Danfoss VLT FC 100 Bedienungsanleitung

MAKING MODERN LIVING POSSIBLE

Service Manual

VLT®FC Series, D-Frame

VLT®HVAC Drive FC 100 • VLT®AQUA Drive FC 200

VLT® Automation Drive FC 300 • VLT® Refrigeration Drive FC 103

www.danfoss.com/drives

Contents

1 Introduction 7

1.1 Purpose 7

1.2 Product Overview 7

1.3 For Your Safety 7

1.4 Electrostatic Discharge (ESD) 8

1.5 Frame Size Definitions 8

1.6 Tools Required 9

1.7 General Torque Tightening Values 10

1.8 Exploded Views 11

1.9 Power-dependent Specifications 13

2 Operator Interface and Adjustable Frequency Drive Control 21

2.1 Introduction 21

2.2 User Interface 21

2.2.1 How to Operate the VLT®Control Panel LCP 102 21

2.2.2 Numeric Local Control Panel (NLCP) 24

2.2.3 Changing Settings with the LCP 25

2.3 Status Messages 26

2.4 Status Message Definitions 26

2.5 Service Functions 28

2.6 Adjustable Frequency Drive Inputs and Outputs 28

2.6.1 Input signals 29

2.6.2 Output signals 29

2.6.3 Control Power Supply 30

2.7 Control Terminals 30

2.8 Control Terminal Functions 31

2.9 Grounding Shielded Cables 32

3 Internal Adjustable Frequency Drive Operation 33

3.1 General 33

3.2 Description of Operation 33

3.2.1 Logic Section 34

3.2.2 Logic to Power Interface 35

3.2.3 Power Section 35

3.3 Sequence of Operation 36

3.3.1 Rectifier section 36

3.3.2 Intermediate Section 38

3.3.3 Inverter Section 40

Contents Service Manual

3.3.4 Brake Option 42

3.3.5 Cooling Fans 44

3.3.6 Fan Speed Control 44

3.3.7 Load Sharing & Regeneration 45

3.3.8 Specific Power Card Connections 45

4 Troubleshooting 46

4.1 Troubleshooting Tips 46

4.2 Exterior Fault Troubleshooting 46

4.3 Fault Symptom Troubleshooting 46

4.4 Visual Inspection 47

4.5 Fault Symptoms 48

4.5.1 No Display 48

4.5.2 Intermittent Display 48

4.5.3 Motor Will not Run 48

4.5.4 Incorrect Motor Operation 49

4.6 Warning/Alarm Messages 49

4.7 After Repair Tests 58

5 Adjustable Frequency Drive and Motor Applications 59

5.1 Torque Limit, Current Limit, and Unstable Motor Operation 59

5.1.1 Overvoltage Trips 60

5.1.2 Line Phase Loss Trips 60

5.1.3 Control Logic Problems 61

5.1.4 Programming Problems 61

5.1.5 Motor/Load Problems 62

5.2 Internal Adjustable Frequency Drive Problems 62

5.2.1 Overtemperature Faults 62

5.2.2 Current Sensor Faults 62

5.2.3 EMI Signal and Power Wiring 63

5.2.4 Effects of EMI 63

5.2.5 Sources of EMI 64

5.2.6 EMI Propagation 64

5.2.7 Preventive Measures 67

5.2.8 Proper EMC Installation 68

6 Test Procedures 69

6.1 Introduction 69

6.1.1 Tools Required 69

Contents Service Manual

6.1.2 Signal Test Board 70

6.2 Access to DC Bus 70

6.3 Static Test Procedures 70

6.3.1 Pre-check Precautions 70

6.3.2 Rectifier Circuits Test 73

6.3.3 Inverter Section Tests 73

6.3.4 Brake IGBT Test 74

6.3.5 Intermediate Section Tests 74

6.3.6 IGBT Temperature Sensor Test 75

6.3.7 Gate Resistor Test 75

6.3.8 Electrical Fuse Test 75

6.3.9 Disconnect Test 76

6.3.10 Circuit Breaker Test 76

6.3.11 Contactor Test 76

6.4 Dynamic Test Procedures 77

6.4.1 No Display Test 79

6.4.2 Input Voltage Test 79

6.4.3 Basic Control Card Voltage Test 79

6.4.4 DC Bus Voltage Test 80

6.4.5 Switch Mode Power Supply (SMPS) Test 80

6.4.6 Input Imbalance of Supply Voltage Test 80

6.4.7 Input Waveform Test 81

6.4.8 Input SCR Test 81

6.4.9 Output Imbalance of Motor Voltage and Current 82

6.4.10 IGBT Switching Test 83

6.4.11 IGBT Gate Drive Signals Test 83

6.4.12 Current Sensors Test 86

6.4.13 Fan Tests 87

6.4.14 Input Terminal Signal Tests 88

6.5 After Repair Tests 89

7 Disassembly and Assembly Instructions 91

7.1 Introduction 91

7.2 Electrostatic Discharge (ESD) 91

7.3 D1h/D3h Disassembly and Assembly Instructions 91

7.3.1 General Information 91

7.3.2 Control Card and Control Card Mounting Plate 91

7.3.3 Power Card Mounting Plate 92

7.3.4 Power Card 93

Contents Service Manual

7.3.5 AC Input Bus Bars 93

7.3.5.1 Electrical Fuses Only 93

7.3.5.2 RFI Only 93

7.3.5.3 Fuses and RFI 94

7.3.5.4 No Options 94

7.3.6 Line Power Input Terminal Block 94

7.3.7 Motor Terminal Block 95

7.3.8 Power Terminal Mounting Plate 95

7.3.9 Current Sensors 95

7.3.10 Mixing Fan 95

7.3.11 Balance/High Frequency Card 95

7.3.11.1 400 V AC Power Size 95

7.3.11.2 690 V AC Power Size 96

7.3.12 DC Bus Rails 96

7.3.13 Inrush Card 97

7.3.14 IGBT Gate Drive Card 97

7.3.15 SCR Input Bus Bars 97

7.3.16 SCRs 98

7.3.17 Brake IGBT Module 98

7.3.18 IGBTs 99

7.3.18.1 400 V AC Power Size 99

7.3.18.2 690 V AC Power Size 99

7.3.19 DC Capacitors 100

7.3.19.1 400 V AC Power Size 100

7.3.19.2 690 V AC Power Size 101

7.3.20 Heatsink Fan 102

7.3.21 Door Fan: IP21 (NEMA 1) or IP54 (NEMA 12) Enclosures Only 102

7.3.22 Top Fan: (IP20 Enclosures Only) 102

7.4 D2h/D4h Disassembly and Assembly Instructions 103

7.4.1 General Information 103

7.4.2 Control Card and Control Card Mounting Plate 103

7.4.3 Power Card Mounting Plate 103

7.4.4 Power Card 104

7.4.5 AC Input Bus Bars 104

7.4.5.1 Electrical Fuses Only 104

7.4.5.2 RFI Only 105

7.4.5.3 Fuses and RFI 105

7.4.5.4 No Options 105

Contents Service Manual

7.4.6 Line Power Input Terminal Block 105

7.4.7 EMC Shield 105

7.4.8 Brake Terminal (optional) 105

7.4.9 Motor Terminal Block 105

7.4.10 Power Terminal Mounting Plate 106

7.4.11 Current Sensors 106

7.4.12 Mixing Fan 107

7.4.13 Balance/High Frequency Card 107

7.4.13.1 400 V AC Power Size 107

7.4.13.2 690 V AC Power Size 107

7.4.14 IGBT Gate Drive Card 108

7.4.15 Inrush Card 108

7.4.16 SCR Input Bus Bars 109

7.4.17 SCRs 109

7.4.18 DC Bus Rails 109

7.4.18.1 Without Optional Brake 109

7.4.18.2 With Optional Brake 110

7.4.19 IGBTs 110

7.4.19.1 400 V AC Power Size 110

7.4.19.2 690 V AC Power Size 111

7.4.20 DC Capacitors 112

7.4.20.1 400 V AC Power Size 112

7.4.20.2 690 V AC Power Size 113

7.4.21 Heatsink Fan 114

7.4.22 Door Fan: IP21 (NEMA 1) or IP54 (NEMA 12) Enclosures Only 114

7.4.23 Top Fan (IP20 Enclosures only) 114

7.4.24 Brake IGBT Module 114

7.5 D6h Disassembly and Assembly Instructions 115

7.5.1 Overview 115

7.5.2 Removing the Heatsink Fan with Options Cabinet Present 115

7.5.3 Removing the Frequency Converter from the Options Cabinet 115

7.5.4 Contactor 116

7.5.5 Disconnect 116

7.6 D8h Disassembly and Assembly Instructions 116

7.6.1 Overview 116

7.6.2 Replacing the Heatsink Fan with Options Cabinet Present 117

7.6.3 Removing the Adjustable Frequency Drive from the Options Cabinet 117

7.6.4 Contactor 118

Contents Service Manual

7.6.5 Disconnect 118

8 Special Test Equipment 120

8.1 Test Equipment 120

8.1.1 Split Bus Power Supply 120

8.1.2 Signal Test Board (p/n 176F8437) 120

8.1.3 Signal Test Board Extension 121

8.1.4 Signal Test Board Pin Outs 121

9 Spare Parts 125

9.1 Spare Parts 125

9.1.1 General Notes 125

9.1.2 DC Capacitor Bank 125

10 Block Diagrams 128

Index 130

Contents Service Manual

1 Introduction

1.1 Purpose

The purpose of this manual is to provide detailed technical

information and instructions to enable a qualified

technician to identify faults and perform repairs on D-

frame adjustable frequency drives.

It provides the reader with a general view of the main

assemblies and a description of the internal processing.

This manual gives technicians the information needed for

troubleshooting and repair.

This manual provides instructions for the adjustable

frequency drive models and voltage ranges described in

chapter 1.5 Frame Size Definitions.

Use this manual with the instruction manual that

accompanied the adjustable frequency drive.

1.2 Product Overview

VLT®HVAC Drive series adjustable frequency drives are

designed for the HVAC markets. They operate in variable

torque mode or constant torque down to 15 Hz and

include special features and options designed for fan and

pump applications.

VLT®AQUA Drive series adjustable frequency drives are

designed for water and wastewater markets. They can

operate in either constant torque or variable torque with

limited overload capabilities. Included are specific features

and options for use on various water pumping and

processing applications.

VLT®AutomationDrive series adjustable frequency drives

are fully programmable for either constant torque or

variable torque industrial applications. They operate a

variety of applications and incorporate a wide range of

control and communication options.

These models are available in IP20 (chassis), IP21 (NEMA 1),

and IP54 (NEMA 12) enclosures.

1.3 For Your Safety

1.3.1 Warnings

WARNING

Adjustable frequency drives contain dangerous voltages

when connected to line power. Only a competent

technician should perform service.

WARNING

For dynamic test procedures, line input power is

required and all devices and power supplies connected

to line power are energized at rated voltage. Use

extreme caution when conducting tests in a powered

adjustable frequency drive. Contact with powered

components could result in electrical shock and personal

injury.

WARNING

In adjustable frequency drives equipped with the

optional contactor or anti-condensation heater, there

may still be power inside the enclosure after the main

power to the unit has been turned off.

1. DO NOT touch electrical parts of the adjustable

frequency drive when connected to line power.

After disconnecting from line power, wait 20

minutes before touching any components.

2. When repair or inspection is made, line power

must be disconnected.

3. The [Stop] key on the control panel does not

disconnect line power.

4. During operation and while programming

parameters, it is possible for the motor to start

without warning. Press [Stop] when changing

data.

Introduction Service Manual

1.4 Electrostatic Discharge (ESD)

WARNING

When performing service, use proper ESD procedures to

prevent damage to sensitive components.

WARNING

Do not touch components on the circuit boards. Hold

circuit boards by the corners and edges only.

Many electronic components within the adjustable

frequency drive are sensitive to static electricity. Voltages

so low that they cannot be felt, seen, or heard can reduce

the life, affect performance, or completely destroy sensitive

electronic components.

1.5 Frame Size Definitions

Model FC 102, FC 103, and FC 202

kW @400 V AC HP @460 V AC Frame Size

N110 110 150 D1h/D3h/

D5h/D6h

N132 132 200 D1h/D3h

D5h/D6h

N160 160 250 D1h/D3h

D5h/D6h

N200 200 300 D2h/D4h/

D7h/D8h

N250 250 350 D2h/D4h/

D7h/D8h

N315 315 450 D2h/D4h/

D7h/D8h

Table 1.1 FC 102, FC 103, and FC 202 380–480 V AC

Model FC 302 High/Normal Overload

kW @400

V AC

HP @460

V AC

kW @500

V AC

Frame

Size

N90K 90/110 125/150 110/132 D1h/D3h/

D5h/D6h

N110 110/132 150/200 132/160 D1h/D3h/

D5h/D6h

N132 132/160 200/250 160/200 D1h/D3h/

D5h/D6h

N160 160/200 250/300 200/250 D2h/D4h/

D7h/D8h

N200 200/250 300/350 250/315 D2h/D4h/

D7h/D8h

N250 250/315 350/450 315/355 D2h/D4h/

D7h/D8h

Table 1.2 FC 302 380–500 V AC

Model FC 102, FC 103, and FC 202

kW @550

V AC

HP @575

V AC

kW @690

V AC

Frame

Size

N75K 55 75 75 D1h/D3h/

D5h/D6h

N90K 75 100 90 D1h/D3h/

D5h/D6h

N110 90 125 110 D1h/D3h/

D5h/D6h

N132 110 150 132 D1h/D3h/

D5h/D6h

N160 132 200 160 D1h/D3h/

D5h/D6h

N200 160 250 200 D2h/D4h/

D7h/D8h

N250 200 300 250 D2h/D4h/

D7h/D8h

N315 250 350 315 D2h/D4h/

D7h/D8h

N400 315 400 400 D2h/D4h/

D7h/D8h

Table 1.3 FC 102, FC 103, and FC 202 525–690 V AC

Model

FC 302

High/Normal Overload

kW @550

V AC

HP @575

V AC

kW @690

V AC

Frame Size

N55k 45/55 60/75 55/75 D1h/ D3h/

D5h/D6h

N75k 55/75 75/100 75/90 D1h/D3h/

D5h/D6h

N90k 75/90 100/125 90/110 D1h/D3h/

D5h/D6h

N110 90/110 125/150 110/132 D1h/D3h/

D5h/D6h

N132 110/132 150/200 132/160 D1h/D3h/

D5h/D6h

N160 132/160 200/250 160/200 D2h/D4h/

D7h/D8h

N200 160/200 250/300 200/250 D2h/D4h/

D7h/D8h

N250 200/250 300/350 250/315 D2h/D4h/

D7h/D8h

N315 250/315 350/400 315/400 D2h/D4h/

D7h/D8h

Table 1.4 FC 302 525–690 V AC

Introduction Service Manual

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