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

Table 10.19: Spare Parts List Capacitors, Fans, Fuses and Inductors & Current Sensors 10-
22
Table 10.20: Spare Parts List Disconnects and Cables 10-23
Table 10.21: Spare Parts List Terminals, Labels & Insulators 10-24
Table 10.22: Spare Parts List Bus Bars and Enclosure 10-25
Contents High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
MG.90.L1.22 - VLT®is a registered Danfoss trademark

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 FC series adjustable frequency
drives in the D and E frames.
It provides the reader with a general view of the unit's main assemblies and a description of the
internal processing. With this information, technicians should have a better understanding of the
adjustable frequency drive's operation to assist in troubleshooting and repair.
This manual provides instructions for the adjustable frequency drive models and voltage ranges
described in the tables on the following page.
1.2 VLT FC Product Overview
VLT HVAC FC 102 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 well suited for fan and pump applications within the HVAC market.
VLT
®
AQUA FC 202 series adjustable frequency drives are designed for water and waste water
markets. They can operate in either constant torque or variable torque with limited overload ca-
pabilities. They include specific features and options which make them well suited for use on a
variety of water pumping and processing applications.
VLT AutomationDrive series adjustable frequency drives are fully programmable for either con-
stant torque or variable torque industrial applications. They are full-featured adjustable frequency
drives capable of operating a myriad of applications and incorporating a wide variety of control
and communication options.
These models are available in Chassis/IP00, NEMA 1/IP21 or NEMA 12/IP54 enclosures.
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives 1 Introduction
MG.90.L1.22 - VLT®is a registered Danfoss trademark 1-1
1

1.3 For Your Safety
Adjustable frequency drives contain dangerous voltages when connected to line
power. Only a competent technician should carry out service.
For dynamic test procedures, main input power is required and all devices and power
supplies connected to line power are energized at rated voltage. Use extreme cau-
tion when conducting tests in a powered adjustable frequency drive. Contact with
powered components could result in electrical shock and personal injury.
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 com-
ponents in D-frame size units or 40 minutes for E-frame size units. See the label on the
front of the adjustable frequency drive door for specific discharge time.
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, the motor may start without
warning. Activate the STOP key when changing data.
When performing service, use proper ESD procedures to prevent damage to sensi-
tive components.
1.4 Electrostatic Discharge (ESD)
Many electronic components withinthe adjustable frequency driveare 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
380–480 VAC Power
Model FC 102Drive and FC 202 VLT
AQUA Drive
kW @400 VAC HP @460 VAC Frame Size
P110 110 150 D1 / D3
P132 132 200 D1 / D3
P160 160 250 D2 / D4
P200 200 300 D2 / D4
P250 250 350 D2 / D4
P315 315 450 E1 / E2
P355 355 500 E1 / E2
P400 400 550 E1 / E2
P450 450 600 E1 / E2
Table 1.1: FC 102 and FC 202 380–480 VAC
1 Introduction High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
1-2 MG.90.L1.22 - VLT®is a registered Danfoss trademark
1

380–500 VAC Power
Model FC 302 High / Normal Overload
kW @400 VAC HP @460 VAC kW @500 VAC Frame Size
P90K 90 / 110 125 / 150 110 / 132 D1 / D3
P110 110 / 132 150 / 200 132 / 160 D1 / D3
P132 132 / 160 200 / 250 160 / 200 D2 / D4
P160 160 / 200 250 / 300 200 / 250 D2 / D4
P200 200 / 250 300 / 350 250 / 315 D2 / D4
P250 250 / 315 350 / 450 315 / 355 E1 / E2
P315 315 / 355 450 / 500 355 / 400 E1 / E2
P355 355 / 400 500 / 550 400 / 500 E1 / E2
P400 400 / 450 550 / 600 500 / 530 E1 / E2
Table 1.2: FC 302 380–500 VAC
525–690 VAC Power
Model FC 102 and FC 202
VLT AQUA Drive
kW @550 VAC HP @575 VAC kW @690 VAC Frame Size
P45K 37 50 45 D1 / D3
P55K 45 60 55 D1 / D3
P75K 55 75 75 D1 / D3
P90K 75 100 90 D1 / D3
P110 90 125 110 D1 / D3
P132 110 150 132 D1 / D3
P160 132 200 160 D1 / D3
P200 160 250 200 D2 / D4
P250 200 300 250 D2 / D4
P315 250 350 315 D2 / D4
P400 315 400 400 D2 / D4
P450 355 450 450 E1 / E2
P500 400 500 500 E1 / E2
P560 450 600 560 E1 / E2
P630 500 650 630 E1 / E2
Table 1.3: FC 102 and FC 202 525–690 VAC
525–690 VAC Power
Model FC 302 High/Normal Overload
kW @550 VAC HP @575 VAC kW @690 VAC Frame Size
P37k 30 / 37 40 / 50 37 / 45 D1/D3
P45k 37 / 45 50 / 60 45 / 55 D1/D3
P55k 45 / 55 60 / 75 55 / 75 D1/D3
P75k 55 / 75 75 / 100 75 / 90 D1/D3
P90k 75 / 90 100 / 125 90 / 110 D1 / D3
P110 90 / 110 125 / 150 110 / 132 D1 / D3
P132 110 / 132 150 / 200 132 / 160 D1 / D3
P160 132 / 160 200 / 250 160 / 200 D2 / D4
P200 160 / 200 250 / 300 200 / 250 D2 / D4
P250 200 / 250 300 / 350 250 / 315 D2 / D4
P315 250 / 315 350 / 400 315 / 400 D2 / D4
P355 315 / 355 400 / 450 355 / 450 E1 / E2
P400 315 / 400 400 / 500 400 / 500 E1 / E2
P500 400 / 450 500 / 600 500 / 560 E1 / E2
P560 450 / 500 600 / 650 560 / 630 E1 / E2
Table 1.4: FC 302 525–690 VAC
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives 1 Introduction
MG.90.L1.22 - VLT®is a registered Danfoss trademark 1-3
1

1.6 Tools Required
Instruction Manual for the FC Series Adjustable Frequency Drive
Metric socket set 7–19 mm
Socket extensions 100 mm–150 mm (4 in and 6 in)
Torx driver set T10 - T50
Torque wrench 0.675–19 Nm (6–170 in-lbs)
Needle nose pliers
Magnetic sockets
Ratchet
Screwdrivers Standard and Philips
Additional Tools Recommended for Testing
Digital volt/ohmmeter (must be rated for 1200 VDC
for 690 V units)
Analog voltmeter
Oscilloscope
Clamp-on style ammeter
Test cable p/n 176F8439
Signal test board p/n 176F8437
1.7 General Torque Tightening Values
For fastening hardware described in this manual, the torque values in the table below are used.
These values are not intended for SCR, diode, or IGBT fasteners. See the instructions included
with those replacement parts for correct values.
Shaft Size Driver Size Torx/Hex Torque (in-lbs) Torque (Nm)
M4 T-20 / 7 mm 10 1.0
M5 T-25 / 8 mm 20 2.3
M6 T-30 / 10 mm 35 4.0
M8 T-40 / 13 mm 85 9.6
M10 T-50 / 17 mm 170 19.2
Table 1.5: Torque Values Table
1 Introduction High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
1-4 MG.90.L1.22 - VLT®is a registered Danfoss trademark
1

1.8 Exploded Views
130BX167.10
1
19 13
12
25
5
4
22
21
20
18
17
3
16
15
14
11
24
2
10
9
8
7
6
23
Figure 1.1: Exploded view D3 Frame size, D1 frame is similar.
1 Control card PCA1 14 SCR/Diode module SCR 1, 2, 3
2Control input terminals 15 IGBT output bus bar
3 Local Control Panel LCP 16 Output motor terminals TB2
4Control card C option 17 Current sensor L2, L3, L4
5 Mounting bracket 18 Fan assembly F1 + C1 +CBL11
6Power card mounting plate 19 Fan transformer TR1
7 Power card PCA 3 20 Main AC power input terminals TB1
8Capacitor bank assembly CBANK1 + PCA9 21 AC input bus bar
9 Soft charge fuses 22 Input terminal mounting plate assembly
10 Soft charge card PCA11 23 Fan fuse FU4
11 DC inductor L1 24 Capacitor bank cover plate
12 Soft charge module R1 + CBL26 25 IGBT gate drive card PCA5
13 IGBT module IGBT 1
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives 1 Introduction
MG.90.L1.22 - VLT®is a registered Danfoss trademark 1-5
1

130BX166.10
4
1
25
67
11
10
9
8
12
15
14
13
16
20
19
18
17
21
22
28
27
26
25
24
23
3
Figure 1.2: Exploded view D4 frame size, D2 frame is similar.
1 Control card PCA1 15 IGBT module IGBT1, 2
2Control input terminals 16 SCR/Diode module SCR1, 2, 3
3 Local Control Panel LCP 17 IGBT output bus bar
4Control card C option 18 Output motor terminals TB2
5 Mounting bracket 19 Current sensor L2, L3, L4
6Power card mounting plate 20 Fan assembly F1 + C1 + CBL11
7 Power card PCA3 21 Main AC power input terminals TB1
8Upper capacitor bank cover plate 22 AC input bus bar
9 Upper capacitor bank assembly CBANK2 + PCA10 23 Input terminal mounting plate assembly
10 Soft charge fuses 24 Fan transformer TR1
11 Soft charge card PCA11 25 Fan fuse FU4
12 DC inductor L1 26 Lower capacitor bank assembly CBANK1 + PCA9
13 Soft charge resistor assy R1 + CBL26 27 Lower capacitor bank cover plate
14 IGBT snubber capacitors C2, C3, C4, C5, C6, C7 28 IGBT gate drive card PCA5
1 Introduction High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
1-6 MG.90.L1.22 - VLT®is a registered Danfoss trademark
1

130BX168.10
3
20
19 18
17
16
15
1
14
13
12
11
10
2
9
8
7
6
5
4
25
24
23
22
21
Figure 1.3: Exploded view E2 frame size, E1 frame is similar.
1 Control card PCA1 14 SCR and Diode SCR1, SCR2, SCR3 and D1, D2, D3
2Control input terminals 15 Fan inductor (not on all units)
3 Local Control Panel LCP 16 Soft charge resistor assy R1
4Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly F1 + C1
6Power card mounting plate 19 Output motor terminals TB2
7 Power card PCA3 20 Current sensor L2, L3, L4
8IGBT gate drive card PCA5 21 Main AC power input terminals TB1
9 Upper capacitor bank assembly CBANK2 + PCA11 22 Input terminal mounting plate assembly
10 Soft charge fuses 23 AC input bus bar
11 DC inductor L1 24 Soft charge card PCA12
12 Fan transformer TR1 25 Lower capacitor bank assembly CBANK1 + PCA10
13 IGBT module IGBT1, 2, 3
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives 1 Introduction
MG.90.L1.22 - VLT®is a registered Danfoss trademark 1-7
1

1.9 Ratings Tables
DC Voltage Levels
380–480 and 380–500 units 525–690 units
Inrush Circuit Enabled 370 VDC 548 VDC
Inrush Circuit Disabled 395 VDC 600 VDC
Inverter Undervoltage Disable 402 VDC 553 VDC
Undervoltage Warning 423 VDC 585 VDC
Inverter Undervoltage Re-Enable (warning re-
set) 442 VDC 602 VDC
Overvoltage Warning (without brake) 817 VDC 1084 VDC
Dynamic Brake Turn On 810 VDC 1099 VDC
Inverter Overvoltage Re-Enable (warning re-
set) 821 VDC 1099 VDC
Overvoltage Warning (with brake) 828 VDC 1109 VDC
Overvoltage Trip 855 VDC 1130 VDC
Line power supply 3 x 380–480/500 V
Model number FC102/202 P110 P132 P160 P200 P250
FC302 P90K P110 P132 P160 P200
Normal overload current ratings (110%):
Output current Nominal [A] (380–440 V) 212 260 315 395 480
MAX (60 sec) [A] (380–440 V) 233 286 347 434 528
Nominal [A] (441–500 V) 190 240 302 361 443
MAX (60 sec) [A] (441–500 V) 209 264 332 397 487
Output Nominal [kVA] (400 V) 147 180 218 274 333
Nominal [kVA] (460 V) 151 191 241 288 353
Nominal [kVA] (500 V) 165 208 262 313 384
Typical shaft output [kW] (400 V) 110 132 160 200 250
[HP] (460 V) 150 200 250 300 350
[kW] (500 V) 132 160 200 250 315
High overload torque (160%):
Output current Nominal [A] (380–440 V) 177 212 260 315 395
MAX (60 sec) [A] (380–440 V) 266 318 390 473 593
Nominal [A] (441–500 V) 160 190 240 302 361
MAX (60 sec) [A] (441–500 V) 240 285 360 453 542
Output Nominal [kVA] (400 V) 123 147 180 218 274
Nominal [kVA] (460 V) 127 151 191 241 288
Nominal [kVA] (500 V) 139 165 208 262 313
Typical shaft output [kW] (400 V) 90 110 132 160 200
[HP] (460 V) 125 150 200 250 300
[kW] (500 V) 110 132 160 200 250
Power loss Normal overload [W] 3234 3782 4213 5117 5893
Power loss High overload [W] 2641 2995 3425 3910 4625
Limits and Ranges
Overcurrent Warning VLT ARMS Out 329 394 484 586 735
Overcurrent Alarm (1.5 sec delay) VLT ARMS Out 329 394 484 586 735
Ground Fault Alarm VLT ARMS Out 80 95 120 151 180
Short Circuit Alarm VLT ARMS Out 420 502 616 747 936
Heatsink Overtemperature Degrees C 85 90 105 105 115
Heatsink Undertemperature Warning Degrees C 0 0 0 0 0
Power Card Ambient Overtemperature Degrees C 60 60 60 60 60
Power Card Ambient Undertemperature Degrees C -20 -20 -20 -20 -20
Line Phase Warning (5 sec delay) DC Bus Ripple VAC 50 50 50 50 50
Line Phase Alarm (25 sec delay) DC Bus Ripple VAC 50 50 50 50 50
1 Introduction High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives
1-8 MG.90.L1.22 - VLT®is a registered Danfoss trademark
1

Line power supply 3 x 380–480/500 V
Model number FC102/202 P315 P355 P400 P450
FC302 P250 P315 P355 P400
Normal overload current ratings (110%):
Output current Nominal [A] (380–440 V) 600 658 745 800
MAX (60 sec) [A] (380–
440 V) 660 724 820 880
Nominal [A] (441–500 V) 540 590 678 730
MAX (60 sec) [A] (441–
500 V) 594 649 746 803
Output Nominal [kVA] (400 V) 416 456 516 554
Nominal [kVA] (460 V) 430 470 540 582
Nominal [kVA] (500 V) 468 511 587 632
Typical shaft output [kW] (400 V) 315 355 400 450
[HP] (460 V) 450 500 550/600 600
[kW] (500 V) 355 400 500 530
High overload torque (160%):
Output current Nominal [A] (380–440 V) 480 600 658 695
MAX (60 sec) [A] (380–
440 V) 720 900 987 1043
Nominal [A] (441–500 V) 443 540 590 678
MAX (60 sec) [A] (441–
500 V) 665 810 885 1017
Output Nominal [kVA] (400 V) 333 416 456 482
Nominal [kVA] (460 V) 353 430 470 540
Nominal [kVA] (500 V) 384 468 511 587
Typical shaft output [kW] (400 V) 250 315 355 400
[HP] (460 V) 350 450 500 550
[kW] (500 V) 315 355 400 500
Power loss Normal overload [W] 6790 7701 8879 9670
Power loss High overload [W] 5165 6960 7691 8636
Limits and Ranges
Overcurrent Warning VLT ARMS Out 893 1169 1169 1301
Overcurrent Alarm (1.5 sec delay) VLT ARMS Out 893 1169 1169 1301
Ground Fault Alarm VLT ARMS Out 265 322 352 405
Short Circuit Alarm VLT ARMS Out 1138 1490 1490 1654
Heatsink Overtemperature Degrees C 95 95 95 95
Heatsink Undertemperature Warning Degrees C 0 0 0 0
Power Card Ambient Overtemperature Degrees C 68 68 68 68
Power Card Ambient Undertemperature Degrees C -20 -20 -20 -20
Line Phase Warning (5 sec delay) DC Bus Ripple VAC 70 70 70 70
Line Phase Alarm (25 sec delay) DC Bus Ripple VAC 70 70 70 70
High Power Service Manual for VLT
®
FC Series
Adjustable Frequency Drives 1 Introduction
MG.90.L1.22 - VLT®is a registered Danfoss trademark 1-9
1