15 Remove the IGBTs by removing 4 screws T25 from each IGBT Disassembly in 690 V AC units 1 Remove the gate drive card Refer to chapter 10 2 17 Gate Drive Card 2 Remove...

Page 157: ...module 1 of 3 4 Screw T30 12 IGBT gate signal connector 5 Screw T30 13 IGBT thermal sensor connector 6 Current sensor cylinder busbar 14 Snubber capacitor 7 Cylinder busbar support bracket 15 Screw T3...

Page 158: ...nder busbar support bracket and remove the bracket from the drive 5 Remove 3 thread forming screws T25 1 from the top of each IGBT output busbar 6 Remove 6 screws T30 2 from the top of each IGBT outpu...

Page 159: ...Fasten 2 screws T25 Number of screws may vary based on drive size 5 Replace insulator sheet 2 6 To replace the DC plate 6a Fasten 3 thread forming screws T20 6b Secure 1 standoff 8 mm 6c Fasten 2 scr...

Page 160: ...C plate 3 DC plate 7 Capacitor locking panel 4 Insulator sheet 2 8 Standard DC capacitor Illustration 10 13 Standard DC Capacitor Bank 240 400 V AC Unit D1h D3h D5h D6h J8 Drive Di VLT FC Series D1h D...

Page 161: ...orming screws T25 15 Lift the standard DC capacitors from the capacitor bank housing Reassembly in 690 V AC units Tighten hardware according to chapter 14 1 Fastener Torque Ratings NOTICE For correct...

Page 162: ...place the gate drive card Refer to chapter 10 2 17 Gate Drive Card D1h D3h D5h D6h J8 Drive Di VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 160 Danfoss A S 02 2019 All rights reserved MG94A502...

Page 163: ...Insulator sheet 3 3 Midplate 1 9 Midplate 2 4 Insulator sheet 1 10 Capacitor locking panel 5 DC plate 11 Standard DC capacitors 6 Plastic alignment cap Illustration 10 14 DC Capacitors 690 V AC Unit D...

Page 164: ...Graphic reference Model FC 102 FC 103 and FC 202 FC 302 Illustration 10 16 N110 N90K Illustration 10 17 N132 N110 Illustration 10 17 N160 N132 Table 10 3 Standard DC Capacitor Bank Layout 380 480 500...

Page 165: ...llustration 10 16 Standard 4 Capacitor Layout e30bc566 10 1 2 2 3 4 4 4 4 4 5 6 6 1 DC plate standoff 2 DC plate screw 3 Midplate standoff 4 Midplate screw 5 DC plate standoff 6 DC plate screw Table 1...

Page 166: ...ng screws T20 near the IGBT modules 11 Remove the midplate by removing 1 standoff 8 mm 12 Remove insulator sheet 3 13 To remove a twistlock DC capacitor use the special tool provided in the parts kit...

Page 167: ...Midplate 9 Twistlock DC capacitor 4 DC plate 10 O ring gasket 5 Insulator sheet 1 11 Capacitor housing 6 Insulator sheet 2 12 Housing gasket Illustration 10 18 Twistlock DC Capacitor Bank 240 400 V A...

Page 168: ...0 V AC units Start all fasteners with hand tightening and then torque according to chapter 14 1 Fastener Torque Ratings 1 Align the arrow on the rim of the twistlock DC capacitor with the arrow on the...

Page 169: ...10 Capacitor locking panel 4 DC plate 11 O ring gasket 5 Midplate 1 12 Twistlock DC capacitor 6 Insulator sheet 1 13 Capacitor bank housing 7 Insulator sheet 2 14 Capacitor bank gasket Illustration 10...

Page 170: ...ustration 10 22 N75K N55K Table 10 7 Twistlock DC Capacitor Bank Layout 200 240 V Graphic reference Model FC 102 FC 103 and FC 202 FC 302 Illustration 10 21 N110 N90K Illustration 10 22 N132 N110 Illu...

Page 171: ...0 Illustration 10 21 Twistlock 4 Capacitor Layout e30bg899 10 Illustration 10 22 Twistlock 6 Capacitor Layout D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019 All rights reserved...

Page 172: ...ve The heat sink fan cable is still connected 4 Squeeze together the top portion of the black rubber cable grommet until it pops through the hole releasing the heat sink fan cable 5 Disconnect the hea...

Page 173: ...screws T25 4 Nut T25 2 Threaded stud 5 Telescoping duct 3 Duct flange 6 Heat sink fan cover Illustration 10 23 Heat Sink Fan Access with Telescoping Cooling Duct D1h D3h D5h D6h J8 Drive Di Service Gu...

Page 174: ...or cable grommet 8 Cable grommet 4 Slots for heat sink fan cover 9 Heat sink fan cover 5 Mounting holes 10 Fan cover tabs Illustration 10 24 Heat Sink Fan in IP21 IP54 UL type 1 12 Drives D1h D3h D5h...

Page 175: ...position the door fan so that the air direction arrow points away from the internal drive components when the door is closed Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Rati...

Page 176: ...nnector 6 Door fan 3 Nut 7 mm 7 Hole for corner post 4 Door fan guard 8 Corner post Illustration 10 26 Interior View of Door Fan Assembly D1h D3h D5h D6h J8 Drive Di VLT FC Series D1h D8h Da2 Db2 Da4...

Page 177: ...n from the drive Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Feed the top fan cable through the cable access hole on the top of the drive 2 Reconnect the in line fa...

Page 178: ...le and connector 2 Screw T25 5 Retaining clip 3 Top fan 6 Cable access hole Illustration 10 27 Top Fan with Housing D1h D3h D5h D6h J8 Drive Di VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 176...

Page 179: ...T25 4 Top fan cable and connector 2 Top fan grill 5 Top vent 3 Top fan 6 Cable access hole Illustration 10 28 Top Fan with Grill D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019...

Page 180: ...ng the following steps In drives with different option configu rations the busbars can vary slightly from the illustrations Disassembly 1 Remove the air baffle covering the interior components 2 Remov...

Page 181: ...n 10 31 5a Remove 3 nuts 13 mm at the bottom of the motor jumper busbars 1 per busbar 5b Remove 3 screws 17 mm from the top of the motor jumper busbars 1 per busbar e30bg414 10 3 4 5 1 2 1 Nut 8 mm 2...

Page 182: ...ars motor jumper busbars and optional brake jumper busbars Refer to chapter 10 2 D1h D3h D5h D6h J8 Disassembly and Assembly 2 To remove the ground tie plate 2a Remove 3 nuts 13 mm at the top of the p...

Page 183: ...wall fastener 3 Heat sink fan access panel 2 Extended options cabinet to drive fastener Illustration 10 32 Extended Options Cabinet Exploded View D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Da...

Page 184: ...ten hardware according to chapter 14 1 Fastener Torque Ratings 10 3 4 Disconnect To remove or reinstall the disconnect use the following steps Refer to Illustration 10 33 Disassembly 1 Remove the fuse...

Page 185: ...ontactor 3 Contactor bracket 2 Disconnect 4 A1 A2 contactor coil terminals Illustration 10 33 D6h Contactor and Disconnect D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019 All ri...

Page 186: ...connecting the access panel to the back of the enclosure There are 5 or 9 screws depending on the size of the drive Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Do...

Page 187: ...30BF880 10 1 2 1 Heat sink access panel 2 Drive enclosure Illustration 10 34 Heat Sink Access Panel D1h D3h D5h D6h J8 Drive Di Service Guide MG94A502 Danfoss A S 02 2019 All rights reserved 185 10 10...

Page 188: ...ropriate voltage measuring device to make sure that the capacitors are fully discharged For parallel drive modules measure DC bus capacitor voltages before and after the individual DC fuses Enclosure...

Page 189: ...l Description D2h drive Standard drive in an IP21 IP54 UL type 1 12 enclosure D4h drive Similar to D2h but IP20 Chassis drive with no enclosure D7h drive Similar to D2h drive but with extended options...

Page 190: ...f the control card mounting plate 5 Unplug the ribbon cable connecting the control card and the power card Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position the...

Page 191: ...card mounting plate 2 LCP cradle 5 Top fan 3 Control terminals 6 Screw T25 Illustration 11 1 Control Card and Control Card Mounting Plate D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A...

Page 192: ...hten hardware according to chapter 14 1 Fastener Torque Ratings 11 2 4 Power Card To remove or reinstall the power card use the following steps Refer to Illustration 11 2 NOTICE PARTS REUSE A current...

Page 193: ...d PCA3 8 MK902 3 MK104 9 MK106 4 MK101 10 Power card mounting plate 5 MK103 11 Standoff 8 mm 6 MK502 12 Plastic standoff Illustration 11 2 Power Card and Power Card Mounting Plate D2h D4h D7h D8h J9 U...

Page 194: ...ut busbars from the drive module RFI filter only 1 Remove 3 nuts 13 mm at the top of the RFI filter 1 per bus phase 2 Remove 6 nuts 13 mm at the bottom of the RFI filter 2 per bus phase 3 Remove 4 thr...

Page 195: ...Brake busbar optional 3 Bottom nut 13 mm 8 U motor busbar 4 Fuse spacer 9 Brake terminal optional 5 Mains input terminal 10 Motor terminal block Illustration 11 3 AC Input Busbars and Power Terminals...

Page 196: ...wnward to disengage it from the 2 metal retaining clips holding it in place Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position the mains input terminal block on...

Page 197: ...2 Cylinder busbar 5 Machine screw 14 EMC shield 23 Nomex tube 6 U V W terminal label 15 Plastic mounting button 24 Current sensor 7 Motor terminal block 16 Busbar insulator sleeve 25 Thread forming sc...

Page 198: ...rminal 2a Remove 1 thread forming screw T25 from the terminal block 2b Remove 1 screw T40 3 To remove the R terminal 3a Remove 1 thread forming screw T25 from the terminal block 3b Remove 1 nut 13 mm...

Page 199: ...ng to chapter 14 1 Fastener Torque Ratings 1 Position the output terminal block by sliding it upward under the 2 metal retaining clips on the power terminal mounting plate 2 Fasten 2 machine screws T2...

Page 200: ...le connector Tape the free end of the fan cable to the mounting plate so that it does not fall back into the drive 3 Remove the mixing fan from the fan housing Reassembly 1 Connect the fan cable to th...

Page 201: ...ease tab 4 Power terminal mounting plate 2 Cable connector 5 Cable access hole 3 Mixing fan 6 Mixing fan slot Illustration 11 5 Mixing Fan D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A...

Page 202: ...of the power terminal mounting plate 4 Remove the power terminal mounting plate from the unit Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position the power termi...

Page 203: ...T20 2 from each of the 3 current sensors 4 Remove the current sensors from the unit Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position 3 current sensors on top o...

Page 204: ...6 Mounting hole 3 Current sensor cable connector 7 Wire guide 4 Mounting hole 8 Cable clip Illustration 11 6 D2h Power Terminal Mounting Plate and Current Sensors D2h D4h D7h D8h J9 Unit Dis VLT FC S...

Page 205: ...frequency card 5 Replace the power terminal mounting plate Refer to chapter 11 2 11 Power Terminal Mounting Plate Disassembly in 690 V AC units 1 Remove the power terminal mounting plate Refer to chap...

Page 206: ...3 DC capacitor plate 7 Capacitor locking panel 4 Insulator sheet 8 DC capacitor Illustration 11 7 Balance High Frequency Card and DC Capacitor Bank 240 400 V unit shown 690 V unit is similar D2h D4h D...

Page 207: ...ing screws T20 from the gate drive card Remove the card from the unit Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Position the gate drive card in the unit 2 Fasten...

Page 208: ...ew T20 3 Screw T20 9 MK101 4 MK102 10 Gate drive card 5 MK100 11 MK701 6 MK501 12 MK601 Illustration 11 8 Gate Drive Card and Inrush Card D2h D4h D7h D8h J9 Unit Dis VLT FC Series D1h D8h Da2 Db2 Da4...

Page 209: ...screws T20 from the inrush card 5 Remove the inrush card from the unit Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Position the inrush card in the drive 2 Secure 5...

Page 210: ...ew T20 3 Screw T20 9 MK101 4 MK102 10 Gate drive card 5 MK100 11 MK701 6 MK501 12 MK601 Illustration 11 9 Inrush Card and Gate Drive Card D2h D4h D7h D8h J9 Unit Dis VLT FC Series D1h D8h Da2 Db2 Da4...

Page 211: ...g the busbars to the SCR modules 1 for each SCR input busbar 3 Fasten 2 standoffs 16 mm in the inrush card support bracket 4 Secure 2 screws T20 in the middle of the inrush card support bracket 5 Repl...

Page 212: ...T30 3 DC busbar 9 Gate lead 4 DC busbar 10 Screw T50 5 SCR input busbar 11 SCR 6 Standoff 16 mm 12 Standoff 19 mm Illustration 11 10 SCRs and SCR Input Busbars D2h D4h D7h D8h J9 Unit Dis VLT FC Serie...

Page 213: ...hardware according to chapter 14 1 Fastener Torque Ratings 1 Secure 2 screws T40 at the top end of the DC bus rails 1 per bus rail 2 Fasten 4 nuts 10 mm at the lower end of the DC bus rails 2 per bus...

Page 214: ...7 Remove the gate drive card Refer to chapter 11 2 14 Gate Drive Card Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Replace the gate drive card Refer to chapter 11 2...

Page 215: ...bus rail 4 IGBT cable 2 Gate drive card 5 DC bus rail 3 Nut 13 mm 6 Screw T40 Illustration 11 12 DC Bus Rails with Brake Option D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A S 02 2019 A...

Page 216: ...the IGBTs by removing 10 screws T25 from each IGBT module Disassembly in 690 V AC units 1 Remove the gate drive card Refer to chapter 11 2 14 Gate Drive Card 2 Remove the balance high frequency card R...

Page 217: ...T20 7 IGBT output busbar 3 IGBT output busbar 8 IGBT terminal screw T40 4 Snubber capacitor 9 IGBT screw T25 5 Nut 8 mm 10 DC bus rail Illustration 11 13 IGBT Modules D2h D4h D7h D8h J9 Unit Dis Serv...

Page 218: ...rminal of capacitor 3 7b Screws T25 connecting the plate to the positive terminals of capacitors 1 2 4 9 and 12 The number of T25 screws varies based on the size of the drive 8 Remove the insulator be...

Page 219: ...7 Insulator sheet 3 Screw T25 8 DC center capacitor plate 4 DC plate 9 Capacitor locking plate 5 Insulator sheet 10 Standard DC capacitor Illustration 11 14 Standard DC Capacitors 400 V AC Unit D2h D...

Page 220: ...ate to the negative terminals of capacitors 1 5 and 6 The number of screws T25 varies based on the size of the drive 10 Remove the insulator sheet between the DC plate and the 2 DC center plates If ne...

Page 221: ...citor bank cover 7 DC center plates 3 DC plate 8 Capacitor locking panel 4 Insulator sheet 9 Standard DC capacitors 5 DC plate Illustration 11 15 Standard DC Capacitors 690 V AC Unit D2h D4h D7h D8h J...

Page 222: ...ate they secure Graphic reference Model FC 102 FC 103 and FC 202 FC 302 Illustration 11 17 N200 N160 Illustration 11 18 N250 N200 Illustration 11 19 N315 N250 Table 11 3 Standard DC Capacitor Bank Lay...

Page 223: ...Standard DC Cap Bank with 8 Capacitor Layout e30bc568 10 2 1 2 2 4 4 3 4 4 4 4 4 8 8 7 8 4 2 8 4 1 DC plate standoff 2 DC plate screw 3 Midplate 1 standoff 4 Midplate 1 screw 5 Midplate 2 standoff 6 M...

Page 224: ...DC Cap Bank with 12 Capacitor Layout e30bc570 10 2 4 4 6 6 7 6 8 2 4 3 6 5 8 2 4 4 6 1 DC plate standoff 2 DC plate screw 3 Midplate 1 standoff 4 Midplate 1 screw 5 Midplate 2 standoff 6 Midplate 2 sc...

Page 225: ...te screw 3 Midplate 1 standoff 4 Midplate 1 screw 5 Midplate 2 standoff 6 Midplate 2 screw 7 DC plate standoff 8 DC plate screw Illustration 11 21 Standard DC Cap Bank 12 Capacitor Layout D2h D4h D7h...

Page 226: ...r of screws varies based on the size of the drive 8 Remove insulator sheet 2 from between the DC plate and the DC plate If necessary first remove the screws connecting the DC plate and the midplate to...

Page 227: ...cking plate 3 Midplate 9 Capacitor gasket 4 DC plate 10 Plug 5 Insulator sheet 1 11 Twistlock DC capacitor 6 Insulator sheet 2 12 Capacitor bank housing Illustration 11 22 DC Twistlock Capacitors 240...

Page 228: ...plate and the 2 midplates If necessary first remove the screws connecting the 2 midplates to the capacitors 11 To remove midplate 1 11a Remove 1 standoff 8 mm connecting midplate 1 to the positive te...

Page 229: ...e 1 10 Capacitor locking panel 4 DC plate 11 O ring gasket 5 Standoff 12 Plug 6 Insulator sheet 1 13 Twistlock DC capacitor 7 Insulator sheet 2 14 Capacitor bank housing Illustration 11 23 Twistlock D...

Page 230: ...e 11 5 Twistlock DC Capacitor Bank Layout 200 240 V Graphic reference Model FC 102 FC 103 and FC 202 FC 302 Illustration 11 25 N200 N160 Illustration 11 26 N250 N200 Illustration 11 27 N315 N250 Table...

Page 231: ...Illustration 11 27 Twistlock 12 Capacitor Layout e30bg903 10 Illustration 11 28 Twistlock 9 Capacitor Layout e30bg904 10 Illustration 11 29 Twistlock 12 Capacitor Layout D2h D4h D7h D8h J9 Unit Dis S...

Page 232: ...ails 3 Remove the snubber capacitor and 3 busbars from the brake IGBT module by removing 3 screws T40 4 Remove the insulator shield by removing 2 plastic standoffs 5 Remove the SCR input busbars See c...

Page 233: ...to brake IGBT busbar 3 Gate drive card 8 Brake IGBT module 4 Insulator shield 9 DC to brake IGBT busbar 5 Brake IGBT output to R terminal busbar Illustration 11 30 Brake IGBT Module D2h D4h D7h D8h J9...

Page 234: ...e The heat sink fan cable is still connected 4 Squeeze together the top portion of the black rubber cable grommet until it pops through the hole releasing the heat sink fan cable 5 Disconnect the heat...

Page 235: ...screws T25 4 Nut T25 2 Threaded stud 5 Telescoping duct 3 Duct flange 6 Heat sink fan cover Illustration 11 31 Heat Sink Fan Access with Telescoping Cooling Duct D2h D4h D7h D8h J9 Unit Dis Service Gu...

Page 236: ...Cable grommet 3 Slot for fan cover 8 Fan cable connector 4 Heat sink fan 9 Fan cover 5 Mounting holes 10 Fan cover tabs Illustration 11 32 Heat Sink Fan in IP20 Chassis Drives D2h D4h D7h D8h J9 Unit...

Page 237: ...roper cooling position the door fan so that the air direction arrow points away from the internal drive components when the door is closed Reassembly Tighten hardware according to chapter 14 1 Fastene...

Page 238: ...nnector 6 Door fan 3 Nut 7 mm 7 Hole for corner post 4 Door fan guard 8 Corner post Illustration 11 34 Interior View of Door Fan Assembly D2h D4h D7h D8h J9 Unit Dis VLT FC Series D1h D8h Da2 Db2 Da4...

Page 239: ...fan from the drive Reassembly Tighten hardware according to chapter 14 1 Fastener Torque Ratings 1 Feed the top fan cable through the cable access hole on the top of the drive 2 Reconnect the in line...

Page 240: ...le and connector 2 Screw T25 5 Retaining clip 3 Top fan 6 Cable access hole Illustration 11 35 Top Fan with Housing D2h D4h D7h D8h J9 Unit Dis VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 238...

Page 241: ...T25 4 Top fan cable and connector 2 Top fan grill 5 Top vent 3 Top fan 6 Cable access hole Illustration 11 36 Top Fan with Grill D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A S 02 2019...

Page 242: ...inside the option cabinet on the bottom of the 3 brackets between the option cabinet and the main enclosure 4 Remove 2 connector plates on the top of the drive by removing 8 screws T25 4 from each pl...

Page 243: ...between the main enclosure and the extended options cabinet See Illustration 11 39 5a Remove 3 nuts 17 mm at the bottom of the motor output busbars 1 per busbar 5b Remove 3 screws 17 mm from the top o...

Page 244: ...ift out the contactor Reassembly Reinstall in reverse order of this procedure Tighten hardware according to chapter 14 1 Fastener Torque Ratings 11 3 4 Disconnect To remove or reinstall the disconnect...

Page 245: ...Contactor 3 A1 A2 contactor coil terminals 2 Disconnect 4 Contactor bracket Illustration 11 40 Contactor and Disconnect D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A S 02 2019 All righ...

Page 246: ...connecting the access panel to the back of the enclosure There are 5 or 9 screws depending on the size of the drive Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Do...

Page 247: ...30BF880 10 1 2 1 Heat sink access panel 2 Drive enclosure Illustration 11 41 Heat Sink Access Panel D2h D4h D7h D8h J9 Unit Dis Service Guide MG94A502 Danfoss A S 02 2019 All rights reserved 245 11 11...

Page 248: ...appropriate voltage measuring device to make sure that the capacitors are fully discharged For parallel drive modules measure DC bus capacitor voltages before and after the individual DC fuses Enclos...

Page 249: ...ing precautions increases risk of death serious injury or equipment damage Never walk under suspended loads To guard against injury wear personal protective equipment such as gloves safety glasses and...

Page 250: ...130BE566 11 65 min Illustration 12 1 Lifting the Drive Module Da2 Db2 Da4 Db4 Parallel Sy VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 248 Danfoss A S 02 2019 All rights reserved MG94A502 12 12...

Page 251: ...ol shelf 4 Unfasten the mounting bracket and remove the control shelf assembly 5 Place the control shelf assembly in an ESD protected package 130BE597 11 1 2 3 5 7 8 4 9 11 6 10 12 1 LCP cradle 7 Mult...

Page 252: ...drive module from below the unit with a lift or jack 3 Remove 2 M10 screws from each DC fuse on the top of the drive module 4 Remove 2 DC fuses and microswitches Refer to Illustration 3 7 5 Remove 2 n...

Page 253: ...the 2 bottom screws on the mounting panel 5 Check that the drive module is aligned correctly on the mounting panel Secure the bottom of the unit to the panel with 2 nuts See Illustration 12 3 Torque...

Page 254: ...BE572 10 Illustration 12 5 Installation of Bottom Mounting Bolts Da2 Db2 Da4 Db4 Parallel Sy VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 252 Danfoss A S 02 2019 All rights reserved MG94A502 12...

Page 255: ...bbon cables from the MDCIC card to the top of the drive modules The numbers next to the connectors on the MDCIC reflect the number of the module 6 Route the 44 pin ribbon cables inside the cabinet 7 C...

Page 256: ...2 Control shelf must stay above this point Illustration 12 6 Positioning the Control Shelf for Correct EMC Installation Da2 Db2 Da4 Db4 Parallel Sy VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9...

Page 257: ...of the blank mounting plate is described in this chapter For other disassembly procedures refer to Table 12 2 Parallel drive system Parallel drive module disassembly instructions Da2 system Refer to c...

Page 258: ...Blank cover plate no LCP 8 Mains terminals to drive module 4 Blank mounting plate no control card 9 Mixing fan 5 Power card 10 Output terminals to motor Illustration 12 7 Parallel Drive Module Da2 Db2...

Page 259: ...front cover of the parallel drive module 2 Remove the blank LCP cover The cover can be removed by hand 3 Remove 4 screws T20 1 from each corner of the blank mounting plate Reassembly Tighten fastener...

Page 260: ...cover 3 Screw T25 2 Blank mounting plate 4 Power card Illustration 12 8 Blank Mounting Plate Da2 Db2 Da4 Db4 Parallel Sy VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 258 Danfoss A S 02 2019 All...

Page 261: ...ork use an appropriate voltage measuring device to make sure that the capacitors are fully discharged For parallel drive modules measure DC bus capacitor voltages before and after the individual DC fu...

Page 262: ...ed for E sized drives and drive modules listed in Table 13 2 Drive model Description E1h drive Standard drive in an IP21 IP54 Type 1 12 enclosure E2h drive Larger standard drive in an IP21 IP54 Type 1...

Page 263: ...l card and power card To release the cable press out on the clasps at each end of the cable connector on the power card NOTICE UNIQUE TORQUE VALUES Tighten screws T20 to the non standard torque value...

Page 264: ...LCP cradle 6 Screws T20 3 LCP cable connector 7 Power card 4 Control card 8 Control card mounting plate Illustration 13 1 LCP and Control Card Mounting Plate E1h E4h Drive Disassembly a VLT FC Series...

Page 265: ...d connectors 3a MK600 3b MK602 3c MK802 3d MK1200 4 Release the cables from the cable retaining clips 5 Feed the cable unplugged from MK105 MK1200 through the cable access hole in the mounting plate 6...

Page 266: ...an power card 6 MK106 to brake temperature switch 16 MK602 to door top fans 7 MK502 to EMC relays 17 MK600 to heat sink fans 8 MK101 to current sensors 18 Cable retaining clip 9 MK103 to gate drive ca...

Page 267: ...power card pinching the tip of the plastic standoff To avoid bending the card lift it parallel to the power card NOTICE UNIQUE TORQUE VALUES Tighten screws T20 to the non standard torque value specif...

Page 268: ...T20 5 MK100 current scaling card connector 14 MK106 to brake temperature switch 6 MK105 to fan power card MK1200 15 Metal standoff 7 mm 7 MK104 signal test connector 16 MK500 to customer relays 8 MK50...

Page 269: ...ps to compress them 6 Remove the fan power card from the drive NOTICE UNIQUE TORQUE VALUES Tighten screws T20 to the non standard torque value specified in the following steps Tighten remaining fasten...

Page 270: ...e 3 Plastic standoff 8 MK602 to door top fans 4 MK1200 to inrush card and power card MK105 9 MK600 to heat sink fans 5 Cable retaining clip 10 Screw T20 Illustration 13 4 Fan Power Card E1h E4h Drive...

Page 271: ...screws T20 from the inrush card 4 Lift the inrush card upward to release it from the alignment tabs at the bottom edge of the plastic inrush card frame Reassembly Tighten fasteners according to chapt...

Page 272: ...ptional 10 MK109 SCR gate 5 Inrush card frame 11 MK110 Signals to power card MK105 and fan power card MK1200 6 Rectifier bus plate 12 Connection point for load share regen optional Illustration 13 5 I...

Page 273: ...4 screws T40 1 from each SCR module and 1 from the DC coil Remove the rectifier bus plate from the drive Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Place the rec...

Page 274: ...sbars 8 Insulator sheet alignment pin 4 Nut 7 mm 9 Rectifier bus plate 5 Rectifier bus plate 10 Bus plate screw T40 Illustration 13 6 Inrush Card Frame and Rectifier Bus Plates E1h E4h Drive Disassemb...

Page 275: ...2 10 Split Input Plate with Options 3 Remove 1 screw T40 which connects the SCR input busbar to the SCR 4 Remove 1 nut 8 mm from the SCR input busbar Remove the busbar from the drive 5 Disconnect the...

Page 276: ...4 SCR input busbar 2 SCR diode module 5 Screw T25 3 Screw T40 6 Nut 8 mm Illustration 13 7 SCR Diode Modules E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 274 Danfoss...

Page 277: ...3 Remove 3 nuts 17 mm and bolts 1 from each input terminal connection L1 L2 L3 at the bottom of the AC input busbars 4 Remove 6 nuts 13 mm 2 from the upper end of each AC input busbar 5 Remove 10 nut...

Page 278: ...not shown 3 Nut 8 mm 7 Cable retaining clip 4 Nuts 17 mm and bolts for L1 L2 L3 connection 8 Nut 8 mm Illustration 13 8 Single Input Plate with Busbars only E1h E4h Drive Disassembly a VLT FC Series D...

Page 279: ...ottom of the lower input plate 5 Remove 5 7 nuts 8 mm from the lower input plate edge The number of fasteners in the input plate varies with enclosure size 6 Lift the lower input plate and attached di...

Page 280: ...n upper input plate 5 Nut 17 mm at terminal L1 12 Lower input plate 6 Nut 30 mm at upper RFI filter 13 Nut 8 mm in lower input plate 7 AC input busbar 14 Nut 8 mm Illustration 13 9 Split Input Plate w...

Page 281: ...ter 13 2 9 Input Plate with Busbars or chapter 13 2 10 Split Input Plate with Options 4 Remove 2 screws T20 from opposite corners of the fan assembly 5 Feed the cable through the fan cable access hole...

Page 282: ...2 Cable retaining clip 6 Mixing fan 3 Mixing fan vent 7 Screw T20 4 Cable access hole 8 Alignment arrow Illustration 13 10 E1h E3h Input Plate Mixing Fan E2h E4h is Similar E1h E4h Drive Disassembly a...

Page 283: ...T20 from opposite corners of the mixing fan 5 Feed the cable through the fan cable access hole 6 Remove the mixing fan from the fan cage Reassembly Tighten fasteners according to chapter 14 1 Fastene...

Page 284: ...cage 2 Mixing fan 5 Cable access hole 3 Screw T25 6 Fan location Illustration 13 11 Power Card Mixing Fan E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 282 Danfoss A...

Page 285: ...leg of the gate drive card mounting plate 4 Lift the mounting plate with attached card from the unit NOTICE CABLE ROUTING To avoid equipment malfunction or damage ensure that the IGBT cables are reat...

Page 286: ...unting plate 3 MK100 8 IGBT output busbar 4 MK601 9 MK701 5 MK101 10 MK 201 for brake option Illustration 13 12 Gate Drive Card Mounting Plate E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2...

Page 287: ...nt malfunction or damage ensure that the IGBT cables are reattached to the correct IGBT cable connectors MK501 MK601 and MK701 NOTICE UNIQUE TORQUE VALUES Tighten screws T20 to the non standard torque...

Page 288: ...crew T20 6 MK701 3 Gate drive card 7 MK201 optional brake 4 MK501 8 MK601 Illustration 13 13 Gate Drive Card E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 286 Danfoss...

Page 289: ...When installing current sensors point the arrow on each current sensor downward Failure to install the current sensors correctly can cause equipment malfunction Reassembly Tighten fasteners according...

Page 290: ...le connector 3 Current sensor busbar 8 Screw T20 4 Screw T25 9 Heat sink fan housing 5 Left motor busbar 10 Right motor busbar Illustration 13 14 Current Sensors E1h E4h Drive Disassembly a VLT FC Ser...

Page 291: ...ing current sensors point the arrow on each current sensor downward Failure to install the current sensors correctly can cause equipment malfunction Reassembly Tighten fasteners according to chapter 1...

Page 292: ...1 Current sensor cable connector 5 Nut 13 mm 12 Screw T20 6 Current sensor 13 Heat sink fan housing 7 Current sensor busbar 14 Right motor busbar Illustration 13 15 E1h E3h Motor Busbar Assembly E2h E...

Page 293: ...also remove 1 screw T25 and retain the screw Using a longer screw can damage the insulator sheet behind the card 8 Lift the balance high frequency card and the insulator sheet from the drive Reassemb...

Page 294: ...ce high frequency card 7 MK100 cable connector only in 690 V drives 4 Nut 8 mm 8 Left current sensor busbar Illustration 13 16 Balance High Frequency Card in E2h E4h 580 690 V AC Other Drives Similar...

Page 295: ...he fan grommet until it pops through the hole in the fan housing releasing the fan cable Take care not to damage the fan wires during removal 10 Remove the fan from the fan housing Reassembly Tighten...

Page 296: ...2 Right motor busbar 5 Nut 8 mm 13 Nut 13 mm 6 Current sensor 14 Fan grommet 7 Fan grommet installed in fan housing 15 Heat sink fan 8 Fan cable heat sink fan 16 Fan cable connector Illustration 13 17...

Page 297: ...rom the bottom of each DC snubber capacitor 7 Remove the 6 DC snubber capacitors from the drive Reassembly in E1h E3h drives Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Posit...

Page 298: ...rives Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Place the DC snubber capacitor pairs in the drive 2 Secure 12 nuts 40 mm 4 in each DC snubber capacitor pair 3 Position the...

Page 299: ...eft DC bus rail where it connects with the DC bus plate 5 Remove screws T25 and any standoff from the DC bus plate Number and type of fasteners varies with drive size and power rating Refer to the cap...

Page 300: ...bus plate 4 Insulator sheet for balance high frequency card 10 Insulator sheet 3 5 DC bus plate 11 Plug 6 Insulator sheet 1 12 DC capacitor Illustration 13 20 E1h E3h Capacitor Bank 380 500 V AC T5 1...

Page 301: ...per and lower midplates Number of fasteners varies with drive size and power rating Refer to chapter 13 2 21 DC Capacitor Layouts 10 Lift the 2 midplates from the drive and remove the insulator sheet...

Page 302: ...1 upper 4 Insulator sheet for balance high frequency card 10 Midplate 2 lower 5 DC bus plate 11 Insulator sheet 3 6 Insulator sheet 1 12 DC capacitors Illustration 13 21 E1h E3h Capacitor Bank 525 690...

Page 303: ...and which DC bus plate or midplate they secure Illustration number Model FC 102 FC 103 and FC 202 FC 302 Illustration 13 22 N355T4 N315T5 Illustration 13 23 N400T4 N450T4 N355T5 N400T5 Illustration 13...

Page 304: ...with 14 Capacitor Layout 5 3 3 1 6 3 3 1 3 1 3 1 3 1 4 1 3 2 3 1 5 3 5 3 5 3 5 3 5 3 5 3 e30bf899 10 1 DC plate screw 4 Midplate standoff 2 DC plate standoff 5 DC plate screw 3 Midplate screw 6 DC pla...

Page 305: ...stration 13 24 E1h E3h T7 355 400 kW with 15 Capacitor Layout 5 3 5 3 e30bf926 10 5 3 5 3 5 3 5 3 5 3 3 2 3 1 4 1 3 1 3 1 3 1 3 1 3 1 5 3 6 3 5 3 3 1 3 1 1 DC plate screw 4 Midplate standoff 2 DC plat...

Page 306: ...with 18 Capacitor Layout e30bf927 10 5 1 5 1 5 1 5 1 5 1 5 1 5 1 7 6 7 5 7 5 7 5 7 5 7 5 7 5 3 8 3 7 4 7 3 7 3 7 3 7 3 7 1 DC plate screw 5 Midplate 1 screw 2 DC plate standoff 6 Midplate 1 standoff 3...

Page 307: ...t 1 cable from the brake IGBT if brake is present 7 Remove 7 screws T25 from each plastic IGBT mounting frame 8 Pull the plastic IGBT mounting frame from the drive 9 Remove 4 screws T25 from each IGBT...

Page 308: ...2 IGBT mounting frame 4 IGBT module Illustration 13 28 IGBT Modules in E2h E4h Drives E1h E3h is Similar E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 306 Danfoss A S...

Page 309: ...posite side of the fan 5 Remove the fan from the enclosure door Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position the fan in the door of the enclosure with the...

Page 310: ...w 2 Release tab 6 Nut 7 mm 3 Filter 7 Corner bracket 4 Screw T20 8 Door fan back view Illustration 13 29 Door Fan Assembly E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8...

Page 311: ...ans from the pins in the fan housing Reassembly Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Place the fans over the pins in the fan housing with the fan arrows pointing away...

Page 312: ...w T25 2 Mounting pin inside housing 5 Cable access hole 3 Fan 6 Retaining clip Illustration 13 30 Top Fan E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h E4h J8 J9 310 Danfoss A...

Page 313: ...sensor busbar 6c 2 nuts 13 mm from the top of the right IGBT output busbar 7 Remove 2 nuts 13 mm from the middle of the R vertical brake busbar Lift the busbar from the drive Reassembly Tighten faste...

Page 314: ...R vertical brake busbar 6 Screw T40 3 Nut 13 mm 7 R vertical brake busbar 4 Screw T40 8 Screw T40 Illustration 13 31 Brake Busbars E1h E4h Drive Disassembly a VLT FC Series D1h D8h Da2 Db2 Da4 Db4 E1h...

Page 315: ...horizontal busbar by removing 6a 4 screws T50 6b 2 screws T20 7 Remove the top horizontal busbar by removing 7a 2 screws T20 7b 2 nuts 13 mm from the right end of the busbar Reassembly Tighten fastene...

Page 316: ...rew T20 6 Middle horizontal brake busbar 3 Screw T40 7 Nut 13 mm 4 Snubber capacitor 8 Vertical brake busbars Illustration 13 32 Horizontal Brake Busbars in E1h E3h Drives E1h E4h Drive Disassembly a...

Page 317: ...from the right end of the busbar Reassembly in E2h E4h drives Tighten fasteners according to chapter 14 1 Fastener Torque Ratings 1 Position the top horizontal busbar in the drive and replace the foll...

Page 318: ...brake busbar 3 Thread forming screw T25 behind snubber capacitor 7 Nut 13 mm 4 Snubber capacitor 8 Vertical brake busbars Illustration 13 33 Horizontal Brake Busbars in E2h E4h Drives E1h E4h Drive Di...

Page 319: ...6c Remove 2 screws T25 from the top of the bus rail 6d Remove the zip ties connecting the cables to the bus rail 6e Lift the left DC bus rail from the unit Reassembly Tighten fasteners according to c...

Page 320: ...crew T25 3 DC bus rail left 8 Screws T40 only with optional regen terminals 4 Nut 13 mm 9 DC bus rail right 5 Regen terminals optional 10 Nut 13 mm for optional brake Illustration 13 34 DC Bus Rails E...

Page 321: ...x drives size Class A Nm in lb Class B Nm in lb M4 T20 7 mm 1 2 10 0 8 7 M5 T25 8 mm 2 3 20 1 2 10 M6 T30 10 mm 3 9 35 2 3 20 M8 T40 13 mm 9 6 85 3 9 35 M10 T50 17 mm 19 1 169 9 6 85 M12 18 mm or 19 m...

Page 322: ...6 M5 fasteners attaching gate drive card Torque 2 27 Nm 20 1 lb in 2 3 M5 fasteners Torque 3 91 Nm 34 6 lb in 5 All M5 fasteners attaching input plates to side mounting rail Torque 3 91 Nm 34 6 lb in...

Page 323: ...pk 711 868 1051 1051 1318 1595 Heat sink overtemperature C 110 110 110 110 110 110 Heat sink undertemperature warning C 0 0 0 0 0 0 Control card overtemperature C 75 75 80 80 80 80 Mains phase warning...

Page 324: ...trip C F 110 230 110 230 110 230 110 230 100 212 Control card overtemperature trip C F 80 176 80 176 80 176 80 176 80 176 Power card overtemperature trip C F 85 185 85 185 85 185 85 185 85 185 Fan po...

Page 325: ...first 5 digits of the type code T C See chapter 3 4 Enclosure Size Identification 3 Under Configure by Type Code enter the type code from the drive label and click Configure Alternatively select the d...

Page 326: ...6F3411 N90K N75K 5 9 176F3411 N110 N90K 5 9 176F3411 N132 N110 5 9 176F3411 N160 N132 5 0 176F3412 N200 N160 4 0 176F3413 N250 N200 3 2 176F3414 N315 N250 2 7 176F3415 N400 N315 5 6 176F3416 Table 15...

Page 327: ...rive Systems and Parallel Drive Modules 525 690 V T7 FC 102 FC 103 FC 202 FC 302 Current scaling card Part number N355 N315 2 7 176F3415 N400 N355 2 5 176F6628 N450 N400 2 3 176F6629 N500 N450 2 0 176...

Page 328: ...no safe stop Ver 2 card 301 301 301 301 301 301 PCA1 130B1126 Control Card FC 301 coated safe stop 301 301 301 301 301 301 PCA1 134B1727 Control Card FC 301 coated safe stop Ver 2 card 301 301 301 30...

Page 329: ...6 IGBT brake module 450A 1700V 1 IGBT pet kit brake brake brake IGBT 4 176F3367 IGBT brake module 650A 1700V 1 IGBT pet kit brake brake brake Capacitors CBANK 1 176F3163 DC bus cap 4700UF 450V in hous...

Page 330: ...ors SW1 176F3433 Disconnect 400A D1h power sizes disconnect 1 1 1 SW1 176F3434 Disconnect 600A D2h power sizes disconnect 1 1 1 SW1 176F8346 Disconnect handle rod D1 frame disconnect handle SW1 176F83...

Page 331: ...4h wire harness inrush crd to SCR gates 1 1 1 CBL11 176F3179 Cable brake IGBT gate signal D1h D3h wire harness gatedrive bd to brake IGBT gate 1 per kit 1 1 1 CBL11 176F3180 Cable brake IGBT gate sign...

Page 332: ...usbars 1 1 1 176F3384 Busbar IGBT AC output D2h D4h busbars 3 3 3 176F3385 Busbar assembly current sensor D2h D4h busbars 1 1 1 176F3386 Busbar assembly cap bank 400V D2h D4h busbars 1 1 1 Other Parts...

Page 333: ...Link Coil Large Dh frame enclosure 1 1 1 176F3549 Cover DC Link Coil Small Dh frame enclosure 1 1 1 176F5000 Anti Condensation Heater Dh frame resistor 1 1 1 1 1 1 176F5734 Front Cover IP21 IP54 D1h...

Page 334: ...er 2 card 302 302 302 302 302 302 Power Cards PCA2 176F3134 Power card NO 110kW 380 480V Conformal coated does not include scaling card T4 PCA2 176F3135 Power card NO 132kW 380 480V Conformal coated d...

Page 335: ...CA3 176F3155 Current scaling card 3 11 ohm 400V Installs on the power card 1 PCA3 176F3156 Current scaling card 2 56 ohm 400V Installs on the power card 1 PCA3 176F3157 Current scaling card 5 10 ohm 4...

Page 336: ...20X25 IP21 IP54 door fan fan only 1 fan 21 54 21 54 21 54 F1 176F3169 Door fan IP21 54 DC 120X38 IP21 IP54 door fan fan only 1 fan 21 54 21 54 21 54 F3 176F3165 Mixing fan DC 40X28 24VDC Mixing fan mo...

Page 337: ...to power card 1 1 1 CBL2 176F3319 Cable control card to power card D2h D4h Ribbon cable control card to power card 1 1 1 CBL3 176F3320 Cable power card to door fan D1h D3h Wire harness power card to H...

Page 338: ...bar DC inductor to cap bank D1h D3h Busbars 1 1 1 176F3341 Busbar IGBT AC output D1h D3h Busbars 3 3 3 176F3346 Busbar assy SCR to DC coil D1h D3h Busbars 1 1 1 176F3347 Busbar assy curr sens D1h D3h...

Page 339: ...375 Door vent kit IP21 IP54 Dxh enclosure Enclosure 21 54 21 54 21 54 21 54 21 54 21 54 176F3389 Front cover IP20 D4h enclosure Enclosure IP20 IP20 IP20 176F3390 Front cover IP20 D3h enclosure Enclosu...

Page 340: ...4 21 54 21 54 176F5736 Front cover no LCP IP21 54 D1h enclosure Enclosure 21 54 21 54 21 54 176F5737 Front cover no LCP IP21 54 D2h enclosure Enclosure 21 54 21 54 21 54 176F5739 Extended option adapt...

Page 341: ...ntrol Card FC202 coated safe stop Ver 2 card 202 202 202 202 202 202 202 202 202 PCA1 130B1109 Control Card FC302 coated safe stop 302 302 302 302 302 302 302 302 302 PCA1 134B1726 Control Card FC302...

Page 342: ...kW 690V Soft charge Inrush card 1 1 1 1 1 1 1 1 1 PCA5 176F3418 Gatedrive card NO 75 400kW 690V Gatedrive card 1 1 1 1 1 1 1 1 1 PCA5 176F3516 Gatedrive card rugged NO 75 400kW 690V Gatedrive card 1 1...

Page 343: ...700V square body Mains fuse 1 per kit 3 3 3 3 Inductors and Current Sensors CT1 2 3 176F8342 Current sensor 300A Current sensor 1 per kit 3 3 3 3 3 3 3 3 CT1 2 3 176F8343 Current sensor 500A Current...

Page 344: ...cable inrush card to gatedrive card 1 1 1 1 1 CBL8 176F3332 Cable gatedrive to inrush D2h D4h Ribbon cable inrush card to gatedrive card 1 1 1 1 CBL10 176F3333 Cable inrush to SCR gate D1h D3h Wire h...

Page 345: ...SCR to DC coil D2h D4h Busbars 1 1 1 1 176F3382 Busbar DC inductor to cap bank D2h D4h Busbars 1 1 1 1 176F3383 Busbar DC inductor to cap bank D2h D4h Busbars 1 1 1 1 176F3384 Busbar IGBT AC output D2...

Page 346: ...D3h enclosure Insulation 1 1 1 1 1 176F3540 Heat Sink fan cover Dxh enclosures Enclosure 1 1 1 1 1 1 1 1 1 176F3548 Cover DC link coil large Dxh enclosure Enclosure 1 1 1 1 176F3549 Cover DC link coil...

Page 347: ...C 103 N75k N90k N110 N132 N160 N200 N250 N315 N400 FC 202 N75k N90k N110 N132 N160 N200 N250 N315 N400 FC 302 N55k N75k N90k N110 N132 N160 N200 N250 N315 176F6314 Top terminal cover D4h inverter only...

Page 348: ...d FC302 coated safe stop 302 302 302 302 302 PCA1 134B1726 Control Card FC302 coated safe stop Ver 2 card 302 302 302 302 302 Printed Circuit Cards PCA2 176F6625 Power card high power S W preloaded al...

Page 349: ...PA1 1 per kit 3 3 3 3 3 L1 176F6730 DC link coil 47uH DC inductor 1 L1 176F6731 DC link coil 42uH DC inductor 1 1 L1 176F6732 DC link coil 28uH DC inductor 1 1 Disconnects SW1 176F6315 Switch disc 800...

Page 350: ...to IGBT module 1 per kit 3 3 CBL14 176F6709 Assy wire CBL14 P4001 DC FPC E1h Wire harness DC bus to fan power card 1 1 1 1 1 CBL15 176F6655 Assy wire CBL15 P4001 FPC HS E1h Wire harness fan power car...

Page 351: ...through sensors 1 per kit 3 3 176F3839 Busbar motor U E1hE3h Busbar connects C T bar to right angle bar 1 1 1 176F3840 Busbar motor V E1hE3h Busbar connects C T bar to right angle bar 1 1 1 176F3841 B...

Page 352: ...450 N500 N560 FC 202 T4 N355 N400 N450 N500 N560 FC 302 T5 N315 N355 N400 N450 N500 176F6692 Tool capacitor removal installation Tool to remove DC bus caps 1 1 1 1 1 Table 15 11 Spare Parts List E1h E...

Page 353: ...oated safe stop Ver 2 card 202 202 202 202 202 202 PCA1 130B1109 Control Card FC302 coated safe stop 302 302 302 302 302 302 PCA1 134B1726 Control Card FC302 coated safe stop Ver 2 card 302 302 302 30...

Page 354: ...t Sensors CT1 2 3 176F6633 Current sensor 1000A LEM LF1010 S SPA1 1 per kit 3 3 3 3 3 3 L1 176F6733 DC link coil 65uH DC inductor 1 1 L1 176F6734 DC link coil 50uH DC inductor 1 1 L1 176F6732 DC link...

Page 355: ...GBT module 1 per kit 3 3 3 3 CBL13 176F6708 Assy wire CBL13 P4001 GD IGBT E2h Wire harness gatedrive to IGBT module 1 per kit 3 3 CBL14 176F6709 Assy wire CBL14 P4001 DC FPC E1h Wire harness DC Bus to...

Page 356: ...le bar 1 1 1 1 176F3840 Busbar motor V E1hE3h Busbar connects C T bar to right angle bar 1 1 1 1 176F3841 Busbar motor W E1hE3h Busbar connects C T bar to right angle bar 1 1 1 1 176F3844 Busbar motor...

Page 357: ...3 N450 N500 N560 N630 N710 N800 FC 202 N450 N500 N560 N630 N710 N800 FC 302 N355 N400 N500 N560 N630 N710 176F6692 Tool capacitor removal installation Tool to remove DC bus caps 1 1 1 1 1 1 Table 15 1...

Page 358: ...1 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...

Page 359: ...RENT SCALING CARD INV4 DIGITAL INPUTS Terminal blocks for customer relay connection To drive module 1 top plate top plate top plate top plate To drive module 2 To drive module 3 To drive module 4 To c...

Page 360: ...R BAL HF PCA7 IGBT1 TB4 TB2 IGBT2 IGBT3 BRAKE IGBT MODULE IGBT4 TOP FAN IP20 DOOR FAN IP54 F3 MIXING FAN CBANK 1 TB1 FUSE OPTION F1 130BF087 10 Illustration 16 3 Internal Block Diagram of Parallel Dri...

Page 361: ...6 11 10 9 C NO NC C NO NC Regen Regen GND 1 2 BRF Jumper CBL114 R R R R R R U V W L1 L2 L3 L1 L2 L3 U V W FK101 2 1 1 2 43 44 1 2 43 44 1 2 43 44 1 2 43 44 TB1 TB2 TB1 TB2 Customer Relay DRIVE MODULE...

Page 362: ...44 43 8 7 6 11 10 9 C NO NC C NO NC Regen Regen GND 1 2 BRF Jumper CBL114 R R R R U V W L1 L2 L3 FK101 2 1 1 2 43 44 1 2 43 44 1 2 43 44 1 2 43 44 CONTROL SHELF To Control Card LCP L130B4630 1 2 2 1 2...

Page 363: ...WER CARD PCA2 FAN POWER CARD INRUSH CARD PCA4 GATEDRIVE CARD PCA5 Illustration 16 6 Electrical Block Diagram of E1h E4h Units Block Diagrams Service Guide MG94A502 Danfoss A S 02 2019 All rights reser...

Page 364: ...or busbar assembly 289 Rectifier bus plate 271 SCR input busbar 273 Vertical brake 311 Busbars AC input 136 137 192 193 SCR input 150 209 C Cable routing 87 Certifications 11 Circuit breaker 29 104 Ci...

Page 365: ...Installation 88 EMC shield 196 Extended options cabinet 178 240 Extended Options Cabinet 180 External commands 37 F Fan Door 58 173 235 Door fan 307 Heat sink 57 170 178 232 293 Mixing 57 142 198 279...

Page 366: ...M Main Menu 31 Main Menu Mode 32 Mains Shield 14 Voltage 35 Warning 73 Manual initialization 33 Manuals 9 MDCIC 25 52 93 Menu keys 31 Menu structure 31 Microprocessor 44 Mixing fan 142 198 279 281 Mot...

Page 367: ...ction 46 Testing 100 Recycling 11 Reference 34 35 36 Regen Illustration 318 Load sharing 58 Terminal 59 Relays 44 Remote reference 35 Replacement Parts 323 Reset 30 31 33 37 69 75 RFI filter 136 192 2...

Page 368: ...CRs 109 Signal test board 90 Static tests 100 Thermistor Warning 75 Top fan 175 237 309 Torque Limit 69 83 Parameters 80 Values 319 Troubleshooting Codes 66 Display 62 Motor operation 62 Symptoms 60 T...

Page 369: ...Index Service Guide MG94A502 Danfoss A S 02 2019 All rights reserved 367...

Page 370: ...ucts already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the resp...

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