Danfoss VLT FC Series User manual

ENGINEERING TOMORROW
Service Guide
VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
VLT®HVAC Drive FC 102 • VLT® Refrigeration Drive FC 103 • VLT®AQUA Drive FC 202
VLT® AutomationDrive FC 302 • VLT® AutomationDrive FC 361 • VLT®Parallel Drive Modules
vlt-drives.danfoss.com

Contents
1 Introduction 9
1.1 Purpose of This Guide 9
1.2 Additional Resources 9
1.3 Abbreviations and Acronyms 10
1.4 Conventions 11
1.5 Document Version 11
1.6 Approvals and Certications 11
1.7 Disposal 11
2 Safety 12
2.1 Introduction 12
2.2 Safety Symbols 12
2.3 Qualied Personnel 12
2.4 Safety Precautions 12
2.5 Electrostatic Discharge 14
3 Product Overview 15
3.1 Introduction 15
3.2 Tools Required 15
3.3 Service Report 15
3.4 Enclosure Size Identication 16
3.5 Enclosure Size Denitions 17
3.6 Product Views 22
3.6.1 Exploded View of D1h/D3h/D5h/D6h/J8 Drive 22
3.6.2 Exploded View of D2h/D4h/D7h/D8h/J9 Drive 23
3.6.3 Exploded View of Multi-Drive System 24
3.6.4 View of Control Shelf 25
3.6.5 Exploded View of Parallel Drive Module 26
3.6.6 View of Parallel Drive Module 27
3.6.7 Exploded View of E-sized Unit 28
3.7 Product Options 29
4 Operator Interface and Drive Control 30
4.1 Introduction 30
4.2 Local Control Panel 30
4.2.1 Layout 30
4.2.2 Menus 31
4.2.3 Parameter Settings 33
4.2.4 Uploading and Downloading Parameter Settings 33
4.2.5 Restoring Factory Default Settings 33
Contents Service Guide
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4.3 Status Messages 34
4.4 Status Message Denitions 34
4.5 Service Functions 37
4.6 Drive Inputs and Outputs 38
4.6.1 Input Signals 38
4.6.2 Output Signals 38
4.6.3 Control Supply 39
4.7 Control Terminals 39
4.8 Control Terminal Functions 40
4.9 Shielded Cable Grounding 41
5 Internal Drive Operation 42
5.1 Introduction 42
5.2 Description of Operation 42
5.2.1 Logic Section 44
5.2.2 Logic-to-power Interface 44
5.2.3 Power Section 45
5.3 Sequence of Operation 46
5.3.1 Rectier Section 46
5.3.2 Intermediate Section 49
5.3.3 Inverter Section 52
5.3.4 Brake Option 55
5.3.5 Cooling Fans 57
5.3.6 Fan Speed Control 57
5.3.7 Load Sharing and Regen 58
5.3.8 Specic Power Card Connections 59
6 Troubleshooting 60
6.1 Troubleshooting Tips 60
6.2 Exterior Fault Troubleshooting 60
6.3 Fault Symptom Troubleshooting 60
6.4 Visual Inspection 61
6.5 Fault Symptoms 62
6.5.1 No Display 62
6.5.2 Intermittent Display 62
6.5.3 Motor Does Not Run 62
6.5.4 Incorrect Motor Operation 62
6.6 Alarms and Warnings 63
6.6.1 Overview of Alarms and Warnings 63
6.6.2 Alarm/Warning Identication Tables 64
6.7 Alarm and Warning Denitions 68
Contents VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
2 Danfoss A/S © 02/2019 All rights reserved. MG94A502

7 Drive and Motor Applications 80
7.1 Torque Limit, Current Limit, and Unstable Motor Operation 80
7.1.1 Overvoltage Trips 81
7.1.2 Mains Phase Loss Trips 81
7.1.3 Control Logic Problems 82
7.1.4 Programming Problems 82
7.1.5 Motor Load Problems 82
7.2 Internal Drive Problems 83
7.2.1 Overtemperature Faults 83
7.2.2 Current Sensor Faults 83
7.3 Electromagnetic Compatibility 83
7.3.1 Eects of EMI 83
7.3.2 EMI Signal and Power Wiring 84
7.3.3 Sources of EMI 84
7.3.4 EMI Propagation 84
7.3.5 Preventive Measures 87
8 Test Procedures 89
8.1 Introduction 89
8.2 Tools Required 90
8.2.1 Special Test Equipment 90
8.2.2 Signal Test Board 90
8.2.3 Metering Tools 91
8.3 Test Preparations 91
8.3.1 Preparations for Parallel Drive Systems 92
8.3.2 Access to Testing Connection Points 92
8.3.3 Card Connectors 93
8.3.4 Power Card in D-sized Drives 94
8.3.5 Power Card in E-sized Drives 95
8.3.6 MDCIC in Parallel Drive Systems 96
8.3.7 Fan Power Card in E-sized Drives 97
8.3.8 Gate Drive Card in D-sized Drives 98
8.3.9 Gate Drive Card in E-sized Drives 99
8.4 Static Test Procedures 100
8.4.1 Rectier Circuits Test 100
8.4.2 Inverter Section Tests 101
8.4.3 Brake IGBT Test 101
8.4.4 Intermediate Section Tests 102
8.4.5 IGBT Temperature Sensor Test 102
8.4.6 Gate Resistor Test 103
Contents Service Guide
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8.4.7 Mains Fuse/DC Fuse Test 103
8.4.8 Disconnect Test 103
8.4.9 Circuit Breaker Test 104
8.4.10 Contactor Test 104
8.5 Dynamic Test Procedures 105
8.5.1 No Display Test 107
8.5.2 Input Voltage Test 107
8.5.3 Basic Control Card Voltage Test 107
8.5.4 DC Bus Voltage Test 107
8.5.5 Switch Mode Power Supply Test 108
8.5.6 Input Imbalance of Supply Voltage Test 108
8.5.7 Input Waveform Test 109
8.5.8 Input SCR Test 109
8.5.9 Output Imbalance of Motor Voltage and Current 110
8.5.10 IGBT Switching Test 111
8.5.11 IGBT Gate Drive Signals Test 112
8.5.12 Current Sensors Test 114
8.5.13 Fan Tests 116
8.5.14 Input Terminal Signal Tests 117
8.6 After-repair Tests 118
8.6.1 After-repair Tests for D-sized and E-sized Drives 119
8.6.2 After-repair Tests for Parallel Drive Systems 119
9 Special Test Equipment 120
9.1 Split Bus Power Supply 120
9.1.1 Overview 120
9.1.2 Split Bus Power Supply Diagrams 120
9.1.3 Split Bus Power Supply Connection 122
9.2 Parallel Drive Module Service Kit 122
9.2.1 Overview 122
9.2.2 Split Bus Power Supply and
Parallel Drive Modules 124
9.2.3 After-test Installation of
Parallel Drive Modules 125
9.2.4 Programming the Parallel Drive Module 125
9.2.5 Service Kit Troubleshooting 125
9.3 Signal Test Board 125
9.3.1 Signal Test Board 125
9.3.2 Signal Test Board Pin Outs 126
10 D1h/D3h/D5h/D6h/J8 Drive Disassembly and Assembly 129
10.1 Before Proceeding 129
Contents VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
4 Danfoss A/S © 02/2019 All rights reserved. MG94A502

10.2 D1h/D3h/D5h/D6h/J8 Disassembly and Assembly 130
10.2.1 General Information 130
10.2.2 Control Card and Control Card Mounting Plate 130
10.2.3 Power Card Mounting Plate 132
10.2.4 Power Card 134
10.2.5 AC Input Busbars 136
10.2.6 Mains Input Terminal Block 138
10.2.7 Motor Terminal Block 140
10.2.8 Brake Terminal Block (Optional) 141
10.2.9 Power Terminal Mounting Plate 141
10.2.10 Mixing Fan 142
10.2.11 Current Sensors 144
10.2.12 Balance/High Frequency Card 146
10.2.13 DC Bus Rails 147
10.2.14 Inrush Card 148
10.2.15 SCR Input Busbars 150
10.2.16 SCRs 150
10.2.17 Gate Drive Card 152
10.2.18 Brake IGBT Module 152
10.2.19 IGBTs 154
10.2.20 Standard DC Capacitors 156
10.2.21 Standard DC Capacitor Bank Layouts 162
10.2.22 Twistlock DC Capacitors 164
10.2.23 Twistlock DC Capacitor Bank Layouts 168
10.2.24 Heat Sink Fan 170
10.2.25 Door Fan 173
10.2.26 Top Fan 175
10.3 D5h/D6h Disassembly and Assembly 178
10.3.1 Accessing the Heat Sink Fan in D5h/D6h Drives 178
10.3.2 Removing the Drive from the Extended Options Cabinet 180
10.3.3 Contactor 182
10.3.4 Disconnect 182
10.4 Heat Sink Access Panel 184
10.4.1 Removing the Heat Sink Access Panel 184
11 D2h/D4h/D7h/D8h/J9 Unit Disassembly and Assembly 186
11.1 Before Proceeding 186
11.2 D2h/D4h/D7h/D8h/J9 Disassembly and Assembly 187
11.2.1 General Information 187
11.2.2 Control Card and Control Card Mounting Plate 188
11.2.3 Power Card Mounting Plate 190
Contents Service Guide
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11.2.4 Power Card 190
11.2.5 AC Input Busbars 192
11.2.6 Mains Input Terminal Block 194
11.2.7 EMC Shield 196
11.2.8 Brake Terminal Block (Optional) 196
11.2.9 Motor Terminal Block 197
11.2.10 Mixing Fan 198
11.2.11 Power Terminal Mounting Plate 200
11.2.12 Current Sensors 201
11.2.13 Balance/High Frequency Card 203
11.2.14 Gate Drive Card 205
11.2.15 Inrush Card 207
11.2.16 SCR Input Busbars 209
11.2.17 SCRs 209
11.2.18 DC Bus Rails 211
11.2.19 IGBTs 214
11.2.20 Standard DC Capacitors 216
11.2.21 Standard DC Capacitor Bank Layouts 220
11.2.22 Twistlock DC Capacitors 224
11.2.23 Twistlock DC Capacitor Bank Layouts 228
11.2.24 Brake IGBT Module 230
11.2.25 Heat Sink Fan 232
11.2.26 Door Fan 235
11.2.27 Top Fan 237
11.3 D7h/D8h Disassembly and Assembly 240
11.3.1 Removing the Drive from the Extended Options Cabinet 240
11.3.2 Accessing the Heat Sink Fan in D7h/D8h Drives 240
11.3.3 Contactor 242
11.3.4 Disconnect 242
11.4 Heat Sink Access Panel 244
11.4.1 Removing the Heat Sink Access Panel 244
12 Da2/Db2/Da4/Db4 Parallel System Disassembly and Assembly 246
12.1 Before Proceeding 246
12.1.1 Lifting the Unit 247
12.2 Parallel Drive System Disassembly and Assembly 249
12.2.1 Removing the Control Shelf 249
12.2.2 Removing a Drive Module 250
12.2.3 Installing the Drive Modules 251
12.2.4 Installing the Control Shelf 253
12.3 Parallel Drive Module Disassembly and Assembly 255
Contents VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
6 Danfoss A/S © 02/2019 All rights reserved. MG94A502

12.3.1 General Information 255
12.3.2 Blank Mounting Plate 257
13 E1h–E4h Drive Disassembly and Assembly 259
13.1 Before Proceeding 259
13.2 E1h–E4h Disassembly and Assembly 260
13.2.1 General Information 260
13.2.2 Control Card and Control Card Mounting Plate 261
13.2.3 Power Card Mounting Plate 263
13.2.4 Power Card 265
13.2.5 Fan Power Card 267
13.2.6 Inrush Card 269
13.2.7 Inrush Card Frame and Rectier Bus Plates 271
13.2.8 SCR/Diode Modules 273
13.2.9 Input Plate with Busbars 275
13.2.10 Split Input Plate with Options 277
13.2.11 Input Plate Mixing Fan 279
13.2.12 Power Card Mixing Fan 281
13.2.13 Gate Drive Card Mounting Plate 283
13.2.14 Gate Drive Card 285
13.2.15 Current Sensors 287
13.2.16 Motor Busbar Assembly 289
13.2.17 Balance/High Frequency Card 291
13.2.18 Heat Sink Fan 293
13.2.19 DC Snubber Capacitors 295
13.2.20 Twistlock DC Capacitors 297
13.2.21 DC Capacitor Layouts 301
13.2.22 IGBTs 305
13.2.23 Door Fan 307
13.2.24 Top Fan 309
13.2.25 Vertical Brake Busbars 311
13.2.26 Horizontal Brake Busbars 313
13.2.27 DC Bus Rails 317
14 Product Specications 319
14.1 Fastener Torque Ratings 319
14.1.1 General Torque Tightening Values 319
14.1.2 Unique Torque Values in E1h–E4h Drives 320
14.2 DC Voltage Levels 321
14.3 Warning and Alarm Trips Points 321
Contents Service Guide
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15 Spare Parts 323
15.1.1 Using the Drive Congurator Tool 323
15.1.2 Spare Parts Lists 323
15.1.3 Recommended Current Scaling Cards 324
16 Block Diagrams 356
Index 362
Contents VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
8 Danfoss A/S © 02/2019 All rights reserved. MG94A502

1 Introduction
1.1 Purpose of This Guide
This guide provides service information for the following
drives and drive modules:
•D1h–D8h drives.
•E1h–E4 drives.
•J8–J9 drives.
•VLT®Parallel Drive Modules.
•Da2/Db2/Da4/Db4 parallel drive systems and VLT®
Parallel Drive Modules.
•Drive modules within D9h–D10h/E5h–E6h
enclosed drive systems. The drive modules within
these enclosed drive systems are based on D3h–
D4h and E3h–E4h drives.
It is intended to be used by authorized technicians to
identify faults and perform repairs.
The guide includes the following information:
•Data for the dierent enclosure sizes.
•Description of user interfaces and internal
processing.
•Troubleshooting and test instructions.
•Disassembly and reassembly instructions.
VLT®is a registered trademark.
1.2 Additional Resources
Additional resources are available to understand advanced
drive functions and programming.
•The Service Guide for Enclosures D9h–D10h and
E5h–E6h provides additional information for
servicing D9h–D10h and E5h–E6h enclosed drive
systems. (However, the drive modules within
these enclosed drive systems are based on D3h–
D4h and E3h–E4h drives, which are documented
in the current manual.)
•The VLT
®
Parallel Drive Modules Installation Guide
provides information required for mechanical and
electrical installation of the VLT®Parallel Drive
Modules.
•The VLT
®
Parallel Drive Modules User Guide
provides detailed information for start-up and
commissioning of parallel drive systems
composed of VLT®Parallel Drive Modules.
•The product-specic programming guide provides
greater detail on working with parameters and
shows many application examples.
•The product-specic design guide provides
detailed capabilities and functionality to design
systems using Danfoss drives.
•The product-specic operating guide provides
information required to install and commission
Danfoss drives.
•The product-specic kit instructions provide
information on installation of various options
available for Danfoss drives.
•Technical documentation for other product
options is available at drives.danfoss.com/
knowledge-center/technical-documentation/.
Introduction Service Guide
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11

1.3 Abbreviations and Acronyms
°CDegrees Celsius
°FDegrees Fahrenheit
ΩOhm
AC Alternating current
ACP Application control processor
AWG American wire gauge
AMA Automatic motor adaptation
CPU Central processing unit
CSIV Customer-specic initialization values
CT Current transformer
DC Direct current
DVM Digital voltmeter
EEPROM Electrically erasable programmable read-only
memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
ESD Electrostatic discharge
ETR Electronic thermal relay
fM,N Nominal motor frequency
FC Frequency converter
FPC Fan power card
HF High frequency
HVAC Heating, ventilation, and air conditioning
Hz Hertz
ILIM Current limit
IINV Rated inverter output current
IM,N Nominal motor current
IVLT,MAX Maximum output current
IVLT,N Rated output current supplied by the drive
IEC International electrotechnical commission
IGBT Insulated-gate bipolar transistor
I/O Input/output
IP Ingress protection
kHz Kilohertz
kW Kilowatt
LdMotor d-axis inductance
LqMotor q-axis inductance
LC Inductor-capacitor
LCP Local control panel
LED Light-emitting diode
LOP Local operation pad
mA Milliamp
MCB Miniature circuit breakers
MCO Motion control option
MCP Motor control processor
MCT Motion control tool
MDCIC Multi-drive control interface card
mV Millivolts
NEMA National Electrical Manufacturers Association
NTC Negative temperature coecient
PM,N Nominal motor power
PCB Printed circuit board
PE Protective earth
PELV Protective extra low voltage
PID Proportional integral derivative
PLC Programmable logic controller
P/N Part number
PROM Programmable read-only memory
PS Power section
PTC Positive temperature coecient
PWM Pulse width modulation
RsStator resistance
RAM Random-access memory
RCD Residual current device
Regen Regenerative terminals
RFI Radio frequency interference
RMS Root means square (cyclically alternating electric
current)
RPM Revolutions per minute
SCR Silicon controlled rectier
SMPS Switch mode power supply
S/N Serial number
STO Safe Torque O
TLIM Torque limit
UM,N Nominal motor voltage
V Volt
VVC Voltage vector control
XhMotor main reactance
Table 1.1 Abbreviations, Acronyms, and Symbols
Introduction VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
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11

1.4 Conventions
•Numbered lists indicate procedures.
•Bulleted lists indicate other information.
•Italicized text indicates the following:
-Cross-reference
-Link
-Parameter name
-Parameter option
-Parameter group name
•All dimensions in drawings are in mm (inch).
•An asterisk (*) indicates default setting of a
parameter.
1.5 Document Version
This guide is regularly reviewed and updated. All
suggestions for improvement are welcome. Table 1.2 shows
the document version and comments about changes made
to the edition.
Edition Remarks
MG94A5xx Updated procedures and
illustrations for D1h–D8h drives.
Added content for J8–J9 drives,
D9h–D10h/E5h–E6h drive modules,
and data for 200–240 V (T2) drives.
Table 1.2 Document Version
1.6 Approvals and Certications
The following list is a selection of possible type approvals
and certications for Danfoss drives:
089
NOTICE
The specic approvals and certication for the drive can
be found on the nameplate. For more information,
contact the local Danfoss oce or partner.
For more information on UL 508C thermal memory
retention requirements, refer to the section Motor Thermal
Protection in the product-specic design guide.
For more information on compliance with the European
Agreement concerning International Carriage of Dangerous
Goods by Inland Waterways (ADN), refer to section ADN-
compliant Installation in the product-specic design guide.
1.7 Disposal
Do not dispose of equipment containing
electrical components together with
domestic waste.
Collect it separately in accordance with
local and currently valid legislation.
Introduction Service Guide
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11

2 Safety
2.1 Introduction
This section describes requirements to personnel and safe
practices to observe when performing service and
maintenance procedures.
2.2 Safety Symbols
The following symbols are used in this guide:
WARNING
Indicates a potentially hazardous situation that could
result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices.
NOTICE
Indicates important information, including situations that
can result in damage to equipment or property.
2.3 Qualied Personnel
Correct and reliable transport, storage, installation,
operation, and maintenance are required for the trouble-
free and safe operation of the drive. Only qualied
personnel are allowed to install or operate this equipment.
Only authorized personnel are allowed to service and
repair this equipment.
Qualied personnel are dened as trained sta, who are
authorized to install, commission, and maintain equipment,
systems, and circuits in accordance with pertinent laws and
regulations. Also, the personnel must be familiar with the
instructions and safety measures described in this manual.
Authorized personnel are qualied personnel, trained by
Danfoss to service Danfoss products.
2.4 Safety Precautions
WARNING
HIGH VOLTAGE
Drives contain high voltage when connected to AC mains
input, DC supply, load sharing, or permanent motors.
Failure to use qualied personnel to install, start up, and
maintain the drive can result in death or serious injury.
•Only qualied personnel must install, start up,
and maintain the drive.
WARNING
UNINTENDED START
When the drive is connected to the AC mains, DC supply,
or load sharing, the motor can start at any time.
Unintended start during programming, service, or repair
work can result in death, serious injury, or property
damage. The motor can start with an external switch, a
eldbus command, an input reference signal from the
LCP or LOP, via remote operation using MCT 10 Set-up
Software, or after a cleared fault condition.
To prevent unintended motor start:
•Press [O/Reset] on the LCP before
programming parameters.
•Disconnect the drive from the mains.
•Completely wire and assemble the drive, motor,
and any driven equipment before connecting
the drive to the AC mains, DC supply, or load
sharing.
Safety VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
12 Danfoss A/S © 02/2019 All rights reserved. MG94A502
22

WARNING
DISCHARGE TIME
The drive contains DC-link capacitors, which can remain
charged even when the drive is not powered. High
voltage can be present even when the warning LED
indicator lights are o. Failure to wait the specied 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 drives.
•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 specied in the
following discharge time table and is also
visible on the drive label.
•Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged. For parallel drive modules, measure
DC-bus capacitor voltages before and after the
individual DC fuses.
Enclosure Size Minimum waiting time
D1h–D8h drives 20 minutes
J8–J9 drives 20 minutes
D9h–D10h enclosed drive systems 20 minutes
Da2/Da4/Db2/Db4 parallel drive systems 20 minutes
E1h–E4h drives 40 minutes
E5h–E6h enclosed drive systems 40 minutes
Table 2.1 Discharge Time
WARNING
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the
drive properly can result in death or serious injury.
•Ensure the correct grounding of the equipment
by a certied electrical installer.
WARNING
LOAD SHARE DISCONNECT
Load share is a connection between DC circuits of several
drives, creating a multiple-drive system to run a single
mechanical load. When servicing a drive that is part of a
load share application:
•Turn o all drives in the system via a
disconnect.
•Wait for the drives to discharge fully, using the
longest waiting period required of the drives in
the multi-drive system. Refer to the discharge
time table for minimum waiting time.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
•Ensure that only trained and qualied personnel
install, start up, and maintain the drive.
•Ensure that electrical work conforms to national
and local electrical codes.
•Follow the procedures in this guide.
WARNING
UNINTENDED MOTOR ROTATION
WINDMILLING
Unintended rotation of permanent magnet motors
creates voltage and can charge the unit, resulting in
death, serious injury, or equipment damage.
•Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
WARNING
SHOCK HAZARD AND RISK OF INJURY
For dynamic test procedures, mains input power is
required, and all devices and supplies connected to
mains are energized at rated voltage. Contact with
powered components can result in death or serious
injury.
•Do not touch energized parts of the drive when
connected to mains.
Safety Service Guide
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22

WARNING
INTERNAL FAILURE HAZARD
Under certain circumstances, an internal failure can
cause a component to explode. Failure to keep the
enclosure closed and properly secured can cause death
or serious injury.
•Do not operate the drive with the door open or
panels o.
•Ensure that the enclosure is properly closed and
secured during operation.
WARNING
SHOCK HAZARD
The drive can cause a DC current in the protective earth/
ground (PE) conductor and thus result in death or
serious injury.
•When a residual current-operated protective
device (RCD) is used for protection against
electrical shock, only an RCD of Type B is
permitted on the supply side.
Failure to follow the recommendation means that the
RCD cannot provide the intended protection.
CAUTION
RISK OF INJURY OR PROPERTY DAMAGE
Do not assume that a motor is wired properly after
completed service of the drive. Failure to perform these
checks can result in personal injury, property damage, or
less than optimal performance.
Check for:
•Loose connections.
•Improper programming.
•Added equipment.
CAUTION
HOT SURFACES
The drive contains metal components that are still hot
even after the drive has been powered o. Failure to
observe the high temperature symbol (yellow triangle)
on the drive can result in serious burns.
•Be aware that internal components, such as
busbars, can be extremely hot even after the
drive has been powered o.
•Exterior areas marked by the high-temperature
symbol (yellow triangle) are hot while the drive
is in use and immediately after being powered
o.
NOTICE
MAINS SHIELD SAFETY OPTION
A mains shield option is available for enclosures with a
protection rating of IP21/IP54 (UL type 1/12). The mains
shield is a cover installed inside the enclosure to protect
against the unintended touch of the power terminals,
according to BGV A2, VBG 4.
NOTICE
LIFTING - EQUIPMENT DAMAGE RISK
Incorrect lifting can result in equipment damage.
•Use lifting lugs where provided.
•Prevent uncontrolled rotation.
2.5 Electrostatic Discharge
NOTICE
STATIC DISCHARGE
When performing service, use proper Electrostatic
Discharge (ESD) procedures to prevent damage to
sensitive components.
NOTICE
AVOID TOUCH
Do not touch components on the circuit boards. Hold
circuit boards by the corners and edges only.
Many electronic components within the drive are sensitive
to static electricity. Voltages so low that they cannot be
felt, seen, or heard can reduce the life, aect performance,
or completely destroy sensitive electronic components.
Safety VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
14 Danfoss A/S © 02/2019 All rights reserved. MG94A502
22

3 Product Overview
3.1 Introduction
The VLT®HVAC Drive series is designed for the HVAC
market. These drives operate in variable torque mode or
constant torque down to 15 Hz and include special
features and options designed for fan and pump
applications.
The VLT®Refrigeration Drive series is designed for use with
refrigeration systems. These drives oer continuous
variable speed control and provide energy savings in a
range of applications including pumps, fans, compressors,
condensers, and evaporators.
The VLT®AQUA Drive series is designed for water and
waste water markets. These drives can operate in either
constant torque or variable torque with limited overload
capabilities. Their features and options make them suitable
for various water pumping and processing applications.
The VLT®AutomationDrive series is fully programmable for
either constant torque or variable torque industrial
applications. These drives operate various applications and
incorporate a wide range of control and communication
options.
These models are available in IP20 (protected chassis), IP21
(UL type 1), and IP54 (UL type 12) enclosures.
Special versions of these 3 drive types are available as VLT®
Parallel Drive Modules in IP00 enclosures. They are used by
panel builders to create 2-module or 4-module systems.
NOTICE
PARALLEL MODULE CONFIGURATION
VLT® Parallel Drive Modules have specialized software
and hardware congurations that dier from standalone
D-sized units. To avoid equipment malfunction, never
attempt to replace standalone modules with VLT®
Parallel Drive Modules.
3.2 Tools Required
Item Description
ESD protection kit Wrist strap and mat
Metric socket set 7–19 mm
Socket extensions 100–150 mm (4 in and 6 in)
Magnetic sockets –
Ratchet wrench –
Torque wrench Torque range 0.5–19 Nm (6–170 in-lb)
Torx driver set T10–T50
Needle nose pliers –
Screwdrivers Standard and Phillips
Table 3.1 Tools Required
Item Description
Digital Volt-Ohm Meter
(PWM-compatible)
•Rated for true RMS.
•Rated for the mains AC
voltage and DC-link voltage of
the drive.
(DC-link voltage = 1.414 x
mains voltage).
•Supports the diode mode.
Analog voltmeter (with
safety probe tip extenders)
–
Oscilloscope –
Clamp-on ammeter Rated for true RMS
Split bus power supply p/n 130B3146
Signal test board p/n 176F8437
Parallel drive module service
kit1)
p/n 176F3745
Table 3.2 Instruments Recommended to Test Drives
1) Used for testing only VLT
®
Parallel Drive Modules.
3.3 Service Report
Report the serial number (S/N) of the drive when
requesting support, or preparing the service report. The
serial number is listed on the nameplate. Refer to
Illustration 3.1 for details.
Product Overview Service Guide
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 15
33

3.4 Enclosure Size Identication
Enclosure size is used throughout this guide whenever
procedures or components dier between drives based on
physical size. This service guide includes the enclosure
sizes listed in Table 3.3.
Enclosure size Power rating
D1h–D8h drives 90–400 kW
E1h–E4h drives 315–710 kW
J8–J9 drives 90–315 kW
Da2/Db2/Da4/Db4 parallel drive systems 250–1200 kW
Drives modules in D9h–D10h and E5h–E6h
enclosed drive systems
315–800 kW
Table 3.3 Enclosure Size Overview
Find the enclosure size using the following steps:
1. Locate the nameplate label:
1a In parallel drive systems, the label is
found on the control shelf to the lower
right of the local control panel (LCP).
See Illustration 3.5.
1b For drives in enclosure sizes D1h-D8h,
E1h-E4h and J8-J9, the label is found
inside the drive enclosure.
2. Obtain the following information from the type
code on the nameplate. Refer to Illustration 3.1.
2a Product group and drive series
(characters 1–6)
2b Power rating (characters 7–10)
2c Voltage rating (phases and mains)
(characters 11–12)
2d Type of drive (character 16). If the
character “P” is shown, note character
17 as well.
3. Find the appropriate voltage rating table for the
product group and drive series. Refer to
chapter 3.5 Enclosure Size Denitions. For example,
T4 for FC 102 and FC 202.
4. Within the table, nd the power rating and look
up the type of drive.
130BF045.10
OUT: 3x0-Vin 0-590Hz 260/240A
IN: 3x380-500V 50/60Hz 251/231A
132 kW/200 HP, High Overload
OUT: 3x0-Vin 0-590Hz 315/302A
IN: 3x380-500V 50/60Hz 304/291A
160 kW/250 HP, Normal Overload
VLT
P/N: 134X5584 S/N: 000201H345
CAUTION:
Stored charge, wait 30 min.
Charge residuelle, attendez 30
See manual for special condition/ mains fuse
Voir manuel de conditions speciales/fusibles
WARNING:
R
AutomationDrive
www.danfoss.com
`
`
3
21 4
T/C: FC-302N132T5E20H2BGR7XXSXXXXAXBKCXRXXD0
5
CHASSIS/IP20
Tamb. 45 C/113 F at Full Output Current
Max Tamb. 55 C/131 F w/ Output Current Derating
SCCR 100 kA at UL Voltage range 380-500V
ASSEMBLED IN USA
Listed 36U0 E70524 IND. CONT. EQ.
UL Voltage range 380-500 V
OUT: 3x0-Vin 0-590Hz 1260/1160 A
IN: 3x380-500V 50/60Hz 1227/1129 A
710 kW / 1000 HP, High Overload
OUT: 3x0-Vin 0-590Hz 1460/1380 A
IN: 3x380-500V 50/60Hz 1422/1344 A
800 kW / 1200 HP, Normal Overload
VLT
T/C: FC-302N710T5E00P2BGC7XXSXXXXAXBXCXXXXDX
P/N: 134X4109 S/N:
RAutomationDrive
www.danfoss.com
ASSEMBLED IN USA
CAUTION - ATTENTION:
Stored charge, wait 20 min.
Charge residuelle, attendez 20
See manual for special condition / prefuses
Voir manuel de conditions speciales / fusibles
WARNING - AVERTISSEMENT:
`
`
Tamb. 45
˚
C/113
˚
F at Full Output Current
CHASSIS (OPEN TYPE) / IP00
SCCR 100 kA at UL Voltage range 380-500 V
Listed 36U0 E70524 IND. CONT. EQ.
UL Voltage range 380-500 V
Max. Tamb. 55
˚
C/131
˚
F w/ Output Current Derating
123456H123
3
21 45
1 Product group and drive series
2 Power rating
3 Voltage rating (phases and mains)
4
Drive type:
H = 6-pulse drive
P2 = 6-pulse, class A2 RFI
P4 = 6-pulse, class A1 RFI
P6 = 12-pulse, class A2 RFI
P8 = 12-pulse, class A1 RFI
5Build date (wwy, where ww = the week and y = last digit
of the year). For example, 345 = week 34 of 2015.
Illustration 3.1 Sample Nameplates
Product Overview VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
16 Danfoss A/S © 02/2019 All rights reserved. MG94A502
33

3.5 Enclosure Size Denitions
Power
rating
Drive type Enclosure size Enclosure size with
extended options cabinet
Number of drive modules
N55K H D1h/D3h – –
N75K H D1h/D3h – –
N90K H D2h/D4h – –
N110 H D2h/D4h – –
N150 H D2h/D4h – –
N160 H D2h/D4h – –
Table 3.4 200–240 V AC (T2) Voltage Rating for FC 102, FC 103, and FC 202
Power
rating
Drive type Enclosure size Enclosure size with
extended options cabinet
Number of drive modules
N45K H D1h/D3h – –
N55K H D1h/D3h – –
N75K H D2h/D4h – –
N90K H D2h/D4h – –
N110 H D2h/D4h – –
N150 H D2h/D4h – –
Table 3.5 200–240 V AC (T2) Voltage Rating for FC 302
Product Overview Service Guide
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 17
33

Power
rating
Drive type Enclosure size Enclosure size with
extended options cabinet
Number of drive modules
N110 H D1h/D3h D5h/D6h –
N132 H D1h/D3h D5h/D6h –
N160 H D1h/D3h D5h/D6h –
N200 H D2h/D4h D7h/D8h –
N250 H D2h/D4h D7h/D8h –
N315 H D2h/D4h D7h/D8h –
N315 P6/P8 Db2 – 2-module system
N355 P6/P8 Db2 – 2-module system
N355 H E1h/E3h – –
N400 P6/P8 Db2 – 2-module system
N400 H E1h/E3h – –
N450 P6/P8 Db2 – 2-module system
N450 H E1h/E3h – –
N500 P2/P4 Da2 – 2-module system
N500 P6/P8 Db2 – 2-module system
N500 H E2h/E4h – –
N560 P2/P4 Da4 – 4-module system
N560 P6/P8 Db4 – 4-module system
N560 H E2h/E4h – –
N630 P2/P4 Da4 – 4-module system
N630 P6/P8 Db4 – 4-module system
N710 P2/P4 Da4 – 4-module system
N710 P6/P8 Db4 – 4-module system
N800 P2/P4 Da4 – 4-module system
N800 P6/P8 Db4 – 4-module system
N1000 P2/P4 Da4 – 4-module system
N1000 P6/P8 Db4 – 4-module system
Table 3.6 380–480 V AC (T4) Voltage Rating for FC 102, FC 103, and FC 202
Power
rating
Drive type Enclosure size Enclosure size with
extended options cabinet
Number of drive modules
N90K H J8 – –
N110 H J8 – –
N132 H J8 – –
N160 H J8 – –
N200 H J9 – –
N250 H J9 – –
N315 H J9 – –
Table 3.7 380–480 V AC (T4) Voltage Rating for FC 361
Product Overview VLT®FC Series, D1h–D8h, Da2/Db2/Da4/Db4, E1h–E4h, J8/J9
18 Danfoss A/S © 02/2019 All rights reserved. MG94A502
33