Page 1 MAKING MODERN LIVING POSSIBLE MAKING MODERN LIVING POSSIBLE High Power Service Manual High Power Service Manual ® HVAC Drive FC 100 ® AQUA Drive FC 200 ® AutomationDrive FC 300 ® HVAC Drive FC 100 ® AQUA Drive FC 200 ®...
Page 2: Table Of Contents
2-19 3 Internal Adjustable Frequency Drive Operation General Description of Operation Logic Section Logic to Power Interface Power Section Sequence of Operation Rectifier Section Intermediate Section Inverter Section Brake Option 3-11 ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 3 Current Sensor Faults Signal and Power Wiring Considerations for Adjustable Frequency Drive Electromagnetic Compatibility Effect of EMI Sources of EMI EMI Propagation Preventive Measures Proper EMC Installation 5-11 6 Test Procedures Introduction ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 4 Input Terminal Signal Tests 6-38 Initial Start Up or After Repair Drive Tests 6-39 7 D-Frame Sizes Disassembly and Assembly Instructions Electrostatic Discharge (ESD) Instructions Control Card and Control Card Mounting Plate ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 5 AC Input, Motor, Load Sharing or Regen Terminals 8-15 IGBT Modules 8-16 9 Special Test Equipment Test Equipment Test Cables and SCR Shorting Plug Kit p/n 176F8439 Signal Test Board (p/n 176F8437) ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 6 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 E1/E2 525–690 VAC 11-7 ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 7 Figure 6.14: AC Input Current Waveform with Diode Bridge 6-26 Figure 6.15: Input Current Waveform with Phase Loss. 6-27 Figure 6.16: SCR Gate Signal 6-28 Figure 6.17: Gate Drive Card Test Connectors 6-31 ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 8 7-29 Figure 8.1: Control Card Access Figure 8.2: Power Card, and Mounting Plate Figure 8.3: Soft Charge Card Figure 8.4: Gate Drive Card. Figure 8.5: Upper and Lower Capacitor Bank Assemblies ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 9 Figure 8.16: IGBT Modules (3 of 4) 8-18 Figure 8.17: IGBT Modules (4 of 4) 8-19 Figure 9.1: SCR Shorting Plug Figure 9.2: Two-pin Figure 9.3: Three-pin Figure 9.4: Signal Test Board ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 10 Table 10.15: Spare Parts List Terminals, Labels, Insulators 10-17 Table 10.16: Spare Parts List Bus Bars 10-19 Table 10.17: Spare Parts List Enclosure 10-20 Table 10.18: Spare Parts List PCA, Semiconductors and Resistors 10-21 ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 11 Table 10.19: Spare Parts List Capacitors, Fans, Fuses and Inductors & Current Sensors 10- Table 10.20: 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 ® MG.90.L1.22 - VLT is a registered Danfoss trademark...
Page 12: Introduction
They are full-featured adjustable frequency drives capable of operating a myriad of applications and incorporating a wide variety of control and communication options. These models are available in Chassis/IP00, NEMA 1/IP21 or NEMA 12/IP54 enclosures. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 13: For Your Safety
D2 / D4 P250 D2 / D4 P315 E1 / E2 P355 E1 / E2 P400 E1 / E2 P450 E1 / E2 Table 1.1: FC 102 and FC 202 380–480 VAC MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 14 400 / 450 500 / 600 500 / 560 E1 / E2 P560 450 / 500 600 / 650 560 / 630 E1 / E2 Table 1.4: FC 302 525–690 VAC MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 15: Tools Required
Driver Size Torx/Hex Torque (in-lbs) Torque (Nm) T-20 / 7 mm T-25 / 8 mm T-30 / 10 mm T-40 / 13 mm T-50 / 17 mm 19.2 Table 1.5: Torque Values Table MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 16: Exploded Views
Input terminal mounting plate assembly Soft charge card PCA11 Fan fuse FU4 DC inductor L1 Capacitor bank cover plate Soft charge module R1 + CBL26 IGBT gate drive card PCA5 IGBT module IGBT 1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 17 Lower capacitor bank assembly CBANK1 + PCA9 Soft charge resistor assy R1 + CBL26 Lower capacitor bank cover plate IGBT snubber capacitors C2, C3, C4, C5, C6, C7 IGBT gate drive card PCA5 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 18 Input terminal mounting plate assembly Soft charge fuses AC input bus bar DC inductor L1 Soft charge card PCA12 Fan transformer TR1 Lower capacitor bank assembly CBANK1 + PCA10 IGBT module IGBT1, 2, 3 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 19: Ratings Tables
Power Card Ambient Overtemperature Degrees C Power Card Ambient Undertemperature Degrees C Line Phase Warning (5 sec delay) DC Bus Ripple VAC Line Phase Alarm (25 sec delay) DC Bus Ripple VAC MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 20 Power Card Ambient Overtemperature Degrees C Power Card Ambient Undertemperature Degrees C Line Phase Warning (5 sec delay) DC Bus Ripple VAC Line Phase Alarm (25 sec delay) DC Bus Ripple VAC MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 21 Degrees C Power Card Ambient Undertem- perature Degrees C Line Phase Warning (5 sec delay) DC Bus Ripple VAC Line Phase Alarm (25 sec delay) DC Bus Ripple VAC 1-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 22 Power Card Ambient Overtemperature Degrees C Power Card Ambient Overtemperature Degrees C Line Phase Warning (5 sec delay) DC Bus Ripple VAC Line Phase Alarm (25 sec delay) DC Bus Ripple VAC 1-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 23 Power Card Ambient Overtemperature Degrees C Power Card Ambient Undertemperature Degrees C Line Phase Warning (5 sec delay) DC Bus Ripple VAC Line Phase Alarm (25 sec delay) DC Bus Ripple VAC 1-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 24: Operator Interface And Adjustable Frequency Drive Control
The LCD display is back-lit with a total of 6 alpha-numeric lines. All data is displayed on the LCP which can show up to five operating variables while in [Status] mode. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 25 Larger numeric values are displayed with few digits after the decimal point. Ex.: Current readout 5.25 A; 15.2 A 105 A. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 26 Middle section Display contrast adjustment Bottom section ▲ Press [status] and [ ] for darker display ▼ Press [status] and [ ] for brighter display MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 27 The Function set-up provides quick and easy access to all parameters required for the majority of applications. Among other features it also includes parameters for selecting which variables to display on the LCP. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 28 [OK] is used for choosing a parameter marked by the cursor and for enabling the change of a parameter. Operation keys for local control are found at the bottom of the control panel. 130BP046.10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 29: Numeric Local Control Panel (Nlcp)
[Main Menu] key for 3 seconds. The parameter shortcut allows direct access to any parameter. 2.2.2 Numeric Local Control Panel (NLCP) See the FC Series Instruction Manual for instructions for using the numeric LCP. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 30: Tips And Tricks
[Off] The adjustable frequency drive does not react to any control signal until [Auto On] or [Hand On] on the LCP are pressed. [Auto On] The adjustable frequency drive is controlled via the control terminals and/or the serial communication. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 31 Coast inverse has been selected as a function for a digital input (parameter group 5-1*). The corresponding terminal (e.g. Terminal 27) is not connected. Coast is on 0 on serial communication MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 32 Freeze output was selected as a function for a digital input (Group 5-1*). The corre- sponding terminal is active. Speed control is only possible via the terminal functions Speed up and Slow. Hold ramp is activated via serial communication. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 33 24 V. Pre-magnetize Function at Stop Pre-magnetization is selected in par. 1-80 . A stop command (e.g. Stop inverse) is activated. A suitable constant magnetizing current is applied to the motor. 2-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 34 , a value is set. The speed of the motor is above this value. Speed low Warning Speed Low In par. 4-52 , a value is set. The speed of the motor is below this value. 2-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 35 . A control word is sent to the adjustable frequency drive via serial communication with Off 1, Off 2 and Off 3 active. Start inhibit is active. To enable start, see operation status Start inhibit. 2-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 36: Service Functions
LCP to scroll through parameters. See the FC Series Instruction Manual for detailed information on accessing and displaying param- eters and for descriptions and procedures for service information available in the 15-** parameter group. 2-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 37: Frequency Converter Inputs And Outputs
Terminal Descriptions Digital I/O terminals RS 485 (EIA-485) terminal Analog I/O terminals USB connector Figure 2.1: Control Terminals 2-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 38: Input Signals
13, or from a customer supplied external 24 VDC power source. Improperly connected control wiring is a common service issue for a motor not operating or the adjustable frequency drive not responding to a remote input. 2-15 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 39: Control Terminals
In summary, for proper adjustable frequency drive functioning, the adjustable fre- quency drive input control terminals must be: wired properly powered programmed correctly for the intended function receiving a signal 2-16 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 40: Control Terminal Functions
Control terminals must be programmed. Each terminal has specific functions it is capable of per- forming and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal. See the FC Series Instruction Manual for details. 2-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 41 ® 2 Operator Interface and Adjustable Frequen- High Power Service Manual for VLT FC Series cy Drive Control Adjustable Frequency Drives Figure 2.2: Control Terminals Electrical Diagram 2-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 42: Grounding Shielded Cables
61. This terminal connects to ground through an internal RC link. It is recommended to use twisted-pair cables to reduce the differential mode interference between conductors. Table 2.3: Grounding Shielded Cables 2-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 43 ® 2 Operator Interface and Adjustable Frequen- High Power Service Manual for VLT FC Series cy Drive Control Adjustable Frequency Drives 2-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 44: Internal Adjustable Frequency Drive Operation
In the sequence of operation description, these three sections will be covered in greater detail while describing how power and control signals move throughout the adjustable frequency drive. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 45: Logic Section
The LCP is removable during operation to prevent undesired program changes. With the addition of a remote mounting kit, the LCP can be mounted in a remote location of up to ten feet away. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 46: Logic To Power Interface
The gate adjustable frequency drive signals from the control card to the output transistors (IGBTs) are isolated and buffered on the gate drive card. In units that have the dynamic brake option, the driver circuits for the brake transistors are also located on this card. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 47: Power Section
CTs introduce into the signal. With Hall sensors, the average, peak, and ground leakage currents can be monitored. Figure 3.3: Typical Power Section MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 48: Sequence Of Operation
It is also fed to the Switch Mode Power Supply (SMPS) on the power card and is used for generating all other low voltage supplies. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 49 Assy 175L9472 DC INDUCTOR DISC/FUSE OPTION RFI OPTION RFI CARD RFI SWITCH No RFI relay on 525–690 V Units. E1 units have 2 RFI cards SOFTCHARGE BOARD Figure 3.4: Rectifier circuit MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 50: Intermediate Section
. This disconnects the ground references to all filters should unbal- anced phase-to-ground voltages create nuisance overvoltage conditions. For 525–690 V adjustable frequency drives, there are no relay contacts that disconnect the grounding. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 51 ® 3 Internal Adjustable Frequency Drive Opera- High Power Service Manual for VLT FC Series tion Adjustable Frequency Drives Figure 3.5: Intermediate section MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 52: Inverter Section
By employing a sophisticated control scheme, the adjustable frequency drive is capable of deliv- ering a current waveform that nearly replicates a true AC sine wave. This waveform, as generated by the Danfoss VVCplus PWM principle at the control card, provides optimal performance and minimal losses in the motor.
Page 53 130B6875-COATED, USED WITH DISC SW AND FUSES CBL5 CBL25 190848 +SCR 190813 -SCR HF SWITCH SOFTCHARGE BOARD PCA11 130B6866 27 Ohms 130B6868 (Coated) Assy 175L9472 ECONOPACK+ MODULE ECONOPACK+ MODULE Figure 3.7: Inverter section 3-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 54: Brake Option
Additionally, the power and control cards monitor the brake IGBT and brake resistor connection for short circuits and overloads. Figure 3.8: Brake option 3-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 55: Cooling Fans
Fan Turn Off from Low Speed 86°F [30°C] 86°F [30°C] Table 3.1: IGBT Thermal Sensor Power card ambient temperature sensor measured temperature. The fan can be off or high speed based on this temperature. 3-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 56: Load Sharing
DC reactors and DC fuses in the DC link connections and AC reactors on line power. Attempting such a configuration requires specific considerations and should not be attempted without first consulting Danfoss Application Engineering. In the second method, the adjustable frequency drive is powered exclusively from a DC source.
Page 57: Specific Card Connections
24 VDC, 10 mA or 24 VAC, 100 mA. The relay can be programmed via par. 5-40 to indicate adjustable frequency drive status. Terminal positions on the power card labeled MK400 and MK103 are reserved for future use. 3-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 58: Troubleshooting
It is best to develop a detailed approach, beginning with a physical inspection of the system. See Table 4-1, Visual In- spection, for items to examine. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 59: Fault Symptom Troubleshooting
Finally, a list of tests called After Repair Tests is provided. These tests should always be performed when first starting an adjustable frequency drive, when approaching an adjustable frequency drive that is suspected of being faulty, or anytime following a repair to the adjustable frequency drive. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 60: Visual Inspection
Although this is a somewhat subjective procedure, look for any unusual amount of vibration that the adjustable frequency drive may be subjected to. The adjustable frequency drive should be mounted solidly or the use of shock mounts employed. Table 4.1: Visual Inspection MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 61: Fault Symptoms
All control wiring should be checked for shorts or incorrect connections. If the display continues to cut out, follow the procedure for No Display as though the display were not lit at all. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 62: Motor Will Not Run
If the unit is equipped with an external 24 VDC option, check that main power is applied to the adjustable frequency drive. Note: In this case, the display will alternately flash Warning 8. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 63: Incorrect Motor Operation
Possible fault in the brake circuit. Possible incorrect setting in the brake parameters. The ramp- down time too short. Note: May be accompanied by an alarm or warning message. Check all brake parameters and ramp-down time (parameters 2-0* and 3-4*). Perform Brake Check (6.3.13). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 64: Warning/Alarm Messages
Power is removed from the motor. A trip lock can only be reset after the condition is cleared by cycling power. Once the problem has been rectified, only the alarm continues flashing until the adjustable frequency drive is reset. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 65 Option configuration has changed Safe stop activated Power card temperature Illegal FC configuration PTC 1 safe stop Dangerous failure Safe stop auto restart Illegal PS config Table 4.2: Warning/alarm code list MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 66 10 common. MCB 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common). Make sure that the adjustable frequency drive programming and switch settings match the analog signal type. Perform the Input Terminal Signal Test in Section 6.3.16. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 67 Troubleshooting: Make sure that the supply voltage matches the adjustable frequency drive voltage. Perform Input voltage test (Section 6.3.2) Perform soft charge and rectifier circuit test (Section 6.2.1 or 6.2.3) 4-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 68 If using a thermal switch or thermistor, check the programming of par. 1-93 Resource matches sensor wiring. If using a KTY sensor, check the programming of parameters 1-95, 1-96, and 1-97 match sensor wiring. 4-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 69 See section 5.2 for more details. ALARM 15, Hardware mismatch A fitted option is not operational with the present control board hardware or software. Record the value of the following parameters and contact your Danfoss supplier: FC Type par. 15-40 Power Section par.
Page 70 100%. Warning: There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short-circuited. 4-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 71 Too many power-ups have occurred within a short time period. Let the unit cool to operating temperature. WARNING/ALARM 34, Fieldbus communication fault The serial communication bus on the communication option card is not working. 4-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 72 Line Failure is NOT set to OFF. Check the fuses to the adjustable frequency drive ALARM 38, Internal fault It may be necessary to contact your Danfoss supplier. Some typical alarm messages: Serial port cannot be initialized. Serious 1792 DSP watchdog is active. Debugging of...
Page 73 WARNING 47, 24 V supply low The 24 VDC is measured on the control card. The external 24 VDC backup 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 measured on the control card.
Page 74 Make sure that the filters for the door fans are not blocked. Make sure that the gland plate is properly installed on IP21 and IP54 (NEMA 1 and NEMA 12) adjustable frequency drives. 4-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 75 Stopping the motor has been delayed due to short cycle protection is active. See parameter group 22-7*. WARNING 98, Clock fault Clock Fault. The time is not set or the RTC clock (if mounted) has failed. See parameter group 0-7*. 4-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 76 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. 4-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 77 Setting according to the label on the unit. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New type code The adjustable frequency drive has a new type code. 4-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 78: After Repair Tests
Using a clamp-on style ammeter, measure the output current on each output phase. All currents should be balanced. If unbalanced current is measured, refer to Current Sensor Test (6.3.14). 4-21 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 79 ® High Power Service Manual for VLT FC Series 4 Troubleshooting Adjustable Frequency Drives 4-22 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 80: Adjustable Frequency Drive And Motor Applications
1-30 and 1-35. If unstable motor operation is experienced and AMA has not been performed, it should be done. AMA can only be performed on single motor applications within the MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 81: Overvoltage Trips
For example, if the deceleration ramp needs to be 100 seconds due to the inertia, and the ramp rate is set at 3 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 82: Line Phase Loss Trips
First, the adjustable frequency drive must be told to run (start command). Second, the adjustable frequency drive must be told how fast to run (ref- erence or speed command). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 83: Programming Problems
I/O function must be thought of as a two step process. The desired I/O terminal must be wired properly, and the corresponding parameter must be set accordingly. Control terminals are pro- grammed in the 5-0* and 6-0* parameter groups. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 84: Motor/Load Problems
Of course, this can easily be detected by feeling the outside of the unit, if the overtemperature condition is still present. If not, the temperature sensor must be checked. This can be done with the use of an ohmmeter in accordance with the thermal sensor test procedure. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 85: Current Sensor Faults
(harmonics, line voltage imbalance, notching) are not covered. Special installations or compliance to the European CE EMC directives will require strict adherence to relevant standards and are not discussed here. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 86: Effect Of Emi
The high rate of voltage change caused by the IGBT switching creates high frequency EMI. Rectifier DC Bus Inverter Filter reactor AC Line Motor IGBT Filter capacitor Sine wave PWM waveform Figure 5.1: Adjustable Frequency Drive Functionality Diagram MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 87: Emi Propagation
Signal conductors are especially vulnerable when they are run parallel to the power conductors for any distance. EMI coupled into these conductors can affect either the adjustable frequency drive or the interconnected control device. See Figure 5-4. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 88: Preventive Measures
Avoid terminating the shield through a pigtail connection as this increases the high frequency impedance and spoils the effectiveness of the shield. Refer to Section 2.8, Grounding Shielded Cables. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 89 While shielded cable provides ad- ditional EMI protection, the shield capacitance may reduce the maximum allowable cable length at high data rates. 5-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 90: Proper Emc Installation
EMI. Should EMI problems arise in an installation, refer to this example. Attempt to replicate this installation recommendation as closely as possible to alleviate such problems. Figure 5.5: Proper EMC Installation 5-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 91 ® 5 Adjustable Frequency Drive and Motor Ap- High Power Service Manual for VLT FC Series plications Adjustable Frequency Drives 5-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 92: Test Procedures
Replace any defective component and retest the adjustable frequency drive with the new com- ponent before applying power to the adjustable frequency drive as described in Initial Start Up or After Repair Drive Tests MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 93: Tools Required For Testing
The test board plugs into connector MK104 on the power card. Signal Test Board Special Its use is described in the procedures where called out. See in Section 9, Test Equipment , for detailed pin descriptions. Figure 6.1: Signal Test Board MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 94: Test Cables
Figure 6.2: SCR Shorting Plug BLACK PIN 1 PIN 2 WHITE Figure 6.3: Two-Pin D frame test cable PIN 1 PIN 2 PIN 2 PIN 3 PIN 1 Figure 6.4: Three-Pin E Frame Test Cable MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 95: Static Test Procedures
525–690V: White tape on the main SMPS transformer in the upper right corner. Power card PCA3 MK106 Mounting plate MK100 MK110 MK109 MK102 FK102 MK104 MK112 terminals 4, 5, 6 MK105 MK112 terminals 1, 2, 3 MK107 Scaling card FK103 Scaling card standoff MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 96: Soft Charge And Rectifier Circuits Test: D-Frame Size
To replace a soft charge fuse, follow the soft charge disassembly instructions in Section 7. F1, F2, F3 Figure 6.6: Soft Charge Card Fuses 380–480/500V: Blue MOV & 8 PTCs 525–690V: Red MOV & 6 PTCs. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 97 Although an open reading is 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. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 98: Soft Charge Rectifier Test: D-Frame Size
4. Connect 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. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 99 Replace any defective assemblies in accordance with the disassembly proce- dures in Section 7. Figure 6.7: Soft Charge Card Connectors 380–480/500V: Blue MOV & 8 PTCs 525–690V: Red MOV & 6 PTCs. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 100: Soft Charge And Rectifier Circuits Test: E-Frame Size
Figure 6.8: Soft Charge Card Fuse Location 380–480/500V: Blue MOV and 8 PTCs. 525–690 V: Red MOV and 6 PTCs. Fuses F1, F2 and F3 MK3 (disconnect for soft charge and rectifier tests) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 101 With the Part IV test connection, the diodes in the main diode modules are reversed biased. If a short circuit exists, the diode module is damaged. Continue to Soft Charge Rectifier Tests: E-frames. 6-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 102: Soft Charge Rectifier Test: E-Frame Size
Reconnect the MK3 on the soft charge card after these tests. 380–480/500V: Blue MOV and 8 PTCs. 525–690 V: Red MOV and 6 PTCs. Figure 6.9: Soft Charge Card Connectors 6-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 103: Inverter Section Tests
Section 7 or 8. It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly. 6-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 104: Brake Igbt Test
Connect the positive (+) meter lead to the brake resistor terminal R- (81). Connect the negative (-) meter lead to the brake resistor terminal R+ (82). The reading should indicate a diode drop. 6-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 105: Intermediate Section Tests
Replace the capacitor bank in accordance with the disassembly procedures in Section 7 or 8. 6-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 106: Heatsink Temperature Sensor Test
Measure from CN2 terminal 2 to terminal 12 on the power card connector MK107. A reading of <1 ohm should be indicated. Incorrect reading An incorrect reading would indicate a faulty cable connection. Replace the cable assembly. 6-15 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 107 On IP21 and IP 54 units: Read the door fan terminals with the wires disconnected. A reading of 400 ohms should be indicated. Reconnect the wires to the door fan. 6-16 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 108 An incorrect reading of one or both of the fans indicates a defective fan. Replace the defective fan. Figure 6.10: Fan Transformer and Fuse Location 380–480/500 V: White label on fan transform- 525–690 V: Orange label on fan transformer. Fan transformer Fan fuse 6-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 109: Fan Continuity Tests: E-Frame Size
P500 525-690 P630 P630 P560 Table 6.1: Fan transformer resistance Incorrect reading An incorrect reading would indicate a defective fan transformer. Replace the fan transformer. When finished, reconnect the MK107. 6-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 110 Read across the fan terminals on each fan. A reading of 400 ohms is expected. Replace any defective fans. Figure 6.11: Fan and DC Bus Fuse Locations Power card Mounting plate DC bus fuse MK107 Fan fuse 6-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 111: Dynamic Test Procedures
Figure 6.12: Drive Power Terminals (D-size Frames) Main 3-phase AC power to adjustable frequency Brake resistor connection drive DC bus/load sharing connections 3-phase output to motor 6-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 112: No Display Test
The adjustable frequency drive can operate within specifications as long as the phase imbalance is not more than 3%. Danfoss calculates line imbalance per an IEC specification. Imbalance = 0.67 X (Vmax – Vmin)/Vavg For example, if three phase readings were taken and the results were 500 VAC, 478.5 VAC, and 478.5 VAC;...
Page 113: Basic Control Card Voltage Test
A correct reading of both control card voltages would indicate the LCP or the control card is de- fective. Replace the LCP with a known good one. If the problem persists, replace the control card in accordance with the disassembly procedures in Section 7 or 8. 6-22 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 114: Switch Mode Power Supply (Smps) Test
This assumes of course that the proper DC bus voltage was read at power card connector MK105 (A) and (B). Replace the power card in accordance with the disassembly pro- cedures in Section 7 or 8. 6-23 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 115: Zero Dc Bus Voltage Test
Reapply power to the adjustable frequency drive after 20 minutes and recheck the DC bus voltage. If voltage remains, a short circuit may exist within the intermediate circuit preventing it from charging. Proceed to static checks (6.2) earlier in this section. 6-24 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 116: Input Phase Imbalance Test
SCR gates. Further tests on the proper gating of the SCRs require an oscilloscope equipped with current probes. Proceed to testing the input waveform and input SCR in accordance with their procedures. 6-25 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 117: Input Waveform Test
6 diode bridge. It is the same for adjustable frequency drives with SCR/diode modules. Figure 6.14: AC Input Current Waveform with Diode Bridge 6-26 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 118: Input Scr Test
If the above tests reveal no abnormalities, it is further possible that the inrush signal has not been enabled by the control card. Using the signal test card, verify the inrush signal is present and the SCR disable signal is at the correct voltage level as follows. 6-27 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 119 R, S, and T at power card connector MK100. The waveform should appear as in Figure 6-16. Figure 6.16: SCR Gate Signal The current pulse should have a waveform as shown. 6-28 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 120: Output Phase Imbalance Test
(U), 97 (V), and 98 (W) with the clamp on the ammeter. An analog device is preferred. To achieve an accurate reading, run the adjustable frequency drive above 40 Hz as this is normally the frequency limitation of such meters. 6-29 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 121: Igbt Gate Drive Signals Test
Disconnect connectors MK100 and MK105 on the power card. Connect the free end of test cable into MK105. Connect the SCR gate shorting plug (included with test cable 176F8437) into the cable that was removed from MK100. 6-30 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 122 2.2 to 2.5 VDC. Figure 6.17: Gate Drive Card Test Connectors Pin 1 MK450 MK850 (brake) MK103 (V) MK105 (brake option) MK550 MK250 MK650 MK102 (U) MK104 (W) MK350 MK750 6-31 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 123 There is no test to verify the signals directly out of the control card. The power card would be suspect if a single gate signal is incorrect. The control 6-32 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 124: Igbt Switching Test
U, V, and W. The meter should effectively indicate a short circuit or around a 0.035 diode drop which indicates upper IGBTs are turned on and shorting the meter to a positive bus. 6-33 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 125: Brake Igbt Test
If the current scaling card is not installed, the adjustable frequency drive will trip. A couple of simple checks can be made to determine the status of the sensors. Apply power to the adjustable frequency drive. 6-34 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 126 A reading of greater than 15 mv suggests that the corresponding current sensor be replaced. See the disassembly instructions in Section 7 or 8. 6-35 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 127: Fan Tests
If the jumpers are in place or an auxiliary supply is connected and powered but no voltage is present at the fan transformer connector CN2, the power card is likely defective. Replace the power card in accordance with the disassembly instructions in Section 7 or 8. 6-36 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 128 Otherwise, the power card is defective. Replace the appropriate assembly in accordance with the disassembly instructions in Section 7 or 6-37 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 129: Input Terminal Signal Tests
If the desired signal is not present in the display, the problem may be either in the external control wiring to the adjustable frequency drive or a faulty control card. To determine the fault location, use a voltmeter to test for a signal at the control terminals. 6-38 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 130: Initial Start Up Or After Repair Drive Tests
Using a clamp-on style ammeter, measure the output current on each output phase. All currents should be balanced. If unbalanced current is measured, refer to Current Sensor Test (6.3.14). 6-39 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 131 ® High Power Service Manual for VLT FC Series 6 Test Procedures Adjustable Frequency Drives 6-40 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 132: Frame Sizes Disassembly And Assembly Instructions
Reinstall in reverse order of this procedure. The red conductor on the ribbon cable between the control card and the power card should be on the bottom of the connector. Tighten the control card mounting plate screws to 1 Nm (8 in-lb). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 133: Control Assembly Support Bracket
Remove the 6 mounting nuts (10 mm), see Figure 7-1. Remove the control assembly support bracket. Reinstall in reverse order of this procedure. Tighten the mounting screws to 4 Nm (35 in-lbs). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 134: Power Card
Power card PCA3 MK106 Mounting plate MK100 MK110 MK109 MK102 FK102 MK104 MK112 terminals 4,5,6 MK105 MK112 terminals 1,2,3 MK107 Current scaling card PCA4 FK103 Current scaling card standoff MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 135: Power Card Mounting Plate
The white wire from the power card connector MK105 connects to the right end of the DC bus fuse holder. Tighten the 10 mm mounting nuts to 4 Nm (35 in-lbs) and the 7 mm nut to 1 Nm (8 in-lbs). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 136: Soft Charge Card
Slide into place and tighten the mounting screws to 4 Nm (35 in-lbs). Figure 7.3: Soft Charge Card Assy 380–480/500V: Blue MOV and 8 PTCs. 525–690 V: Red MOV and 6 PTCs. Retaining screw (Step 2) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 137: Gate Drive Card
Reinstall in reverse order of this procedure. Tighten the mounting screws to 2.3 Nm (20 in-lbs). Figure 7.4: Gate Drive Card MK100 (temperature sensor) MK101 (RFI filter) MK106 MK105 (brake option) MK102 (U) MK103 (V) MK104 (W) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 138: Capacitor Bank(S)
Upper cap bank assy retaining nuts (step 2) Lower cover plate retaining nut (step 3) Upper cover plate Gate drive card Upper cover plate retaining nut (step 3) Lower cap bank assy retaining nuts (step 1) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 139 Reinstall in reverse order of this procedure. Tighten the mounting screws to 4 Nm (35 in-lbs). Retaining nuts (step 2) Retaining nuts (step 4) Gate drive card (step 3) 380–480/500V: Blue DC Link Capacitors. 525–690V: Black DC Link Capacitors. Figure 7.6: D1/D3 Single Capacitor Bank Assembly MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 140: Soft Charge (Sc) Resistors D2/D4 Units
Tighten 10 mm mounting nuts to 4 Nm (35 in-lbs). Figure 7.7: D2/D4 Soft Charge Resistor 380–480/500V: Clear wire leads. 525–690 V: Black wire leads. Bus bars BB27 (do not remove) Soft charge resistor Retaining nut (loosen) (Step 3) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 141: Soft Charge (Sc) Resistors D1/D3 Units
Figure 7.8: D2/D4 Soft Charge Resistor (1 of 3) 380–480/500V: Clear wire leads. 525–690 V: Black wire leads. Soft charge resistor Bus bar BB2 (Step 3) Retaining screw (Step 3) 7-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 142 Figure 7.9: D1/D3 Soft Charge Resistor (2 of 3) 380–480/500V: Clear wire leads. 525–690 V: Black wire leads. Retaining screws (Step 4) DC input bus assembly BB3 Retaining nuts (Step 5) Soft charge resistor 7-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 143 Reassemble the remaining parts in reverse order of their removal. Tighten the T25 and 8 mm mounting screws to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs). 7-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 144: Input Terminal Mounting Plate Assembly
380–480/500V: White label on fan transform- 525–690 V: Orange label on fan transformer. Input power connector (Step 1) Bus bar retaining nuts (shown removed) (Step 2) Transformer connector (Step 3) Retaining nuts (Step 4) 7-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 145: Scr/Diode Module D2/D4 Units
IGBT output bus bar retaining nut (Step 6) SRC/diode terminal screw (Step 5) SRC/diode terminal screw (Step 5) SRC/diode input bus bar BB21 or BB22 per drive power rating 6 IGBT output bus bar BB32 (Step 6) 7-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 146 Retaining screws (Step 9) IGBT module Intermediate IGBT output bus bar BB30 (Step 8) Main DC bus bar BB25 (Step 9) Bus bar BB31 Bus bar BB27 Bus bar BB30 Bus bar BB26 7-15 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 147 Figure 7.14: D2/D4 SCR/Diode Module (3 of 4) Bus bar BB27 Bus bar BB28 Retaining screws (Step 10) Rectifier DC bus bars BB23 or BB24 per drive power rating (Step 10) 7-16 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 148 Reassemble in reverse order. Tighten the remaining T25 and 8 mm screws to 2.3 Nm (20 in-lbs) and T30 to 4 Nm (35 in-lbs). Be sure to cross the tighten replacement unit with the spare part per instructions. 7-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 149: Scr/Diode Module D1/D3 Units
CONTINUED ON NEXT PAGES Figure 7.16: D1/D3 SCR/Diode Module (1 of 3) Bus bar BB2 (Step 4) Retaining screw access (Step 3) Retaining nut (Step 4) Bus bar BB1 SCR/diode module 7-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 150 Remove the DC input bus assembly. Figure 7.17: D1/D3 SCR/Diode Module (2 of 3) Bus bar BB4 Retaining nuts (Step 6) DC input bus assembly BB3 (Step 6) Retaining screws (Step 5) SCR/diode module 7-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 151 Reinstall the module and mounting screws. Tighten the remaining T25 and 8 mm screws to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs). Reassemble the remaining parts in reverse order of their removal. 7-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 152: Current Sensor
Reinstall in reverse order of this procedure. Tighten the 8 mm mounting nuts to 2.3 Nm (20 in- lbs). Figure 7.19: Current Sensors Terminal Current sensor mounting screws (2) Current sensor Terminal mounting screws (2) Terminal mounting screw Output motor cable connection screws (2) 7-21 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 153: Heatsink Fan Assembly
Figure 7.20: Fan Assembly (1 of 2) Terminal (Step 3) Intermediate SCR input bus bar (Step 3) Retaining nut (Step 4) Retaining nut (Step 2) IGBT output bus bar (Step 2) Retaining nut (Step 2) 7-22 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 154 Reinstall in reverse order of this procedure. Tighten mounting nuts to 2.3 Nm (20 in-lbs). Figure 7.21: Fan Assembly (2 of 2) Inline Molex connector (Step 5) Retaining nut (Step 6) 7-23 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 155: Ac Input Terminals
380–480V: White label on fan transformer. 525–690 V: Orange label on fan transformer. AC input terminal AC input cable connector (Step 1) Retaining screws (Step 2) Retaining screw (Step 2) 7-24 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 156: Igbt Modules D2/D4 Units
SCR/diode input bus bar retaining nut and stud (Steps 3 & 4) SCR/diode terminal screw (Step 5) IGBT gate signal input terminal (Step 2) IGBT output bus bar BB32 (Step 6) 7-25 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 157 IGBT bus bar assembly BB29 (Steps 7 & 10) Retaining nut (Step 12) Retaining nut (Step 7) Retaining screws (Step 11) IGBT module IGBT module BB30 Retaining screws (shown removed) (Step 8) BB31 Retaining nut (Step 9) 7-26 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 158 Reassemble the remaining parts in reverse order of their removal. Reinstall the module and mounting screws. Tighten the remaining T25 and 8 mm screws to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs). 7-27 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 159: Igbt Modules D1/D3 Units
Do not remove (Step 6) Retaining screw (Step 6) Gate drive cable connectors (Steps 3 & 4) High frequency card IGBT module Connector MK100 (Step 5) IGBT output bus bar retaining nut (Step 7) 7-28 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 160 IGBT module Retaining screw (Step 9) Snubber capacitor (Step 9) Retaining nut (Step 11) IGBT bus bar assembly (Step 8) Intermediate IGBT output bus bar (Step 11) Retaining nut (Step 8) 7-29 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 161 ® 7 D-Frame Sizes Disassembly and Assembly High Power Service Manual for VLT FC Series Instructions Adjustable Frequency Drives 7-30 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 162: Frame Sizes Disassembly And Assembly Instructions
Reinstall in reverse order of this procedure. The red conductor on the ribbon cable between the control card and the power card should be on the bottom of the connector. Tighten the control card mounting plate screws to 1 Nm (8 in-lb). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 163 Remove the 6 mounting nuts (10 mm), see Figure 8-1. Remove the control assembly support bracket. Reinstall in reverse order of this procedure. Tighten the mounting screws to 4 Nm (35 in-lbs). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 164: Power Card
Power card PCA3 MK106 Mounting plate MK100 MK110 MK109 MK102 FK102 MK104 MK112 terminals 4,5,6 MK105 MK112 terminals 1,2,3 MK107 Current scaling card PCA4 FK103 Current scaling card standoff MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 165: Soft Charge Card
Reinstall by mounting the insulation onto the standoffs. Mount the soft charge card and tighten the mounting screws to 2.3 Nm (20 in-lbs). Figure 8.3: Soft Charge Card 380–480/500V: Blue MOV and 8 PTCs. 525–690 V: Red MOV and 6 PTCs. Mounting screw (Step 2) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 166: Gate Drive Card
Reinstall in reverse order of this procedure. Tighten the mounting screws to 2.3 Nm (20 in-lbs). Figure 8.4: Gate Drive Card. MK100 MK102 (U) MK101 (RFI filter) MK103 (V) MK106 MK104 (W) MK105 (brake option) MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 167: Capacitor Banks
Reinstall in reverse order of this procedure. Note: DO NOT overtorque. Tighten the electrical con- nection nuts (8 mm) to 2.3 Nm (20 in-lbs) and the mechanical connection nuts (10 mm) to 4 Nm (35 in-lbs). MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 168 Lower cap bank assy retaining nut (Step 3) Soft charge card *380–480/500V: Blue DC Link Capacitors. 525–690V: Black DC Link Capacitors. **380–480/500V: Blue MOV and 8 PTCs. 525–690 V: Red MOV and 6 PTCs. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 169: Input Terminal Mounting Plate Assy Option
Figure 8.6: Input Terminal Mounting Plate Assy (shown with RFI and electrical fuses options) Input terminals (Step 1) Retaining nut (Step 2) Connection nut (Step 3a) Cooling fan (Step 4) Fuse Input terminal mounting plate RFI filter assembly MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 170: Soft Charge Resistor
Figure 8.7: Soft Charge Resistor Soft charge card Soft charge resistor MK4 connector (Step 2) Bottom retaining nut (Step 4) Top retaining nut (Step 3) *380–480/500V: Clear wire leads. 525–690 V: Black wire leads. MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 171: Scr And Diode Modules
Figure 8.8: SCR and Diode Modules (1 of 3) Retaining nuts (Step 7) Diode module Wire retaining nut on bus bar BB41 (Step 3) Wire retaining nuts for output bus bars BB42 (Steps 5 & 6) SCR module 8-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 172 SCR and diode input bus bar BB41 (Step 10) Negative (-) output bus bar BB42 (Step 9) Positive (+) output bus bar BB42 (Step 9) Negative (-) output bus bar connecting screw (Step 9) 8-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 173 Per spare part instruction Per spare part instruction 17 mm 19 Nm (170 in-lbs) 13 mm 9.5 Nm (85 in-lbs) 10 mm 4 Nm (35 in-lbs) 8 mm 2.3 Nm (20 in-lbs) 8-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 174: Current Sensor
Figure 8.11: Current Sensors Current sensor Current sensor mounting screws (2) (Step 5) IGBT terminal bus bar mounting screw (Step 3) Output motor terminal bus bar retaining nut (Step 2) 8-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 175: Heatsink Fan Assembly
17 mm connecting nuts or T50 screw to 19 Nm (170 in-lbs). Figure 8.12: Fan Assembly IGBT output bus bar BB49 Retaining nut (Step 3) Fan housing Molex connector (Step 4) Retaining nut (Step 5) Retaining nut (Step 2) 8-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 176: Ac Input, Motor, Load Sharing Or Regen Terminals
13 mm or T40 Torx screw to 9.5 Nm (85 in-lbs). Figure 8.13: Terminal Blocks Retaining nuts (Step 3) Terminal block insulation (Step 4 or 5) Retaining nut (Step 2) 8-15 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 177: Igbt Modules
Figure 8.14: IGBT Modules (1 of 4) Retaining nuts (Step 7) 3 IGBT board Wire retaining nut on bus bar BB41 (Step 3) 4 Wire retaining nuts for output bus bars BB42 (Steps 5 & 6) 8-16 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 178 SCR and diode input bus bar BB41 (Step 10) Negative (-) output bus bar BB42 (Step 9) Positive (+) output bus bar BB42 (Step 9) Negative (-) output bus bar connecting screw (Step 9) 8-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 179 Figure 8.16: IGBT Modules (3 of 4) Retaining screw (Step 11) Retaining nut (Step 12) Retaining nut (Step 14) Overfan bus bar Output bus bar Retaining nut (Step 13) Retaining nut (Step 14) 8-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 180 Retaining screw (Step 15) Retaining nut (Step 17) IGBT-Cap bus bar BB47 Retaining nut (Step 21) IGBT board High Frequency board IGBT retaining screw (Step 22) Retaining screw (Step 18) 8-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 181 Reassemble in reverse 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) 8-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 182: Special Test Equipment
Test equip- ment described in this section is available from Danfoss. Using the test cable allows powering the adjustable frequency drive without having to charge DC bus capacitors.
Page 183: Signal Test Board (P/N 176F8437)
Although in some cases, a digital voltmeter can be used to verify the presence of such signals, it cannot be relied upon to verify that the waveform is correct. An oscilloscope is the instrument preferred. However, when similar signals are being measured at multiple points, a digital voltmeter MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 184 Varies w/ brake duty cycle Not used FAN_TS Control signal for Indicates Fan Test switch is activated to +5VDC – disabled fans force the fans on high 0VDC – fans on high MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 185 2v/div 100us/div Run@10Hz GWN_T IGBT gate signal, 2.2–2.5 VDC buffered, W Equal on all phases TP25-TP30 phase, negative. Signal originates on the control card. 2v/div 100us/div Run@10Hz MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 186 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 list, visit the Danfoss website at www.danfossdrives.com 10-1 MG.90.L1.22 - VLT ®...
Page 187 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-2 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 188 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-3 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 189 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-4 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 190 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-5 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 191 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-6 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 192 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-7 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 193 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-8 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 194 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-9 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 195 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-10 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 196 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-11 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 197 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-12 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 198 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-13 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 199 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-14 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 200 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-15 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 201 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-16 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 202 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-17 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 203 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-18 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 204 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-19 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 205 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-20 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 206 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-21 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 207 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-22 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 208 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-23 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 209 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-24 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 210 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 10 Spare Parts List 10-25 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 211 ® High Power Service Manual for VLT FC Series 10 Spare Parts List Adjustable Frequency Drives 10-26 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 212 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 213 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 214 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 215 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 216 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 217 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 218 ® High Power Service Manual for VLT FC Series Adjustable Frequency Drives 11 Block Diagrams 11 Block Diagrams 11-1 MG.90.L1.22 - VLT ® is a registered Danfoss trademark...
Page 220 *MG90L122* 130R0438 MG90L122 Rev. 2008-09-01...

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Danfoss VLT HVAC Drive FC 100 Service Manual

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