Danfoss VLT HVAC Drive FC100 Service Manual

Danfoss VLT HVAC Drive FC100 Service Manual

High power f frames
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MAKING MODERN LIVING POSSIBLE
S S ervice Manual
High Power F Frames
VLT HVAC Drive FC100
VLT AQUA Drive FC200
VLT
VLT

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Summary of Contents for Danfoss VLT HVAC Drive FC100

  • Page 1 MAKING MODERN LIVING POSSIBLE S S ervice Manual High Power F Frames VLT HVAC Drive FC100 VLT AQUA Drive FC200...
  • Page 2: Table Of Contents

    2.2.7 Numeric Local Control Panel (NLCP) 2.2.8 Tips and Tricks 2.3 Status Messages 2.4 Service Functions 2.5 Frequency Converter Inputs and Outputs 2.5.1 Input signals 2.5.2 Output signals 2.6 Control Terminals 2.7 Control Terminal Functions ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 3 5.1 Torque Limit, Current Limit, and Unstable Motor Operation 5.1.1 Overvoltage Trips 5.1.2 Mains Phase Loss Trips 5.1.3 Control Logic Problems 5.1.4 Programming Problems 5.1.5 Motor/Load Problems 5.2 Internal Frequency Converter Problems 5.2.1 Overtemperature Faults ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 4 6.3.12 Testing Current Feedback with the Signal Test Board 6.3.13 Input Terminal Signal Test 6.4 Module-level Static Test Procedures 6.4.1 Inverter Module 6.4.2 Rectifier Module 6.5 After Repair Drive Test 6.5.1 Procedure ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 5 8.2.9 Brake IGBT Module (Optional) 8.2.10 IGBT Module 9 Disassembly/Assembly - Rectifier Module 9.1 For Your Safety 9.1.1 Danfoss Training Required 9.2 Rectifier Module 9.2.1 Internal Access 9.2.2 Power Card 9.2.3 12-Pulse MPIC ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 6 11.1.1 Spare Parts for 380-480/500 VAC Drives 11.2.1 Spare Parts for 525-690 VAC Drives 11.3 Spare Parts for 380-500 VAC 12 Pulse 11.4 Spare Parts for 525-690 VAC 12 Pulse 12 Block Diagrams ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 7: Introduction

    12-pulse frequency converter input rectifiers to a separately mounted phase shifting transformer naturally cancels low order current harmonics to levels near 12%. No special set up or controls are required. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 8: Frame Size Definitions

    850 / 1000 1150 / 1350 1000 / 1200 F12 / F13 P1M2 1000 / 1100 1350 / 1550 1200 / 1400 F12 / F13 Table 1.8 12-Pulse FC 302 525-690 VAC ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 9: Ratings Tables

    Inverter Undervoltage Disable Undervoltage Warning Inverter Undervoltage Re-Enable (warning reset) Overvoltage Warning (w/o Brake) 1084 Dynamic Brake Turn-on 1099 Inverter Overvoltage Re-Enable (warning reset) 1099 Overvoltage Warning (with Brake) 1109 Overvoltage Trip 1130 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 10 Temperature ° C Power Card Ambient Under Temperature ° C Mains Phase Warning (5 sec delay) DC Bus Ripple Vpeak Mains Phase Alarm (25 sec delay) DC Bus Ripple Vpeak Table 1.9 T4/T5 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 11 Over Temperature ° C Power Card Ambient Under Temperature ° C Mains Phase Warning (5 sec delay) DC Bus Ripple Vpeak Mains Phase Alarm (25 sec delay) DC Bus Ripple Vpeak Table 1.10 T7 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 12: 12-Pulse Ratings Tables

    0 - 600Hz Heatsink overtemp. trip 95 °C Power card ambient trip 68 °C * High overload = 160% torque during 60 sec, Normal overload = 110% torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 13 Output frequency 0-600 Hz Heatsink overtemp. trip 95 °C Power card ambient trip 68 °C * High overload = 160% torque during 60 sec., Normal overload = 110% torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 14: Mains Supply 3 X 525 - 690 Vac

    0 - 500 Hz Heatsink overtemp. trip 85 °C Power card ambient trip 68 °C * High overload = 160% torque during 60 sec, Normal overload = 110% torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 15 Output frequency 0-500 Hz Heatsink overtemp. trip 85 °C Power card ambient trip 68 °C * High overload = 160% torque during 60 sec., Normal overload = 110% torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 16 30W to the losses. (Though typical only 4W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/-5%). ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 17: Mains Supply 3 X 380 - 480/500 Vac

    0 - 60 Hz Heatsink overtemp. trip 95° C Power card ambient trip 75° C * High overload = 160 % torque during 60 sec., Normal overload = 110 % torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 18 0-600 Hz Heatsink overtemp. trip 95 °C Power card ambient trip 75 °C * High overload = 160% torque during 60 sec., Normal overload = 110 % torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 19: Mains Supply 3 X 525 -690 Vac

    0 - 500 Hz Heatsink overtemp. trip 85 °C Power card ambient trip 75 °C * High overload = 160% torque during 60 sec., Normal overload = 110 % torque during 60 sec. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 20 0-50 Hz Heatsink overtemp. trip 85 °C Power card ambient trip 75 °C * High overload = 160% torque during 60 s, Normal overload = 110 % torque during 60 s ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 21 30W to the losses. (Though typical only 4W extra for a fully loaded control card, or options for slot A or slot B, each). Although measurements are made with state of the art equipment, some measurement inaccuracy must be allowed for (+/-5%). ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 22: Optional Components

    Manual motor starter Rectifier 30 amp fused circuit Rectifier 24 VDC power supply Rectifier Monitoring Options Residual current monitor Option Insulation resistance monitor Option Motor temperature monitor Inverter Pilz safety relay Inverter ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 23: General Torque Tightening Values

    Dynamic Brake Turn On 810 VDC 1099 VDC Inverter Over Voltage Re-Enable (warning reset) 821 VDC 1099 VDC Over Voltage Warning (with brake) 828 VDC 1109 VDC Over Voltage Trip 855 VDC 1130 VDC ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 24: Exploded Views

    (Optional) brake output bus bar (+) DC bus bar Motor output bus bar Mounting bracket SMPS fuse and fan fuse DC Fuse Control card Panel connectors MDCIC board Inverter module Top cover plate ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 25 IGBT module Panel connectors Current sensor SMPS fuse and fan fuse Fan assembly Upper capacitor bank assembly Lower capacitor bank assembly DC bus fuses (not included in F8/F9) Gate driver card ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 26 SMPS fuse Fan door cover (Optional) back AC fuse mounting bracket (T) SMPS fuse (Optional) middle AC fuse mounting bracket (S) Power card (Optional) front AC fuse mounting bracket (R) Panel connectors ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 27 Soft charge cards Power card Soft charge card mounting plate Panel connectors SCR module SMPS fuse Fan assembly Power card mounting plate flange Diode module Power card mounting plate Soft charge resistor ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 28 Introduction High Power Service Manual for Modular F Frame Drives Illustration 1.5 F-frame Options Cabinet Contactor Circuit breaker or disconnect RFI filter AC mains/line fuses Mains AC power input terminals ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 29 Mains input L11, L21, L31 SCR enable/disable Mains input L21, L22, L32 Relay 1 (01, 02, 03), relay 2 (04, 05, 06) Motor connection 96 (U), 97 (V), 98 (W) Auxiliary fan (104, 106) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 30 High Power Service Manual for Modular F Frame Drives Illustration 1.7 12-Pulse Rectifier Module F8/F9 MPIC card Diode Rectifier module cover plate Power card Fan assembly Soft charge resistor Soft charge card ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 31 Mains input L11, L21, L31, L21, L22, L32 AUX fan (100, 101, 102, 103) BC bus connections for common DC bus (DC+, DC-) Line fuses BC bus connections for common DC bus (DC+, DC-) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 32 High Power Service Manual for Modular F Frame Drives Illustration 1.9 12-Pulse Rectifier Module F10 - F13 Transformer Diode Rectifier module cover plate Power card Fan assembly Soft charge resistor Soft charge card ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 33 Motor connection 96 (U), 97 (V), 98 (W) Relay 1 (01, 02, 03), relay 2 (04, 05, 06) NAMUR fuses NAMUR Fan fuses AUX Fan (100, 101, 102, 103) SMPS fuses Brake terminals 81 (-R), 82 (+R) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 34 Motor connection 96 (U), 97 (V), 98 (W) Relay 1 (01, 02, 03), relay 2 (04, 05, 06) NAMUR fuses NAMUR Fan fuses AUX Fan (100, 101, 102, 103) SMPS fuses Brake terminals 81 (-R), 82 (+R) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 35 Illustration 1.12 12-Pulse Options Cabinet F8/F9 Pilz relay terminal Safety relay coil fuse with PILS relay RCD or IRM terminal Line fuses Mains input L11, L21, L31, L21, L22, L32 2 x 3-phase manual disconnect ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 36 Illustration 1.13 12-Pulse Options Cabinet F10 - F13 Pilz relay terminal Safety relay coil fuse with PILS relay RCD or IRM terminal Line fuses Mains input L11, L21, L31, L21, L22, L32 2 x 3-phase manual disconnect ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 37: Operator Interface And Control

    Additional diagnostic data can be accessed moving the display cursor, and speed control in easily through the LCP. local operation (along with status indicator lights) Operation mode keys and reset ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 38: Display Area

    (1.3), and drive output frequency (2) in large scale. Use the [INFO] key for definition of the displayed operating variables. Automatically generated mode and status messages appear on this line. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 39: Controller Operation Keys

    See the Operating Instructions for instructions for using the numeric LCP. Operation keys for local or auto (remote) control are found at the bottom of the LCP along with Off and Reset. Hand Auto Reset ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 40: Tips And Tricks

    Motor Adaptation is ready to start. Press [Hand On] on the LCP to start. AMA running Enable complete or reduced AMA was selected in 1-29 Automatic Motor Adaptation (AMA). The AMA process is in progress. Braking ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 41 The motor is momentarily driven with a DC current, stopped until a Run permissive signal is received via a 2-01 DC Brake Current, for a specified time, 2-02 DC Braking digital input. Time. Jogging ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 42 (alarm), protection mode is activated, which Speed down was activated via serial communi- includes reducing the switching frequency to 4 kHz. If cation. possible, protection mode ends after approximately 10 s. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 43: Service Functions

    Off 1, Off 2 and Off 3 active. Start inhibit is active. To Alarm enable start, see operation status Start inhibit. Auto Hand Reset See the FC Series Programming Guide for detailed information on accessing and displaying parameters and ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 44: Frequency Converter Inputs And Outputs

    The RS-485 serial communication connector is wired to terminals (+) 68 and (-) 69. Terminal 61 is common and may be used for terminating screens only when the control cable run between frequency converters, not ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 45: Output Signals

    Parameter settings are displayed by pressing the [Status] key on the LCP. Quick Main Alarm Status Menu Menu ▲ ▼ Use the arrow keys [ ], [ ], [►] and [◄] on the LCP to scroll through parameters. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 46: Control Terminal Functions

    See the Operating Instructions for details. 91 92 93 95 L1 L2 W PE 96 97 24 Vdc Illustration 2.4 Control Terminals Electrical Diagram, F-frame ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 47 Terminal 37 is for Safe Stop. See Safe Stop requirements in the Operating Instructions and Design Guide. (2) F10/F11 = two sets of terminals (3) F12/F13 = three sets of terminals ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 48: Earthing Screened Cables

    61. This terminal connects to earth through an internal RC link. It is recommended to use twisted-pair cables to reduce the differential mode interference between conductors. Table 2.3 Earthing Screened Cables ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 49: Internal Frequency Converter Operation

    A custom integrated circuit generates a pulse width modulation (PWM) waveform which is then sent to the interface circuitry located on the power card. Illustration 3.1 F-frame Internal Processing ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 50: Logic To Power Interface

    ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 51: Power Section

    IGBT modules run in parallel are contained in each inverter due to the high current handling requirements. Each inverter can be paralleled with one or two additional inverter modules to provide the required current for the power size. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 52: Sequence Of Operation

    This protects the soft charge module. resistor from damage along with any other components ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 53 2 4 6 7 9 11 8 10 12 2 4 6 BRAKE TERMINALS TERMINALS TERMINALS MOTOR TERMINALS MOTOR TERMINALS MOTOR TERMINALS MAINS FUSES MAINS FUSES Illustration 3.7 12-pulse rectifier circuit ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 54: Intermediate Section

    MAINS FUSES 14 11 OF1 CBL8 CONTACTOR DISCONNECT C1 C2 C21 C22 C13 C14 LOCATED IN OPTIONS CABINET: CB AND CONTACTOR TERMINAL BLOCKS SHUNT TRIP Illustration 3.8 Intermediate and inverter sections ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 55: Inverter Section

    AC sine wave. Illustration 3.9 Output Voltage and Current Waveforms plus This waveform, as generated by the Danfoss VVC principle at the control card, provides optimal performance and minimal losses in the motor. ®...
  • Page 56 MOTOR TERMINALS MAINS FUSES 14 11 OF1 CBL8 CONTACTOR DISCONNECT C1 C2 C21 C22 C13 C14 LOCATED IN OPTIONS CABINET: CB AND CONTACTOR TERMINAL BLOCKS SHUNT TRIP Illustration 3.10 Inverter section ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 57: Brake Option

    MOTOR TERMINALS MAINS FUSES 14 11 OF1 CBL8 CONTACTOR DISCONNECT C1 C2 C21 C22 C13 C14 LOCATED IN OPTIONS CABINET: CB AND CONTACTOR TERMINAL BLOCKS SHUNT TRIP Illustration 3.11 Brake option ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 58: Cooling Fans

    Last, a mains voltage source is required to power the fans measured temperature. The fan can be off or within the frequency converter. Again such a configuration high speed based on this temperature. should not be attempted without first consulting Danfoss Application Engineering. ® MG90K202 - VLT...
  • Page 59: Specific Card Connections

    100 mA. The relay can be programmed via 5-40 Function Relay to indicate frequency converter status. Terminal positions on the power card labelled MK400 and MK103 are reserved for future use. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 60: Troubleshooting

    The frequency converter has been designed to Finally, a list of tests called After Repair Tests is provided. operate within certain specifications. Incorrect These tests should always be performed when first starting ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 61 High Power Service Manual for Modular F Frame Drives a frequency converter, when approaching a frequency converter that is suspected of being faulty, or anytime following a repair to the frequency converter. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 62: Visual Inspection

    Look for any unusual amount of vibration that the frequency converter may be subjected to. The unit should be mounted solidly or the use of shock mounts employed. Table 4.1 Visual Inspection ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 63: Fault Symptoms

    Ensure that terminal 27 is logic “1”. Refer to the Input Terminal Signal Test. Check the settings of all motor parameters, including all motor compensation settings (Slip Compensation, Load Compensation, etc.) For Closed Loop operation, check PID settings. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 64: Alarms And Warnings

    (see also table on following page). Alarms that are trip-locked offer additional protection, since the mains supply must be switched off before the alarm can be reset. After being switched back on, the ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 65 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 AMA timeout Table 4.2 Alarm/Warning code list ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 66 Illegal PS config New spare part New type code Table 4.3 Alarm/Warning code list, continued.. (X) Dependent on parameter LED indication Warning yellow Alarm flashing red Trip locked yellow and red ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 67 Warning Word 2 00000001 Start Delayed 00000002 Stop Delayed 00000200 Discharge Temperature High Discharge Temperature High 00000400 1024 Start Limit 00000800 2048 Speed Limit Table 4.5 Compressor specific Alarms and Warnings ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 68: Warning And Alarm Definitions

    The intermediate circuit voltage (DC) is lower than the low 100% for too long. Check that 1-24 Motor Current is set voltage warning limit. The limit is dependent on the correctly. frequency converter voltage rating. The unit is still active. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 69 A fitted option is not operational with the present control 1-93 Thermistor Source selects terminal 53 or 54. board hardware or software. Record the value of the following parameters and contact your Danfoss supplier: When using digital inputs 18 or 19, check that the thermistor is connected correctly between...
  • Page 70 For the D, E, and F Frame frequency converters, this alarm card. is based on the temperature measured by the heatsink sensor mounted inside the IGBT modules. For the F Frame ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 71 High Power Service Manual for Modular F Frame Drives frequency converters, this alarm can also be caused by the It may be necessary to contact your Danfoss supplier or thermal sensor in the rectifier module. service department. Note the code number for further troubleshooting directions.
  • Page 72 “Start delay” time window. ALARM 50, AMA calibration failed WARNING 64, Voltage limit Contact your Danfoss supplier or Danfoss Service The load and speed combination demands a motor Department. voltage higher than the actual DC link voltage.
  • Page 73 22-60 Broken Belt Function is set for alarm. the spare part and its power card are the correct part Troubleshoot the system and reset the frequency converter number. after the fault has been cleared. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 74 It is equivalent to Alarm 79. The report value in 2 = middle inverter module in F2 or F4/F12 or the alarm log indicates which power module generated F13 frequency converter. the alarm: ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 75: After Repair Tests

    This can be done on the DC bus output of the rectifier module or the bus bars connecting to the top side of the DC fuses on any of the inverter modules. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 76: Frequency Converter And Motor Applications

    Enter the motor data required as listed on the motor of this type. The timer can be displayed. nameplate. For effective and efficient load control, the frequency converter relies on this information for ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 77: Overvoltage Trips

    (terminals 18, 19, 27, 29, 32, 33), two analog inputs of influence applies. The frequency converter will add (53 and 54), and the fieldbus (68, 69). The presence of a about 10% to the base speed before a trip occurs. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 78: Programming Problems

    These parameters must be set according to the requirements of the particular installation. References are set in the parameter group 3-0*. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 79: Internal Frequency Converter Problems

    With the motor disconnected, ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 80: Electromagnetic Interference

    EMI. Detrimental effects to these systems may include the following: Pressure/flow/temperature signal transmitter signal distortion or aberrant behaviour Radio and TV interference Telephone interference Computer network data loss Digital control system faults ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 81: Sources Of Emi

    Illustration 5.1 F-frame Functionality Diagram Recti er DC Bus Inverter Filter reactor AC Line IGBT Motor Filter capacitor PWM waveform Sine wave Filter reactor AC Line Filter capacitor Illustration 5.2 12-pulse Functionality Diagram ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 82: Emi Propagation

    High frequency currents can be coupled into the mains supplying the frequency converter when the mains conductors are located close to the motor cables. Motor Stray capacitance Stray capacitance Ground Potential 1 Potential 2 Potential 3 Illustration 5.3 Earth Currents ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 83 High Power Service Manual for Modular F Frame Drives Frequency Converter Motor Stray capacitance Signal wiring to BMS Illustration 5.4 Signal Conductor Currents Frequency Converter Motor Stray capacitance AC Line Illustration 5.5 Alternate Signal Conductor Currents ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 84: Preventive Measures

    EMI is a problem. Single conductor wires provide the least protection from EMI emissions. Often, if these conductors are routed separately from the signal and mains wiring, then no further consideration is needed. If ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 85: Proper Emc Installation

    Control cables Min. 200mm Motor cable between con- trol cables, motor cable and Mains-supply mains cable Motor, 3 phases and Reinforced protective earth Protective earth Illustration 5.6 Proper EMC Installation ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 86: Test Procedures

    Rx100 scale. Before making any checks disconnect all input, motor and Replace any defective component and retest the frequency brake resistor connections. converter with the new component before applying power ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 87 With a typical DVM, the voltage drop across most components will be around 0.300 to 0.500. The opposite reading is referred to as infinity and most DMVs will display the value OL for overload. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 88: Rectifier Module Static Test

    SMPS fuse Fan door cover (Optional) back AC fuse mounting bracket (T) SMPS fuse (Optional) middle AC fuse mounting bracket (S) Power card (Optional) front AC fuse mounting bracket (R) Panel connectors ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 89 High Power Service Manual for Modular F Frame Drives Illustration 6.3 12-pulse Rectifier Module Test Points 12-pulse rectifier module Fan fuses DC bus bar AC mains fuses SMPS fuse AC connectors ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 90 Connect negative (–) meter lead to terminals L1, are open. Should that occur, replace both diodes. L2, and L3 in turn. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 91: Inverter Module Static Tests

    Remove positive DC jumper bus bar from fuse by removing attaching hardware on each end of bus bar. Remove negative DC jumper bus bar from fuse by removing attaching hardware on each end of bus bar. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 92: Inverter Test Part I

    Connect the positive (+) meter lead to the negative (-) DC bus bar. Connect the negative (–) meter lead to terminals U, V, and W in sequence. Each reading should show a diode drop. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 93: Brake Igbt Test

    Check the wire harness between the Rectifier out at a value and climb toward infinity as capacitance is Module and each Inverter Module. At the Rectifier charged within the frequency converter. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 94 Inverter Module number 1. Inverter Module number 2. Read the terminals on Check 6: Heat Sink Fan Ohm Test Check the resistance of the heat sink fan on each module. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 95: Dynamic Test Procedures

    LCP. This is because the fan circuitry is not harness side of the connector (male connector). powered in this mode. This will not affect the operation. Measure between pins 5 and 8. Should read approximately 47 Ω. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 96: Warnings

    3%. WARNING Danfoss calculates line imbalance per an IEC specification. Take all the necessary safety precautions for system start Imbalance = 0.67 X (Vmax – Vmin) / Vavg up prior to applying power to the frequency converter.
  • Page 97: Dc Undervoltage Test

    L1 (R), L2 (S), and L3 (T). NOTE: For 12-pulse units, L11/L12 (R), L21/L22 (S), L31/L32 (T). Typically, the current should not vary from phase to phase by more than 5%. Should a greater ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 98: Gate Signal Test

    All waveform readings should appear similar to Perform the static soft charge and rectifier tests. the below figure. Repeat this procedure for all inverter modules. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 99: Current Sensor Test

    Read the output current in the display. The signal. display should indicate less than 1 amp. Incorrect reading If an incorrect reading was obtained from the above tests, further tests of the current feedback signals are required ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 100: Module-Level Static Test Procedures

    60 is shown in line 2 of the display. 6.4 Module-level Static Test Procedures 6.4.1 Inverter Module Heatsink Temperature Sensor Test Remove the inverter module from the drive in accordance with disassembly procedures. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 101: Rectifier Module

    Remove the rectifier module from the drive in accordance with disassembly procedures. Remove the power card mounting plate in accordance with disassembly procedures. Disconnect the connector MK3 from each soft charge card. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 102: After Repair Drive Test

    (The fans will not operate when powered in this manner.) Give the frequency converter a run command (press [Hand on]) and slowly increase the reference (speed command) to approximately 40 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 103: Top Level Module Removal Instructions

    If supplied with a circuit breaker or disconnect switch, the cabinet doors are interlocked. To open the cabinet doors, the circuit breaker and disconnect switch must be in the OFF position. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 104: F-Frame Service Shelf

    176F8835, is available from presented here are the same for 12-pulse units as F-frame Danfoss to provide support of the modules for removal units with the exception that 12-pulse units may vary in from the units. This shelf, or other suitable support the number of SCR and diode modules as described for F- equipment, is recommended.
  • Page 105 Motor connection 96 (U), 97 (V), 98 (W) Brake terminals 81 (-R), 82 (+R) 12- pulse inverter module SCR enable/disable Relay 1 (01, 02, 03), relay 2 (04, 05, 06) Auxiliary fan (104, 106) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 106: Dc Link Fuses

    For this reason, ensure that the fan is installed with the printed arrow on the fan pointing inward. Incorrect installation can cause excess heating and an overtemperature fault. Tighten nuts to 20 in/lbs (2.3 Nm). ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 107: Heatsink Fans

    The plug for the fan is keyed to only fit one way. However, if too much force is used, the plug can be forced the wrong way. 130BX257.10 Heatsink Heatsink fan Plug Cover ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 108: Rectifier Module

    Front AC input power bus bar (step 4) Eye bolt location in rectifier cabinet from cabinet. Eye-bolt washer Eye bolt Rectifier module DC bus bar (step 3) DC bus bar (step 3) Mounting bracket ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 109: Inverter Module

    Motor output bus bar (Step 3) Mounting bracket (Step 7) SMPS fuse and fan fuse DC Fuse (Step 6) Control card Panel connectors (Steps 4 and 5) MDCIC board Inverter module Top cover plate ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 110: Mdcic Mounting Panel

    Relay connector (not shown) (step 5) MDCIC ribbon cable (step 3) MDCIC board cover plate Control card to MDCIC ribbon cable (step 2) Attaching screw (step 7) Reinstall in reverse order of this procedure. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 111: Fan Transformers

    Reinstall DC link reactors in reverse order of this procedure. 130BX255.10 Fan transformer Nut (M8) (step 3) Fan transformer connector (step 2) 130BX253.10 DC link inductor Bus bars (step 2) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 112: Mdcic Board

    Remove MDCIC board by removing 9 screws Angle bracket bus bar (not removed) securing board to panel standoffs. 130BX266.10 MDCIC board cover (step 3) Ribbon cable (step 4) Retaining screws (step 1) Left-side ribbon cable (step 2) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 113 130BX267.10 MDCIC cover (step 3) MDCIC mounting panel Scaling card (step 5) Ribbon cable (step 4) MK101 connector (step 5) Left-side ribbon cable (step 2) MDCIC board attaching screw (step 6) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 114: Disassembly/Assembly - Inverter Module

    8.1 For Your Safety 8.1.1 Danfoss Training Required CAUTION Only Danfoss trained and certified technicians are permitted to test and repair components within the unit modules. The procedures described in this section are intended for Danfoss qualified technicians. Repair work conducted by non-certified technicians can result in personal injury or equipment damage.
  • Page 115: Inverter Module

    High frequency board Inverter power card IGBT module Panel connectors Current sensor SMPS fuse and fan fuse Fan assembly Upper capacitor bank assembly Lower capacitor bank assembly DC bus fuses Gate driver card ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 116: Internal Access

    Reassembly is done in reverse order. 130BX274.10 Upper capacitor bank assembly Inverter power card 10 mm retaining nut (step 8) 8 mm electrical connection nut (step 7) Lower capacitor bank assembly IGBT gate driver card ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 117: Lower Capacitor Bank Assembly

    8 mm retaining nut (step 4) Upper capacitor bank assembly Inverter power card 8 mm electrical connection nut (step 2) 10 mm retaining nut (step 3) Lower capacitor bank assembly IGBT gate driver card (step 1) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 118: Gate Drive Card

    Remove gate drive card by removing 6 mounting screws (T25) from standoffs. Reinstall in reverse order of this procedure. Tighten mounting screws to 2.3 Nm (20 in-lbs). 130BX256.10 MK104 (W) MK100 MK103 (V) MK105 (brake option) MK102 (U) MK106 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 119: Current Sensor

    Remove four retaining nuts (13mm) connecting T40 screw (step 4) IGBT-Ind base bar assembly to two DC bus bars Mounting bracket (1000A sensor) (step 8) from inductor. Remove IGBT-Ind bus bar assembly. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 120: Igbt Module

    Reassemble in reverse order of this procedure. NOTE: Connect temperature sensor cable from gate drive card MK100 to center IGBT module connector MK103. NOTE The special torque requirements on the instructions included with the replacement module. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 121: Disassembly/Assembly - Rectifier Module

    Disconnect cabling. CAUTION Disconnect cabling from power card: MK100, Only Danfoss trained and certified technicians are MK102, MK103, MK104, MK105, MK106, MK108, permitted to test and repair components within the unit MK110, Mk112, and FK102.
  • Page 122: 12-Pulse Mpic

    Power card (step 2) Cable connectors (step 3) Fuse block (step 1) Power card mounting plate flange Attaching screw (step 4) Illustration 9.1 MPIC MK 110 MPIC MK106 MK105 MK104 MK102 MK101 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 123: Soft Charge Card Mounting Plate

    Reinstall in reverse order of this procedure. Tighten 8mm nuts to 2.3 Nm (20 in-lbs). Soft charge card Attaching screw (step 3) Soft charge card Soft charge card mounting plate Attaching nut (step 4) ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 124: Soft Charge Resistor

    13 mm retaining nut (step 5) 17 mm retaining nut (step 4) Reinstall in reverse order of this procedure. Tighten T20 13 mm retaining nut (step 3) screws to 1.0 Nm (20 in-lbs). SCR module ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 125: Diode Module

    Reassembly Replace diode module in accordance with instructions included with replacement module. Reassemble in reverse order of this procedure. 17 mm retaining nut (step 3) T30 screws (step 4) Diode module ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 126: Special Test Equipment

    If a motor is connected to the drive, remove all output bus bars from each inverter module. Also remove the brake bus bars if the drive is equipped with the brake option. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 127: Signal Test Board Pin Outs: Description And Voltage Levels

    Values are provided for using a digital voltmeter for testing as well. ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 128 0.6 to 0.8 VDC – SCRs enabled front end 0VDC – SCR disabled INV_DIS Control signal from Disables IGBT gate voltages 5VDC – inverter disabled Power Card 0VDC – inverter enabled Not used ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 129 0.6 to 0.8 VDC – SCRs enabled front end 0VDC – SCR disabled INV_DIS Control signal from Disables IGBT gate voltages 5VDC – inverter disabled Power Card 0VDC – inverter enabled Not used ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 130 Input A 8.00 buffered, W phase, Equal on all phases TP25-TP30 6.00 negative. Signal 4.00 originates on Control 2.00 Card. 0.00 V -2.00 -4.00 -6.00 -8.00 -4.0ms 50Us/Div 2v/div 100us/div Run@10Hz ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 131 Input A 8.00 buffered, W phase, Equal on all phases 6.00 positive. Signal TP25-TP30 4.00 originates on Control 2.00 Card. 0.00 V -2.00 -4.00 -6.00 -8.00 -4.0ms 50Us/Div 2v/div 100us/div Run@10Hz ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 132 Input A 8.00 buffered, W phase, Equal on all phases TP25-TP30 6.00 negative. Signal 4.00 originates on Control 2.00 Card. 0.00 V -2.00 -4.00 -6.00 -8.00 -4.0ms 50Us/Div 2v/div 100us/div Run@10Hz ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 133: Spare Part Lists

    FC 102FC 102 and FC-202 power ratings match the drive type code. Example: FC-302P90KT5 uses a P110T5 spare part. FC-102P110T4 or FC-202P110T4 uses a P110T4 spare part. NOTE For the latest spare parts information, visit the Danfoss Website at www.Danfoss.com ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 134 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 135 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 136 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 137 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 138 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 139 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 140 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 141 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 142 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 143 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 144 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 145: Spare Parts For 525-690 Vac Drives

    FC 102FC 102 and FC-202 power ratings match the drive type code. Example: FC-302P90KT7 uses a P110T7 spare part. FC-102P110T7 or FC-202P110T7 uses a P110T7 spare part. NOTE For the latest spare parts information, visit the Danfoss Website at www.Danfoss.com ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 146 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 147 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 148 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 149 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 150 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 151 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 152 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 153 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 154 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 155 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 156: Spare Parts For 380-500 Vac 12 Pulse

    Spare Part Lists High Power Service Manual for Modular F Frame Drives 11.3 Spare Parts for 380-500 VAC 12 Pulse ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 157 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 158 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 159 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 160 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 161 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 162 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 163 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 164 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 165 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 166 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 167 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 168 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 169 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 170: Spare Parts For 525-690 Vac 12 Pulse

    Spare Part Lists High Power Service Manual for Modular F Frame Drives 11.4 Spare Parts for 525-690 VAC 12 Pulse ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 171 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 172 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 173 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 174 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 175 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 176 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 177 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 178 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 179 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 180 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 181 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 182 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 183 Spare Part Lists High Power Service Manual for Modular F Frame Drives ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 184: Block Diagrams

    12 Block Diagrams 10-Pin 8-Pin 6 2 5 3 4 7 5 10 10-Pin 8-Pin 3 4 7 5 10 10-Pin 8-Pin 3 4 7 6 2 5 8 5 4 8-Pin ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 185 Block Diagrams High Power Service Manual for Modular F Frame Drives TO INVERTERS 1, 2, & 3 12-PIN ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 186 7 9 11 8 10 12 TERMINALS INV 2 MOTOR TERMINALS MAINS FUSES MAINS FUSES 91-1 INV 1 Not Used 92-1 CBL18 93-1 Illustration 12.3 12-Pulse Top Level Block Diagram F8/F9 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 187 Block Diagrams High Power Service Manual for Modular F Frame Drives TO INVERTERS 1, 2, & 3 12-PIN RECTIFIER HS TEMP SENSOR ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 188 Block Diagrams High Power Service Manual for Modular F Frame Drives NTC2 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 MK108 FK102 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1 ELO1 EUP1 GLO1 GUP1 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 189 7 2 1 10-Pin 8-Pin 6 2 5 3 4 7 8 5 10 7 2 1 10-Pin 8-Pin 5 10 10-Pin 8-Pin 3 4 7 8 6 2 5 8-Pin ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 190 Block Diagrams High Power Service Manual for Modular F Frame Drives TO INVERTERS 1, 2, & 3 12-PIN FK103 Pin 102 FK103 Pin 100 FK103 Pin 101 FK103 Pin 103 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 191 Block Diagrams High Power Service Manual for Modular F Frame Drives TO INVERTERS 1, 2, & 3 12-PIN FK103 Pin 102 FK103 Pin 100 FK103 Pin 101 FK103 Pin 103 ® MG90K202 - VLT is a registered Danfoss trademark...
  • Page 192 130R0364 MG90K202 Rev. 2011-09-07 *MG90K202*...

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