Danfoss iC7 Series User manual

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NOTICE
SPARE PARTS COMPATIBILITY
Danfoss recommends replacement of all IGBT modules or all brake IGBT modules when 1 or more modules fail.
For best results, replace modules with parts from the same lot number.
Table 1: Number of IGBT Modules Required by iC7 Series Frequency Converters
Frame designation
IGBT modules
Brake IGBT modules
FX09–Fx10 (no brake)
3
0
FX09–Fx10 (with brake option)
3
1
FX11–Fx12 (no brake)
6
0
FX11–Fx12 (with brake option)
6
2
Table 2: Number of IGBT Modules Required by VLT®FC Series Drives
Drive designation
IGBT modules
Brake IGBT modules
E1h–E4h (no brake)
6
0
E1h–E4h (with brake option)
6
2
1.2 Kit Numbers
Use these instructions with the following kits.
Table 3: IGBT Module Replacement Kits for iC7 Series Fx09–Fx12 Frequency Converters
Kit number
Description
176F3944
IGBT dual module 300 A 1200 V Fx09
176F3945
IGBT dual module 450 A 1200 V Fx09
176F3949
IGBT dual module 600 A 1200 V Fx09
176F3943
IGBT module 900 A 1200 V Fx10
176F4141
IGBT brake module 450 A 1700 V Fx09
176F4143
IGBT brake module 650 A 1700 V Fx10
176F3950
IGBT dual module 600 A 1200 V Fx11
176F3956
IGBT module 900 A 1200 V Fx12
AN361427984575en-000101 / 130R0770 | 1Danfoss A/S © 2022.03
Installation Guide
IGBT Module Replacement for Fx09-Fx12
and E1h–E4h
iC7 Series Frequency Converters and VLT® FC Series Drives
1 Overview
1.1 Description
This IGBT module replacement kit contains all components required to replace 1 IGBT module or 1 brake IGBT module. For the num-
ber of IGBTs installed in the frequency converter, see Table 1 and Table 2.

Kit number
Description
176F3957
IGBT module 1200 A 1200 V Fx12
176F3946
IGBT brake module 450 A 1700 V Fx11
176F4012
IGBT brake module 450 A 1700 V Fx12
Table 4: IGBT Module Replacement Kits for VLT® FC Series E1h–E4h Drives
Kit number
Description
176F6641
IGBT module 600 A T4/T5
176F6642
IGBT module 900 A T4/T5
176F6643
IGBT module 600 A 1700 V T7
176F6644
IGBT module 650 A 1700 V T7
176F6711
IGBT brake module 450 A E1, E3
176F6646
IGBT brake module 450 A E2, E4
1.3 Items Supplied
The following parts are contained in the kit.
Table 5: Items Supplied in IGBT Module Kits
Item
Quantity
IGBT module
1
Fasteners
varies depending on IGBT type
Syringe of thermal grease
1
AN361427984575en-000101 / 130R07702 | Danfoss A/S © 2022.03
Overview
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

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2 Installation
2.1 Safety Information
NOTICE
QUALIFIED PERSONNEL
Only qualified, Danfoss authorized personnel are allowed to install the parts described in these installation instructions.
Disassembly and reassembly of the frequency converter must be done in accordance with the service guide.
Use the standard fastener torque values from the service guide, unless the torque value is specified in these instructions.
WARNING
ELECTRICAL SHOCK HAZARD
Danfoss frequency converters contain dangerous voltages when connected to mains voltage. Improper installation, and instal-
ling or servicing with power connected, can cause death, serious injury, or equipment failure.
Only use qualified electricians for the installation.
Disconnect the frequency converter from all power sources before installation or service.
Treat the frequency converter as live whenever the mains voltage is connected.
Follow the guidelines in these instructions and local electrical safety codes.
WARNING
DISCHARGE TIME
The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not pow-
ered. High voltage can be present even when the warning LED indicator lights are off. Failure to wait the specified time after
power has been removed before performing service or repair work can result in death or serious injury.
Stop the motor.
Disconnect AC mains and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other
frequency converters.
Disconnect or lock the motor.
Disconnect any brake option.
Disconnect any regen/load share option.
Wait for the capacitors to discharge fully. The minimum waiting time is listed on the frequency converter label and also in the
following discharge time table.
Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors
are fully discharged.
Table 6: Discharge Time
Frame
Minimum waiting time
Fx09–Fx10
20 minutes
E1h–E4h
40 minutes
Fx11–Fx12
40 minutes
AN361427984575en-000101 / 130R0770 | 3Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

1.
2.
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NOTICE
ELECTROSTATIC DISCHARGE
Electrostatic discharge can damage components.
Ensure discharge before touching internal frequency converter components, for example by touching a grounded, conduc-
tive surface or by wearing a grounded armband.
2.2 Installing the IGBT Module
For IGBT module disassembly procedures, refer to service guide. To install the replacement IGBT module or brake IGBT module, use
the following steps.
NOTICE
THERMAL INTERFACE
A proper thermal interface is required between the IGBT module and heat sink. Failure to follow these instructions results in a
poor thermal bond and causes premature IGBT failure.
Ensure that the environment is free of airborne dust and contaminants while applying the thermal grease.
Clean the heat sink using a cloth and solvent or alcohol solution to remove debris and remaining thermal grease.
With the syringe, apply a layer of thermal grease to the bottom of the IGBT module in the pattern shown in Illustration 1.
e30bh996.10
1
2
Illustration 1: IGBT Thermal Grease Pattern
1
Bottom of IGBT module
2
Thermal grease
Once the module is mounted, thermal grease seeps out to coat the area between the module and heat sink. Excess
grease is acceptable.
AN361427984575en-000101 / 130R07704 | Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

3.
4.
5.
6.
Place the IGBT module on the heat sink by aligning the mounting holes in the module to those in the heat sink. Refer to
Illustration 2.
130BF943.10
2
1
3
4
Illustration 2: Mounting the IGBT Module on the Heat Sink
1
IGBT module fastener
2
IGBT modules
3
Brake IGBT modules
4
Plastic IGBT mounting frame
Insert the mounting screws and hand tighten them.
The IGBT module requires either 4 or 10 screws to fasten it to the heat sink.
Following the fastener tightening sequence shown in Illustration 3, slowly tighten (maximum 20 RPM) all screws to 50% of
the torque values listed in Table 7 and Table 8.
Repeat the same tightening sequence and slowly tighten (maximum 5 RPM) all screws to 100% of the torque value.
AN361427984575en-000101 / 130R0770 | 5Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

7. Tighten the busbar connection terminals to the torque value listed in Table 7 and Table 8.
Example
1 2
3
4
5
6
7
89
10
1
2
3
4
e30bf941.10
AB
Illustration 3: IGBT Fastener Tightening Sequence
Table 7: Torque Tightening Values and Sequence for iC7 Series Frequency Converters
Kit number
Mounting torque
[Nm (in-lb)]
Busbar connection
torque [Nm (in-lb)]
Diagram
Screw tightening order
176F3944
3.3 (29)
3.3 (29)
A
1-2-3-4
176F3945
3.3 (29)
3.3 (29)
A
1-2-3-4
176F3949
3.3 (29)
3.3 (29)
A
1-2-3-4
176F3943
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
176F4141
3.3 (29)
3.3 (29)
A
1-2-3-4
176F4143
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
176F3950
3.3 (29)
3.3 (29)
A
1-2-3-4
176F3956
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
AN361427984575en-000101 / 130R07706 | Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

Kit number
Mounting torque
[Nm (in-lb)]
Busbar connection
torque [Nm (in-lb)]
Diagram
Screw tightening order
176F3957
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
176F3946
3.3 (29)
3.3 (29)
A
1-2-3-4
176F4012
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
Table 8: Torque Tightening Values and Sequence for VLT®FC Series Drives
Kit number
Mounting torque
[Nm (in-lb)]
Busbar connection
torque [Nm (in-lb)]
Diagram
Screw tightening order
176F6641
3.3 (29)
4.0 (35)
A
1-2-3-4
176F6642
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
176F6643
3.3 (29)
4.0 (35)
A
1-2-3-4
176F6644
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
176F6711
3.3 (29)
4.0 (35)
A
1-2-3-4
176F6646
4.5 (40)
9.0 (80)
B
1-2-3-4-5-6-7-8-9-10
AN361427984575en-000101 / 130R0770 | 7Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide

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*130R0770*
*M00275* AN361427984575en-000101 / 130R07708 | Danfoss A/S © 2022.03
Installation
IGBT Module Replacement for Fx09-Fx12 and E1h–E4h
Installation Guide