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7 Drive and Motor Applications

7.1 Torque Limit, Current Limit, and Unstable Motor Operation

7.1.1 Overvoltage Trips

7.1.2 Mains Phase Loss Trips

7.1.3 Control Logic Problems

7.1.4 Programming Problems

7.1.5 Motor Load Problems

7.2 Internal Drive Problems

7.2.1 Overtemperature Faults

7.2.2 Current Sensor Faults

7.3 Electromagnetic Compatibility

7.3.1 Effects of EMI

7.3.2 EMI Signal and Power Wiring

7.3.3 Sources of EMI

7.3.4 EMI Propagation

7.3.5 Preventive Measures

8 Test Procedures

8.1 Introduction

8.2 Tools Required

8.2.1 Special Test Equipment

8.2.2 Signal Test Board

8.2.3 Metering Tools

8.3 Test Preparations

8.3.1 Preparations for Parallel Drive Systems

8.3.2 Access to Testing Connection Points

8.3.3 Card Connectors

8.3.4 Power Card in D-sized Drives

8.3.5 Power Card in E-sized Drives

8.3.6 MDCIC in Parallel Drive Systems

8.3.7 Fan Power Card in E-sized Drives

8.3.8 Gate Drive Card in D-sized Drives

8.3.9 Gate Drive Card in E-sized Drives

8.4 Static Test Procedures

100

8.4.1 Rectifier Circuits Test

100

8.4.2 Inverter Section Tests

101

8.4.3 Brake IGBT Test

101

8.4.4 Intermediate Section Tests

102

8.4.5 IGBT Temperature Sensor Test

102

8.4.6 Gate Resistor Test

103

Contents

Service Guide

MG94A502

Содержание VLT FC Series

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

Страница 2: ......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 49: ...SCR3 T CBANK 1 C2 C3 96 U 97 V 98 W TB2 89 LS 88 LS TB3 82 R REGEN 81 R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WH...

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

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

Страница 52: ...TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED...

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

Страница 54: ...at the motor detects also varies The resulting current waveform takes on the sine wave shape common to an AC system The rate at which the pulses occur determines the frequency of the waveform By emplo...

Страница 55: ...CR1 R L1 DC INDUCTOR SCR2 S SCR3 T CBANK 1 C2 C3 96 U 97 V 98 W TB2 89 LS 88 LS TB3 82 R REGEN 81 R 83 REGEN TB4 A1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK...

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

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

Страница 58: ...1 RFI INRUSH PCA4 GATEDRIVE PCA5 BAL HF PCA7 F1 S1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED WHT...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 109: ...h as DC bus capacitors Incorrect reading An incorrect reading here requires further investigation of the main supply Typical items to check would be Open blown input fuses or tripped circuit breakers...

Страница 110: ...age range 11 18 V 16 5 19 5 V DC 12 18 V 16 5 19 5 V DC 23 24 V 23 25 V DC 24 5 V 4 75 5 25 V DC Table 8 5 Measured Voltages at Select Terminals In addition the signal test board contains 3 LED indica...

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

Страница 112: ...er 1 Monitor 3 output phases at motor terminals 96 U 97 V and 98 W with the clamp on the ammeter An analog device is preferred To achieve an accurate reading run the drive above 40 Hz which is normall...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 130: ...v Run at 10 Hz 2 2 2 5 V DC Equal on all phases TP25 TP30 29 GWP_T IGBT gate signal buffered W phase positive Signal originates on control card 8 00 6 00 4 00 2 00 0 00 V 2 00 4 00 6 00 8 00 4 0ms 50U...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 358: ...1 F2 S2 POWER CARD PCA2 CBL10 RED BLK BLK RED BLK RED BLK RED WHT BLK WHT BLK WHT BLK 10 PIN MK102 BLK RED BLK RED BLK RED BLK RED BLK RED BLK RED WHT BLK RED 30 PIN MK103 30 PIN MK101 YEL BLK RED BRN...

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

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

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

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

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

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

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

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

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

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

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

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