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Danfoss VLT HVAC Drive FC100, Service Manual

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Danfoss VLT HVAC Drive FC100 Service Manual Download Page 53

GND

L1

R

S
L2

T
L3

91

92

93

94

FU3

FU2

FU1

TB1

DIFF. MODE

MK3

MK2

MK1

FILTER

RECTIFIER

R

MK106

FK101

MDCIC CARD

INVERTER 1

S

T

LOAD SHARE

(UNIDIRECTIONAL)

INVERTER 2

INVERTER 3

FK100

FK103

T'

S'

R'

R'

T'

S'

R'

T'

S'

3

DC

U

MK1

0

0

GND

FAN-

FAN+

GND

FAN-

FAN+

GND

FAN-

FAN+

1

30

1

44

FK102

GND

FAN-

FAN+

1

44

1

44

1

44

1

44

44

1

44

1

44

1

1

30

1

30

1

30

1011

5

1 8

1

2

1

2

7 6

3

1

Aux 1

Relay

Aux 2

Relay

8

7

6

11 10 9

INVERTER

RFI/CAN/SCR DIS/ENA

12-Pin

8

-Pin

8

5

L

N

PE

L

N

PE

4

1

7 9 11

8 10 12

2 4 6

7

2

1

2

2

BLK

WHT

RED

3

3

1

1

6-Pin

8

-Pin

1

0

-Pin

6-Pin

6

2

5

8

-Pin

6

2
5

8

-Pin

6

2

5

16-Pin

BLK

WHT

RED

BLK

RED

1

3

4

6

1

0

-Pin

7

2

1

1

0

-Pin

7

2

1

14-Pin

8

7

6

11 10 9

16-Pin

8

7

6

11 10 9

16-Pin

8

7

6

11 10 9

16-Pin

5

10

5
10

1

2

1

2

RFI 

CARD

+

-

MK1

3

1

2

MK7

MK5

MK6

RFI 

CARD

+

-

MK7

MK5

MK6

RFI 

CARD

+

-

MK7

MK5

MK6

MK1

3

1

2

MK1

3

1

2

3

3

DIFF. MODE

MK3

MK2

MK1

FILTER

DIFF. MODE

MK3

MK2

MK1

FILTER

BLK

WHT

RED

BLK

WHT

BLK

WHT

WHT

BLK

BLK

WHT

BLK

WHT

BLK

WHT

BLK
WHT

BLK
WHT

BLK

WHT

6-Pin

1

3

4

6

BLK

WHT

BLK

WHT

1

3

4

6

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

BLK

WHT

RED

BLK

WHT

BLK

WHT

BLK

WHT

3

MK101

6

4

5

CAN

2

1

3

MK102

6

4

5

CAN

2

1

SCALING

CURRENT

CARD

MK1

07

SCALING

CURRENT

CARD

MK1

08

SCALING

CURRENT

CARD

MK1

09

FC-X02

LCP

RED

BLK

WHT

POWER 

CARD

TEST

 CONNECT

OR

POWER 

CARD

TEST

 CONNECT

OR

POWER 

CARD

TEST

 CONNECT

OR

Aux 1

Relay

Aux 2

Relay

Aux 1

Relay

Aux 2

Relay

Aux 1

Relay

Aux 2

Relay

DC-Link

DC-Link

DC-Link

DC-Link

R' S' T'

DC+

DC-

+SCR

-SCR

DC+

DC-

DC+

DC-

6-Pin

20

1

2

1

2

2

2

1

1

3

4

7

8

3

4

7

8

3

4

7

8

2

2

3

3

1

1

2

2

3

3

1

1

Not used

POWER 

CARD

TEST

 CONNECT

OR

FU4

FU5

FU6

FU7

FU8

FU9

INV1

INV2

INV3

NOT USED

NOT USED

NOT USED

FOUR-POLE 

FUSIBLE 

DISCONNECT

400VA 

TRANSFORMER

  24V AC/DC 

 POWER SUPPLY

BLK

+

-

OPTION CABINET 

DOOR INTERLOCK

RECTIFIER CABINET 

DOOR INTERLOCK

INVERTER CABINET 

DOOR INTERLOCK

BLK

WHT

BLK

WHT

BLK

WHT

BLK

WHT

-

+

-

+

-

+

WHT

WHT

BLK

WHT

BLK

Fu2

Fu1

Fu3

Fu4

WHT

BLK

WHT

BLK

WHT

BLK

GRN/YEL

106 104

14 11 OF1

C1

C2

MX

C1

C2

BLK

WHT

SHUNT TRIP

1

2

1

2

CBL1

CBL2

CBL3

CBL4

CBL7

CBL8

CBL9

CBL10

CBL11

CBL3

CBL7

CBL3

CBL3

CBL3

CBL17

CBL18

CBL19

 A1/C2

 

RFI

 CB

CBL20

CBL20

MAINS FUSES

CBL21

CBL23

61 68 69

+

S

-

RS-485

50

39 42

53 54 55

18

12 13

27

19

29 32 33 20 37

ANALOG I/O

DIGITAL INPUTS

MOTOR TERMINALS

W1

V1

U1

BRAKE 

TERMINALS

R+

R-

MOTOR TERMINALS

W2

V2

U2

BRAKE 

TERMINALS

R+

R-

MOTOR TERMINALS

W3

V3

U3

BRAKE 

TERMINALS

R+

R-

JUMPER IS INSTALLED 

IN CASE THERE IS 

NO OPTION CABINET

SCR DIS/ENA TERMINAL BLOCKS 

LOCATED IN RECTIFIER CABINET

OPTION CABINET DOOR FAN

RECTIFIER CABINET DOOR FAN

INVERTER CABINET DOOR FAN

INVERTER CABINET DOOR FAN

REGEN

TERMINALS

LOAD SHARE

TERMINALS

HEATSINK/DOOR

FAN TRASNFORMER

HEATSINK/DOOR

FAN TRASNFORMER

HEATSINK/DOOR

FAN TRASNFORMER

DOOR INTERLOCKS

PCA13

KLIXON IS INSTALLED IN CASE THERE IS AN OPTION CABINET

 

RFI KLIXON

A1

A2

C21 C22

C13 C14

WHT

WHT

WHT

BLK

BLK

BLK

CONTACTOR

DISCONNECT

6A

6A

6A

6A

H1

H2

X1

X2

LOCATED IN OPTIONS CABINET: CB AND CONTACTOR TERMINAL BLOCKS

LOCATED IN RECTIFIER CABINET: 400VA TRANSFORMER, FUSIBLE DISCONNECT AND 24V POWER 
SUPPLY

SPLICE

LOCATED IN OPTIONS CABINET

CBL1

LOCATED IN RECTIFIER CABINET

LOCATED IN INVERTER

CABINET

T1

A2

A1

C21

C22

C13

C14

DS1

M1

CB1

Illustration 3.6 F-frame rectifier circuit

RECTIFIER 2

R2

MK106

FK101

61 68

69

+

S

-

RS-485

MDCIC CARD

INVERTER 1

S2

T2

INVERTER 2

INVERTER 3

FK100

FK103

T'

S'

R'

R'

T'

S'

R'

T'

S'

3

DC

U

00

1K

M

GND

FAN-

FAN+

GND

FAN-

FAN+

1

30

1

44

FK102

1

44

1

44

1

44

1

44

44

1

44

1

44

1

1

30

1

30

1

30

10 11

5

1 8

1

2

1

2

7 6

3

1

Aux 1

Relay

Aux 2

Relay

8

7

6

11 10 9

INVERTER

RFI/CAN/SCR DIS/ENA

12-Pin

7 9 11 8 10 12

2 4 6

7
2
1

2

2

BLK

WHT

RED

3

3

1

1

6-Pin

8-

Pin

10-

Pin

6-Pin

6
2
5

8-

Pin

6
2

5

8-

Pin

6
2
5

16-Pin

BLK

WHT

RED

BLK

RED

1

3

4

6

10-

Pin

7
2
1

10-

Pin

7

2
1

14-Pin

8 7 6

11 10 9

16-Pin

8

7

6

11 10 9

16-Pin

8 7 6

11 10 9

16-Pin

5

10

5

10

1

2

1

2

WHT

BLK

3

3

RED

WHT

BLK

BLK

WHT

BLK

WHT

BLK

WHT

6-Pin

1

3

4

6

BLK

WHT

6-Pin

1

3

4

6

BLK

WHT

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

RED

BLK

WHT

BLK

WHT

RED

BLK

WHT

BLK

WHT

3

MK101

6

4

5

CAN

2 1

3

MK102

6

4

5

CAN

2 1

SCALING

CURRENT

CARD

MK107

SCALING

CURRENT

CARD

MK108

SCALING

CURRENT

CARD

MK109

FC-X02

LCP

RED

BLK

WHT

POWER 

CARD

RO

TC

EN

NO

C T

SE

T

POWER 

CARD

RO

TC

EN

NO

C T

SE

T

POWER 

CARD

RO

TC

EN

NO

C T

SE

T

Aux 1

Relay

Aux 2

Relay

Aux 1

Relay

Aux 2

Relay

Aux 1

Relay

Aux 2

Relay

DC-Link

DC-Link

DC-Link

DC-Link

R' S' T'

DC+

DC-

+SCR

-SCR

DC+

DC-

DC+

DC-

20

1

2

3
4
7
8

3
4
7
8

3
4
7
8

JUMPER IS INSTALLED

IN CASE THERE IS

NO OPTION CABINET

2

2

3

3

1

1

2

2

3

3

1

1

SCR DIS/ENA TERMINAL BLOCKS

LOCATED IN RECTIFIER CABINET

Not used

POWER 

CARD

RO

TC

EN

NO

C T

SE

T

FU4

FU5

FU6

FU7

FU8

FU9

INV1

INV2

INV3

NOT USED

NOT USED

106 104

50

39

42

53

54 55

PCA13

L2

TR1

TR2

TR3

F3

F4

REG+

TB5

REG-

18

12 13

27

19

29

32

33 20 37

REGEN

TERMINALS

INVERTER CABINET

DOOR FAN

HEATSINK/DOOR

FAN TRASNFORMER

HEATSINK/DOOR

FAN TRASNFORMER

HEATSINK/DOOR

FAN TRASNFORMER

BRAKE

TERMINALS

BRAKE

TERMINALS

BRAKE

TERMINALS

MOTOR TERMINALS

MOTOR TERMINALS

MOTOR TERMINALS

W1

V1
U1

R+
R-

W2
V2
U2

R+
R-

R+
R-

W3
V3
U3

ANALOG I/O

DIGITAL INPUTS

MAINS FUSES

FU5

FU4

GND

R2

S2

T2

95

96

97

98

TB2

FU6

RECTIFIER 1

R1

S1

T1

3

DC

U

1

30

1

44

GND

FAN-

FAN+

1011

5 1 8 7 6

3

1

Aux 1

Relay

Aux 2

Relay

8 7 6

11 10 9

INVERTER

RFI/CAN/SCR DIS/ENA

12-Pin

8-

Pin

8
5

L

N

PE

4
1

7 9 11 8 10 12

2 4 6

6-Pin

16-Pin

14-Pin

WHT

BLK

RED

BLK

WHT

BLK

BLK

WHT

DC-Link

R' S' T'

+SCR

-SCR

20

2

2

1

1

Not used

POWER 

CARD

RO

TC

EN

NO

C T

SE

T

L1

F5

MAINS FUSES

FU2

FU1

GND

R1

S1

T1

91

92

93

94

TB1

FU3

1

2

1

2

1

2

3

3

WHT

BLK

BLK

WHT

1

2

106 104

S1

WHT

RED

BLK

WHT

INVERTER CABINET

   DOOR FAN

RECTIFIER CABINET

   DOOR FAN

F1

S2

F2

S1

F1

S2

F2

18

3

GND

FAN-

FAN+

L

N

PE

F1

OPTIONS CABINET

   DOOR FAN

P6

P4

P2

P1

P5

P3

P6

P6

P4

P4

P2

P2

P1

P1

P5

P5

P3

P3

P1

P2

P3

P4

P7

P5

P6

P1

P5

P7

P4

P3

P6

P2

RFI1

RFI2

C1

C2

6

3

8

5
4

1

6

3

GND

FAN-

FAN+

L

N

PE

BLK

WHT

2

2

1

1

F6

RECTIFIER CABINET

   DOOR FAN

GND

FAN-

FAN+

L

N

PE

F2

OPTIONS CABINET

   DOOR FAN

RECT2

RECT1

CBL100

CBL101

CBL102

CBL103

CBL104

CBL105

CBL108

CBL110

CBL107

CBL106

J1

J2

CBL109

CBL111

CBL112

CBL113

CBL114

CBL115

130BX423.10

Illustration 3.7 12-pulse rectifier circuit

Internal Frequency Converte...

High Power Service Manual for Modular F Frame Drives

52

MG90K202 - VLT

®

 is a registered Danfoss trademark

3

3

Summary of Contents for VLT HVAC Drive FC100

Page 1: ...F Frames MG90K202 MAKING MODERN LIVING POSSIBLE S Service Manual High Power F Frames VLTp HVAC Drive FC100 VLTp AQUA Drive FC200 VLTp XWRPDWLRQ ULYH VLTp 3XOVH www danfoss com drives MG90K202 130R036...

Page 2: ...quired 21 1 10 General Torque Tightening Values 22 1 11 Exploded Views 23 2 Operator Interface and Control 36 2 1 Introduction 36 2 2 Operating the Frequency Converter 36 2 2 1 Operation and Programmi...

Page 3: ...59 4 3 Fault Symptom Troubleshooting 59 4 4 Visual Inspection 61 4 5 Fault Symptoms 62 4 5 1 No Display 62 4 5 2 Intermittent Display 62 4 5 3 Motor Will not Run 62 4 5 4 Incorrect Motor Operation 62...

Page 4: ...t 92 6 2 4 Fan Continuity Test 92 6 3 Dynamic Test Procedures 94 6 3 1 Split Bus Mode 94 6 3 2 Warnings 95 6 3 3 No Display Text 95 6 3 4 Input Voltage Test 95 6 3 5 Basic Control Card Voltage Test 95...

Page 5: ...13 8 1 For Your Safety 113 8 1 1 Danfoss Training Required 113 8 2 Inverter Module 114 8 2 1 Inverter Module Exploded View 114 8 2 2 Internal Access 115 8 2 3 Power Card 115 8 2 4 Upper Capacitor Bank...

Page 6: ...it bus Power Supply 125 10 1 2 Signal Test Board p n 176F8437 125 10 1 3 Signal Test Board Pin Outs Description and Voltage Levels 126 11 Spare Part Lists 132 11 1 1 Spare Parts for 380 480 500 VAC Dr...

Page 7: ...T 12 pulse frequency converter is a high power passive solution to reduce harmonic distortion on mains power lines Connecting each of the two 12 pulse frequency converter input rectifiers to a separat...

Page 8: ...F9 P500 500 650 F10 F11 P560 560 750 F10 F11 P630 630 900 F10 F11 P710 710 1000 F10 F11 P800 800 1200 F12 F13 P1M0 1000 1350 F12 F13 Table 1 5 12 Pulse FC 102FC 102 FC 202 380 480 VAC 380 500 VAC Powe...

Page 9: ...oltage Warning 410 585 Inverter Undervoltage Re Enable warning reset 413 602 Overvoltage Warning w o Brake 817 1084 Dynamic Brake Turn on 810 1099 Inverter Overvoltage Re Enable warning reset 821 1099...

Page 10: ...l kVA 500 V 632 675 771 909 1005 1195 Typical shaft output kW 400 V 450 500 560 630 710 800 HP 460 V 600 650 750 900 1000 1200 kW 500 V 530 560 630 710 800 1000 400V Power loss Normal overload W 10161...

Page 11: ...VA 690 V 753 872 1016 1129 1267 1506 Typical shaft output kW 550 V 500 560 670 750 850 1000 HP 575 V 650 750 950 1050 1150 1350 kW 690 V 630 710 800 900 1000 1200 600V Power loss Normal overload W 893...

Page 12: ...t 500 V KVA 468 511 587 632 Max input current Continuous at 400 V A 590 647 733 787 Continuous at 460 500 V A 531 580 667 718 Max cable size mains mm2 AWG2 4x90 3 0 4x90 3 0 4x240 500 mcm 4x240 500 mc...

Page 13: ...ontinuous at 460 500 V A 759 867 1022 1129 1344 1490 Max cable size motor mm2 AWG2 8x150 8x300 mcm 12x150 12x300 mcm Max cable size mains mm2 AWG2 6x120 6x250 mcm Max cable size brake mm2 AWG2 4x185 4...

Page 14: ...90 V KVA 538 598 681 753 Max input current Continuous at 550 V A 453 504 574 607 Continuous at 575 V A 434 482 549 607 Continuous at 690 V A 434 482 549 607 Max cable size mains mm2 AWG 4x85 3 0 Max c...

Page 15: ...at 690 V A 711 828 920 Max cable size motor mm2 AWG2 8x150 8x300 mcm Max cable size mains mm2 AWG2 6x120 6x250 mcm Max cable size brake mm2 AWG2 4x185 4x350 mcm Max external mains fuses A 1 900 Estim...

Page 16: ...ax panel options losses 400 Weight enclosure IP21 IP 54 kg 1246 1541 1246 1541 1280 1575 Weight Rectifier Module kg 136 136 136 Weight Inverter Module kg 102 102 136 Efficiency4 0 98 Output frequency...

Page 17: ...470 470 540 540 582 Continuous KVA at 500V KVA 384 468 468 511 511 587 587 632 Max input current Continuous at 400 V A 472 590 590 647 647 733 684 787 Continuous at 460 500V A 436 531 531 580 580 667...

Page 18: ...05 1005 1195 1195 1325 Max input current Continuous at 400 V A 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675 Continuous at 460 500 V A 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490 M...

Page 19: ...8 448 408 498 498 568 568 627 Continuous KVA at 690 V KVA 454 538 490 598 598 681 681 753 Max input current Continuous at 550 V A 381 453 413 504 504 574 574 607 Continuous at 575 V A 366 434 395 482...

Page 20: ...s at 550 V A 642 743 743 866 866 962 Continuous at 575 V A 613 711 711 828 828 920 Continuous at 690 V A 613 711 711 828 828 920 Max cable size motor mm2 AWG2 8x150 8x300 mcm Max cable size mains mm2...

Page 21: ...690 V W 4 14457 16375 15899 19207 19105 21857 F3 F4 Max added losses CB or Disconnect Contactor 556 665 634 863 861 1044 Max panel options losses 400 Weight enclosure IP21 IP 54 kg 1246 1541 1246 154...

Page 22: ...ed between rectifier and inverter cabinets Control Options NAMUR terminals Inverter Manual motor starter Rectifier 30 amp fused circuit Rectifier 24 VDC power supply Rectifier Monitoring Options Resid...

Page 23: ...lues Table DC Voltage Levels 380 480 and 380 500 units 525 690 units Inrush Circuit Enabled 370 VDC 548 VDC Inrush Circuit Disabled 395 VDC 600 VDC Inverter Under Voltage Disable 402 VDC 553 VDC Under...

Page 24: ...similar 1 DC link inductor 9 Module heatsink fan 2 Fan transformer 10 Fan door cover 3 DC bus bar 11 Optional brake output bus bar 4 DC bus bar 12 Motor output bus bar 5 Mounting bracket 13 SMPS fuse...

Page 25: ...rd 8 IGBT module 3 Panel connectors 9 Current sensor 4 SMPS fuse and fan fuse 10 Fan assembly 5 Upper capacitor bank assembly 11 Lower capacitor bank assembly 6 DC bus fuses not included in F8 F9 12 G...

Page 26: ...ain DC bus fuses 1 Rectifier module 7 Module lifting eye bolts mounted on vertical strut 2 DC bus bar 8 Module heatsink fan 3 SMPS fuse 9 Fan door cover 4 Optional back AC fuse mounting bracket T 10 S...

Page 27: ...2 Power card 8 Soft charge card mounting plate 3 Panel connectors 9 SCR module 4 SMPS fuse 10 Fan assembly 5 Power card mounting plate flange 11 Diode module 6 Power card mounting plate 12 Soft charg...

Page 28: ...Options Cabinet 1 Contactor 4 Circuit breaker or disconnect 2 RFI filter 5 AC mains line fuses 3 Mains AC power input terminals Introduction High Power Service Manual for Modular F Frame Drives MG90K2...

Page 29: ...Earth ground PE terminals 7 12 pulse inverter module 3 Mains input L11 L21 L31 8 SCR enable disable 4 Mains input L21 L22 L32 9 Relay 1 01 02 03 relay 2 04 05 06 5 Motor connection 96 U 97 V 98 W 10...

Page 30: ...r Module F8 F9 1 MPIC card 5 Diode 2 Rectifier module cover plate 6 SCR 3 Power card 7 Fan assembly 4 Soft charge resistor 8 Soft charge card Introduction High Power Service Manual for Modular F Frame...

Page 31: ...ve in addition two inverter modules while the F12 F13 models have in addition three inverter modules 1 12 pulse rectifier module 4 Mains input L11 L21 L31 L21 L22 L32 2 AUX fan 100 101 102 103 5 BC bu...

Page 32: ...Module F10 F13 1 Transformer 5 Diode 2 Rectifier module cover plate 6 SCR 3 Power card 7 Fan assembly 4 Soft charge resistor 8 Soft charge card Introduction High Power Service Manual for Modular F Fra...

Page 33: ...e monitoring 6 Motor connection 96 U 97 V 98 W 2 Relay 1 01 02 03 relay 2 04 05 06 7 NAMUR fuses 3 NAMUR 8 Fan fuses 4 AUX Fan 100 101 102 103 9 SMPS fuses 5 Brake terminals 81 R 82 R Introduction Hig...

Page 34: ...7 130BA862 12 Illustration 1 11 12 Pulse Inverter Cabinet F12 F13 1 External temperature monitoring 6 Motor connection 96 U 97 V 98 W 2 Relay 1 01 02 03 relay 2 04 05 06 7 NAMUR fuses 3 NAMUR 8 Fan f...

Page 35: ...ptions Cabinet F8 F9 1 Pilz relay terminal 4 Safety relay coil fuse with PILS relay 2 RCD or IRM terminal 5 Line fuses 3 Mains input L11 L21 L31 L21 L22 L32 6 2 x 3 phase manual disconnect Introductio...

Page 36: ...lz relay terminal 4 Safety relay coil fuse with PILS relay 2 RCD or IRM terminal 5 Line fuses 3 Mains input L11 L21 L31 L21 L22 L32 6 2 x 3 phase manual disconnect Introduction High Power Service Manu...

Page 37: ...st procedures to help isolate a fault condition whether in the frequency converter or elsewhere Familiarity with the information provided on the display is important Additional diagnostic data can be...

Page 38: ...Illustration 2 2 LCP Display Area 2 2 4 Menu Keys Menu keys are used for parameter set up toggling through status display modes during normal operation and viewing fault log data 130BP045 10 Status Qu...

Page 39: ...and Reset 130BP046 10 Hand on Off Auto on Reset Hand on Starts or operates the motor in local control through the LCP Use the up and down arrow keys to give the motor a speed command The key can be En...

Page 40: ...tus messages may appear related to the software version and frequency converter type Status 799RPM 7 83A 36 4kW 0 000 53 2 1 1 Auto Hand Off Remote Local Ramping Stop Running Jogging Stand by 130BB037...

Page 41: ...02 DC Braking Time 1 DC Brake is activated OFF in 2 03 DC Brake Cut In Speed RPM and a Stop command e g Stop inverse is active 2 DC Brake inverse is selected as a function for a digital input paramete...

Page 42: ...t overvoltage To avoid tripping the frequency converter alarm protection mode is activated which includes reducing the switching frequency to 4 kHz If possible protection mode ends after approximately...

Page 43: ...inal or serial communication Trip lock A serious alarm occurred It is possible provided the cause of the alarm was cleared to reset the alarm after the mains have been switched off and on again This c...

Page 44: ...1 Input signals The frequency converter can receive two types of remote input signals digital or analog Digital inputs are wired to terminals 18 19 20 common 27 29 32 and 33 Analog or digital inputs...

Page 45: ...terminals must be programmed Each terminal has specific functions it is capable of performing and a numbered parameter associated with it See table Control Terminals and Associated Parameters The sett...

Page 46: ...og signal is 0 4 to 20 mA at a maximum of 500 The digital signal is 24 VDC at a minimum of 500 50 10 VDC 15 mA maximum analog supply voltage for potentiometer or thermistor 53 54 Selectable for 0 to 1...

Page 47: ...IN 2 CONTROL CARD PIN 37 CONTROL CARD PIN 53 CONTROL CARD PIN 55 TB08 PIN 01 TB08 PIN 02 TB08 PIN 04 TB08 PIN 05 1 1 1 1 2 2 3 3 4 5 5 3 3 10 12 13 14 15 16 17 18 30 31 32 33 34 35 36 37 38 39 40 41 4...

Page 48: ...n disturb the entire system This can be resolved by fitting an equalizing cable next to the control cable Minimum cable cross section is 8 AWG 50 60Hz earth loops When using very long control cables 5...

Page 49: ...tor Filter reactor Rectifier DC Bus Inverter AC Line AC Line Sine wave IGBT Motor PWM waveform Illustration 3 2 12 pulse Internal Processing The main frequency converter components are grouped into th...

Page 50: ...le of supplying 200 mA of power part of which may be used to power external encoders or other devices A 10 VDC supply on terminal 50 is rated at 17 mA is also available for use with speed reference ci...

Page 51: ...DC coil has two coils wound on a common core One coil resides in the positive side of the DC bus and the other in the negative The coil reduces mains harmonics The DC bus capacitors are arranged into...

Page 52: ...e eventually adding enough resistance to the circuit to prevent significant current flow This protects the soft charge resistor from damage along with any other components that could be damaged by con...

Page 53: ...UPPLY SPLICE LOCATED IN OPTIONS CABINET CBL1 LOCATED IN RECTIFIER CABINET LOCATED IN INVERTER CABINET T1 A2 A1 C21 C22 C13 C14 DS1 M1 CB1 Illustration 3 6 F frame rectifier circuit RECTIFIER 2 R2 MK10...

Page 54: ...in BLK WHT RED BLK RED 1 3 4 6 10 Pin 7 2 1 10 Pin 7 2 1 14 Pin 8 7 6 11 10 9 16 Pin 8 7 6 11 10 9 16 Pin 8 7 6 11 10 9 16 Pin 5 10 5 10 1 2 1 2 RFI CARD MK1 3 1 2 MK7 MK5 MK6 RFI CARD MK7 MK5 MK6 RFI...

Page 55: ...f the waveform is then determined by the rate at which the pulses occur By employing a sophisticated control scheme the frequency converter is capable of delivering a current waveform that nearly repl...

Page 56: ...T CONNECTOR FU4 FU5 FU6 FU7 FU8 FU9 INV1 INV2 INV3 NOT USED NOT USED NOT USED FOUR POLE FUSIBLE DISCONNECT 400VA TRANSFORMER 24V AC DC POWER SUPPLY BLK OPTION CABINET DOOR INTERLOCK RECTIFIER CABINET...

Page 57: ...HT BLK BLK WHT BLK WHT BLK WHT BLK WHT BLK WHT BLK WHT 6 Pin 1 3 4 6 BLK WHT BLK WHT 1 3 4 6 BLK WHT RED BLK WHT RED BLK WHT RED BLK WHT RED BLK WHT BLK WHT RED BLK WHT BLK WHT BLK WHT 3 MK101 6 4 5 C...

Page 58: ...n this temperature Control Card Ambient Temperature Fan turn ON to low speed 55 C Fan turn OFF from low speed 45 C Table 3 3 Control Card Thermal Sensor Output current value If the output current is g...

Page 59: ...he AC cooling fans from an external source This is required when the frequency converter is used in a load sharing application where no AC power is provided to the main input terminals To make use of...

Page 60: ...urther damage to the unit 8 Read the instruction and service manuals A thorough understanding of the unit is the best approach If ever in doubt consult the factory or authorized repair centre for assi...

Page 61: ...g a frequency converter that is suspected of being faulty or anytime following a repair to the frequency converter Troubleshooting High Power Service Manual for Modular F Frame Drives 60 MG90K202 VLT...

Page 62: ...r 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 cons...

Page 63: ...he proper reference signal is present at the frequency converter input terminals and that the unit is properly programmed to accept the signal provided Refer to the Input Terminal Signal Test Off 1 2...

Page 64: ...ontrol button on the LCP 2 Via a digital input with the Reset function 3 Via serial communication optional fieldbus 4 By resetting automatically using the Auto Reset function NOTE After a manual reset...

Page 65: ...Brake check X X 2 15 29 Heatsink temp X X X 30 Motor phase U missing X X X 4 58 31 Motor phase V missing X X X 4 58 32 Motor phase W missing X X X 4 58 33 Inrush fault X X 34 Fieldbus communication fa...

Page 66: ...81 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 22 2 93 Dry Pump X X 22 2 94 End of Curve X X 22 5 95 Broken Belt X X 22 6 96 Start D...

Page 67: ...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 4194304 Fieldbus Faul...

Page 68: ...rning limit The limit is dependent on the frequency converter voltage rating The unit is still active WARNING ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency...

Page 69: ...rent limit approximately 200 of the rated current is exceeded The warning lasts about 1 5 secs then the frequency converter trips and issues an alarm This fault may be caused by shock loading or fast...

Page 70: ...rs The frequency converter is still operational but without the brake function Remove power to the frequency converter and replace the brake resistor see 2 15 Brake Check WARNING ALARM 26 Brake resist...

Page 71: ...0 Serial port cannot be initialised Contact your Danfoss supplier or Danfoss Service Department 256 258 Power EEPROM data is defective or too old 512 519 Internal fault Contact your Danfoss supplier...

Page 72: ...r heat the motor ALARM 58 AMA internal fault Contact your Danfoss supplier WARNING 59 Current limit The current is higher than the value in 4 18 Current Limit Ensure that Motor data in parameters 1 20...

Page 73: ...operating in reduced power mode i e less than the allowed number of inverter sections This warning will be generated on power cycle when the frequency converter is set to run with fewer inverters and...

Page 74: ...ivalent to Alarm 29 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 F12 or F13 frequency converter 2...

Page 75: ...Hand on and slowly increase the reference speed command to approximately 40 Hz 7 Using the Signal Test Board 176F8437 and an oscilloscope check the waveform at pins 25 30 with the scope referenced to...

Page 76: ...demands of the application 1 29 Automatic Motor Adaptation AMA activates the automatic motor adaptation AMA function When AMA is performed the frequency converter measures the electrical resistance of...

Page 77: ...the frequency converter is running at a steady state speed the overvoltage circuit will increase the frequency to match the speed of the load The same restriction on the amount of influence applies Th...

Page 78: ...These parameters must be set according to the requirements of the particular installation References are set in the parameter group 3 0 Incorrectly set I O configuration usually results in the frequen...

Page 79: ...n fuse on each inverter module protects the fan circuitry from excessive damage in the event of a failure in the heatsink or door fans Perform the fan continuity test to determine the location of the...

Page 80: ...national and European CE EMC directives are required While electromagnetic interference EMI related distur bances to frequency converter operation are uncommon the following detrimental EMI effects ma...

Page 81: ...rs generated EMI 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 wa...

Page 82: ...network Unprotected or poorly routed signal conductors located close to or in parallel to motor and mains conductors are susceptible to EMI Signal conductors are especially vulnerable when they are r...

Page 83: ...ion 5 4 Signal Conductor Currents 130BX140 12 e l b a c r o t o M e n i L C A Converter Motor Stray capacitance AC Line Frequency Illustration 5 5 Alternate Signal Conductor Currents Frequency Convert...

Page 84: ...gle conductors to provide a balanced capacitive and inductive coupling This cancels out differential mode interference While not as effective as true twisted pair cable it can be implemented in the fi...

Page 85: ...installation recommendation as closely as possible to alleviate such problems 130BA048 13 L1 L2 L3 PE Min 16 mm2 Equalizing cable Control cables All cable entries in one side of panel Earthing rail Ca...

Page 86: ...l line powered devices and power supplies are energized at rated voltage Contact with powered components could result in electrical shock and personal injury Dynamic tests are performed with power app...

Page 87: ...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 components will be around 0 300 to 0 500 The opposite...

Page 88: ...ical strut 2 DC bus bar 8 Module heatsink fan 3 SMPS fuse 9 Fan door cover 4 Optional back AC fuse mounting bracket T 10 SMPS fuse 5 Optional middle AC fuse mounting bracket S 11 Power card 6 Optional...

Page 89: ...Rectifier Module Test Points 1 12 pulse rectifier module 4 Fan fuses 2 DC bus bar 5 AC mains fuses 3 SMPS fuse 6 AC connectors Test Procedures High Power Service Manual for Modular F Frame Drives 88 M...

Page 90: ...erse meter leads by connecting negative meter lead to positive DC bus 2 Connect positive meter lead to L1 L2 and L3 in turn Each reading should show a diode drop Incorrect reading With the Part II tes...

Page 91: ...e per module The frequency converter also has snubber capacitors on each IGBT module WARNING Before testing the inverter module ohm check the top and bottom of the DC fuses to ensure no voltage is pre...

Page 92: ...how infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the frequency converter being charged by the meter 6 2 2 3 Inverter test part II 1 Reverse t...

Page 93: ...fective Replace the brake IGBT per the disassembly procedure The inverter module must be removed to replace the IGBT brake 6 2 4 Fan Continuity Test Make all continuity checks using an ohmmeter set to...

Page 94: ...inverter module in F1 F3 drive 1 Unplug the 10 pin connector from the top of Inverter Module number 2 Read the terminals on the wire harness side of the connector male connector 2 Measure between pin...

Page 95: ...abinet Door Fan If bad replace the door fan If good replace the wire harness Reconnect the 8 pin connector on top of the Rectifier Module 6 3 Dynamic Test Procedures 6 3 1 Split Bus Mode Powering the...

Page 96: ...nce of the voltage between the phases is also important The drive can operate within specifications as long as the phase imbalance is not more than 3 Danfoss calculates line imbalance per an IEC speci...

Page 97: ...d L3 T NOTE For 12 pulse units L11 L12 R L21 L22 S L31 L32 T Typically the current should not vary from phase to phase by more than 5 Should a greater current variation exist it would indicate a possi...

Page 98: ...ode See split bus powering 3 Connect a 24VDC power supply to the and DC bus bars 4 Connect the signal test board p n 176F8437 to the 30 pin connector at the top of the inverter module 5 Apply a run co...

Page 99: ...olding torque while at zero speed the current displayed will be greater than expected To make this test disable such parameters 1 Remove power to drive 2 Ensure DC bus is fully discharged 3 Install si...

Page 100: ...is not present in the display the problem may be either in the external control wiring to the drive or a faulty control card To determine the fault location use a volt meter to test for a signal at t...

Page 101: ...nnect the connector MK3 from each soft charge card Since the rectifier test requires the soft charge resistor to be in the circuit verify the resistor is good before proceeding 1 Measure the resistanc...

Page 102: ...nced to pin 4 This procedure must be performed on each inverter module Each waveform should approximate the illustration below 8 Connect a 24 VDC power supply to the DC bus of the drive This can be do...

Page 103: ...e is still present inside the frequency converter cabinet Door interlock Space heater Cabinet light and outlet RCD monitor IRM monitor Emergency stop 24 VDC customer power supply NOTE If supplied with...

Page 104: ...1 AC Line Input Fuses AC Fuse Location AC line fuses are optional AC fuses are located in the rectifier cabinet if they are the only power option added to the frequency converter If additional power...

Page 105: ...ion 7 3 12 pulse Frequency Converter F8 F9 1 12 pulse rectifier module 2 Earth ground PE terminals 3 Mains input L11 L21 L31 4 Mains input L21 L22 L32 5 Motor connection 96 U 97 V 98 W 6 Brake termina...

Page 106: ...use bus bar 4 DC link fuse none in 12 pulse models F8 F9 5 Bottom DC link fuse bus bar 7 2 3 Door Fans 1 Disconnect the leads from the terminal strip on the fan noting the correct terminal that each w...

Page 107: ...place Reinstall in reverse order of disassembly NOTE The plug for the fan is keyed to only fit one way However if too much force is used the plug can be forced the wrong way 1 2 3 4 130BX257 10 1 Heat...

Page 108: ...uts M6 from bracket at back of rectifier securing module to cabinet NOTE Four eye bolts and washers are stored at left bottom side of rectifier cabinet for use in lifting rectifier If desired attach w...

Page 109: ...cabinet for use in lifting inverter If desired attach bolts to holes provided at top of inverter module Module weighs approx 136 kg 300 lbs 7 Remove 2 nuts M6 from bracket at back of inverter securing...

Page 110: ...Remove rectifier control cable from MDCIC board 5 Remove relay connector from MDCIC panel 6 Remove any customer interconnect wiring 7 Remove MDCIC panel by removing four screws M5 attaching panel to i...

Page 111: ...or by removing four screws 8mm on each bus bar 3 Remove 4 mounting bracket bus bars that bus bars removed previously in Step 2 were mounted to by removing screw 8mm from each mounting bracket 4 Remove...

Page 112: ...reinstallation Remove ribbon cables 5 Note position of rectifier control cable MK101 connected to left 6 pin connector for reassembly Disconnect rectifier control cable NOTE Scaling card one on each...

Page 113: ...card step 5 6 Ribbon cable step 4 3 MK101 connector step 5 7 Left side ribbon cable step 2 4 MDCIC board attaching screw step 6 Top Level Module Removal In High Power Service Manual for Modular F Fra...

Page 114: ...and repair components within the unit modules The procedures described in this section are intended for Danfoss qualified technicians Repair work conducted by non certified technicians can result in p...

Page 115: ...er power card 8 IGBT module 3 Panel connectors 9 Current sensor 4 SMPS fuse and fan fuse 10 Fan assembly 5 Upper capacitor bank assembly 11 Lower capacitor bank assembly 6 DC bus fuses 12 Gate driver...

Page 116: ...MK107 on power card 3 Remove two red wires from 15 A fuse block attached to cover plate flange 4 Free cable entirely with the 2 red wires attached to it by disconnecting 10 pin connector next to fuse...

Page 117: ...0 1 Upper capacitor bank assembly 2 Inverter power card 3 8 mm electrical connection nut step 2 4 10 mm retaining nut step 3 5 Lower capacitor bank assembly 6 IGBT gate driver card step 1 8 2 6 High F...

Page 118: ...d by removing 6 mounting screws T25 from standoffs Reinstall in reverse order of this procedure Tighten mounting screws to 2 3 Nm 20 in lbs 1 2 3 4 5 6 130BX256 10 1 MK104 W 4 MK100 2 MK103 V 5 MK105...

Page 119: ...5 6 7 8 9 10 1 1 Attaching nut step 4 2 Left attached bus bar step 4 3 Jumper bus bar between brakes step 5 4 Attaching nut step 5 5 IGBT Ind bus bar assembly step 6 6 Brake IGBT cable step 3 7 Brake...

Page 120: ...GBT module 6 Remove nine snubber capacitors by removing two screws T30 for from each capacitor 7 Remove the three IGBT capacitor bus bars freed by removing screws in step 6 8 Remove four retaining nut...

Page 121: ...those units 9 2 1 Internal Access 1 Remove rectifier module from frequency converter in accordance with instruction in section Rectifier Module 2 Remove right side panel from rectifier module by remov...

Page 122: ...tors from fuse block attached to power card mounting plate flange 2 Disconnect from power card connectors MK100 MK103 MK104 MK105 MK106 and MK110 3 Disconnect three cable connectors 6 pin 8 pin and 12...

Page 123: ...r card mounting plate in accordance with instructions 2 Remove R red S white and T black ring lugs from input power bus bar Two soft charge cards are present for units with two inverter modules three...

Page 124: ...in reverse order of this procedure Tighten T20 screws to 1 0 Nm 20 in lbs 9 2 9 SCR Modules 1 Remove power card mounting plate in accordance with instructions 2 Remove soft charge mounting plate in a...

Page 125: ...dule 4 Remove diode module by removing four retaining screws T30 and washers from corners of module Reassembly 1 Replace diode module in accordance with instructions included with replacement module 2...

Page 126: ...e will be referred to throughout the dynamic test section Powering the Drive in Split Bus Mode 1 Ensure that AC power has been removed and that all DC capacitors are fully discharged 2 Remove the top...

Page 127: ...o verify the presence of such signals it cannot be relied upon to verify that the waveform is correct An oscilloscope is the instrument prefered However when similar signals are being measured at mult...

Page 128: ...VDC Relay active 0 7 VDC inactive 9 Not used 10 Not used 11 VPOS 18 VDC regulated supply 16 5 to 19 5 VDC The red LED indicates voltage is present between VPOS and VNEG terminals 18 VDC regulated supp...

Page 129: ...us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 28 GVN_T IGBT gate signal buffered V 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 50U...

Page 130: ...hases TP25 TP30 27 GVP_T IGBT gate signal buffered V 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 50Us Div Input A 130BX153 10 2v div 100us div...

Page 131: ...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 50Us Div Input A 130BX153 10 2v div 100us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 26 GUN_...

Page 132: ...egative 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 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 Special...

Page 133: ...up from the drive type code FC 102FC 102 and FC 202 power ratings match the drive type code Example FC 302P90KT5 uses a P110T5 spare part FC 102P110T4 or FC 202P110T4 uses a P110T4 spare part NOTE Fo...

Page 134: ...ctifier module P1M0T4 102 202 1 per drive 202 Rectifier 176F8718 Spare rectifier module P500T5 302 1 per drive 302 Rectifier 176F8719 Spare rectifier module P560T5 302 1 per drive 302 Rectifier 176F87...

Page 135: ...302 Power Cards PCA12 176F8774 Spare power card pdefc xxxP500T4xxxxxUxC 102 202 1 per module 102 PCA12 176F8775 Spare power card pdefc xxxP560T4xxxxxUxC 102 202 1 per module 102 PCA12 176F8776 Spare...

Page 136: ...r module 302 PCA12 176F8781 Spare power card pdefc xxxP560T5xxxxxUxC 302 1 per module 302 PCA12 176F8782 Spare power card pdefc xxxP630T5xxxxxUxC 302 1 per module 302 PCA12 176F8783 Spare power card p...

Page 137: ...Current Scaling PCA 4 21 Ohm mounts on MDCIC Card 1 per inverter module 2 2 3 176F8627 Spare Current Scaling PCA 2 32 Ohm mounts on MDCIC Card 1 per inverter module 2 Inductors 176F8564 Spare DC Link...

Page 138: ...brake jumper Inverter cabinet 4 4 4 4 6 6 176F8886 Spare BB IC F Frame motor jumper Inverter cabinet 6 6 6 6 9 9 176F8887 Spare BB IC F Frame motor terminal W Inverter cabinet 2 2 2 2 3 3 176F8888 Sp...

Page 139: ...176F8970 Spare BB RC cu fuse L2 after fuse Fuse in Rectifier Cabinet 1 1 176F8971 Spare BB RC a1 fuse L3 after fuse Fuse in Rectifier Cabinet 1 1 176F8972 Spare BB RC a2 fuse L3 after fuse Fuse in Rec...

Page 140: ...F1 frame 1 1 1 1 CBL08 176F8992 Spare cable F1 RST rectifier to inverter 1 1 1 1 CBL09 10 11 176F8993 Spare cable 44pin inverter to MDCIC from MDCIC to each Inverter Module 2 2 2 2 3 3 CBL19 176F8641...

Page 141: ...176F8563 Spare i sensor 1000a current sensor 3 per inverter module 6 6 9 Capacitors 176F8323 Spare cap igbt snubber 1000v 1 5uf mounts on IGBT 3 per IGBT 18 18 18 18 27 27 176F8996 Spare cap bank f fr...

Page 142: ...1 per module 2 2 2 2 3 3 CBL32 176F9011 Spare cable 30pin power pca f frame from 30 pin plug to power card 1 per module 2 2 2 2 3 3 CBL31 176F9012 Spare cable 44pin power pca f frame from 44 pin plug...

Page 143: ...odule from 16 pin plug to power card 1 per module 1 1 1 1 1 1 CBL51 176F9011 Spare cable 30pin power pca f frame from 30 pin plug to power card 1 per module 1 1 1 1 1 1 CBL52 176F9012 Spare cable 44pi...

Page 144: ...stor 2 2 2 2 3 3 Bus Bars 176F9053 Spare BB rec mod dc bus small al output of SCR and diode modules 1 per kit 2 per drive 2 2 176F9054 Spare BB rec mod dc bus small cu output of SCR and diode modules...

Page 145: ...drive type code FC 102FC 102 and FC 202 power ratings match the drive type code Example FC 302P90KT7 uses a P110T7 spare part FC 102P110T7 or FC 202P110T7 uses a P110T7 spare part NOTE For the latest...

Page 146: ...ectifier 176F8729 Spare rectifier module P710T7 102 202 302 1 per drive 302 Rectifier 176F8730 Spare rectifier module P800T7 102 202 302 1 per drive 302 Rectifier 176F8731 Spare rectifier module P900T...

Page 147: ...xxUxC 102 202 302 1 per module 102 PCA12 176F8793 Spare power card pdefc xxxP800T7xxxxxUxC 102 202 302 1 per module 102 PCA12 176F8794 Spare power card pdefc xxxP900T7xxxxxUxC 102 202 302 1 per module...

Page 148: ...2 302 1 per module 302 PCA12 176F8793 Spare power card pdefc xxxP800T7xxxxxUxC 102 202 302 1 per module 302 PCA12 176F8794 Spare power card pdefc xxxP900T7xxxxxUxC 102 202 302 1 per module 302 PCA12 1...

Page 149: ...connect 3 pol 1200a 690V main disconnect 1 1 176F9060 Spare switch disconnect 3 pol 2000a 690V main disconnect 1 1 1 1 176F9061 Spare contactor 3 pol 650a 690V main contactor 1 1 1 176F9062 Spare cont...

Page 150: ...r Cabinet 1 1 1 176F8901 Spare BB RC a1 fuse L2 to fuse Fuse in Rectifier Cabinet 1 1 1 176F8903 Spare BB RC cu fuse L2 to fuse Fuse in Rectifier Cabinet 1 1 1 176F8904 Spare BB RC a1 fuse L3 to fuse...

Page 151: ...tomer relay F1 frame 1 1 1 CBL08 176F8992 Spare cable F1 RST rectifier to inverter 1 1 1 CBL09 10 11 176F8993 Spare cable 44pin inverter to MDCIC from MDCIC to each Inverter Module 2 2 2 3 3 3 CBL19 1...

Page 152: ...Sensors 176F8343 Spare i sensor 500a current sensor 3 per inverter module 6 6 9 9 176F8563 Spare i sensor 1000a current sensor 3 per inverter module 6 9 Capacitors 176F8534 Spare cap igbt snubber 1250...

Page 153: ...le 2 2 2 3 3 3 CBL32 176F9011 Spare cable 30pin power pca f frame from 30 pin plug to power card 1 per module 2 2 2 3 3 3 CBL31 176F9012 Spare cable 44pin power pca f frame from 44 pin plug to power c...

Page 154: ...ble 30pin power pca f frame from 30 pin plug to power card 1 per module 1 1 1 1 1 1 CBL52 176F9012 Spare cable 44pin power pca f frame from 44 pin plug to power card 1 per module 1 1 1 1 1 1 CBL54 176...

Page 155: ...e 68ohm 155w f softcharge resistor 2 2 2 3 3 3 Bus Bars 176F9053 Spare BB rec mod dc bus small al output of SCR and diode modules 1 per kit 2 per drive 2 2 2 176F9055 Spare BB rec mod dc bus large out...

Page 156: ...PDEFC XXXP710T5 B 2 T5 176F2171 spare rm 1sc 12p PDEFC XXXP800T5 B 1 T5 176F2172 spare rm 2sc 12p PDEFC XXXP800T5 B 1 T5 176F2962 spare rm 1sc 12p PDEFC XXXP1M0T5 B 1 T5 176F2965 spare rm 2sc 12p PDEF...

Page 157: ...spare rm 12p PDEFC XXXP560T7 B 176F3011 spare rm 12p PDEFC XXXP630T7 B 176F3012 spare rm 12p PDEFC XXXP710T7 B 176F3013 spare rm 12p PDEFC XXXP800T7 B 176F3014 spare rm 12p PDEFC XXXP900T7 B 176F3015...

Page 158: ...12p PDEFC XXXP710T5 B 2 T5 176F2165 spare im 12p PDEFC XXXP800T5 B 3 T5 176F2164 spare im 12p PDEFC XXXP1M0T5 B 3 T5 176F2842 spare im 12p PDEFC XXXP315T4 B 1 T4 176F2843 spare im 12p PDEFC XXXP355T4...

Page 159: ...F11 F10 F11 F10 F11 F12 F13 F12 F13 Note all descriptions refer to normal overload ratings Spare Part Number Spare Part Name Inverter Modules 176F2222 spare im 12p PDEFC XXXP900T7 B 176F2876 spare im...

Page 160: ...e pc 12p PDEFC XXXP500T5 B 4 T5 176F3021 spare pc 12p PDEFC XXXP560T5 B 4 T5 176F3022 spare pc 12p PDEFC XXXP630T5 B 4 T5 176F3023 spare pc 12p PDEFC XXXP710T5 B 4 T5 176F3024 spare pc 12p PDEFC XXXP8...

Page 161: ...2144 spare pc im 12p PDEFC XXXP500T7 B 176F2146 spare pc im 12p PDEFC XXXP560T7 B 176F2147 spare pc im 12p PDEFC XXXP630T7 B 176F2129 spare pc rm 12p PDEFC XXXP450T7 B 176F2130 spare pc rm 12p PDEFC X...

Page 162: ...im 176F2428 spare bb brake plus 1 im 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F2432 spare bb brake minus 1 im 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F2433 spare bb brake plus 2 im 1 1 1 1 1 im 1 im...

Page 163: ...1 1 176F2198 spare bb common input c shape rect 400mm 6 6 6 6 176F2199 spare bb r input lower rectifier 400mm 2 2 2 2 176F2200 spare bb t input lower rectifier 400mm 1 1 1 1 176F2204 spare bb s input...

Page 164: ...t 1 1 1 1 176F9187 spare bb s input jumper front cabinet 1 1 1 1 Capacitors 176F8323 spare cap igbt snubber 1000v 1 5uf 9 9 9 9 9 im 9 im 9 im 9 im 9 im 9 im 176F8534 spare cap igbt snubber 1250v 1uf...

Page 165: ...ormal overload ratings Spare Part Number Spare Part Name Current Sensors 176F8343 spare i sensor 500 amp 3 176F8563 spare i sensor 1000a 3 3 3 Disconnects 176F8593 spare disc sw 600a 600v e1 frame 2 2...

Page 166: ...6F8440 spare fuse ppca fan 4a pkg3 d frame 1 1 1 1 1 m 1 m 1 m 1 m 1 m 1 m 176F8440 spare fuse ppca fan 4a pkg3 d frame 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 176F8440 spare fuse ppca fan 4...

Page 167: ...e fc302 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F8466 spare softcharge pca cc t7 e1 frame 176F8555 spare softcharge pca cc t5 e1 frame 2 2 2 2 2 2 2 2 3 3 176F8307 spare hf pca vlt5122 5302t4 5 1 1 1...

Page 168: ...spare cable rec mod 14pin plug power pca 1 1 1 1 1 1 1 1 1 rm 1 rm 176F9012 spare cable 44pin power pca f frame 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 176F9012 spare cable 44pin power pca f frame 1 1...

Page 169: ...pare assy wire scr 2 rect f8 1 1 1 1 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 176F2484 spare assy wire temp sense rect f8 1 1 1 1 176F2498 spare assy wire rst p250 p400 f8 1 1 1 1 2 2 2 2 2 2 176F2502 spare assy...

Page 170: ...170 spare rm 12p PDEFC XXXP710T5 B 176F2171 spare rm 1sc 12p PDEFC XXXP800T5 B 176F2172 spare rm 2sc 12p PDEFC XXXP800T5 B 176F2962 spare rm 1sc 12p PDEFC XXXP1M0T5 B 176F2965 spare rm 2sc 12p PDEFC X...

Page 171: ...C XXXP560T7 B 1 176F3011 spare rm 12p PDEFC XXXP630T7 B 1 176F3012 spare rm 12p PDEFC XXXP710T7 B 2 176F3013 spare rm 12p PDEFC XXXP800T7 B 2 176F3014 spare rm 12p PDEFC XXXP900T7 B 2 176F3015 spare r...

Page 172: ...im 12p PDEFC XXXP710T5 B 176F2165 spare im 12p PDEFC XXXP800T5 B 176F2164 spare im 12p PDEFC XXXP1M0T5 B 176F2842 spare im 12p PDEFC XXXP315T4 B 176F2843 spare im 12p PDEFC XXXP355T4 B 176F2844 spare...

Page 173: ...11 F10 F11 F12 F13 F12 F13 Note all descriptions refer to normal overload ratings Spare Part Number Spare Part Name Inverter Modules 176F2222 spare im 12p PDEFC XXXP900T7 B 2 176F2876 spare im 12p PDE...

Page 174: ...450T5 B 176F3020 spare pc 12p PDEFC XXXP500T5 B 176F3021 spare pc 12p PDEFC XXXP560T5 B 176F3022 spare pc 12p PDEFC XXXP630T5 B 176F3023 spare pc 12p PDEFC XXXP710T5 B 176F3024 spare pc 12p PDEFC XXXP...

Page 175: ...PDEFC XXXP500T7 B 1 176F2146 spare pc im 12p PDEFC XXXP560T7 B 1 176F2147 spare pc im 12p PDEFC XXXP630T7 B 1 176F2129 spare pc rm 12p PDEFC XXXP450T7 B 1 176F2130 spare pc rm 12p PDEFC XXXP500T7 B 1...

Page 176: ...lus 1 im 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F2432 spare bb brake minus 1 im 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F2433 spare bb brake plus 2 im 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F2434...

Page 177: ...76F2198 spare bb common input c shape rect 400mm 6 6 6 6 176F2199 spare bb r input lower rectifier 400mm 2 2 2 2 176F2200 spare bb t input lower rectifier 400mm 1 1 1 1 176F2204 spare bb s input upper...

Page 178: ...76F9187 spare bb s input jumper front cabinet 1 1 1 1 Capacitors 176F8323 spare cap igbt snubber 1000v 1 5uf 176F8534 spare cap igbt snubber 1250v 1uf 9 9 9 9 9 im 9 im 9 im 9 im 9 im 9 im 176F9002 sp...

Page 179: ...ad ratings Spare Part Number Spare Part Name Current Sensors 176F8343 spare i sensor 500 amp 3 im 3 im 3 im 176F8563 spare i sensor 1000a 3 im Disconnects 176F8593 spare disc sw 600a 600v e1 frame 2 2...

Page 180: ...frame 1 1 1 1 1 m 1 m 1 m 1 m 1 m 1 m 176F8440 spare fuse ppca fan 4a pkg3 d frame 1 im 1 im 1 im 1 im 1 im 1 im 1 im 1 im 1 im 1 im 176F8440 spare fuse ppca fan 4a pkg3 d frame 1 1 1 1 1 m 1 m 1 m 1...

Page 181: ...fc302 1 1 1 1 1 im 1 im 1 im 1 im 1 im 1 im 176F8466 spare softcharge pca cc t7 e1 frame 2 2 2 2 2 2 2 3 3 3 176F8555 spare softcharge pca cc t5 e1 frame 176F8307 spare hf pca vlt5122 5302t4 5 Power...

Page 182: ...ower pca 1 1 1 1 1 1 1 1 rm 1 rm 1 rm 176F9012 spare cable 44pin power pca f frame 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 1 m 176F9012 spare cable 44pin power pca f frame 1 1 1 1 1 im 1 im 1 im 1 im 1 im...

Page 183: ...1 176F2485 spare assy wire scr 2 rect f8 1 1 1 1 1 rm 1 rm 1 rm 1 rm 1 rm 1 rm 176F2484 spare assy wire temp sense rect f8 1 1 1 1 176F2498 spare assy wire rst p250 p400 f8 1 1 1 1 2 2 2 1 1 1 176F250...

Page 184: ...TEST CONNECTOR FU4 FU5 FU6 FU7 FU8 FU9 INV1 INV2 INV3 NOT USED NOT USED NOT USED FOUR POLE FUSIBLE DISCONNECT 400VA TRANSFORMER 24V AC DC POWER SUPPLY BLK OPTION CABINET DOOR INTERLOCK RECTIFIER CABIN...

Page 185: ...tor 3 10 11 1 8 5 7 6 5 7 3 10 11 14 PIN 8 MK112 RELAY AUX 2 NC NO C 2 3 1 NC NO C RELAY AUX 1 6 5 4 8 7 6 11 10 9 8 PIN 5 1 5 8 8 4 4 1 12 PIN BLK RED WHT BLK RED WHT BLK RED WHT BLK RED WHT BLK RED...

Page 186: ...O T C E N N O C T S E T 50 39 42 53 54 55 L2 TR1 F1 F3 F4 REG TB5 REG 18 12 13 27 19 29 32 33 20 37 REGEN TERMINALS RECTIFIER CABINET DOOR FAN INVERTER DOOR FAN OPTIONS CABINET DOOR FAN HEATSINK DOOR...

Page 187: ...ERTERS 1 2 3 TEST CONNECTOR SPLICE 43 1 29 1 SCR4 D4 D5 D6 SCR5 SCR6 WHT WHT WHT BLK BLK BLK 1 1 2 2 HEATSINK NTC N2 MK107 L2 L1 FANS L1 L1 L2 11 13 5 4 3 X2 AUX_S L1 AUX_S AUX_T X1 AUX_T 9 12 1 16 8...

Page 188: ...1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 DC DC 4 4 BLK 2 3 WHT 1 2 3 1 FAN CAPACITOR HEATSINK...

Page 189: ...SED NOT USED 106 104 50 39 42 53 54 55 PCA13 L2 TR1 TR2 TR3 F3 F4 REG TB5 REG 18 12 13 27 19 29 32 33 20 37 REGEN TERMINALS INVERTER CABINET DOOR FAN HEATSINK DOOR FAN TRASNFORMER HEATSINK DOOR FAN TR...

Page 190: ...1 3 3 2 2 4 4 5 5 6 6 6 PIN BLK WHT 1 Heatsink Temp Sensor BLK WHT BLK WHT RED RED BLK WHT BLK WHT BLK RED WHT RED WHT BLK RED WHT BLK 1 2 2 Fu1 4A HEATSINK NTC TH1 1 29 1 43 1 20 TO OPTION AND INVER...

Page 191: ...6 PIN SCR2 SCR3 BLK WHT BLK WHT BLK WHT WHT WHT WHT BLK BLK BLK DC B A MK105 DC 1 1 3 3 2 2 4 4 5 5 6 6 6 PIN BLK WHT 1 Heatsink Temp Sensor BLK WHT BLK WHT RED RED BLK WHT BLK WHT BLK RED WHT RED WHT...

Page 192: ...F Frames MG90K202 MAKING MODERN LIVING POSSIBLE S Service Manual High Power F Frames VLTp HVAC Drive FC100 VLTp AQUA Drive FC200 VLTp XWRPDWLRQ ULYH VLTp 3XOVH www danfoss com drives MG90K202 130R036...

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