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Danfoss VLT HVAC FC 100 Service Manual Download Page 1

Rev. 2008-09-01

www.danfoss.com/drives

130R0438

MG90L122

*MG90L122*

High Power

Service Manual

High Power Service Manual

MG90L122

VLT

®

 HVAC Drive FC 100

VLT

®

 AQUA Drive FC 200

VLT

®

 AutomationDrive FC 300

MAKING MODERN LIVING POSSIBLE

Rev. 2008-09-01

www.danfoss.com/drives

130R0438

MG90L122

*MG90L122*

High Power

Service Manual

High Power Service Manual

MG90L122

VLT

®

 HVAC Drive FC 100

VLT

®

 AQUA Drive FC 200

VLT

®

 AutomationDrive FC 300

MAKING MODERN LIVING POSSIBLE

Summary of Contents for VLT HVAC FC 100

Page 1: ...LT HVAC Drive FC 100 VLT AQUA Drive FC 200 VLT AutomationDrive FC 300 MAKING MODERN LIVING POSSIBLE High Power Service Manual VLT HVAC Drive FC 100 VLT AQUA Drive FC 200 VLT AutomationDrive FC 300 MAK...

Page 2: ...Messages 2 7 Service Functions 2 13 Frequency Converter Inputs and Outputs 2 14 Input Signals 2 15 Output Signals 2 15 Control Terminals 2 16 Control Terminal Functions 2 17 Grounding Shielded Cables...

Page 3: ...1 Torque Limit Current Limit and Unstable Motor Operation 5 1 Overvoltage Trips 5 2 Line Phase Loss Trips 5 3 Control Logic Problems 5 3 Programming Problems 5 4 Motor Load Problems 5 5 Internal Adju...

Page 4: ...Voltage Test 6 21 Basic Control Card Voltage Test 6 22 Switch Mode Power Supply SMPS Test 6 23 Zero DC Bus Voltage Test 6 24 DC Undervoltage Test 6 24 Input Phase Imbalance Test 6 25 Input Waveform Te...

Page 5: ...Instructions 8 1 Electrostatic Discharge ESD 8 1 Instructions 8 1 Control Card and Control Card Mounting Plate 8 1 Control Assembly Support Bracket 8 2 Power Card 8 3 Soft Charge Card 8 4 Gate Drive C...

Page 6: ...Block Diagrams 11 1 Block Diagrams for D Frames 11 2 D1 D3 380 500 VAC 11 2 D2 D4 380 500 VAC 11 3 D1 D3 525 690 VAC 11 4 D2 D4 525 690 VAC 11 5 Block Diagrams for E Frames 11 6 E1 E2 380 500 VAC 11 6...

Page 7: ...ternate Signal Conductor Currents 5 9 Figure 5 5 Proper EMC Installation 5 11 Figure 6 1 Signal Test Board 6 2 Figure 6 2 SCR Shorting Plug 6 3 Figure 6 3 Two Pin 6 3 Figure 6 4 Three Pin 6 3 Figure 6...

Page 8: ...3 7 11 Figure 7 10 D1 D3 7 12 Figure 7 11 Input Terminal Mounting Plate Assembly no options shown 7 13 Figure 7 12 D2 D4 7 14 Figure 7 13 D2 D4 7 15 Figure 7 14 D2 D4 7 16 Figure 7 15 D2 D4 7 17 Figur...

Page 9: ...Current Sensors 8 13 Figure 8 12 Fan Assembly 8 14 Figure 8 13 Terminal Blocks 8 15 Figure 8 14 IGBT Modules 1 of 4 8 16 Figure 8 15 IGBT Modules 2 of 4 8 17 Figure 8 16 IGBT Modules 3 of 4 8 18 Figu...

Page 10: ...3 Spare Parts List Fuses Inductors Current Sensors and Disconnects 10 4 Table 10 4 Spare Parts List Cables 1 2 10 5 Table 10 5 Spare Parts List Cables 2 2 10 6 Table 10 6 Spare Parts List Cables 10 7...

Page 11: ...Spare Parts List Disconnects and Cables 10 23 Table 10 21 Spare Parts List Terminals Labels Insulators 10 24 Table 10 22 Spare Parts List Bus Bars and Enclosure 10 25 Contents High Power Service Manu...

Page 12: ...or constant torque down to 15 Hz and include special features and options well suited for fan and pump applications within the HVAC market VLT AQUA FC 202 series adjustable frequency drives are desig...

Page 13: ...disconnected 3 The STOP key on the control panel does not disconnect line power 4 During operation and while programming parameters the motor may start without warning Activate the STOP key when chang...

Page 14: ...250 350 315 D2 D4 P400 315 400 400 D2 D4 P450 355 450 450 E1 E2 P500 400 500 500 E1 E2 P560 450 600 560 E1 E2 P630 500 650 630 E1 E2 Table 1 3 FC 102 and FC 202 525 690 VAC 525 690 VAC Power Model FC...

Page 15: ...t cable p n 176F8439 Signal test board p n 176F8437 1 7 General Torque Tightening Values For fastening hardware described in this manual the torque values in the table below are used These values are...

Page 16: ...acket 18 Fan assembly F1 C1 CBL11 6 Power card mounting plate 19 Fan transformer TR1 7 Power card PCA 3 20 Main AC power input terminals TB1 8 Capacitor bank assembly CBANK1 PCA9 21 AC input bus bar 9...

Page 17: ...CBL11 7 Power card PCA3 21 Main AC power input terminals TB1 8 Upper capacitor bank cover plate 22 AC input bus bar 9 Upper capacitor bank assembly CBANK2 PCA10 23 Input terminal mounting plate assemb...

Page 18: ...assembly F1 C1 6 Power card mounting plate 19 Output motor terminals TB2 7 Power card PCA3 20 Current sensor L2 L3 L4 8 IGBT gate drive card PCA5 21 Main AC power input terminals TB1 9 Upper capacitor...

Page 19: ...00 250 315 High overload torque 160 Output current Nominal A 380 440 V 177 212 260 315 395 MAX 60 sec A 380 440 V 266 318 390 473 593 Nominal A 441 500 V 160 190 240 302 361 MAX 60 sec A 441 500 V 240...

Page 20: ...460 V 353 430 470 540 Nominal kVA 500 V 384 468 511 587 Typical shaft output kW 400 V 250 315 355 400 HP 460 V 350 450 500 550 kW 500 V 315 355 400 500 Power loss Normal overload W 6790 7701 8879 9670...

Page 21: ...kVA 575 V 130 154 191 241 289 343 Nominal kVA 690 V 157 185 229 289 347 411 Typical shaft output kW 550 V 90 110 132 160 200 250 HP 575 V 125 150 200 250 300 350 kW 690 V 110 132 160 200 250 315 Powe...

Page 22: ...6 54 73 86 108 Nominal kVA 690 V 55 65 87 103 129 Typical shaft output kW 550 V 30 37 45 55 75 HP 575 V 40 50 60 75 100 kW 690 V 37 45 55 75 90 Power loss Normal overload W 1458 1717 1913 2262 2662 Po...

Page 23: ...5 V 376 408 498 568 Nominal kVA 690 V 454 490 598 681 Typical shaft output kW 550 V 315 315 400 450 HP 575 V 400 400 500 600 kW 690 V 355 400 500 560 Power loss Normal overload W 6449 7249 8727 9673 P...

Page 24: ...and alarms that the adjustable frequency drive displays are generated by response to faults outside of the adjustable frequency drive This service manual provides tech niques and test procedures to h...

Page 25: ...the warning is shown instead of the variables It is possible to toggle between three status readout displays by pressing the Status key Operating variables with different formatting are shown in each...

Page 26: ...otor power and Frequency are selected as varia bles in the first and second lines 1 1 1 2 and 1 3 are shown in small size 2 is shown in large size 130BP062 10 1 1 1 3 1 2 2 Status display III This sta...

Page 27: ...otor Three different readouts can be chosen by pressing the Status key 5 line readouts 4 line readouts or Smart Logic Control Use Status for selecting the mode of display or for changing back to displ...

Page 28: ...rts to the previous step or layer in the navigation structure Cancel last change or command will be canceled as long as the display has not been changed Info displays information about a command param...

Page 29: ...er supply Auto On enables the adjustable frequency drive to be controlled via the control terminals and or serial communication When a start signal is applied on the control terminals and or the bus t...

Page 30: ...icks 2 3 Status Messages Status messages appear in the bottom of the display see the example below The left part of the status line indicates the active operation model of the adjustable frequency dri...

Page 31: ...ble complete or reduced AMA was selected in par 1 29 Automatic Motor Adaptation AMA The AMA process is in progress Braking The brake chopper is in operation Generative energy is absorbed by the brake...

Page 32: ...rresponding terminal is not active 3 The DC Brake is activated via serial communication DC Voltage U0 In par 1 01 Motor Control Principle U f and in par 1 80 Function at Stop DC Voltage U0 is selected...

Page 33: ...hat a motor is connected to the adjustable frequency drive a per manent test current is applied to the motor Off1 PROFIDrive profile was selected in par 8 10 Control Word Profile The OFF 1 function is...

Page 34: ...rence value Run request FC 100 200 only A start command has been given but the motor will be stopped until a Run permissive signal is received via digital input Running The motor is driven by the adju...

Page 35: ...eration status control ready Stop Off was pressed on the LCP or Stop inverse was selected as a function for a digital input Group 5 1 The corresponding terminal is not active Trip An alarm occurred It...

Page 36: ...c cessed by displaying items in the adjustable frequency drive s 15 parameter group Parameter settings are displayed by pressing the MAIN MENU key on the LCP 130BP045 10 Use the arrow keys and on the...

Page 37: ...equency drive and reads status data from the adjustable frequency drive The serial bus connects to the adjustable frequency drive through the RS 485 serial port or through a com munication option card...

Page 38: ...and 69 Terminal 61 is common and may be used for terminating shields only when the control cable run between adjustable frequency drives not between adjustable frequency drives and other devices See G...

Page 39: ...n addition the input terminal must be receiving a signal Confirm that the control and power sources are wired to the terminal Then check the signal Signals can be checked in two ways Digital input can...

Page 40: ...es such as frequency ref erence current and torque The analog 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...

Page 41: ...Terminals Electrical Diagram 2 Operator Interface and Adjustable Frequen cy Drive Control High Power Service Manual for VLT FC Series Adjustable Frequency Drives 2 18 MG 90 L1 22 VLT is a registered D...

Page 42: ...ved by fitting an equalizing cable next to the control cable Minimum cable cross section is 8 AWG 50 60 Hz ground loops When using very long control cables 50 60 Hz ground loops may occur that can dis...

Page 43: ...2 Operator Interface and Adjustable Frequen cy Drive Control High Power Service Manual for VLT FC Series Adjustable Frequency Drives 2 20 MG 90 L1 22 VLT is a registered Danfoss trademark 2...

Page 44: ...as the load on the motor changes The adjustable frequency drive can also stop and start a motor without the mechanical stress associated with a line start In its basic form the adjustable frequency d...

Page 45: ...tor which matches the requirements of the motor Also available is the continuous pulsing SFAVM PWM Selection can be made in parameter group 14 The dynamic response of the system changes to meet the va...

Page 46: ...r or custom oper ating software 3 2 2 Logic to Power Interface The logic to power interface isolates the high voltage components of the power section from the low voltage signals of the logic section...

Page 47: ...duction of line harmonics The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing cir cuitry Due to the requirement for higher power capacity some adjustable frequenc...

Page 48: ...e PTC resistors to heat up due to the current flow Resistance of the PTC device increases with temperature eventually adding enough resistance to the circuit to pre vent significant current flow This...

Page 49: ...ITCH RFI SWITCH PCA8 CBANK1 RFI CARD GATE EM COL LOAD SHARE OPTION FU5 NC NO C RELAY 1 RELAY 2 C NO NC 27 Ohms 90kW 175L9426 110kW 175L9427 130B6868 Coated PCA 12 130B6872 RFI ONLY 130B6873 COATED RFI...

Page 50: ...ate section is the high frequency HF filter card It contains a high frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interfer ence with other sensitive equipm...

Page 51: ...re 3 5 Intermediate section 3 Internal Adjustable Frequency Drive Opera tion High Power Service Manual for VLT FC Series Adjustable Frequency Drives 3 8 MG 90 L1 22 VLT is a registered Danfoss tradema...

Page 52: ...eform is then determined by the rate at which the pulses occur By employing a sophisticated control scheme the adjustable frequency drive is capable of deliv ering a current waveform that nearly repli...

Page 53: ...175L9421 ASSY 175L8314 ASSY 175L8314 ECONOPACK MODULE LEGEND AUX FAN C NC NO GND GND GATE DRIVER OUT IN PRE TEST RFI SWITCH RFI CARD GATE EM COL FU5 NC NO C RELAY 1 RELAY 2 C NO NC PCA 12 130B6872 RFI...

Page 54: ...xample when the load drives the motor causing the voltage to return to the DC bus circuit Placing the brake resistor externally has the advantages of selecting the resistor based on appli cation need...

Page 55: ...s 60 of nominal current exceeded Specific heatsink temperature exceeded power size dependent DC hold active DC brake active Pre magnetization of the motor Automatic motor adaptation in progress Regard...

Page 56: ...e generative mode to share its excess bus voltage with another adjustable frequency drive that is in motoring mode When applied correctly this can reduce the need for external dynamic brake resistors...

Page 57: ...w powering the AC cooling fans from an external source This is required when the adjustable frequency drive is used in a load sharing application where no AC power is provided to the main input termin...

Page 58: ...ocedures 3 Never attempt to defeat any fault protection circuitry within the adjustable frequency drive That will result in unnecessary component damage and may cause personal injury 4 Always use fact...

Page 59: ...unctions so an alarm or warning does not necessary indicate a problem within the adjustable frequency drive itself Each incident has further descriptions on how to troubleshoot that particular symptom...

Page 60: ...ion with regard to electromagnetic capability Refer to the adjust able frequency drive instruction manual and Section 5 of this manual for further details Environmental conditions Under specific condi...

Page 61: ...ay be elsewhere Proceed to the No Display test 6 3 1 to carry out further troubleshooting steps 4 5 2 Intermittent Display Cutting out or flashing of the entire display and power LED indicates that th...

Page 62: ...esent at the adjustable frequency drive input terminals and that the unit is properly programmed to accept the signal provided Refer to the Input Terminal Signal Test 6 3 16 Off 1 2 or 3 This indicate...

Page 63: ...balance Test 6 3 10 to check for loss of motor phase Motor runs rough Possible over magnetization incorrect motor settings or an IGBT misfiring Note Motor may also stall when loaded or the adjustable...

Page 64: ...e a dangerous condition Alarms must be reset to restart operation once their cause has been rectified This may be done in three ways 1 Pressing the reset button on the control panel LCP 2 A digital re...

Page 65: ...8 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 X 41 Overload of Digital Output Terminal 29 X 42 Overload of Digital Output on X30 6 or Overload of Digital Output...

Page 66: ...Max 15 mA or minimum 590 This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning...

Page 67: ...s dependent on the adjustable frequency drive voltage rating The adjustable frequency drive is still active See ratings table in Section 1 9 for the voltage limits WARNING ALARM 7 DC overvoltage If th...

Page 68: ...counter reaches 100 in par 1 90 Motor Thermal Protection The fault is that the motor is overloaded by more than 100 for too long Troubleshooting Check if motor is overheating If the motor is mechanic...

Page 69: ...a discharge from the output phases to ground either in the cable between the adjustable frequency drive and the motor or in the motor itself See section 1 9 for trip levels Troubleshooting Turn off t...

Page 70: ...function that checks if the fan is running mounted The fan warning can be disabled in par 14 53 Fan Monitor 0 Disabled For the D E and F frame adjustable frequency drives the regulated voltage to the...

Page 71: ...maged heatsink fan For the D E and F frame adjustable frequency drives this alarm is based on the temperature measured by the heatsink sensor mounted inside the IGBT modules For the F frame adjustable...

Page 72: ...id not respond when calculating Platform Version 1536 An exception in the Application Orientated Control is registered Debug information written in LCP 1792 DSP watchdog is active Debugging of power p...

Page 73: ...p power supply may be overloaded otherwise contact your Danfoss supplier WARNING 48 1 8 V supply low The 1 8 Volt DC supply used on the control card is outside of allowable limits The power supply is...

Page 74: ...temperature of the control card is 176 F 80 C WARNING 66 Heatsink temperature low This warning is based on the temperature sensor in the IGBT module See the ratings table in Section 1 9 for the temper...

Page 75: ...er settings are initialized to default settings after a manual reset WARNING 81 CSIV corrupt CSIV file has syntax errors WARNING 82 CSIV parameter error CSIV has failed to record a parameter ALARM 91...

Page 76: ...he alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 245 Heatsin...

Page 77: ...log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F...

Page 78: ...ximately 40 Hz 6 Using an analog voltmeter or a DVM capable of measuring true RMS measure phase to phase output voltage on all three phases U to V U to W V to W All voltages must be balanced within 8...

Page 79: ...4 Troubleshooting High Power Service Manual for VLT FC Series Adjustable Frequency Drives 4 22 MG 90 L1 22 VLT is a registered Danfoss trademark 4...

Page 80: ...e motor Par 1 03 Torque Characteristics sets the adjustable frequency drive for constant or variable torque operation It is imperative that the correct torque characteristic is selected based on the a...

Page 81: ...stable frequency drive will trip on inverter time Adjustments cannot be made to alter this circuit Improper pa rameter settings effecting load current can result in premature trips of this type The ti...

Page 82: ...he capacitors and DC coil would be drastically reduced When the input voltage becomes unbalanced or a phase disappears completely the ripple voltage increases causing the adjustable frequency drive to...

Page 83: ...and motor operation are motor settings references and limits and I O configuration See Drive Inputs and Outputs in Section 2 The adjustable frequency drive must be set up correctly for the motor s co...

Page 84: ...uency drive is functioning correctly The problem therefore is external to the adjustable frequency drive If the voltage measurements are not balanced the adjustable frequency drive is malfunctioning T...

Page 85: ...to disconnect the motor from the adjustable frequency drive then observe the current in the display of the adjust able frequency drive With the motor disconnected the current should of course be zero...

Page 86: ...network data loss Digital control system faults 5 2 5 Sources of EMI Modern adjustable frequency drives see Figure 5 1 utilize Insulated Gate Bipolar Transistors IGBTs to provide an efficient and cost...

Page 87: ...bus via the ground circuit and a high frequency HF bypass network within the adjustable frequency drive itself However imperfections in the adjustable frequency drive grounding or the equipment groun...

Page 88: ...ed cable has lower high frequency impedance than round cable Simply mounting the adjustable frequency drive or motor onto a painted surface will not create an effective ground connection In addition r...

Page 89: ...gets back into the power network or takes other undesirable and unpredictable high frequency paths Unlike most signal wiring the shielding on the motor cable should be terminated at both ends If shiel...

Page 90: ...e better immunity the network will have against EMI Should EMI problems arise in an installation refer to this example Attempt to replicate this installation recommendation as closely as possible to a...

Page 91: ...5 Adjustable Frequency Drive and Motor Ap plications High Power Service Manual for VLT FC Series Adjustable Frequency Drives 5 12 MG 90 L1 22 VLT is a registered Danfoss trademark 5...

Page 92: ...p or After Repair Drive Tests Static tests are conducted without power applied to the adjustable frequency drive Most adjustable frequency drive problems can be diagnosed simply with these tests Stati...

Page 93: ...ithin the adjustable frequency drive and pro vides easy access to test points The test board plugs into connector MK104 on the power card Its use is described in the procedures where called out See Si...

Page 94: ...e adjustable frequency drives use the 3 pin cable see the figures below The D frame cable connects to the wire harness above the power card by the SMPS fuse to the power card connector MK105 The E fra...

Page 95: ...on the model of ohmmeter Whatever the ohmmeter displays as a typical forward bias diode is defined as a diode drop in these procedures With a typical DVM the voltage drop across most components will b...

Page 96: ...only It is not necessary to remove the card to perform the tests Soft charge fuse test Use a digital ohmmeter to test continuity on rectifier fuses F1 F2 and F3 at connector MK106 on the power card N...

Page 97: ...diodes in the soft charge rectifier are open It could also indicate that one or more of the soft charge fuses are open It could further indicate that the soft charge resistor is open To isolate betwe...

Page 98: ...possible it is unlikely since that indicates that both the diodes in the SCR diode modules and the lower diodes in the soft charge rectifier are open Should that occur replace both diodes 1 Extract t...

Page 99: ...dance with the disassembly proce dures in Section 7 7 Reverse the meter leads with the negative meter lead to the negative MK3 C Connect the positive meter lead to MK1 terminals R S and T in sequence...

Page 100: ...cuit Continue test procedures Figure 6 6 shows the soft charge card and the location of the fuses It is for reference only It is not necessary to remove the card to perform the tests Disconnect the MK...

Page 101: ...nnect the positive meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the negative meter lead to terminals L1 L2 and L3 in sequence Each reading should show a diode drop I...

Page 102: ...nect the negative meter lead to the positive MK3 A DC output to DC bus and connect the positive meter lead to MK1 terminals R S and T in sequence Each reading should show a diode drop 3 Reverse meter...

Page 103: ...er card 2 Connect the positive meter lead to U V and W in sequence Each reading should show a diode drop Incorrect reading An incorrect reading in any inverter test indicates a failed IGBT module Repl...

Page 104: ...ure pins 1 and 2 of each test connector Reading should indicate 7 8K ohms for D1 D3 frames 3 9K ohms for D2 D4 frames and 2 6K ohms for E1 E2 frames Incorrect reading An incorrect reading indicates th...

Page 105: ...and then move towards infinity as the meter charges the capacitors 4 Reverse meter leads on connector MK105 on the power card 5 The meter will peg at zero while the capacitors are discharged by the m...

Page 106: ...sistance will be approximately 1 5k Ohms The higher the temperature the lower the resistance 6 2 9 Fan Continuity Tests D frame Size Make all continuity checks using an ohmmeter set to Rx1 scale Digit...

Page 107: ...s should be read 2 Measure between CN2 terminals 1 and 2 Approximately 8 ohms should be read 3 Measure between CN2 terminals 2 and 3 Approximately 12 ohms should be read Incorrect reading An incorrect...

Page 108: ...10 1 2 3 Figure 6 10 Fan Transformer and Fuse Location 380 480 500 V White label on fan transform er 525 690 V Orange label on fan transformer 1 Fan transformer 3 Fan fuse 2 CN2 High Power Service Ma...

Page 109: ...fuse and continue the fan checks Ohm test of transformer For the following tests read the plug end of the wire connected to MK107 on the power card 1 Measure between MK107 terminals 1 and 8 Should rea...

Page 110: ...rrect replace the inductor 2 Measure between terminals 11 and 13 of power card connector MK107 For units with one top mounted fan a reading of 400 ohms is expected For units with two door moun ted fan...

Page 111: ...ith power applied due to danger of severe injury or death Take all the necessary safety precautions for system start up prior to applying power to the adjustable frequency drive 130BX79 10 1 2 3 4 Fig...

Page 112: ...C Readings of less than 342 VAC indicate problems with the input AC line voltage For 525 690 V adjustable frequency drives all measurements must be within the range of 446 759 VAC Readings of less tha...

Page 113: ...rminal strip and repeat the test If this test is successful then continue Remember to check the customer connections If still unsuccessful proceed to the Switch Mode Power Supply SMPS test 2 Measure t...

Page 114: ...board into the power card con nector MK104 4 Connect the negative meter lead to terminal 4 common of the signal board With a positive meter lead check the following terminals on the signal board Termi...

Page 115: ...of the power supplies on the power card The power card and fuse require replacement If the fuse checks good there may be a problem with the soft charge circuitry Proceed to the static checks of the s...

Page 116: ...cy drive or a problem within the adjustable frequency drive itself One way to determine if the line power supply is at fault is to swap two of the incoming phases This assumes that two phases read one...

Page 117: ...an oscilloscope with voltage and current probes Under normal operating conditions the waveform of a single phase of input AC voltage to the adjustable frequency drive appears as in Figure 6 13 Figure...

Page 118: ...sult of an input or lack of input at power card connector FK102 the external brake temperature switch Unless used as an input a jumper must be placed between terminals 104 and 106 of FK102 The SCRs ar...

Page 119: ...the inrush signal is inactive and the SCRs are not gated With a reading of 5 VDC and proper line power applied to the adjustable frequency drive it would be likely that the control card is defective I...

Page 120: ...drive card and IGBTs or the output circuitry of the drive improperly connected NOTE Use an analog voltmeter for monitoring output voltage Digital voltmeters are sen sitive to waveform and switching fr...

Page 121: ...the gate signals can be performed with a DVM however to actually check the waveforms an oscilloscope is required Disable the DC bus when performing this test with Test Cable p n 176F8437 Failure to do...

Page 122: ...drive 9 Measure pins 1 and 2 of each test connector Each reading should be approximately 9 VDC indicating all IGBTs are turned off 10 Apply the run command to the adjustable frequency drive and 30 Hz...

Page 123: ...six gate signals at signal board terminals 25 through 30 14 Place the adjustable frequency drive in run at 30 Hz The waveform should appear as in Figure 6 19 Figure 6 19 Gate Signal Waveform from Sign...

Page 124: ...3 Leave the positive meter lead connected to cable MK105 and run the adjustable fre quency drive at 30 Hz 4 In sequence again connect the negative meter lead to the adjustable frequency drive output t...

Page 125: ...he signal on terminal 13 is not correct first check that the adjustable frequency drive is correctly programmed for dynamic braking parameter 2 10 If the programming is correct replace the control car...

Page 126: ...test board Resistance should be the same for all three readings Table 6 2 shows approximate resistance readings based on adjustable frequency drive power and voltage rating Note that values listed are...

Page 127: ...verify the supply voltage is present as follows 1 Use a voltmeter to measure the AC phase to phase voltage at R S and T of power card connector MK106 It should equal main supply voltage applied to adj...

Page 128: ...board can be used to verify those signals 1 Remove power from the adjustable frequency drive and allow the DC bus to fully dis charge 2 Install the signal test board into power connector MK104 3 Reap...

Page 129: ...C If the 24 V supply voltage is not present conduct the Control Card Test 6 3 17 later in this section If 24 V is present proceed with checking the individual inputs as follows 2 Connect the negative...

Page 130: ...in Table 4 1 2 Perform static test procedures 6 2 1 6 2 2 and 6 2 5 for D frame size units or 6 2 3 6 2 4 and 6 2 5 for E frame size units to ensure the adjustable frequency drive is safe to start 3 D...

Page 131: ...6 Test Procedures High Power Service Manual for VLT FC Series Adjustable Frequency Drives 6 40 MG 90 L1 22 VLT is a registered Danfoss trademark 6...

Page 132: ...it s physical size Refer to the tables in the Introduction section to determine frame size definitions See Section 8 for E frame sizes disassembly and assembly instructions 7 2 Instructions 7 2 1 Cont...

Page 133: ...upport bracket 12 Control card terminal block 6 Attaching hardware 13 Control card under LCP 7 Power card mounting plate 7 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate...

Page 134: ...part of the replacement power card Reinstall in reverse order of this procedure When installing the power card ensure that the in sulator sheet is installed behind the power card Tighten the mounting...

Page 135: ...us fuse holder 7 Remove the 2 nuts 10 mm on the right side of the power card mounting plate Two nuts that secure the control assembly mounting bracket also secure the left side of the power card mount...

Page 136: ...by aligning the soft charge card with fastening clips on the side of the chassis Reattach the connectors Slide into place and tighten the mounting screws to 4 Nm 35 in lbs 130BX122 10 1 2 3 5 4 Figur...

Page 137: ...ews T25 Torx from the standoffs Reinstall in reverse order of this procedure Tighten the mounting screws to 2 3 Nm 20 in lbs 130BX160 10 2 3 4 5 6 7 1 Figure 7 4 Gate Drive Card 1 MK100 temperature se...

Page 138: ...4 retaining nuts 10 mm from the cap bank cover plate and remove the cover plate 4 Note that the weight of the cap bank is approximately 20 lbs 9 kg Remove the cap bank by pulling it free from the mou...

Page 139: ...racket in accordance with instructions 2 Remove the 2 capacitor bank retaining nuts 10 mm from the DC bus bars A minimum 4 in 100 mm extension is required 3 Note that the IGBT gate drive card can rema...

Page 140: ...the retaining nut 8 mm furthest to the right 4 Remove the 8 mm retaining nut furthest to the left 5 Lift the left side of the SC resistor and remove the resistor by sliding it to the left and out fro...

Page 141: ...Remove the wiring from the studs Remove the retaining screw T25 from terminal 1 of each of 3 SCR diode modules and remove the bus bar CONTINUED ON NEXT PAGE 130BX87 10 1 2 3 Figure 7 8 D2 D4 Soft Char...

Page 142: ...ts with load sharing Remove the DC input bus assembly CONTINUED ON NEXT PAGE 130BX85 10 1 2 3 4 Figure 7 9 D1 D3 Soft Charge Resistor 2 of 3 380 480 500V Clear wire leads 525 690 V Black wire leads 1...

Page 143: ...ep 6 Reassembly 1 Clean the heatsink surface with a mild solvent or alcohol solution 2 Reassemble the remaining parts in reverse order of their removal Tighten the T25 and 8 mm mounting screws to 2 3...

Page 144: ...5 Remove the entire assembly from the mounting studs Reinstall in reverse order of this procedure Tighten the 10 mm mounting nuts to 4 Nm 35 in lbs and the 13 mm nuts to 9 5 Nm 85 in lb 130BX81 10 1 2...

Page 145: ...de input bus bar Remove the SCR input bus bars 6 Remove each IGBT output bus bar by removing the nut 13 mm from the stud Also remove the retaining screw T40 at other end of the IGBT output bus bars no...

Page 146: ...CONTINUED NEXT PAGE 130BX84 10 1 2 3 4 5 6 7 8 9 10 11 Figure 7 13 D2 D4 SCR Diode Module 2 of 4 1 Retaining screws Step 9 7 IGBT output retaining screws Step 7 2 Retaining nut Step 8 8 Retaining scr...

Page 147: ...ach rec tifier DC bus bar to standoffs on the SCR diode modules Figure 7 14 D2 D4 SCR Diode Module 3 of 4 1 Bus bar BB27 2 Bus bar BB28 3 Retaining screws Step 10 4 Rectifier DC bus bars BB23 or BB24...

Page 148: ...screws Step 12 REASSEMBLY 1 To replace SCR diode modules follow the instructions included with the replacement module 2 Reassemble in reverse order Tighten the remaining T25 and 8 mm screws to 2 3 Nm...

Page 149: ...e bus bar holding bracket and remove the bus bar one for each input phase CONTINUED ON NEXT PAGES 130BX165 10 1 2 3 4 5 Figure 7 16 D1 D3 SCR Diode Module 1 of 3 1 Bus bar BB2 Step 4 2 Retaining screw...

Page 150: ...bus bars are only present on units with load sharing Remove the DC input bus assembly 130BX93 10 1 2 3 4 5 Figure 7 17 D1 D3 SCR Diode Module 2 of 3 1 Bus bar BB4 2 Retaining nuts Step 6 3 DC input bu...

Page 151: ...of 3 1 SCR diode module 2 Mounting screws Step 8 REASSEMBLY 1 To replace SCR diode modules follow the instructions included with the replacement module 2 Reinstall the module and mounting screws Tight...

Page 152: ...ly Remove the 2 8 mm retaining nuts from the stud on the chassis base plate and remove the sensor Reinstall in reverse order of this procedure Tighten the 8 mm mounting nuts to 2 3 Nm 20 in lbs Figure...

Page 153: ...ed to the retaining studs Ensure that the correct wire is attached to the applicable stud during reassembly Remove the AC power lead to the intermediate SCR input bus bar by removing the nut 8 mm and...

Page 154: ...g Reinstall in reverse order of this procedure Tighten mounting nuts to 2 3 Nm 20 in lbs 130BX89 10 1 2 Figure 7 21 Fan Assembly 2 of 2 1 Inline Molex connector Step 5 2 Retaining nut Step 6 High Powe...

Page 155: ...truction manual 130BX125 10 1 2 3 4 Figure 7 22 AC Input Terminals no options shown 380 480V White label on fan transformer 525 690 V Orange label on fan transformer 1 AC input terminal 2 AC input cab...

Page 156: ...om terminal 1 of each SCR diode module by accessing the screw through the access hole in the SCR diode input bus bar Remove the SCR input bus bars 6 Remove each IGBT output bus bar by removing the nut...

Page 157: ...termediate IGBT output bus bars 12 Remove the retaining nut 8 mm from the 3 intermediate IGBT output bus bars Remove the intermediate IGBT output bus bars CONTINUED ON NEXT PAGE 130BX98 10 2 3 4 5 6 7...

Page 158: ...ASSEMBLY 1 Replace the IGBT module in accordance with the instructions provided with the replace ment unit 2 Reassemble the remaining parts in reverse order of their removal 3 Reinstall the module and...

Page 159: ...IGBT bus bar assembly and the brake IGBT Remove the DC input bus bar assembly per steps 3 5 of SCR Diode Module Removal D1 units 6b For units with brake option remove the bus bars between the IGBT bus...

Page 160: ...hol solution REASSEMBLY 1 Replace the IGBT module in accordance with the instructions enclosed with the replace ment module 2 Tighten the remaining T25 and 8 mm screws to 2 3 Nm 20 in lbs and T30 and...

Page 161: ...7 D Frame Sizes Disassembly and Assembly Instructions High Power Service Manual for VLT FC Series Adjustable Frequency Drives 7 30 MG 90 L1 22 VLT is a registered Danfoss trademark 7...

Page 162: ...ncy drives based upon the unit s physical size Refer to the tables in the Introduction section to determine E frame size definitions 8 2 Instructions 8 2 1 Control Card and Control Card Mounting Plate...

Page 163: ...upport bracket 12 Control card terminal block 6 Attaching hardware 13 Control card under LCP 7 Power card mounting plate 8 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate...

Page 164: ...part of the replacement power card Reinstall in reverse order of this procedure When installing the power card ensure that the in sulator sheet is installed behind the power card Tighten the mounting...

Page 165: ...by mounting the insulation onto the standoffs Mount the soft charge card and tighten the mounting screws to 2 3 Nm 20 in lbs 130BX155 10 3 4 2 5 1 Figure 8 3 Soft Charge Card 380 480 500V Blue MOV an...

Page 166: ...ing screws T25 Torx from the standoffs Reinstall in reverse order of this procedure Tighten the mounting screws to 2 3 Nm 20 in lbs 130BX160 10 2 3 4 5 6 7 1 Figure 8 4 Gate Drive Card 1 MK100 5 MK102...

Page 167: ...l connection nuts 10 mm to 4 Nm 35 in lbs Lower Capacitor Banks 1 Remove the soft charge card in accordance with procedures 2 The capacitor bank connection to the DC bus bars can be seen recessed in t...

Page 168: ...ts Step 2 7 Upper cap bank assy retaining nut Step 4 4 Lower cap bank assy retaining nut Step 3 8 Soft charge card 380 480 500V Blue DC Link Capacitors 525 690V Black DC Link Capacitors 380 480 500V B...

Page 169: ...the weight of the disconnect can be up to 35 lbs 16 kg Slide dis connect down to clear fuses and remove 4 If a cooling fan is mounted disconnect the fan cable 5 If an RFI filter is mounted disconnect...

Page 170: ...istor by sliding it down Reinstall in reverse order of this procedure Tighten the 8 mm retaining nuts to 2 3 Nm 20 in lbs 130BX101 10 1 2 3 4 5 Figure 8 7 Soft Charge Resistor 1 Soft charge card 4 Sof...

Page 171: ...om the DC bus bar and one from the DC bus bar 6 Note color coding for each wire attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remove t...

Page 172: ...g the 6 con nection screws T50 There are 3 screws per bus bar 10 Remove the three SCR and diode input bus bars by removing the 6 connection screws T50 There are 2 screws per bus bar CONTINUED NEXT PAG...

Page 173: ...modules during installation Reversing the SCR and diode modules can result in equipment damage NOTE For each AC input phase there is one SCR module and one diode module The SCR is on the left the diod...

Page 174: ...able from the current sensor being removed 5 Remove the 2 retaining nuts size varies with model from the stud on the base plate and remove the sensor Reinstall in reverse order of this procedure Tight...

Page 175: ...m frame 5 Remove the fan assembly by removing the 6 retaining nuts 10 mm Note that the fan assembly weighs approximately 25 lbs 11 kg Reinstall in reverse order of this procedure Tighten the 10 mm ret...

Page 176: ...terminal block insulation otherwise go to step 5 5 If the terminal block is not attached to the input terminal plate remove the retaining nut 13 mm attaching the terminal block insulation Reinstall i...

Page 177: ...from the DC bus bar and one from the DC bus bar 6 Note color coding for each wire attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remov...

Page 178: ...ving the 6 con nection screws T50 There are 3 screws per bus bar 10 Remove the three SCR and diode input bus bars by removing the 6 connection screws T50 There are 2 screws per bus bar CONTINUED NEXT...

Page 179: ...bar 14 Remove the 3 retaining nuts 17 mm at top and one retaining nut 8 mm at bottom attaching IGBT output bus bar to standoffs Remove the IGBT output bus bar CONTINUED NEXT PAGE 130BX104 10 1 2 3 4 5...

Page 180: ...the IGBT Ind bus bar assembly to the Brake IGBT Note that there are 2 screws per Brake IGBT module 21 Remove the 4 retaining nuts 13 mm connecting the IGBT Ind bus bar assembly to two DC bus bars fro...

Page 181: ...se order Attaching Hardware Tightening Torque 8 mm T25 2 3 Nm 20 in lbs 10 mm T30 4 Nm 35 in lbs 13 mm 9 5 Nm 85 in lbs 17 mm T50 19 Nm 170 in lbs 8 E Frame Sizes Disassembly and Assembly Instructions...

Page 182: ...stable frequency drive Contact with powered components could result in electrical shock and personal injury 9 1 1 Test Cables and SCR Shorting Plug Kit p n 176F8439 This tool provides the ability to p...

Page 183: ...drive The signal test board is plugged into power card connector MK104 Points on the signal test board can be monitored with or without the DC bus disabled In some cases the ad justable frequency driv...

Page 184: ...ard to turn the fans on and off 0 VDC ON command 5 VDC OFF command 7 INRUSH Control Card sig nal Signal from the control card to start gating the SCR front end 3 3 VDC SCRs disabled 0 VDC SCRs enabled...

Page 185: ...supply 4 75 to 5 25 VDC 25 GUP_T IGBT gate signal buffered U phase positive Signal originates on the control card 2v div 100us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 26 GUN_T IGBT gat...

Page 186: ...coated adjustable frequency drives Bus bars used in some units are aluminum Spare part bus bars are always plated copper Plated copper bus bars are useable for all units For the latest spare parts li...

Page 187: ...lude scaling card 202 PCA3 176F8660 Spare power card pdefc xxxP450T4xxxxxUxC Power card conformal coated does not include scaling card 202 PCA3 176F8643 Spare power card pdefc xxxP110T5xxxxxUxC Power...

Page 188: ...ANK1 2 176F8325 Spare CAP Bank D Frame 6cap T5 Capacitor bank includes balance card 1 1 1 CBANK1 2 176F8636 Spare CAP Bank E Frame 6cap T5 Capacitor bank includes balance card 2 1 CBANK1 2 176F8637 Sp...

Page 189: ...D Frame 1 L1 176F8341 Spare Bus Inductor 87uH DC Link Coil Large D Frame 1 L1 176F8564 Spare Bus Inductor 62uH E Frame DC Link Coil E Frame 1 L1 176F8565 Spare Bus Inductor 51uH E Frame DC Link Coil E...

Page 190: ...arness for all AC fans on IP00 units IP00 CBL8 176F8572 Spare Cable Fan IP21 54 small E Frame wire harness for all AC fans on IP21 and IP54 units 21 5 4 CBL8 176F8573 Spare Cable Fan IP00 large E Fram...

Page 191: ...gate drive card to IGBT module 1 per kit 3 3 CBL17 18 19 176F8351 Spare Cable IGBT Gate D2 Frame wire harness from gate drive card to IGBT module 1 per kit 3 3 3 CBL17 18 19 176F8582 Spare Cable IGBT...

Page 192: ...om brake IGBT to brake minus terminal 1 1 1 CBL24 176F8543 Spare Cable Softchg RST D1 Frame wire harness from input power to soft charge board 1 1 CBL24 176F8353 Spare Cable Softchg RST D2 Frame wire...

Page 193: ...lation block 1 1 1 1 1 TB1 176F8588 Spare Insul Terminal Block E Frame line power terminal insulation block 1 per kit 3 3 3 3 TB2 176F8371 Spare Terminal Insul line power motor D Frame motor terminal...

Page 194: ...Frame connects DC coil output to IGBT input bus bar assembly 1 per kit 2 2 2 176F8599 Space BB DC Bus After Coil E Frame from DC Coil output to IGBT sandwich 1 per kit 2 2 2 2 176F83761 76F8376 Spare...

Page 195: ...are BB LS Minus D Frame connects SCR bus bar to minus load share terminal 1 1 1 176F8607 Spare BB Load Share Plus E Frame load share plus bus bar 1 1 1 1 176F8608 Spare BB Load Share Minus E Frame loa...

Page 196: ...p 2 36 in 60 mm Power cable clamp 2 36 in 60 mm 176F8490 Spare Brkt HF board gnd D Frame mounting bracket for high frequency board 1 1 176F8491 Spare Brkt HF board gnd D Frame mounting bracket for hig...

Page 197: ...coated does not include scaling card 202 PCA3 176F8684 Spare power card pdefc xxxP315T7xxxxxUxC Power card conformal coated does not include scaling card 202 PCA3 176F8685 Spare power card pdefc xxxP...

Page 198: ...76F8312 Spare Current Scaling PCA 5 10 Ohm Installs on the Power Card 1 PCA4 176F8525 Spare Current Scaling PCA 5 85 Ohm Installs on the Power Card 1 PCA5 176F8626 Spare Gate Drive PCA CC D E Frame Ga...

Page 199: ...CBANK1 2 176F8533 Spare CAP Bank D Frame 6cap T7 Capacitor bank includes balance card 1 1 2 CBANK1 2 176F8638 Spare CAP Bank E Frame 8cap T7 Capacitor bank includes balance card 2 2 2 2 Fans F1 C1 17...

Page 200: ...pare Bus Inductor 350uH DC Link Coil Small D Frame 1 L1 176F8537 Spare Bus Inductor 250uH DC Link Coil Small D Frame 1 L1 176F8538 Spare Bus Inductor 195uH DC Link Coil Large D Frame 1 1 L1 176F8469 S...

Page 201: ...e voltage from DC bus to power card 1 1 1 1 1 1 CBL14 176F8576 Spare Cable DC to Power PCA E Frame voltage from DC bus to power card 1 1 1 1 CBL16 176F8363 Spare Cable Gate Drive 16 pin D1 Frame ribbo...

Page 202: ...ock 1 1 1 1 1 1 TB1 176F8588 Spare Insul Terminal Block E Frame line power terminal insulation block 1 per kit 3 3 3 3 TB2 176F8371 Spare Terminal Insul line power motor D Frame motor terminal insulat...

Page 203: ...8382 Spare BB DC Link Minus D Frame connects DC coil output to IGBT input bus bar assembly 1 per kit 2 2 2 2 176F8599 Space BB DC Bus After Coil E Frame from DC Coil output to IGBT sandwich 1 per kit...

Page 204: ...Spare BB LS Minus D Frame connects SCR bus bar to minus load share terminal 1 1 1 1 176F8607 Spare BB Load Share Plus E Frame load share plus bus bar 1 1 1 1 176F8702 Spare BB Load Share Minus T7 E Fr...

Page 205: ...mp 2 36 in 60 mm Power cable clamp 2 36 in 60 mm 176F8490 Spare Brkt HF board gnd D Frame mounting bracket for high frequency board 1 1 176F8491 Spare Brkt HF board gnd D Frame mounting bracket for hi...

Page 206: ...ower card pdefc xxxP45kT7xxxxxUxC Power card conformal coated does not include scaling card 302 PCA3 176F8693 Spare power card pdefc xxxP55kT7xxxxxUxC Power card conformal coated does not include scal...

Page 207: ...an Only 1 fan per kit IP00 IP00 IP00 IP00 IP00 F2 3 176F8333 Spare Door Top AC Fan D E Frame IP21 IP54 Door Fan Fan Only 1 fan per kit 21 54 21 54 21 54 21 54 21 54 Fuses FU1 2 3 176F8334 Spare Fuse M...

Page 208: ...e SCR D1 Frame wire harness from power card to SCR 1 1 1 1 1 CBL14 176F8356 Spare Cable DC to Power PCA D Frame voltage from DC bus to power card 1 1 1 1 1 CBL16 176F8363 Spare Cable Gate Drive 16 pin...

Page 209: ...1 Spare Terminal Insul line power motor D Frame motor terminal insulation block 1 1 1 1 1 TB3 176F8372 Spare Terminal Insul Brk LD Shr D Frame brake terminal insulation block 1 1 1 1 1 TB4 176F8372 Sp...

Page 210: ...Spare BB IGBT U V W D Frame connects IGBT output to long bus bar over the fan 1 per kit 3 3 3 3 3 176F8392 Spare BB Motor 2 D Frame long output bus bar over the fan 1 per kit 3 3 3 3 3 176F8397 Spare...

Page 211: ...10 Spare Parts List High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 26 MG 90 L1 22 VLT is a registered Danfoss trademark 10...

Page 212: ...11 Block Diagrams High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams MG 90 L1 22 VLT is a registered Danfoss trademark 11 1 11...

Page 213: ...LY FAN FAN FAN FAN TOP FAN USED ON CHASSIS AND IP00 UNITS ONLY TOP FAN HF SWITCH EXT BRAKE RESISTOR BRAKE IGBT BRAKE OPTION BRAKE GATE RES CARD GATE DRIVE CARD GATE RESISTOR CARD PRE TEST RFI SWITCH D...

Page 214: ...LU ORN GRN BLK BLK GRN WHT DOOR FAN GND FAN FAN NEMA 1 UNITS ONLY FAN FAN FAN FAN TOP FAN CHASSIS AND IP00 UNITS ONLY TOP FAN CHASSIS AND IP00 UNITS ONLY NEMA 12 IP 21 IP 54 EXT BRAKE RESISTOR BRAKE I...

Page 215: ...Y FAN FAN FAN FAN TOP FAN USED ON CHASSIS AND IP00 UNITS ONLY TOP FAN USED ON CHASSIS AND IP00 UNITS ONLY NEMA 12 IP 21 IP 54 EXT BRAKE RESISTOR BRAKE IGBT BRAKE OPTION EM GATE COL BRAKE GATE RES CARD...

Page 216: ...IP 54 EXT BRAKE RESISTOR BRAKE IGBT BRAKE IGBT BRAKE IGBT BRAKE IGBT EM GATE COL BRAKE GATE RES CARD EM GATE COL BRAKE GATE RES CARD BRAKE OPTION HF SWITCH IN OUT IN OUT GATE RESISTOR CARD GATE RESIS...

Page 217: ...FAN GND FAN FAN GND FAN FAN BRAKE OPTION BRAKE IGBT BRAKE IGBT BRAKE GATE RES CARD BRAKE GATE RES CARD EM GATE COL EM GATE COL GATE RESISTOR CARD IN OUT GATE RESISTOR CARD IN OUT GATE RESISTOR CARD IN...

Page 218: ...IGBT HF SWITCH BRAKE GATE RES CARD BRAKE GATE RES CARD EM GATE COL EM GATE COL RFI FAN GATE RESISTOR CARD GATE RESISTOR CARD GATE RESISTOR CARD IN OUT IN OUT IN OUT GATE DRIVE CARD PRE TEST CBANK1 LOW...

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Page 220: ...Rev 2008 09 01 www danfoss com drives 130R0438 MG90L122 MG90L122 High Power Service Manual MG90L122...

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