Danfoss VLT HVAC Basic Drive FC 101 Manual de servicio

MAKING MODERN LIVING POSSIBLEService ManualVLT® HVAC Basic Drive FC 101

Model HP @380–480 V AC kW @380–480 V AC Frame Size IP Rating Repairable Yes/NoPK37 0.5 0.37 H1 IP20 NoPK75 1.0 0.75 H1 IP20 NoP1K5 2.0 1.5 H1 IP20 NoP

9.1.3 H7, H8, I7, I8 Frame Sizex 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC / DCThyristor x3BRP _BRFRL 2InrushSAFE_FBTmp_VGDSVCCFA

9.1.4 H9 Frame Sizex 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC/DCx3BRP _BRFRL 2RFI_RL 1InrushSAFE_FBTmp_VGDSVCCFAN 1CANAAImax2 co

9.1.5 H10 Frame Sizex 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC /DCx3BRP_BRFRL 2RFI_RL 1InrushSAFE_FBTmp_VGDSVCCFAN 1CANAAImax2

IndexAAMA... 34, 36, 37, 39, 41, 42AnalogInputs...

Relay... 12, 13, 15, 16, 24, 26, 63, 70Remote Input...

IndexVLT® HVAC Basic Drive Service ManualMG90X202 - VLT® is a registered Danfoss trademark 103

www.danfoss.com/drives *MG90X202*130R0242 MG90X202 Rev. 2012-05-22

Model HP @525–600 V AC kW @525–600 V AC Frame Size IP Rating Repairable Yes/NoP2K2 3.0 2.2 H9 IP20 NoP3K0 4.0 3.0 H9 IP20 NoP5K5 7.5 5.5 H9 IP20 NoP7K

1.6 Electrical Installation in GeneralAll cabling must comply with national and localregulations on cable cross-sections and ambienttemperature. Copp

1.7 Exploded Views – H Frame SizeNOTENon-repairable units are not shown with exploded views.130BC341.10123456789101112131415161718Illustration 1.1 Ex

130BC342.10123456789101112131415161718192021232422Illustration 1.2 Exploded View - H7 Frame Size1Blind cover 13 Relay/transducer card mounting plate2

130BC214.1112345678910111213141516171819202122Illustration 1.3 Exploded View - H8 Frame Size1LCP 12 SMPS card2 Front cover 13 Cable mounting plate3 Cr

1.8 Exploded Views - I Frame Size130BC046.1112 345679101112131415168Illustration 1.4 Exploded View - I6 Frame Size1Local Control Panel (LCP) 9 DC coi

130BC215.1112345678910111213141516171819202122232425Illustration 1.5 Exploded View - I7 Frame Size1Local Control Panel (LCP) 14 DC coil 2 Front door

130BC216.11123456 7 8101112131415161718199Illustration 1.6 Exploded View - I8 Frame Size1LCP 11 DC coil 2 Front cover 12 Rectifier modules3 Cradle 13

1.9 Ratings Tables1.9.1 Short Circuit and Over-current TripsThe frequency converter is protected against short circuitswith current measurement in ea

2 Frequency Converter Control2.1 IntroductionFrequency converters are designed with self-diagnosticcircuitry to isolate fault conditions and activate

control cable is run between frequency converters, and notbetween frequency converters and other devices. Parameters for configuring the input and out

2.6 Control Terminal FunctionsTable 2.2 describes the functions of the control terminals.Many of these terminals have multiple functionsdetermined by

L1L2L33 PhasepowerinputPEPE+10Vdc0-10Vdc-0-10Vdc-50 (+10V OUT)54 (A IN)53 (A IN)55 (COM A IN/OUT)0/4-20 mA0/4-20 mA42 0/4-20mA A OUT / DIG OUT45 0/4-2

2.7 Earthing Shielded CablesConnect the screened control cables to the metal cabinetof the frequency converter with cable camps at both ends.Table 2.

3 Internal Frequency Converter Operation3.1 GeneralThis section provides an operational overview of the mainassemblies and circuitry in the frequency

The control card logic •communicates via serial link with outside devicessuch as personal computers or ProgrammableLogic Controllers (PLC).•provides t

The low voltage power supplies are activated when the DCbus reaches approximately 50 V DC less than the alarmvoltage low for the DC bus (see rating ta

x 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC / DCThyristor x3BRP _BRFRL 2InrushSAFE_FBTmp_VGDSVCCFANCANAAImax 2 comp.RL2RL1Tmp_VG

x 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC/DCx3BRP_BRFRL 2RFI _ RL 1InrushSAFE_FBTmp_VGDSVCCFAN1CANAAImax2 comp.MAINSRL 2 RL 1RF

Contents1 Introduction61.1 Purpose61.2 Product Overview61.3 Safety61.4 Electrostatic Discharge (ESD)61.5 Tools Required91.6 Electrical Installation i

3.3.3 Inverter SectionIn the inverter section (see Illustration 3.8), gate signals aredelivered from the control card, through the power card tothe ga

x 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC/DCx3BRP_BRFRL 2RFI _ RL 1InrushSAFE_FBTmp_VGDSVCCFAN1CANAAImax2 comp.MAINSRL 2 RL 1RF

3.3.4 Fan Speed Control IP20Enclosure H6 H7 H8Voltage T2 T2 T2 T2 T2 T2Power Rating(kW)15 18. 5 22 30 37 45FAN starttemperature °C45 45 45 45 45 45FA

4 Troubleshooting4.1 Troubleshooting TipsBefore repairing a frequency converter, read andunderstand the following instructions.1. Note all warnings c

4.4 Visual InspectionVisually inspect the conditions in Table 4.1 as part of anyinitial troubleshooting procedure.Inspect For DescriptionAuxiliary eq

4.5 Fault Symptoms4.5.1 No DisplayThe LCP display provides two display indications. One withthe backlit LCD alphanumeric display. The other is threeL

Check control wiring to ensure that the proper referencesignal is present at the input terminals. Also check that theunit is properly programmed to ac

TRIPLOCK (DISC> MAINS): Requires that the main AC inputpower to the frequency converter must be disconnectedlong enough for the display to go blank

No. Description Warning Alarm Trip Lock Parameter Reference24 Fan Fault (Only on 400 V30-90 kW) (X) 14–5330 Motor phase U missing (X) (X) 4–583

WARNING/ALARM 4, Mains phase lossA phase is missing on the supply side, or the mainsvoltage imbalance is too high. This message also appearsfor a faul

4.4 Visual Inspection324.5 Fault Symptoms334.5.1 No Display 334.5.2 Intermittent Display 334.5.3 Display (Line2) Flashing 334.5.4 WRONG or WRONG LCP D

ALARM 14, Earth (ground) faultThere is current from the output phases to earth, either inthe cable between the frequency converter and the motoror in

TroubleshootingTurn off the frequency converter and remove theearth fault.Measure the resistance to ground of the motorleads and the motor with a mego

4. Apply AC power to frequency converter.5. Give the frequency converter a run commandand slowly increase reference (speed command)to approximately 40

5 Frequency Converter and Motor Applications5.1 Torque Limit, Current Limit, andUnstable Motor OperationExcessive loading of the frequency converter

When the input voltage becomes unbalanced or a phasedisappears completely, the ripple voltage increases. Thissituation causes the frequency converter

5.1.5 Motor/Load ProblemsProblems with the motor, motor wiring, or mechanical loadon the motor can develop in a number of ways. The motoror motor wiri

5.2.4 Sources of EMIModern frequency converters (see Illustration 5.1) utilizeIGBTs to provide an efficient and cost effective means tocreate the Puls

to flow in undesirable paths, thus exposing other locationsto the EMI.130BC345.10134562Illustration 5.4 Alternate Signal Conductor CurrentsNOTEHigh fr

6 Test Procedures6.1 Non-repairable UnitsH1-H5 and I2-I4 are non-repairable units and should not berepaired. The information about Line/Motor/UDC+-te

130BC201.10Illustration 6.3 I3 FrameIP54 380-480 V, 5.5-7.5 kW1RS-4852 Line in3 Earth4 Wire clamps5 Motor6 UDC7 Relays8 I/OTable 6.3130BD011.10Illustr

6.4.3 Basic Control Card Voltage Test 536.4.4 Input Imbalance of Supply Voltage Test 546.4.5 Input Waveform Test 546.4.6 Output Imbalance of Motor Sup

6.2 IntroductionWARNINGDISCHARGE TIME!Frequency converters contain DC-link capacitors that canremain charged even when the frequency converter is not

6.3.2 Rectifier Circuit TestPay close attention to the polarity of the meter leads toensure the identification of any faulty component, in casean inco

6.3.4 Intermediate Section TestsNOTEThis test is applicable for H7, H8, I7, and I8 units only.The intermediate section of the frequency converter isma

130BC354.10Illustration 6.7 The UDC Terminals on the Circuit BoardH7 and H8Remove the IP20 front cover to access the terminalsdirectly on the power ca

H10Remove the front terminal cover to access the connectors.The UDC terminals are located inside the frequencyconverter.130BC351.10DC-DC+L1L2L3VWUIllu

Dynamic tests are performed without the motor beingconnected to UVW connector. Program the frequencyconverter to approximately 50 Hz on start.Dynamic

control wiring and repeat the test. If this test is successful,then continue. Remember to check the customerconnections. If still unsuccessful, change

With a phase loss, the current waveform of the remainingphases would take on the appearance shown inIllustration 6.17.0.0 ms 5 ms/Div.130BX144.10Input

Digital InputsWith digital inputs displayed, control terminals 18, 19, 27,and 29 are shown left to right, with a 1 indicating thepresence of a signal.

7 H-Frame Size Disassembly and Assembly Instructions7.1 Electrostatic Discharge (ESD)CAUTIONFrequency converters contain dangerous voltages whenconne

7.6.2 Power Card Cover 737.6.3 Power Card 747.6.4 Heatsink and DC Coils 747.6.5 Heatsink Fan Assembly 758 I-Frame Size Disassembly and Assembly Proced

130BC108.111234Illustration 7.1 Control Card and Control Card Mounting Plate1LCP2 Cradle3 Control card4 Control card mounting plateTable 7.17.3.2Heats

7.3.3 DC Coil1. Remove the 4 screws on the DC coil cover toaccess the DC coils.2. Remove the 4 screws to loosen the cables fromthe DC Link card.3. Rem

7.3.5 RFI Filter1. Remove the protection cover.2. Remove the 6 distance bushes.3. Remove the 2 screws on the frame side.4. Remove the 3 screws from U

7.4 H7 Frame Size Disassembly andAssembly Instructions7.4.1 Control Card and Control CardMounting Plate1. Remove the LCP by pressing the barbs on the

7.4.2 Power Card 1. Remove the LCP ribbon cable from the powercard. 2. Unplug all other cables from the power card,including the 3 gate cables at the

7.4.4 RFI Filter1. Remove the red/black cables from the filter cable.2. Remove the protective foil.3. Remove the 3 filter cables screws using a hex 8k

7.4.6 Rectifier Modules1. Loosen and remove the 2 cables (T20).2. Remove the 6 screws (T20) from the shield.3. Remove metal shield and plastic cover.4

7.4.8 Heatsink Fan Assembly1. Remove the 4 screws (T20) from the fan coverplate.2. Press the fan cover plate outwards using ascrewdriver.3. Remove the

7.4.10 Capacitor Bank1. Remove the foil.2. Remove the 6 screws on the bottom plate.3. Remove the bottom plate.4. Remove the 4 screws (T20) from the ca

130BC108.111234Illustration 7.16 Control Card and Control Card Mounting Plate1LCP2 Cradle3 Control card4 Control card mounting plateTable 7.167.5.2Pow

8.4.9 DC Bus Bar Assembly 938.4.10 Heatsink Fan Assembly 938.4.11 Capacitor Bank 948.4.12 DC Coil 948.4.13 IGBT 958.4.14 Thyristor 959 Block Diagrams9

7.5.3 Inrush Card1. Remove the 4 screws (T20) from the power cardmounting plate. 2. Remove the power card mounting plate.3. Unplug all cables from the

130BC128.111324Illustration 7.19 Rectifier Modules1Foil2 Bus bar3 Plastic cover4 Rectifier modulesTable 7.197.5.5RFI Filter1. Remove the 3 screws (T20

7.5.6 Relay Transducer Card1. Remove the 4 screws (T20) on the plate.2. Carefully remove cables before removing theplate.3. Loosen the cables in the r

130BC131.111234Illustration 7.22 IGBT1Cable mounting plate2 IGBT3 Bus bar4 CapacitorTable 7.227.5.8Heatsink Fan Assembly1. Remove the 4 screws (T20) f

7.5.9 DC Coil1. Remove the 4 screws (T20) from the DC coilcover plate.2. Remove the 4 screws (T20) from the heatsink. 3. Remove the heatsink.4. Remove

7.6 H10 Frame Size Disassembly andAssembly Instructions7.6.1 Control Card and Control CardMounting Plate1. Remove the LCP cradle. LCP cradle can bere

7.6.3 Power Card1. Remove the 4 screws (T10) for the DC coil cables.2. Remove the 5 screws (T10) for the heatsink. 3. Remove the 4 IGBT screws (T25).4

7.6.5 Heatsink Fan Assembly1. Remove 2 screws (T10) on the DC coil mountingplate2. Remove the plate.3. Press and loosen the 2 barbs on the fan.4. Remo

8 I-Frame Size Disassembly and Assembly Procedures8.1 General Disassembly ProcedureThis procedure explains how to remove the outer parts ofthe freque

8.2.2 Cable Mounting Plate1. Remove the ribbon cable.2. Remove 1 screw (T20) from shield metal.3. Use a flat screwdriver to release the retainers andc

1 Introduction1.1 PurposeThis manual provides detailed technical information andinstructions to enable a qualified technician to identifyfaults and p

8.2.4 SMPS Card1. Remove the 3 black plastic covers.2. Unplug and remove the fan.3. Unplug all other cables.4. Remove the 2 screws (T20) at MK101.5. R

8.2.6 Power Card1. Remove 7 screws (T20)2. Remove 5 screws (T10) on the Power Card. 3. Lift out the power card.Reinstall in the reverse order.130BC063

8.2.8 RFI Filter1. Remove 2 screws (T20) from the filter.2. Lift out the filter.Reinstall in the reverse order.130BC066.111Illustration 8.81 RFI filte

12345130BC059.11Illustration 8.9 Control Card Mounting Plate1LCP and cradle2 Control card and mounting plate3 EMC shieldTable 8.98.3.2Power Card1. Unp

8.3.3 Power Card Mounting Plate1. Remove 4 screws (T20) from the power cardmounting plate. 2. Remove the power card mounting plate with thefan attache

8.3.5 Bus Bar1. Unplug and remove the red/black cable.2. Remove the black plastic cover.3. Remove 8 screws (T20) from the support bracket.4. Remove th

8.3.7 Relay Transducer Card1. Remove the 3 clamps on each side of the 2 cableconnectors.2. Remove the cable connector with no cablesattached.3. Remove

8.3.9 Terminal Plate1. Remove the black plastic cover.2. Remove 4 screws (T20) on the cover plate.3. Remove the terminal plate.Reinstall in the revers

8.3.11 Heatsink Fan Assembly1. Remove gate cables from IGBTs.2. Remove 2 screws (T20) from the heatsink fanassembly. 3. Push the fan cable down throug

8.3.13 DC Coil1. Remove 5 screws (T20) on the potted coil.2. Remove the DC coil.Reinstall in the reverse order.12130BC082.11Illustration 8.21 DC Coil1

1.4.1 Frame Size DefinitionsModel HP @200–240 V AC kW @200–240 V AC Frame Size IP Rating Repairable Yes/NoPK25 0.33 0.25 H1 IP20 NoPK37 0.5 0.37 H1 IP

8.3.15 Thyristor1. Remove 2 screws (T20) from each of the 3thyristors.CAUTIONThe thyristors and the heatsink have thermal paste onthem. Wear protectiv

12345130BC059.11Illustration 8.24 Control Card Mounting Plate1LCP and cradle2 Control card and mounting plate3 EMC shieldTable 8.248.4.2Power Card1. U

8.4.3 Power Card Mounting Plate1. Remove 4 screws (T20) from the power cardmounting plate. 2. Remove the power card mounting plate with thefan attache

8.4.5 Bus Bar1. Unplug and remove the red/black cable.2. Remove the black plastic cover.3. Remove 6 screws (T20) and 2 screws (T30) fromthe support br

8.4.7 Relay Transducer Card1. Remove 2 screws (T20) from each of the 2 cableconnectors.2. Remove the cable connector.3. Remove 3 screws (T20) from the

8.4.9 DC Bus Bar Assembly1. Remove 2 screws (T30) from each of the 2snubbers.2. Remove the snubbers.3. Loosen and remove the 2 cables from bus barasse

8.4.11 Capacitor Bank1. Remove 4 screws (T20) from each of thecapacitors.2. Remove the capacitors.Reinstall in the reverse order.130BC081.111Illustrat

8.4.13 IGBT1. Remove 4 screws (T20) from each of the 3 IGBTs.CAUTIONThe UGBTs and the heatsink have thermal paste on them.Wear protective gloves as th

9 Block Diagrams9.1.1 H6 Frame Sizex 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC/DCx3BRP_BRFRL 2RFI _ RL 1InrushSAFE_FBTmp_VGDSVCCF

9.1.2 I6 Frame Size x 3DC /ACoCTemp.conv.uC+EEP7 xGDRL 1GD SupplyABR GDBR FBINV GDAC /DCx3BRP_BRFRL 2RFI_RL 1InrushSAFE_FBTmp_VGDSVCCFAN 1CANAAImax