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
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 1

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
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 3

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
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 5

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
MG94A502 Danfoss A/S © 02/2019 All rights reserved. 7

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