Danfoss iC7 Series User manual

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NOTICE
MATCHING SCR/DIODE MODULES
If all 3 SCR/diode modules installed in a frequency converter are not the same type and manufacturer, the frequency converter
can malfunction.
Check that the replacement module matches the existing modules. If not, replace all 3 SCR/diode modules.
If replacing multiple SCR/diode modules, verify that all kit numbers match.
Use these instructions with the following kits. See Table 1 for iC7 Series kits. See Table 2 and Table 3 for VLT®FC Series kits.
Table 1: Kit Numbers for iC7 Series SCR/Diode Module Kits
Kit num-
ber
Kit description
Frame/enclosure
Voltage
Current rating
176F8318
Rectifier SCR/diode 181A 1600V
FA09/FK09a/FK09c/FB09a/
FB09c
380–480/500 V AC
206A, 245A, 302A
176F8320
Rectifier SCR/diode 320A 1600V
FA09/FK09a/FK09c/FB09a/
FB09c
380–480/500 V AC
385A
176F6647
Rectifier SCR/diode 700A 1600V
FA10-FA11/FK10a/FK10c/
FB10a/FB10c/FK11/FB11
380–480/500 V AC
395A, 480A ,588A, 658A,
736A, 799A
FA12/FK12/FB12
380–480/500 V AC
893A, 1000
176F3934
Rectifier SCR 1400A 1600V
FA12/FK12/FB12
380–480/500 V AC
1120, 1260
176F4099
Rectifier Diode 1400A 1600V
FA12/FK12/FB12
380–480/500 V AC
1120, 1260
Table 2: Kit Numbers for VLT®FC Series SCR/Diode Module Kits
Kit num-
ber
Kit description
Frame/enclosure
Voltage
Power rating
176F3426
Rectifier SCR 429A 2200V
D2h/D4h/D7h/D8h
525–690 V AC
N250, N315, N400
176F3859
Rectifier SCR 320A 1600V
D1h/D3h/D5h/D6h
N160
176F3860
Rectifier SCR 586A 1600V
D1h/D3h/D5h/D6h
N200, N250
176F6647
Rectifier SCR 700A 1600V
E1h–E4h
380–480/500 V AC
All
176F6648
Rectifier SCR 650A 2200V
E1h–E4h
525–690 V AC
All
176F8318
Rectifier SCR 181A 1600V
D1h/D3h/D5h/D6h
200–240 V AC
N45K, N55K, N75K, N90K
AN334838812834en-000201 / 130R0771 | 1Danfoss A/S © 2022.07
Installation Guide
SCR/Diode Module Replacement for
Fx09-Fx12/D1h–D8h/E1h–E4h
iC7 Series Frequency Converters and VLT® FC Series Drives
1 Overview
1.1 Description
Both iC7 Series Frequency Converters and VLT®FC Series drives contain 3 SCR/diode modules. SCR/diode module replacement kits
contain the components required to replace 1 SCR/diode module. SCR/diode module conversion kits contain 3 SCR/diode modules
along with busbars and fasteners required to upgrade the drive.
1.2 Kit Numbers

Kit num-
ber
Kit description
Frame/enclosure
Voltage
Power rating
380–480/500 V AC
N90K, N110, N132, N150,
N160
176F8529
Rectifier SCR 165A 2200V
D1h/D3h/D5h/D6h
525–690 V AC
N55K, N75K, N90K, N110,
N132, N160
176F8530
Rectifier SCR 280A 2200V
D2h/D4h/D7h/D8h
525–690 V AC
N160, N200, N250
Table 3: Kit Number for VLT®FC Series SCR/Diode Module Conversion Kit
Kit num-
ber
Kit description
Frame/enclosure
Voltage
Power rating
176F3890
SCR Conversion Kit 568A
N200T5/N250T5 HO
D2h/D4h/D7h/D8h
1.3 Items Supplied
See Table 4 for the parts included in SCR/diode module replacement kits. See Table 5 for items supplied in conversion kits.
Table 4: Items Supplied in SCR/Diode Module Replacement Kits
Item description
Quantity
SCR/diode module
1
3 cc syringe of thermal grease
1
Fasteners for SCR mounting
2–4
Fasteners for busbar connection
varies
Table 5: Items Supplied in SCR/Diode Module Conversion Kits (176F3890)
Item description
Quantity
SCR/diode module
3
SCR input busbar
3
SCR-to-DC busbar
2
DC(-) busbar
1
DC(+) busbar
1
M6 x 24 mm Torx screw
12
M10 x 22 mm Torx screw
6
Standoff
3
3 cc syringe of thermal grease
3
AN334838812834en-000201 / 130R07712 | Danfoss A/S © 2022.07
Overview
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/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
D1h–D8h
20 minutes
Fx09–Fx10
20 minutes
E1h–E4h
40 minutes
Fx11–Fx12
40 minutes
AN334838812834en-000201 / 130R0771 | 3Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide

1.
2.
3.
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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 SCR/Diode Modules
NOTICE
THERMAL INTERFACE
A proper thermal interface is required between the SCR/diode module and heat sink. Failure to follow these instructions results in
a poor thermal bond.
Ensure that the environment is free of airborne dust and contaminants while applying the thermal grease.
NOTICE
FASTENER SIZE
For some spare part kits, 2 different sizes of screws are included.
Use the screw size that fits the heat sink.
NOTICE
HEAT SINK DAMAGE
A damaged heat sink can cause a frequency converter to malfunction. A clean and undamaged mounting surface allows proper
thermal dissipation.
Take care not to scratch or damage the heat sink when cleaning and servicing the frequency converter.
Refer to the service guide for SCR/diode module disassembly. To install replacement SCR/diode modules, use the following steps.
Procedure
Clean the heat sink using a cloth and isopropyl alcohol to remove debris and remaining thermal grease.
Verify that the thermal grease is not expired by checking the expiration date on the package.
If expired, order a new syringe of thermal grease (176F6769).
With the syringe, apply thermal grease to the bottom of the SCR/diode module in the pattern shown in Illustration 1.
It is not required to use the entire syringe, but excess thermal grease is not a problem.
AN334838812834en-000201 / 130R07714 | Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide

4.
5.
6.
7.
8.
9.
e30bh996.10
1
2
Illustration 1: SCR/Diode Module Thermal Grease Pattern
1
Bottom surface of SCR/diode module
2
Thermal grease
Place the module on the heat sink, and twist it back and forth to spread the thermal grease evenly on the SCR/diode mod-
ule and the heat sink surface.
Align the mounting holes in the SCR/diode module with the holes in the heat sink.
Insert the screws into the SCR/diode modules and hand tighten them.
Wait 1 minute.
Using a manual torque wrench to avoid over torquing the screws, follow the tightening sequence shown in Illustration 2.
Apply 0.6 Nm (5.3 in-lb) of initial torque at a maximum of 100 RPM. Then apply final torque in the same sequence using
the values listed in Table 7.
Connect the gate lead to the cable connector on the SCR/diode module.
For SCR/diode module conversion kits, continue to 2.3 Installing the SCR/Diode Module Busbars to install the rest of the
kit. Otherwise, complete the frequency converter reassembly as described in the service guide.
AN334838812834en-000201 / 130R0771 | 5Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide

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2.
3.
4.
5.
e30bh997.10
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1
2
3
4
1
2
3
4
A B
CD
1
2
3
4
Illustration 2: SCR/Diode Module Fastener Tightening Sequences
Table 7: Torque Tightening Values and Sequence
Kit number
Mounting torque [Nm (in-lb)]
Busbar connection torque [Nm (in-lb)]
Tightening order
Diagram
176F3426
6.0 (53)
12.0 (106)
1-2-3-4
B
176F3859
5.0 (44)
9.0 (80)
1-2-3-4
C
176F3860
6.0 (53)
12.0 (106)
1-2-3-4
C
176F3890
6.0 (53)
12.0 (106)
1-2-3-4
C
176F3934
5.5 (49)
11.0 (97)
1-2-3-4
D
176F4099
5.5 (49)
11.0 (97)
1-2-3-4
D
176F6647
5.5 (49)
11.0 (97)
1-2-3-4
D
176F6648
5.5 (49)
11.0 (97)
1-2-3-4
D
176F8318
2.5 (22)
5.0 (44)
1-2
A
176F8320
5.8 (51)
12.0 (106)
1-2-3-4
B
176F8529
2.5 (22)
5.0 (44)
1-2
A
176F8530
5.8 (51)
12.0 (106)
1-2-3-4
B
2.3 Installing the SCR/Diode Module Busbars
SCR/diode module conversion kits contain 3 SCRs plus new busbars. Use the following steps to install the busbars. See Illustration 3.
Procedure
Position the 3 SCR input busbars in the frequency converter, 1 on each SCR/diode module.
Fasten 3 standoffs (19 mm), 1 in each SCR/diode module connecting it to the busbar.
Fasten 3 M10 screws (T50) in the SCR-to-DC(-) busbar, connecting it to the 3 SCR/diode modules.
Fasten 3 M10 screws (T50) in the SCR-to-DC(+) busbar, connecting it to the 3 SCR/diode modules.
Position the DC(-) busbar behind the SCR-to-DC(-) busbar and fasten 1 screw connecting the busbars.
AN334838812834en-000201 / 130R07716 | Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide

6. Position the DC(+) busbar behind the SCR-to-DC(+) busbar and fasten 1 standoff connecting the busbars.
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2
3
4
6
7
8
9
10
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e30bh998.10
Illustration 3: SCR/Diode Module Busbar Installation
1
SCR/diode module
2
M10 screws
3
Standoff
4
SCR input busbars
5
Heat sink
6
DC(+) busbar
7
DC(-) busbar
8
M6 screw
9
SCR-to-DC(-) busbar
10
SCR-to-DC(+) busbar
AN334838812834en-000201 / 130R0771 | 7Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide

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*130R0771*
*M00228* AN334838812834en-000201 / 130R07718 | Danfoss A/S © 2022.07
Installation
SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h
Installation Guide