Danfoss VLT FC 100 Service Manual
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Danfoss VLT FC 100 Service Manual

Vlt fc series d-frame hvac drive
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MAKING MODERN LIVING POSSIBLE
Service Manual
®
VLT
FC Series, D-Frame
®
VLT
HVAC Drive FC 100 • VLT
®
VLT
Automation Drive FC 300 • VLT
®
AQUA Drive FC 200
®
Refrigeration Drive FC 103
www.danfoss.com/drives

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  • Page 1 MAKING MODERN LIVING POSSIBLE Service Manual ® FC Series, D-Frame ® ® HVAC Drive FC 100 • VLT AQUA Drive FC 200 ® ® Automation Drive FC 300 • VLT Refrigeration Drive FC 103 www.danfoss.com/drives...

  • Page 3: Table Of Contents

    3 Internal Adjustable Frequency Drive Operation 3.1 General 3.2 Description of Operation 3.2.1 Logic Section 3.2.2 Logic to Power Interface 3.2.3 Power Section 3.3 Sequence of Operation 3.3.1 Rectifier section 3.3.2 Intermediate Section 3.3.3 Inverter Section MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 4 5.2.3 EMI Signal and Power Wiring 5.2.4 Effects of EMI 5.2.5 Sources of EMI 5.2.6 EMI Propagation 5.2.7 Preventive Measures 5.2.8 Proper EMC Installation 6 Test Procedures 6.1 Introduction 6.1.1 Tools Required Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 5 7.1 Introduction 7.2 Electrostatic Discharge (ESD) 7.3 D1h/D3h Disassembly and Assembly Instructions 7.3.1 General Information 7.3.2 Control Card and Control Card Mounting Plate 7.3.3 Power Card Mounting Plate 7.3.4 Power Card MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 6 7.4.2 Control Card and Control Card Mounting Plate 7.4.3 Power Card Mounting Plate 7.4.4 Power Card 7.4.5 AC Input Bus Bars 7.4.5.1 Electrical Fuses Only 7.4.5.2 RFI Only 7.4.5.3 Fuses and RFI 7.4.5.4 No Options Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 7 7.5.5 Disconnect 7.6 D8h Disassembly and Assembly Instructions 7.6.1 Overview 7.6.2 Replacing the Heatsink Fan with Options Cabinet Present 7.6.3 Removing the Adjustable Frequency Drive from the Options Cabinet 7.6.4 Contactor MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 8 8.1.2 Signal Test Board (p/n 176F8437) 8.1.3 Signal Test Board Extension 8.1.4 Signal Test Board Pin Outs 9 Spare Parts 9.1 Spare Parts 9.1.1 General Notes 9.1.2 DC Capacitor Bank 10 Block Diagrams Index Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 9: Introduction

    Press [Stop] when changing control and communication options. data. These models are available in IP20 (chassis), IP21 (NEMA 1), and IP54 (NEMA 12) enclosures. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 10: Electrostatic Discharge (Esd)

    250/300 200/250 D2h/D4h/ D7h/D8h D7h/D8h N200 200/250 300/350 250/315 D2h/D4h/ Table 1.4 FC 302 525–690 V AC D7h/D8h N250 250/315 350/450 315/355 D2h/D4h/ D7h/D8h Table 1.2 FC 302 380–500 V AC Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 11: Tools Required

    Socket extensions (3.94–5.91 in [100–150 mm]) • Torx driver set (T10–T50) • Torque wrench (4.4–168.2 in-lbs [0.5–19 Nm]) • Needle nose pliers • Magnetic sockets • Ratchet • Screwdrivers • ESD protective mat and wrist strap MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 12: General Torque Tightening Values

    Circuit breaker* Contactor + disconnect* Table 1.8 Options Locations *Contactor, disconnect, or circuit breaker options always include fuses. When these options are selected, the electrical fuses are in the options cabinet. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 13: Exploded Views

    Balance/High frequency card Top fan (IP20 only) Motor output terminals DC inductor Line power input terminals SCR/Diode modules Gate drive card IGBT modules (optional) RFI filter Table 1.9 Legend to Figure 1.1 MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 14 Inrush card mounting bracket Motor output terminals Top fan (IP20 only) Line power input terminals DC inductor Gate drive card SCR/Diode modules (optional) RFI filter IGBT modules Table 1.10 Legend to Figure 1.2 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 15: Power-Dependent Specifications

    Efficiency Output frequency 0–800 Hz 0–600 Hz *High overload = 150% current for 60 s, Normal overload = 110% current for 60 s Table 1.11 Line Power Supply 3x380–500 V AC MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 16 30 W to the losses. (Though typically, only 4 W extra for a fully loaded control card, or options for slot A or slot B, each). Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 17 Heatsink overtemperature trip 230°F [110°C] Control card ambient trip 167°F [75°C] *High overload=150% current for 60 s, Normal overload=110% current for 60 s. Table 1.13 Line Power Supply 3 x 525–690 V AC MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 18 The losses are based on the default switching frequency. The losses increase significantly at higher switching frequencies. The options cabinet adds weight to the adjustable frequency drive. The maximum weights of the D5h–D8h frames is shown in the instruction manual. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 19 Output frequency 0–590 Hz Heatsink overtemp. trip 230°F [110°C] Power card ambient trip 167°F [75°C] *Normal overload=110% current for 60 s Table 1.15 Line Power Supply 3 x 525–690 V AC MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 20 The losses are based on the default switching frequency. The losses increase significantly at higher switching frequencies. The options cabinet adds weight to the adjustable frequency drive. The maximum weights of the D5h–D8h frames is shown in the instruction manual. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 21 DC Bus Ripple (30 s delay) Vpkpk Line Phase Alarm DC Bus Ripple (60 s delay) Vpkpk 1) Based on crest factor of 1.414 Table 1.18 Warning and Alarm Trip Points MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 22 Dynamic Brake Turn On [V DC] 1099 Inverter Overvoltage Re-Enable (warning reset) 1099 [V DC] Overvoltage Warning (with brake) [V DC] 1109 Overvoltage Trip [V DC] 1130 Table 1.19 DC Voltage Levels Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 23: 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. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 24 (1.1, 1.2, 1.3, 2, and 3). Status 1 (1) 778 RPM 0.86 A 4.0 kW State: 0 o 0 (o ) When: - Do: - Auto Remote Running Figure 2.4 Status Display III Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 25 LEDs are used for parameter set-up, including choice of display indication during normal operation. Figure 2.8 Back Icon Quick Main Alarm Status Menu Menu Figure 2.7 Menu Keys MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 26: Numeric Local Control Panel (Nlcp)

    (trip). It can be selected as [1] Enable or [0] Disable via 0-43 [Reset] Key on LCP. Hand Auto Reset 2.2.2 Numeric Local Control Panel (NLCP) Figure 2.12 Operation Keys See the Design Guide for instructions for using the numeric LCP. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 27: Changing Settings With The Lcp

    Press [OK] Select “Initialization” Press [OK] Cut off the line power supply and wait until the display turns off. Reconnect the line power supply - the adjustable frequency drive is now reset. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 28: Status Messages

    The adjustable frequency drive uses [Hand On] Feedback high The sum of all active feedbacks is above the control or reference values from the LCP. feedback limit set in 4-57 Warning Feedback High. Table 2.3 Reference Site Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 29 4-52 Warning Speed Low. adjustable frequency drive from tripping. Standby In Auto On mode, the adjustable frequency drive will start the motor with a start signal from a digital input or serial communication. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 30: Service Functions

    The serial bus connects to the adjustable frequency drive through the RS 485 serial port or through a communi- cation option card. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 31: Input Signals

    Analog inputs are wired to terminals 53 or 54 and 55 (common). The terminal functions are set by a switch found by removing the LCP. Some options include additional terminals for input signals. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 32: Control Power Supply

    In summary, for proper adjustable frequency drive functioning, the adjustable frequency drive input control terminals must be: • wired properly • powered • programmed correctly for the intended function • receiving a signal Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 33: Control Terminal Functions

    Control terminals must be programmed. Each terminal has specific functions it performs and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal. See the Instruction Manual for details. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 34: Grounding Shielded Cables

    61. This terminal connects to ground through an internal RC link. Use twisted-pair cables to reduce the differential mode interference between conductors. Table 2.8 Grounding Shielded Cables Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 35: Internal Adjustable Frequency Drive Operation

    The sequence of operation description describes these sections in greater detail while explaining how power and control signals move throughout the adjustable frequency drive. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 36: Logic Section

    5–4* Relays. The matches the requirements of the motor. relays have different ratings. See the corresponding Instruction Manual or Design Guide for more information on ratings. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 37: Logic To Power Interface

    (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 on this card. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 38: Sequence Of Operation

    As long as power is applied to the adjustable frequency drive, this voltage is present in the intermediate and inverter circuits. It is also fed to the switch mode power supply on the power card and is used for generating all other low voltage supplies. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 39 REGEN- INRUSH PCA4 CBL8 REC+ REC- MK1802 K1G1K2G2K3G3 1 4 2 5 3 6 CBL10 DC INDUCTOR REC+ RFI PCA6 REC- SCR1 SCR2 SCR3 A1 RFI PCA6 Figure 3.4 Rectifier Circuit MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 40: Intermediate Section

    The relay is tied into the RFI/HF switch, which can be switched on or off in 14-50 RFI 1. This disconnects the ground references to all filters in case unbalanced phase-to-ground voltages create nuisance overvoltage conditions. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 41 IGBT2 IGBT3 PCA7 MODULE IGBT4 REC- SCR1 SCR2 SCR3 REGEN+ A1 RFI PCA6 REGEN- BAL/HF PCA7 130B7184 130B7185 DC INDUCTOR CBANK 1 REC+ HF PCA7 BAL/HF PCA7 Figure 3.5 Intermediate Section MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 42: Inverter Section

    The DC bus voltage is monitored as well as the voltage delivered to the motor. A thermal sensor mounted inside each IGBT module provides heatsink temperature feedback. Figure 3.6 Output Voltage and Current Waveforms Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 43 CBL13 CBL13 CBL13 1 6 10 5 1 6 10 5 1 6 10 5 PCA9 NTC1 PCA10 NTC2 PCA11 NTC3 + M - IGBT1 IGBT2 IGBT3 Figure 3.7 Inverter Section MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 44: Brake Option

    IGBT via the power card and gate drive card. Additionally, the power and control cards monitor the brake IGBT and brake resistor connection for short circuits and overloads. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 45 CIRCUIT BAL/HF BREAKER BRAKE IGBT IGBT1 IGBT2 IGBT3 PCA7 MODULE IGBT4 REC- SCR1 SCR2 SCR3 REGEN+ A1 RFI PCA6 REGEN- PCA8 BRAKE IGBT MODULE IGBT4 REGEN+ REGEN- Figure 3.8 Brake Option MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 46: Cooling Fans

    If the output is greater than 60% of the nominal current, the fan runs at 100% speed. If the output current is less than 60% of the nominal current, the fan is turned off. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 47: Load Sharing & Regeneration

    240 V AC, 2 A and a minimum of 24 V DC, 10 mA, or 24 V AC, 100 mA. The relays can be programmed via 5-40 Function Relay to indicate frequency converter status. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 48: Troubleshooting

    Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 49: Visual Inspection

    Adjustable frequency drives require adequate top and bottom clearance to ensure proper air flow for cooling in accordance with the adjustable frequency drive size. Adjustable frequency drives with exposed heatsinks out the back must be mounted on a flat solid surface. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 50: Fault Symptoms

    Stop Inverse and the corresponding terminal is low (logic “0”). If the display continues to cut out, follow the procedure for No Display as though the display were not lit at all. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 51: Incorrect Motor Operation

    Motor draws high current but cannot start Possible open winding in the motor or open phase in connection to the motor. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 52 1.8 V supply low Speed limit AMA calibration failed AMA check U and I AMA low I AMA motor too big AMA motor too small AMA parameter out of range AMA interrupted by user Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 53 Power card supply Power card temperature Illegal PS config New spare part New type code Table 4.2 Warning/Alarm Code List (X) Programmable: dependent on parameter setting. Cannot be auto reset via parameter selection. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 54 The fault is that the adjustable frequency drive has run Troubleshooting with more than 100% overload for too long. Check the supply voltage and supply currents to the adjustable frequency drive. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 55 Check for ground faults in the motor by Check 1-93 Thermistor Source selects terminal 53 measuring the resistance to ground of the motor or 54. leads and the motor with a megohmmeter. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 56 The brake resistor is not connected or not working. can be disabled in 14-53 Fan Monitor ([0] Disabled). Check 2-15 Brake Check. For the D, E, and F Frame filters, the regulated voltage to the fans is monitored. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 57 Troubleshooting Check for loose or missing wiring Check for the following conditions. Ambient temperature too high. It may be necessary to contact your Danfoss supplier or service department. Note the code number for further Motor cable too long. troubleshooting directions.
  • Page 58 High Limit [RPM], the adjustable frequency drive shows a warning. When the speed is below the specified limit in 1-86 Trip Speed Low [RPM] (except when starting or stopping), the adjustable frequency drive will trip. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 59 22-23 No-Flow Function is set for alarm. Troubleshoot the an underload condition was detected. This could indicate a system and reset the adjustable frequency drive after the missing motor. Inspect the system for proper operation. fault has been cleared. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 60: After Repair Tests

    Reapply power and restart adjustable frequency drive. Adjust motor speed to a nominal level. Using a clamp-on style ammeter, measure output current on each output phase. All currents must be balanced. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 61: Adjustable Frequency Drive And Motor Applications

    Consult the factory if uncertain about the cause nuisance tripping. torque characteristics of an application. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 62: Overvoltage Trips

    Loads affecting the form factor of the AC waveform, such as notching or defective transformers, cause line disturbances. Line imbalances that exceed 3% cause sufficient DC bus ripple to initiate a trip. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 63: Control Logic Problems

    If there is not a correct indication, the next step is to determine whether the signal is present at the input terminals. Perform this test with a voltmeter or oscilloscope in accordance with the chapter 6.4.14 Input Terminal Signal Tests. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 64: Motor/Load Problems

    However, that value should be considerably less than one amp. If the display shows more than one amp of current, a current sensor is defective. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 65: Emi Signal And Power Wiring

    • Pressure/flow/temperature signal transmitter signal distortion or aberrant behavior • Radio and TV interference • Telephone interference • Computer network data loss • Digital control system faults MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 66: Sources Of Emi

    Adjustable frequency drive generated EMI is both conducted to the line power and radiated to nearby conductors. See Figure 5.2. Motor AC Line Motor Cable Stray capacitance Stray capacitance Ground Potential 1 Potential 2 Potential 3 Figure 5.2 Ground Currents Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 67 However, imperfections in the adjustable frequency drive grounding or the equipment ground system can cause some of the currents to travel out to the power network. Motor AC Line Motor Cable Stray capacitance Signal wiring to BMS Figure 5.3 Signal Conductor Currents MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 68 Figure 5.4 Alternate Signal Conductor Currents High frequency currents can be coupled into the line power supplying the adjustable frequency drive when the line power conductors are located close to the motor cables. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 69: Preventive Measures

    While not as effective as true twisted-pair cable, it can be implemented in the field using the materials on hand. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 70: Proper Emc Installation

    Output contactor (generally not Line power, 3-phase and reinforced PE recommended) Ground rail (PE) Control wiring Cable insulation (stripped) Equalizing min. 16 mm (0.025 in Table 5.1 Legend to Figure 5.5 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 71: Test Procedures

    Use extreme caution when conducting tests on a powered adjustable frequency drive. Contact with powered components could result in electrical shock and personal injury. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 72: Signal Test Board

    Fasteners are M5 studs • All necessary precautions for system startup must be completed before applying power to Table 6.1 Legend to Figure 6.2 adjustable frequency drive. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 73 With a typical DVM, the voltage drop across most components is around 0.300 to 0.500. The opposite reading is referred to as infinity and most display the value OL for overload. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 74 MK500: Customer terminals for relays 1 and 2 MK102: Control card to power card connection MK501: Heatsink and door/top fan control Current scaling MK502: RFI relay control Table 6.2 Legend to Figure 6.3 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 75: Rectifier Circuits Test

    A diode drop indicates a correct reading. Infinity is the correct reading. The meter starts at a low value and slowly climbs toward infinity due to the meter charging capacitance within the adjustable frequency drive. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 76: Brake Igbt Test

    (+) DC and the value and climb toward infinity as capacitance is charged positive (+) meter lead is connected to the within the adjustable frequency drive. negative (-) DC. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 77: Igbt Temperature Sensor Test

    Ohms. At 32°F [0°C], the resistance is approximately 13.7 Perform the additional static checks before replacing the kΩ. At 140°F [60°C], the resistance is approximately 1.5 kΩ. fuse. The higher the temperature, the lower the resistance. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 78: Disconnect Test

    If there is a problem with any of the phases, replace the If there is a problem with any of the phases, replace the circuit breaker. contactor. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 79: Dynamic Test Procedures

    Do not disconnect the input cabling to the adjustable frequency drive with power applied due to danger of severe injury or death. WARNING Before starting the adjustable frequency drive, take all the necessary safety precautions for system startup. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 80 Whenever possible, perform these procedures with a split bus power supply. For more information, see chapter 8.1.1 Split Bus Power Supply. NOTICE! Always perform static tests (chapter 6.3 Static Test Procedures) before applying power to the unit. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 81: No Display Test

    Unplug more than 3%. the terminal strip and repeat the test. If this test is successful, continue. Remember to check the customer Danfoss calculates line imbalance per an IEC specification. connections. Imbalance = 0.67 X (V – V...

  • Page 82: Dc Bus Voltage Test

    8.1.1 Split Bus Power Supply. within the adjustable frequency drive itself. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 83: Input Waveform Test

    Unless used as an input, a jumper must be placed between terminals 104 and 106 of MK106. The following test is to measure the SCR gate resistance. Figure 6.5 Normal AC Input Voltage Waveform MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 84: Output Imbalance Of Motor Voltage And Current

    Use a PWM-compatible digital or analog voltmeter for overloads. Also, check for burned or open contacts in such monitoring output voltage. Digital voltmeters are devices. sensitive to waveform and switching frequencies and commonly return erroneous readings. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 85: Igbt Switching Test

    An incorrect reading indicates either a defective IGBT or gate drive signal. Perform the gate drive signal test (see chapter 6.4.11 IGBT Gate Drive Signals Test) to determine if the gate drive signal is correct. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 86 MK200: Brake IGBT test point (optional) MK501: U phase IGBT gate signal MK201: Brake IGBT gate signal (optional) MK502: U phase lower IGBT test point Table 6.5 Legend to Figure 6.9 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 87 25 through 30. Place the adjustable frequency drive in run at 30 Hz. The waveform in Figure 6.11 is the correct result. Figure 6.11 Gate Signal Waveform from Signal Test Board MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 88: Current Sensors Test

    If these parameters are not diable, the current signal. displayed exceeds 1–2 A. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 89: Fan Tests

    The mixing fan should operate any time the adjustable frequency drive is powered up. If the adjustable frequency drive is powered and the mixing fan is not running, replace the mixing fan. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 90: Input Terminal Signal Tests

    19 V DC is 0. If the display does not correspond with the measured inputs, the digital inputs on the control card have failed. Replace the control card. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 91: After Repair Tests

    Apply AC power to adjustable frequency drive. drive and change switches S201 and S202. Give the adjustable frequency drive a run command and slowly increase reference (speed command) to approximately 40 Hz. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 92 Reapply power and restart adjustable frequency drive. Adjust motor speed to a nominal level. Using a clamp-on style ammeter, measure output current on each output phase. All currents must be balanced. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 93: Disassembly And Assembly Instructions

    CAUTION Use the correct ESD procedures to prevent damage to sensitive components when servicing the adjustable frequency drive. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 94: Power Card Mounting Plate

    (T20) Bottom bus bar mounting The IP20 enclosure has a different type and number of nuts (0.5 in [13 mm]) fasteners. Table 7.1 Legend to Figure 7.1 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 95: Power Card

    RFI filter, two per phase. • MK501 Remove four mounting screws (T20 thread- • cutting) connecting the RFI filter to the side MK502 channels of the adjustable frequency drive. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 96: Fuses And Rfi

    Table 7.4 Legend to Figure 7.4 Remove the two screws (T25) at the bottom of the terminal block. Remove the terminal by sliding it down to disengage it from the metal clips holding it in place. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 97: Motor Terminal Block

    Remove three nuts (0.3 in [8 mm]). Reinstall in reverse order of this procedure and tighten hardware according to chapter 1.7 General Torque Tightening Values. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 98: Ac Power Size

    Balance/High frequency card DC center capacitor Tightening Values. plate Capacitor bank cover (+) DC capacitor plate (-) DC capacitor plate Capacitor locking panel Mylar insulator DC capacitor Table 7.5 Legend to Figure 7.5 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 99: Inrush Card

    0.43 in [11 mm] threaded and then place the inrush support to align all before standoff tightening the fasteners. T30 screw Inrush Support Bracket (-) DC bus bar Table 7.6 Legend to Figure 7.6 MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 100: Scrs

    Remove the (-) DC bus bar SCR to DC coil Remove the brake snubber capacitor by removing following the same procedure as with the (+) DC. two screws (T30), one from each bus bar. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 101: Igbts

    IGBT module. negative terminals of capacitors 4 and 5. Remove the gate leads, one from each IGBT. Number of T25 screws varies based on the size of the adjustable frequency drive. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 102: Dc Capacitors

    Note for reassembly: DC capacitor must fit into the Remove one screw (T25 thread-forming) from retaining stud at the bottom. each IGBT output bus bar, one bus bar per IGBT module. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 103: Ac Power Size

    7.3.11 Balance/High Reinstall in reverse order of this procedure and tighten Frequency Card. hardware according to chapter 1.7 General Torque Remove the Mylar cover from the capacitor bank. Tightening Values. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 104: How To Operate The Vlt ® Control Panel Lcp

    Unplug the fan electrical connector. Remove the fan by pulling it free from the mounting studs. Reinstall in reverse order of this procedure and tighten hardware according to chapter 1.7 General Torque Tightening Values. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 105: D2H/D4H Disassembly And Assembly Instructions

    Remove the one screw (T25) from the top center Reinstall in reverse order of this procedure and tighten of the mounting plate. hardware according to chapter 1.7 General Torque Tightening Values. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 106: Power Card

    Remove three nuts (0.5 in [13 mm]) at the top of the bus bars. One per phase. Remove the bus bars. Reinstall in reverse order of this procedure and tighten hardware according to chapter 1.7 General Torque Tightening Values. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 107: Rfi Only

    (T40) at the current Disconnect the customer input power wiring. sensor end. Remove the AC input bus bars in accordance with chapter 7.4.5 AC Input Bus Bars. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 108: Power Terminal Mounting Plate

    Fan retaining screw three current sensors. T25 screw The center current sensor is covered by a shield. Table 7.14 Legend to Figure 7.14 Remove the two screws (T20) screws to take it off. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 109: Mixing Fan

    7.4.13.2 690 V AC Power Size Remove the power terminal mounting plate in accordance with chapter 7.4.10 Power Terminal Mounting Plate. Unplug the cable MK 100 on the balance/high frequency card. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 110: Igbt Gate Drive Card

    Figure 7.17 IGBT Gate Drive Card MK1802 MK501 Inrush card MK601 T20 screw MK102 T20 screw MK101 Gate drive card T20 screw MK701 MK1800 MK100 Table 7.17 Legend to Figure 7.17 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 111: Scr Input Bus Bars

    1.7 General Torque Table 7.19 Legend to Figure 7.19 Tightening Values. NOTICE! Note for reassembly: Fasten all components hand-tight and then place the inrush support to align all before tightening the fasteners. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 112: With Optional Brake

    7.4.13 Balance/High Remove the power terminal mounting plate in Frequency Card. accordance with chapter 7.4.10 Power Terminal Mounting Plate. Remove the DC bus rails in accordance with chapter 7.4.18 DC Bus Rails. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 113: Ac Power Size

    Remove the DC bus rails in accordance with chapter 7.4.18 DC Bus Rails. Remove the Mylar cover from the capacitor bank. Remove the one screw (T20 thread-forming) from each IGBT output bus bar. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 114: Dc Capacitors

    10 and 11. Number of T25 screws varies Table 7.22 Legend to Figure 7.22 based on the size of the adjustable frequency drive Remove the capacitor locking panel by removing the ten screws (T25 thread-forming). Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 115: Ac Power Size

    (T20 thread forming), and screws (T25) connecting the plate to the positive terminals of capacitors 4, 8, 10, and 12. Number of T25 screws varies based on the size of the frequency converter. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 116: Heatsink Fan

    Reinstall in reverse order of this procedure and tighten from the brake IGBT by removing three screws hardware according to chapter 1.7 General Torque (T40) Tightening Values. Remove the Mylar shield by removing two plastic standoffs. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 117: D6H Disassembly And Assembly Instructions

    Remove the air baffle covering the interior option cabinet and the main enclosure. components. Remove 2 connector plates from the top of the Remove the EMC shield by removing 2 screws frequency converter. (T25). MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 118: Contactor

    1 Contactor 2 Contactor Bracket 3 A1/A2 terminals 4 Disconnect Table 7.27 Legend to Figure 7.27 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 119: Replacing The Heatsink Fan With Options Cabinet Present

    Remove the three output jumper bus bars between the main enclosure and the options cabinet by removing three screws (0.7 in [17 mm]) from the top of the bus bars, one per bus bar. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 120: Contactor

    1.7 General Torque Tightening Values See Figure 7.29. Figure 7.29 Contactor and Disconnect 1 Contactor 2 Contactor bracket 3 A1/A2 Terminals 4 Disconnect Table 7.29 Legend to Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 121 There are five or nine screws depending on the size of the adjustable frequency drive. Reinstall in reverse order of this procedure and tighten fasteners according to chapter 1.7 General Torque Tightening Values. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 122: Special Test Equipment

    The power card supply should provide between 610 and 750 V DC of power. The Danfoss split bus power supply provides 650 V DC with a capacity of 250 mA. The DC bus supply should provide a low level DC voltage.

  • Page 123: Signal Test Board Extension

    Values are provided for using a digital voltmeter for testing as well. MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 124 The red LED indicates voltage is present between VPOS and VNEG (-)18 V DC regulated regulated supply terminals. supply (-) 16.5 to 19.5 V (-)16.5 to 19.5 V DC Not used Not used Not used Not used Not used Not used Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 125 Input A 8.00 buffered, V phase, Equal on all phases 6.00 positive. Signal TP25-TP30 4.00 originates on 2.00 control card. 0.00 V -2.00 -4.00 -6.00 -8.00 -4.0ms 50Us/Div 2v/div 100us/div Run@10 Hz MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 126 Equal on all phases 6.00 phase, negative. TP25-TP30 4.00 Signal originates 2.00 on control card. 0.00 V -2.00 -4.00 -6.00 -8.00 -4.0ms 50Us/Div 2v/div 100us/div Run@10 Hz Table 8.1 Signal Test Board Pins Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...

  • Page 127: Spare Parts

    Bus bars used in some units are aluminum. Spare part bus bars are copper-plated when available. Copper-plated bus bars are useable for all units. For the latest spare parts list, visit the Danfoss website using the directions below. Spare Parts Lookup Procedure Go to www.danfoss.com/...
  • Page 128 See Table 9.1 and Table 9.2 for Details. See Table 9.1 for Details. Figure 9.3 DC Capacitor Bank Layout. Figure 9.5 DC Capacitor Bank Layout. See Table 9.1 for Details. See Table 9.1 for Details. Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 129 Figure 9.6 DC Capacitor Bank Layout. Figure 9.6 N200T7 N160T7 See Table 9.2 for Details. Figure 9.6 N250T7 N200T7 Figure 9.7 N315T7 N250T7 Figure 9.7 N400T7 N315T7 Table 9.2 DC Capacitor Bank Layout 525-690 V MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 130: Block Diagrams

    Block Diagrams Service Manual 10 Block Diagrams Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 131 Block Diagrams Service Manual MK102 TEST CONNECTOR MK104 MK102 30 PIN 44 PIN MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.

  • Page 132: Index

    Feedback................... 26, 55, 57 Fuses......................55 Serial communication............26, 27, 28 Setpoint....................27 Graphical display.................. 21 Short circuit.................... 54 Sleep Mode..................... 27 Speed reference..................26 Indicator lights..................23 Status......................23 Initialization.................... 25 Danfoss A/S © Rev. 2014-02-10 All rights reserved. MG94A222...
  • Page 133 Index Service Manual Status messages..................21 Status mode................... 26 Stop command..................27 Supply voltage..................55 Switching frequency................27 Voltage imbalance................52 Warning....................49 MG94A222 Danfoss A/S © Rev. 2014-02-10 All rights reserved.
  • Page 134 Danfoss shall not be responsible for any errors in catalogs, brochures or other printed material. Danfoss reserves the right to alter its products at any time without notice, provided that alterations to products already on order shall not require material changes in specifications previously agreed upon by Danfoss and the Purchaser. All trademarks in this material are property of the respective companies.

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