Danfoss E4h Manuals

Manuals and User Guides for Danfoss E4h. We have 3 Danfoss E4h manuals available for free PDF download: Service Manual, Installation Manual, Installation Instructions

Danfoss E4h Service Manual (370 pages)

Brand: Danfoss | Category: DC Drives | Size: 41.25 MB

Table of Contents
3
1 Introduction

11
- Purpose of this Guide
  11
- Additional Resources
  11
- Abbreviations and Acronyms
  12
- Conventions
  13
- Document Version
  13
- Approvals and Certifications
  13
- Disposal
  13
2 Safety

14
- Introduction
  14
- Safety Symbols
  14
- Qualified Personnel
  14
- Safety Precautions
  14
- Electrostatic Discharge
  16
3 Product Overview

17
- Introduction
  17
- Tools Required
  17
- Service Report
  17
- Enclosure Size Identification
  18
- Enclosure Size Definitions
  19
- Product Views
  24
- Product Options
  31
4 Operator Interface and Drive Control

32
- Introduction
  32
- Local Control Panel
  32
  - Layout
    32
  - Menus
    33
  - Parameter Settings
    35
  - Uploading and Downloading Parameter Settings
    35
  - Restoring Factory Default Settings
    35
- Status Messages
  36
- Status Message Definitions
  36
- Service Functions
  39
- Drive Inputs and Outputs
  40
  - Input Signals
    40
  - Output Signals
    40
  - Control Supply
    41
- Control Terminals
  41
- Control Terminal Functions
  42
- Shielded Cable Grounding
  43
5 Internal Drive Operation

44
- Introduction
  44
- Description of Operation
  44
  - Logic Section
    46
  - Logic-To-Power Interface
    46
  - Power Section
    47
- Sequence of Operation
  48
  - Rectifier Section
    48
  - Intermediate Section
    51
  - Inverter Section
    54
  - Brake Option
    57
  - Cooling Fans
    59
  - Fan Speed Control
    59
  - Load Sharing and Regen
    60
  - Specific Power Card Connections
    61
6 Troubleshooting

62
- Troubleshooting Tips
  62
- Exterior Fault Troubleshooting
  62
- Fault Symptom Troubleshooting
  62
- Visual Inspection
  63
- Fault Symptoms
  64
  - No Display
    64
  - Intermittent Display
    64
  - Motor Does Not Run
    64
  - Incorrect Motor Operation
    64
- Alarms and Warnings
  65
  - Overview of Alarms and Warnings
    65
  - Alarm/Warning Identification Tables
    66
- Alarm and Warning Definitions
  70
7 Drive and Motor Applications

82
- Torque Limit, Current Limit, and Unstable Motor Operation
  82
  - Overvoltage Trips
    83
  - Mains Phase Loss Trips
    83
  - Control Logic Problems
    84
  - Programming Problems
    84
  - Motor Load Problems
    84
- Internal Drive Problems
  85
  - Overtemperature Faults
    85
  - Current Sensor Faults
    85
- Electromagnetic Compatibility
  85
  - Effects of EMI
    85
  - EMI Signal and Power Wiring
    86
  - Sources of EMI
    86
  - EMI Propagation
    86
  - Preventive Measures
    89
8 Test Procedures

91
- Introduction
  91
- Tools Required
  92
  - Special Test Equipment
    92
  - Signal Test Board
    92
  - Metering Tools
    93
- Test Preparations
  93
- Static Test Procedures
  102
  - Rectifier Circuits Test
    102
  - Inverter Section Tests
    103
  - Brake IGBT Test
    103
  - Intermediate Section Tests
    104
  - IGBT Temperature Sensor Test
    104
  - Gate Resistor Test
    105
  - Mains Fuse/DC Fuse Test
    105
  - Disconnect Test
    105
  - Circuit Breaker Test
    106
  - Contactor Test
    106
- Dynamic Test Procedures
  107
  - No Display Test
    109
  - Input Voltage Test
    109
  - Basic Control Card Voltage Test
    109
  - DC Bus Voltage Test
    109
  - Switch Mode Power Supply Test
    110
  - Input Imbalance of Supply Voltage Test
    110
  - Input Waveform Test
    111
  - Input SCR Test
    111
  - Output Imbalance of Motor Voltage and Current
    112
  - IGBT Switching Test
    113
  - IGBT Gate Drive Signals Test
    114
  - Current Sensors Test
    116
  - Fan Tests
    118
  - Input Terminal Signal Tests
    119
- After-Repair Tests
  120
  - After-Repair Tests for D-Sized and E-Sized Drives
    121
  - After-Repair Tests for Parallel Drive Systems
    121
9 Special Test Equipment

122
- Split Bus Power Supply
  122
  - Overview
    122
  - Split Bus Power Supply Diagrams
    122
  - Split Bus Power Supply Connection
    124
- Parallel Drive Module Service Kit
  124
- Signal Test Board
  127
  - Signal Test Board Pin Outs
    128
10 D1H/D3H/D5H/D6H/J8 Drive Disassembly and Assembly

131
- Before Proceeding
  131
- D1H/D3H/D5H/D6H/J8 Disassembly and Assembly
  132
  - General Information
    132
  - Control Card and Control Card Mounting Plate
    132
  - Power Card Mounting Plate
    134
  - Power Card
    136
  - AC Input Busbars
    138
  - Mains Input Terminal Block
    140
  - Motor Terminal Block
    142
  - Brake Terminal Block (Optional)
    143
  - Power Terminal Mounting Plate
    143
  - Mixing Fan
    144
  - Current Sensors
    146
  - Balance/High Frequency Card
    148
  - DC Bus Rails
    149
  - Inrush Card
    150
  - SCR Input Busbars
    152
  - Scrs
    152
  - Gate Drive Card
    154
  - Brake IGBT Module
    154
  - Igbts
    156
  - Standard DC Capacitors
    158
  - Standard DC Capacitor Bank Layouts
    164
  - Twistlock DC Capacitors
    166
  - Twistlock DC Capacitor Bank Layouts
    170
  - Heat Sink Fan
    172
  - Door Fan
    175
  - Top Fan
    177
- D5H/D6H Disassembly and Assembly
  180
  - Accessing the Heat Sink Fan in D5H/D6H Drives
    180
  - Removing the Drive from the Extended Options Cabinet
    182
  - Contactor
    184
  - Disconnect
    184
- Heat Sink Access Panel
  186
  - Removing the Heat Sink Access Panel
    186
11 D2H/D4H/D7H/D8H/J9 Unit Disassembly and Assembly

188
- Before Proceeding
  188
- D2H/D4H/D7H/D8H/J9 Disassembly and Assembly
  189
  - General Information
    189
  - Control Card and Control Card Mounting Plate
    190
  - Power Card Mounting Plate
    192
  - Power Card
    192
  - AC Input Busbars
    194
  - Mains Input Terminal Block
    196
  - EMC Shield
    198
  - Brake Terminal Block (Optional)
    198
  - Motor Terminal Block
    199
  - Mixing Fan
    200
  - Power Terminal Mounting Plate
    202
  - Current Sensors
    203
  - Balance/High Frequency Card
    205
  - Gate Drive Card
    207
  - Inrush Card
    209
  - SCR Input Busbars
    211
  - Scrs
    211
  - DC Bus Rails
    213
  - Igbts
    216
  - Standard DC Capacitors
    218
  - Standard DC Capacitor Bank Layouts
    222
  - Twistlock DC Capacitors
    226
  - Twistlock DC Capacitor Bank Layouts
    230
  - Brake IGBT Module
    232
  - Heat Sink Fan
    234
  - Door Fan
    237
  - Top Fan
    239
- D7H/D8H Disassembly and Assembly
  242
  - Removing the Drive from the Extended Options Cabinet
    242
  - Accessing the Heat Sink Fan in D7H/D8H Drives
    242
  - Contactor
    244
  - Disconnect
    244
- Heat Sink Access Panel
  246
  - Removing the Heat Sink Access Panel
    246
12 Da2/Db2/Da4/Db4 Parallel System Disassembly and Assembly

248
- Before Proceeding
  248
  - Lifting the Unit
    249
- Parallel Drive System Disassembly and Assembly
  251
  - Removing the Control Shelf
    251
  - Removing a Drive Module
    252
  - Installing the Drive Modules
    253
  - Installing the Control Shelf
    255
- Parallel Drive Module Disassembly and Assembly
  257
  - General Information
    257
  - Blank Mounting Plate
    259
13 E1H-E4H Drive Disassembly and Assembly

261
- Before Proceeding
  261
- E1H-E4H Disassembly and Assembly
  262
  - General Information
    262
  - Control Card and Control Card Mounting Plate
    263
  - Power Card Mounting Plate
    265
  - Power Card
    267
  - Fan Power Card
    269
  - Inrush Card
    271
  - Inrush Card Frame and Rectifier Bus Plates
    273
  - Scr/Diode Modules
    275
  - Input Plate with Busbars
    277
  - Split Input Plate with Options
    279
  - Input Plate Mixing Fan
    281
  - Power Card Mixing Fan
    283
  - Gate Drive Card Mounting Plate
    285
  - Gate Drive Card
    287
  - Current Sensors
    289
  - Motor Busbar Assembly
    291
  - Balance/High Frequency Card
    293
  - Heat Sink Fan
    295
  - DC Snubber Capacitors
    297
  - Twistlock DC Capacitors
    299
  - DC Capacitor Layouts
    303
  - Igbts
    307
  - Door Fan
    309
  - Top Fan
    311
  - Vertical Brake Busbars
    313
  - Horizontal Brake Busbars
    315
  - DC Bus Rails
    319
14 Product Specifications

321
- Fastener Torque Ratings
  321
  - General Torque Tightening Values
    321
  - Unique Torque Values in E1H-E4H Drives
    322
- DC Voltage Levels
  323
- Warning and Alarm Trips Points
  323
15 Spare Parts

325
- Using the Drive Configurator Tool
  325
- Spare Parts Lists
  325
- Recommended Current Scaling Cards
  326
16 Block Diagrams

358
Index

364

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Danfoss E4h Service Manual (370 pages)

Table of Contents

1 Introduction

2 Safety

3 Product Overview

4 Operator Interface and Drive Control

5 Internal Drive Operation

6 Troubleshooting

7 Drive and Motor Applications

8 Test Procedures

9 Special Test Equipment

10 D1H/D3H/D5H/D6H/J8 Drive Disassembly and Assembly

11 D2H/D4H/D7H/D8H/J9 Unit Disassembly and Assembly

12 Da2/Db2/Da4/Db4 Parallel System Disassembly and Assembly

13 E1H-E4H Drive Disassembly and Assembly

14 Product Specifications

15 Spare Parts

16 Block Diagrams

Index

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