Danfoss VLT HVAC FC 100 User manual

Rev. 2008-09-01
www.danfoss.com/drives
130R0438 MG90L122 *MG90L122*
High Power
Service Manual
High Power Service Manual MG90L122
VLT ®HVAC Drive FC 100
VLT®AQUA Drive FC 200
VLT ®AutomationDrive FC 300
MAKING MODERN LIVING POSSIBLE
Rev. 2008-09-01
www.danfoss.com/drives
130R0438 MG90L122 *MG90L122*
High Power
Service Manual
High Power Service Manual MG90L122
VLT®HVAC Drive FC 100
VLT®AQUA Drive FC 200
VLT®AutomationDrive FC 300
MAKING MODERN LIVING POSSIBLE

Contents
1 Introduction
1-1
Purpose 1-1
VLT FC Product Overview 1-1
For Your Safety 1-2
Electrostatic Discharge (ESD) 1-2
Frame Size Definitions 1-2
Tools Required 1-4
General Torque Tightening Values 1-4
Exploded Views 1-5
Ratings Tables 1-8
2 Operator Interface and Adjustable Frequency Drive
Control
2-1
Introduction 2-1
User Interface 2-1
Numeric Local Control Panel (NLCP) 2-6
Tips and Tricks 2-7
Status Messages 2-7
Service Functions 2-13
Frequency Converter Inputs and Outputs 2-14
Input Signals 2-15
Output Signals 2-15
Control Terminals 2-16
Control Terminal Functions 2-17
Grounding Shielded Cables 2-19
3 Internal Adjustable Frequency Drive Operation 3-1
General 3-1
Description of Operation 3-1
Logic Section 3-2
Logic to Power Interface 3-3
Power Section 3-4
Sequence of Operation 3-5
Rectifier Section 3-5
Intermediate Section 3-7
Inverter Section 3-9
Brake Option 3-11
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives Contents
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Cooling Fans 3-12
Fan Speed Control 3-12
Load Sharing 3-13
Specific Card Connections 3-14
4 Troubleshooting 4-1
Troubleshooting Tips 4-1
Exterior Fault Troubleshooting 4-1
Fault Symptom Troubleshooting 4-2
Visual Inspection 4-3
Fault Symptoms 4-4
No Display 4-4
Intermittent Display 4-4
Motor Will not Run 4-5
Incorrect Motor Operation 4-6
Warning/Alarm Messages 4-7
Warning/Alarm Code List 4-7
After Repair Tests 4-21
5 Adjustable Frequency Drive and Motor Applications 5-1
Torque Limit, Current Limit, and Unstable Motor Operation 5-1
Overvoltage Trips 5-2
Line Phase Loss Trips 5-3
Control Logic Problems 5-3
Programming Problems 5-4
Motor/Load Problems 5-5
Internal Adjustable Frequency Drive Problems 5-5
Overtemperature Faults 5-5
Current Sensor Faults 5-6
Signal and Power Wiring Considerations for Adjustable Frequency Drive
Electromagnetic Compatibility 5-6
Effect of EMI 5-7
Sources of EMI 5-7
EMI Propagation 5-8
Preventive Measures 5-9
Proper EMC Installation 5-11
6 Test Procedures 6-1
Introduction 6-1
Contents High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Tools Required for Testing 6-2
Signal Test Board 6-2
Test Cables 6-3
Static Test Procedures 6-4
Soft Charge and Rectifier Circuits Test: D-frame Size 6-5
Soft Charge Rectifier Test: D-frame Size 6-7
Soft Charge and Rectifier Circuits Test: E-frame Size 6-9
Soft Charge Rectifier Test: E-frame Size 6-11
Inverter Section Tests 6-12
Brake IGBT Test 6-13
Intermediate Section Tests 6-14
Heatsink Temperature Sensor Test 6-15
Fan Continuity Tests: D-frame Size 6-15
Fan Continuity Tests: E-frame Size 6-18
Dynamic Test Procedures 6-20
No Display Test 6-21
Input Voltage Test 6-21
Basic Control Card Voltage Test 6-22
Switch Mode Power Supply (SMPS) Test 6-23
Zero DC Bus Voltage Test 6-24
DC Undervoltage Test 6-24
Input Phase Imbalance Test 6-25
Input Waveform Test 6-26
Input SCR Test 6-27
Output Phase Imbalance Test 6-29
IGBT Gate Drive Signals Test 6-30
IGBT Switching Test 6-33
Brake IGBT Test 6-34
Current Sensors Test 6-34
Fan Tests 6-36
Input Terminal Signal Tests 6-38
Initial Start Up or After Repair Drive Tests 6-39
7 D-Frame Sizes Disassembly and Assembly Instructions 7-1
Electrostatic Discharge (ESD) 7-1
Instructions 7-1
Control Card and Control Card Mounting Plate 7-1
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives Contents
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Control Assembly Support Bracket 7-2
Power Card 7-3
Power Card Mounting Plate 7-4
Soft Charge Card 7-5
Gate Drive Card 7-6
Capacitor Bank(s) 7-7
Soft Charge (SC) Resistors D2/D4 Units 7-9
Soft Charge (SC) Resistors D1/D3 Units 7-10
Input Terminal Mounting Plate Assembly 7-13
SCR/Diode Module D2/D4 Units 7-14
SCR/Diode Module D1/D3 Units 7-18
Current Sensor 7-21
Heatsink Fan Assembly 7-22
AC Input Terminals 7-24
IGBT Modules D2/D4 Units 7-25
IGBT Modules D1/D3 Units 7-28
8 E-Frame Sizes Disassembly and Assembly Instructions 8-1
Electrostatic Discharge (ESD) 8-1
Instructions 8-1
Control Card and Control Card Mounting Plate 8-1
Control Assembly Support Bracket 8-2
Power Card 8-3
Soft Charge Card 8-4
Gate Drive Card 8-5
Capacitor Banks 8-6
Input Terminal Mounting Plate Assy Option 8-8
Soft Charge Resistor 8-9
SCR and Diode Modules 8-10
Current Sensor 8-13
Heatsink Fan Assembly 8-14
AC Input, Motor, Load Sharing or Regen Terminals 8-15
IGBT Modules 8-16
9 Special Test Equipment 9-1
Test Equipment 9-1
Test Cables and SCR Shorting Plug Kit p/n 176F8439 9-1
Signal Test Board (p/n 176F8437) 9-2
Contents High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Signal Test Board Pin Outs: Description and Voltage Levels 9-2
10 Spare Parts List 10-1
Spare Parts List 10-1
General Notes 10-1
Spare Parts Lists 10-2
11 Block Diagrams 11-1
Block Diagrams for D-Frames 11-2
D1/D3 380–500 VAC 11-2
D2/D4 380–500 VAC 11-3
D1/D3 525–690 VAC 11-4
D2/D4 525–690 VAC 11-5
Block Diagrams for E-Frames 11-6
E1/E2 380–500 VAC 11-6
E1/E2 525–690 VAC 11-7
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives Contents
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Contents | Figure
Figure 1.1: Exploded view D3 Frame size, D1 frame is similar. 1-5
Figure 1.2: Exploded view D4 frame size, D2 frame is similar. 1-6
Figure 1.3: Exploded view E2 frame size, E1 frame is similar. 1-7
Figure 2.1: Control Terminals 2-14
Figure 2.2: Control Terminals Electrical Diagram 2-18
Figure 3.1: Control Card Logic 3-1
Figure 3.2: Logic Section 3-2
Figure 3.3: Typical Power Section 3-4
Figure 3.4: Rectifier circuit 3-6
Figure 3.5: Intermediate section 3-8
Figure 3.6: Output Voltage and Current Waveforms 3-9
Figure 3.7: Inverter section 3-10
Figure 3.8: Brake option 3-11
Figure 5.1: Adjustable Frequency Drive Functionality Diagram 5-7
Figure 5.2: Ground Currents 5-8
Figure 5.3: Signal Conductor Currents 5-8
Figure 5.4: Alternate Signal Conductor Currents 5-9
Figure 5.5: Proper EMC Installation 5-11
Figure 6.1: Signal Test Board 6-2
Figure 6.2: SCR Shorting Plug 6-3
Figure 6.3: Two-Pin 6-3
Figure 6.4: Three-Pin 6-3
Figure 6.5: Power Card, and Mounting Plate 6-4
Figure 6.6: Soft Charge Card Fuses 6-5
Figure 6.7: Soft Charge Card Connectors 6-8
Figure 6.8: Soft Charge Card Fuse Location 6-9
Figure 6.9: Soft Charge Card Connectors 6-11
Figure 6.10: Fan Transformer and Fuse Location 6-17
Figure 6.11: Fan and DC Bus Fuse Locations 6-19
Figure 6.12: Drive Power Terminals ( 6-20
Figure 6.13: Normal AC Input Voltage Waveform 6-26
Figure 6.14: AC Input Current Waveform with Diode Bridge 6-26
Figure 6.15: Input Current Waveform with Phase Loss. 6-27
Figure 6.16: SCR Gate Signal 6-28
Figure 6.17: Gate Drive Card Test Connectors 6-31
Contents High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Figure 6.18: Gate Signal Waveform from Gate Drive Card. IGBT Gate Signal measured on
the Gate Drive Card: 5 volts per division vertical scale, 50 microseconds per division time
scale. Unit running at 30 Hz. 6-32
Figure 6.19: Gate Signal Waveform from Signal Test Board. IGBT Gate Signal measured with
the Signal Test Board: 2 volts per division vertical scale, 50 microseconds per division time
scale. Unit running at 30 Hertz. 6-32
Figure 7.1: Control Card Access 7-2
Figure 7.2: Power Card, and Mounting Plate 7-3
Figure 7.3: Soft Charge Card Assy 7-5
Figure 7.4: Gate Drive Card 7-6
Figure 7.5: D2/D4 7-7
Figure 7.6: D1/D3 7-8
Figure 7.7: D2/D4 7-9
Figure 7.8: D2/D4 7-10
Figure 7.9: D1/D3 7-11
Figure 7.10: D1/D3 7-12
Figure 7.11: Input Terminal Mounting Plate Assembly (no options shown) 7-13
Figure 7.12: D2/D4 7-14
Figure 7.13: D2/D4 7-15
Figure 7.14: D2/D4 7-16
Figure 7.15: D2/D4 7-17
Figure 7.16: D1/D3 7-18
Figure 7.17: D1/D3 7-19
Figure 7.18: D1/D3 7-20
Figure 7.19: Current Sensors 7-21
Figure 7.20: Fan Assembly (1 of 2) 7-22
Figure 7.21: Fan Assembly (2 of 2) 7-23
Figure 7.22: AC Input Terminals (no options shown) 7-24
Figure 7.23: D2/D4 7-25
Figure 7.24: D2/D4 7-26
Figure 7.25: D2/D4 7-27
Figure 7.26: D1/D3 7-28
Figure 7.27: D1/D3 7-29
Figure 8.1: Control Card Access 8-2
Figure 8.2: Power Card, and Mounting Plate 8-3
Figure 8.3: Soft Charge Card 8-4
Figure 8.4: Gate Drive Card. 8-5
Figure 8.5: Upper and Lower Capacitor Bank Assemblies 8-7
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives Contents
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Figure 8.6: Input Terminal Mounting Plate Assy (shown with RFI and electrical fuses options)
8-8
Figure 8.7: Soft Charge Resistor 8-9
Figure 8.8: SCR and Diode Modules (1 of 3) 8-10
Figure 8.9: SCR and Diode Modules (2 of 3) 8-11
Figure 8.10: SCR and Diode Modules (3 of 3) 8-12
Figure 8.11: Current Sensors 8-13
Figure 8.12: Fan Assembly 8-14
Figure 8.13: Terminal Blocks 8-15
Figure 8.14: IGBT Modules (1 of 4) 8-16
Figure 8.15: IGBT Modules (2 of 4) 8-17
Figure 8.16: IGBT Modules (3 of 4) 8-18
Figure 8.17: IGBT Modules (4 of 4) 8-19
Figure 9.1: SCR Shorting Plug 9-1
Figure 9.2: Two-pin 9-1
Figure 9.3: Three-pin 9-1
Figure 9.4: Signal Test Board 9-2
Contents High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
MG.90.L1.22 - VLT®is a registered Danfoss trademark

Contents | Table
Table 1.1: FC 102 and FC 202 380–480 VAC 1-2
Table 1.2: FC 302 380–500 VAC 1-3
Table 1.3: FC 102 and FC 202 525–690 VAC 1-3
Table 1.4: FC 302 525–690 VAC 1-3
Table 1.5: Torque Values Table 1-4
Table 2.1: Tips and tricks 2-7
Table 2.2: Control Terminals and Associated Parameter 2-17
Table 2.3: Grounding Shielded Cables 2-19
Table 3.1: IGBT Thermal Sensor 3-12
Table 3.2: Power Card Ambient Temperature Sensor 3-13
Table 3.3: Control Card Thermal Sensor 3-13
Table 4.1: Visual Inspection 4-3
Table 4.2: Warning/alarm code list 4-8
Table 4.3: Alarm/warning code list 4-9
Table 6.1: Fan transformer resistance 6-18
Table 6.2: Scaling Card Resistance Values 6-36
Table 10.1: Spare Parts List PCA3, PCA4, PCA5, PCA8 and PCA11 10-2
Table 10.2: Spare Parts List Semiconductors, Resistors, Capacitors and Fans 10-3
Table 10.3: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects 10-
4
Table 10.4: Spare Parts List Cables 1:2 10-5
Table 10.5: Spare Parts List Cables 2:2 10-6
Table 10.6: Spare Parts List Cables 10-7
Table 10.7: Spare parts list: Terminals, Labels, Insulators 10-8
Table 10.8: Spare parts lists: Bus Bars (tabel 1) 10-9
Table 10.9: Spare parts list: Bus Bars (table 2) 10-10
Table 10.10: Spare parts list: Enclosure 10-11
Table 10.11: Spare Parts List PCA3-11 10-13
Table 10.12: Spare Parts List Semiconductors, Resistors, Capacitors and Fans 10-14
Table 10.13: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects 10-
15
Table 10.14: Spare Parts List Cables 10-16
Table 10.15: Spare Parts List Terminals, Labels, Insulators 10-17
Table 10.16: Spare Parts List Bus Bars 10-19
Table 10.17: Spare Parts List Enclosure 10-20
Table 10.18: Spare Parts List PCA, Semiconductors and Resistors 10-21
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives Contents
MG.90.L1.22 - VLT®is a registered Danfoss trademark