FC100 ServiceManual MG90L102

High Power Service Manual for VLT FC Series
Frequency Converters Contents
Contents
1 Introduction 11
Purpose 11
VLT FC Product Overview 11
For Your Safety 11
Electrostatic Discharge (ESD) 12
Frame Size Definitions 12
Tools Required 13
General Torque Tightening Values 13
Exploded Views 15
Ratings Tables 18
2 Operator Interface and Frequency Converter Control 23

Introduction 23
User Interface 23
Numeric Local Control Panel (NLCP) 29
Tips and Tricks 29
Status Messages 30
Service Functions 35
Frequency Converter Inputs and Outputs 36
Input signals 37
Output signals 37
Control Terminals 38
Control Terminal Functions 39
Earthing Screened Cables 41
3 Internal Frequency Converter Operation 43

General 43
Description of Operation 43
Logic Section 44
Logic to Power Interface 45
Power Section 46
Sequence of Operation 47
Rectifier Section 47
Intermediate Section 49
Inverter Section 51
Brake Option 53
Cooling Fans 54
Fan Speed Control 54
Load Sharing 55
MG.90.L1.02 - VLT is a registered Danfoss trademark 1

Contents Frequency Converters
Specific Card Connections 55
4 Troubleshooting 57
Troubleshooting Tips 57
Exterior Fault Troubleshooting 57
Fault Symptom Troubleshooting 57
Visual Inspection 59
Fault Symptoms 60
No Display 60
Intermittent Display 60
Motor Will not Run 61
Incorrect Motor Operation 62
Warning/Alarm Messages 63
Warning/Alarm Code List 63
After Repair Tests 75
5 Frequency Converter and Motor Applications 77

Torque Limit, Current Limit, and Unstable Motor Operation 77
Overvoltage Trips 78
Mains Phase Loss Trips 79
Control Logic Problems 79
Programming Problems 80
Motor/Load Problems 80
Internal Frequency Converter Problems 81
Overtemperature Faults 81
Current Sensor Faults 81
Signal and Power Wiring Considerations for Frequency Converter Electromagnetic
Compatibility 82
Effect of EMI 82
Sources of EMI 82
EMI Propagation 83
Preventive Measures 85
Proper EMC Installation 86
6 Test Procedures 87
Introduction 87
Tools Required for Testing 88
Signal Test Board 88
Test Cables 89
Static Test Procedures 90
Soft Charge and Rectifier Circuits Test: D-frame Size 91
Soft Charge Rectifier Test: D-frame Size 93
2 MG.90.L1.02 - VLT is a registered Danfoss trademark

Soft Charge and Rectifier Circuits Test: E-frame Size 95

Soft Charge Rectifier Test: E-frame Size 97
Inverter Section Tests 98
Brake IGBT Test 99
Intermediate Section Tests 100
Heatsink Temperature Sensor Test 101
Fan Continuity Tests: D-frame Size 101
Fan Continuity Tests: E-frame Size 103
Dynamic Test Procedures 105
No Display Test 106
Input Voltage Test 106
Basic Control Card Voltage Test 107
Switch Mode Power Supply (SMPS) Test 107
Zero DC Bus Voltage Test 108
DC Undervoltage Test 109
Input Imbalance of Supply Voltage Test 109
Input Waveform Test 110
Input SCR Test 111
Output Imbalance of Supply Voltage Test 113
IGBT Gate Drive Signals Test 114
IGBT Switching Test 116
Brake IGBT Test 117
Current Sensors Test 118
Fan Tests 119
Input Terminal Signal Tests 121
Initial Start Up or After Repair Drive Tests 122
7 D-Frame Sizes Disassembly and Assembly Instructions 123

Instructions 123
Control Card and Control Card Mounting Plate 123
Control Assembly Support Bracket 124
Power Card 125
Power Card Mounting Plate 126
Soft Charge Card 126
Gate Drive Card 128
Capacitor Bank(s) 129
Soft Charge (SC) Resistors D2/D4 Units 131
Soft Charge (SC) Resistors D1/D3 Units 132
Input Terminal Mounting Plate Assembly 135

SCR/Diode Module D2/D4 Units 136

SCR/Diode Module D1/D3 Units 140
Current Sensor 143
Heatsink Fan Assembly 144
AC Input Terminals 146
IGBT Modules D2/D4 Units 147
IGBT Modules D1/D3 Units 150
8 E-Frame Sizes Disassembly and Assembly Instructions 153

Instructions 153
Control Card and Control Card Mounting Plate 153
Control Assembly Support Bracket 154
Power Card 155
Soft Charge Card 156
Gate Drive Card 157
Capacitor Banks 158
Input Terminal Mounting Plate Assy Option 160
Soft Charge Resistor 161
SCR and Diode Modules 162
Current Sensor 165
Heatsink Fan Assembly 166
AC Input, Motor, Load Sharing or Regen Terminals 167
IGBT Modules 168
9 Special Test Equipment 173

Test Equipment 173
Test Cables and SCR Shorting Plug Kit p/n 176F8439 173
Signal Test Board (p/n 176F8437) 174
Signal Test Board Pin Outs: Description and Voltage Levels 174
10 Spare Parts List 177

Spare Parts List 177
General Notes 177
Spare Parts Lists 178
11 Block Diagrams 201

Block Diagrams for D-Frames 201
D1/D3 380500 VAC 201
D2/D4 380500 VAC 203
D1/D3 525690 VAC 205
D2/D4 525690 VAC 207

Block Diagrams for E-Frames 208

E1/E2 380500 VAC 208
E1/E2 525690 VAC 209

Contents | Illustration
Illustration 1.1: Exploded view D3 Frame size, D1 frame is similar. 15
Illustration 1.2: Exploded view D4 frame size, D2 frame is similar. 16
Illustration 1.3: Exploded view E2 frame size, E1 frame is similar. 17
Illustration 2.1: Control Terminals 36
Illustration 2.2: Control Terminals Electrical Diagram 40
Illustration 3.1: Control Card Logic 43
Illustration 3.2: Logic Section 44
Illustration 3.3: Typical Power Section 46
Illustration 3.4: Rectifier circuit 48
Illustration 3.5: Intermediate section 50
Illustration 3.6: Output Voltage and Current Waveforms 51
Illustration 3.7: Inverter section 52
Illustration 3.8: Brake option 53
Illustration 5.1: Frequency Converter Functionality Diagram 83
Illustration 5.2: Earth Currents 83
Illustration 5.3: Signal Conductor Currents 84
Illustration 5.4: Alternate Signal Conductor Currents 84
Illustration 5.5: Proper EMC Installation 86
Illustration 6.1: Signal Test Board 88
Illustration 6.2: SCR Shorting Plug 89
Illustration 6.3: Two-Pin 89
Illustration 6.4: Three-Pin 89
Illustration 6.5: Power Card, and Mounting Plate 90
Illustration 6.6: Soft Charge Card Fuses 91
Illustration 6.7: Soft Charge Card Connectors 94
Illustration 6.8: Soft Charge Card Fuse Location 95
Illustration 6.9: Soft Charge Card Connectors 97
Illustration 6.10: Fan Transformer and Fuse Location 102
Illustration 6.11: Fan and DC Bus Fuse Locations 104
Illustration 6.12: Drive Power Terminals ( 105
Illustration 6.13: Normal AC Input Voltage Waveform 110
Illustration 6.14: AC Input Current Waveform with Diode Bridge 110
Illustration 6.15: Input Current Waveform with Phase Loss. 111
Illustration 6.16: SCR Gate Signal 112
Illustration 6.17: Gate Drive Card Test Connectors 115
Illustration 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. 115

Illustration 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. 116
Illustration 7.1: Control Card Access 124
Illustration 7.1: Soft Charge Card Assy 127
Illustration 7.1: Gate Drive Card 128
Illustration 7.1: D2/D4 129
Illustration 7.1: Input Terminal Mounting Plate Assembly (no options shown) 135
Illustration 7.1: Current Sensors 143
Illustration 7.1: Fan Assembly (1 of 2) 144
Illustration 7.1: Fan Assembly (2 of 2) 145
Illustration 7.1: AC Input Terminals (no options shown) 146
Illustration 8.1: Control Card Access 154
Illustration 8.1: Soft Charge Card 156
Illustration 8.1: Gate Drive Card. 157
Illustration 8.1: Upper and Lower Capacitor Bank Assemblies 159
Illustration 8.1: Input Terminal Mounting Plate Assy (shown with RFI and mains fuse options)
160
Illustration 8.1: Soft Charge Resistor 161
Illustration 8.1: SCR and Diode Modules (1 of 3) 162
Illustration 8.1: Current Sensors 165

Illustration 8.1: Fan Assembly 166

Illustration 8.1: Terminal Blocks 167
Illustration 8.1: IGBT Modules (1 of 4) 168
Illustration 9.1: SCR Shorting Plug 173
Illustration 9.2: Two-pin 173
Illustration 9.3: Three-pin 173
Illustration 9.4: Signal Test Board 174

Contents | Table
Table 1.1: FC 102 and FC 202 380-480 VAC 12
Table 1.2: FC 302 380-500 VAC 12
Table 1.3: FC 102 and FC 202 525-690 VAC 13
Table 1.4: AF-600 FP 525-600 VAC 0
Table 1.5: FC 302 AF-650 GP 525-690 VAC 13
Table 1.6: AF-650 GP 525-690 VAC 0
Table 1.7: Torque Values Table 14
Table 2.1: Tips and tricks 29
Table 2.2: Control Terminals and Associated Parameter 39
Table 2.3: Earthing Screened Cables 41
Table 3.1: IGBT Thermal Sensor 54
Table 3.2: Power Card Ambient Temperature Sensor 54
Table 3.3: Control Card Thermal Sensor 55
Table 4.1: Visual Inspection 59
Table 4.2: Warning/alarm code list 63
Table 4.3: Alarm/warning code list 64
Table 6.1: Fan transformer resistance 103
Table 6.2: Scaling Card Resistance Values 119
Table 6.3: Scaling Card Resistance Values
AF-600 FP only up to 600 V 0
Table 10.1: Spare Parts List PCA3, PCA4, PCA5, PCA8 and PCA11 178
Table 10.2: Spare Parts List Semiconductors, Resistors, Capacitors and Fans 179
Table 10.3: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects 180
Table 10.4: Spare Parts List Cables 181
Table 10.6: Spare parts list: Terminals, Labels, Insulators 183
Table 10.7: Spare parts lists: Bus Bars (tabel 1) 184
Table 10.8: Spare parts list: Bus Bars (table 2) 185
Table 10.9: Spare parts list: Enclosure 186
Table 10.10: Spare Parts List PCA3-11 188
Table 10.11: Spare Parts List Semiconductors, Resistors, Capacitors and Fans 189
Table 10.12: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects 190
Table 10.14: Spare Parts List terminals, Labels, Insulators 192
Table 10.15: Spare Parts List Bus Bars 194
Table 10.16: Spare Parts List Enclosure 195
Table 10.17: Spare Parts List PCA, Semiconductors and Resistors 196
Table 10.18: Spare Parts List Capacitors, Fans, Fuses and Inductors & Current Sensors
197
Table 10.19: Spare Parts List Disconnects and Cables 198

Table 10.20: Spare Parts List Terminals, Labels & Insulators 199
Table 10.21: Spare Parts List Bus Bars and Enclosure 200

Frequency Converters 1 Introduction
1 Introduction 1
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 frequency converters 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
frequency converter's operation to assist in troubleshooting and repair.
This manual provides instructions for the frequency converter models and voltage ranges descri-
bed in the tables on the following page.
1.2 VLT FC Product Overview

VLT HVAC FC 102 series frequency converters 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 frequency converters are designed for water and waste water markets.
They can operate in either constant torque or variable torque with limited overload capabilities.
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 frequency converters are fully programmable for either constant
torque or variable torque industrial applications. They are full-featured frequency converters ca-
pable 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.
1.3 For Your Safety
Frequency converters contain dangerous voltages when connected to mains. 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 mains are energised at rated voltage. Use extreme caution
when conducting tests in a powered frequency converter. Contact with powered
components could result in electrical shock and personal injury.
1. DO NOT touch electrical parts of frequency converter when connected to mains. After
disconnecting from mains, wait 20 minutes before touching any components in D-frame
size units or 40 minutes for E-frame size units. See the label on the front of the frequency
converter door for specific discharge time.
2. When repair or inspection is made, mains must be disconnected.

1 Introduction Frequency Converters
3. The STOP key on the control panel does not disconnect mains.
1 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 within the frequency converter are sensitive to static electricity. Vol-
tages 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
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
1
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

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 1.5: FC 302 AF-650 GP 525-690 VAC
1.6 Tools Required

Operating Instructions for the FC Series Frequency Converter
Metric socket set 719 mm

Socket extensions 100 mm150 mm (4 in and 6 in)
Torx driver set T10 - T50
Torque wrench 0.67519 Nm (6170 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 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 1.7: Torque Values Table

1.8 Exploded Views 1

3 4
2
1 5
6 7
25
24 8
9
10
11
23
22
21
12
20
13
19
18
14
17 15
130BX167.10
16
Illustration 1.1: Exploded view D3 Frame size, D1 frame is similar.
1 Control card PCA1 14 SCR/Diode module SCR 1, 2, 3

2 Control input terminals 15 IGBT output bus bar
3 Local Control Panel LCP 16 Output motor terminals TB2
4 Control card C option 17 Current sensor L2, L3, L4
5 Mounting bracket 18 Fan assembly F1 + C1 +CBL11
6 Power card mounting plate 19 Fan transformer TR1
7 Power card PCA 3 20 Main AC power input terminals TB1
8 Capacitor 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

3
1
4
2
1 5
6 7
28 8
27
9
10
11
12
26
25
24
23
22
13
14
21
20
15
19
16
130BX166.10
17
18
Illustration 1.2: Exploded view D4 frame size, D2 frame is similar.
1 Control card PCA1 15 IGBT module IGBT1, 2

2 Control input terminals 16 SCR/Diode module SCR1, 2, 3
3 Local Control Panel LCP 17 IGBT output bus bar
4 Control card C option 18 Output motor terminals TB2
5 Mounting bracket 19 Current sensor L2, L3, L4
6 Power card mounting plate 20 Fan assembly F1 + C1 + CBL11
7 Power card PCA3 21 Main AC power input terminals TB1
8 Upper 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

3
1
2
1
4
6
7
25 8
9
24
23
22
21
11
10
12
20
13
14
130BX168.10
15
16
17
19 18
Illustration 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
2 Control input terminals 15 Fan inductor (not on all units)

3 Local Control Panel LCP 16 Soft charge resistor assy R1
4 Control card C option 17 IGBT output bus bar
5 Mounting bracket 18 Fan assembly F1 + C1
6 Power card mounting plate 19 Output motor terminals TB2
7 Power card PCA3 20 Current sensor L2, L3, L4
8 IGBT 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

1 1.9 Ratings Tables

DC Voltage Levels
380480 and 380500 units 525690 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- 442 VDC 602 VDC
set)
Overvoltage Warning (without brake) 817 VDC 1084 VDC
Dynamic Brake Turn On 810 VDC 1099 VDC
Inverter Overvoltage Re-Enable (warning re- 821 VDC 1099 VDC
set)
Overvoltage Warning (with brake) 828 VDC 1109 VDC
Overvoltage Trip 855 VDC 1130 VDC
Mains supply 3 x 380480/500 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] (380440 V) 212 260 315 395 480
MAX (60 sec) [A] (380440
V) 233 286 347 434 528
Nominal [A] (441500 V) 190 240 302 361 443
MAX (60 sec) [A] (441500
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%):

MAX (60 sec) [A] (380440
V) 266 318 390 473 593
Nominal [A] (441500 V) 160 190 240 302 361
MAX (60 sec) [A] (441500
V) 240 285 360 453 542

Nominal [kVA] (460 V) 127 151 191 241 288
Nominal [kVA] (500 V) 139 165 208 262 313

[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
Earth (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
Mains Phase Warning (5 sec delay) DC Bus Ripple VAC 50 50 50 50 50

Mains Phase Alarm (25 sec delay) DC Bus Ripple VAC 50 50 50 50 50

Mains supply 3 x 380480/500 V

Model number FC102/202
FC302
P315
P250
P355
P315
P400
P355
P450
P400
1
Output current Nominal [A] (380440 V) 600 658 745 800
MAX (60 sec) [A] (380
440 V) 660 724 820 880
Nominal [A] (441500 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

MAX (60 sec) [A] (380
440 V) 720 900 987 1043
Nominal [A] (441500 V) 443 540 590 678
MAX (60 sec) [A] (441
500 V) 665 810 885 1017

Nominal [kVA] (460 V) 353 430 470 540
Nominal [kVA] (500 V) 384 468 511 587

[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
Earth (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
Mains Phase Warning (5 sec delay) DC Bus Ripple VAC 70 70 70 70

Mains Phase Alarm (25 sec delay) DC Bus Ripple VAC 70 70 70 70

Mains supply 3 x 525690 V

1 Model number FC102/202
P132 P160 P200
P25
0
P31
5
P40
0
FC302 P20 P25 P31
P110 P132 P160 0 0 5
Output current Nominal [A] (525550 V) 162 204 253 303 360 418
MAX (60 sec) [A] (525550 V) 178 224 278 333 396 460
Nominal [A] (551690 V) 155 192 242 290 344 400
MAX (60 sec) [A] (551690 V) 171 211 266 319 378 440
Output Nominal [kVA] (550 V) 154 194 241 289 343 398
Nominal [kVA] (575 V) 154 191 241 289 343 398
Nominal [kVA] (690 V) 185 229 289 347 411 478
Typical shaft output [kW] (550 V) 110 132 160 200 250 315
[HP] (575 V) 150 200 250 300 350 400
[kW] (690 V) 132 160 200 250 315 400

Output current Nominal [A] (525550 V) 137 162 204 253 303 360
MAX (60 sec) [A] (525550 V) 206 243 306 380 455 540
Nominal [A] (551690 V) 131 155 192 242 290 344
MAX (60 sec) [A] (551690 V) 197 233 288 363 435 516
Output Nominal [kVA] (550 V) 131 154 194 241 289 343
Nominal [kVA] (575 V) 130 154 191 241 289 343
Nominal [kVA] (690 V) 157 185 229 289 347 411
Typical shaft output [kW] (550 V) 90 110 132 160 200 250
[HP] (575 V) 125 150 200 250 300 350
[kW] (690 V) 110 132 160 200 250 315
515 582 614

Power loss Normal overload [W] 3114 3612 4293 5 1 9
427 487 518
Power loss High overload [W] 2665 2953 3451 5 5 5
Limits and Ranges

Overcurrent Warning VLT ARMS Out 256 329 483 483 585 734
Overcurrent Alarm (1.5 sec
delay) VLT ARMS Out 256 329 483 483 585 734
Earth (Ground) Fault Alarm VLT ARMS Out 66 78 96 121 145 172
Short Circuit Alarm VLT ARMS Out 325 420 614 614 742 932
Heatsink Overtemperature Degrees C 85 90 110 110 110 110

Heatsink Undertemperature
Warning Degrees C 0 0 0 0 0 0
Power Card Ambient Overtem-
perature Degrees C 60 60 60 60 60 60
Power Card Ambient Under-
temperature Degrees C -20 -20 -20 -20 -20 -20
Mains Phase Warning (5 sec

delay) DC Bus Ripple VAC 70 70 70 70 70 70
Mains Phase Alarm (25 sec de-
lay) DC Bus Ripple VAC 70 70 70 70 70 70


Model number FC102/202
FC302
P45K
P37K
P55K P75K P90K P110K
P45K P55K P75K P90K
1
MAX (60 sec) [A] (525550 V) 62 84 99 124 151
Nominal [A] (551690 V) 54 73 86 108 131
MAX (60 sec) [A] (551690 V) 59 80 95 119 144

Nominal [kVA] (575 V) 54 73 86 108 130
Nominal [kVA] (690 V) 65 87 103 129 157

[HP] (575 V) 50 60 75 100 125
[kW] (690 V) 45 55 75 90 110

MAX (60 sec) [A] (525550 V) 77 90 122 135 170
Nominal [A] (551690 V) 46 54 73 86 108
MAX (60 sec) [A] (551690 V) 74 86 117 129 162

Nominal [kVA] (575 V) 46 54 73 86 108
Nominal [kVA] (690 V) 55 65 87 103 129

[HP] (575 V) 40 50 60 75 100
[kW] (690 V) 37 45 55 75 90
Power loss Normal overload [W] 1458 1717 1913 2262 2662
Power loss High overload [W] 1355 1459 1721 1913 2264
Limits and Ranges

Overcurrent Warning VLT ARMS Out 256 256 256 256 256
Overcurrent Alarm (1.5 sec delay) VLT ARMS Out 256 256 256 256 256
Earth (Ground) Fault Alarm VLT ARMS Out 23 27 37 43 54

Short Circuit Alarm VLT ARMS Out 325 325 325 325 325
Heatsink Overtemperature Degrees C 85 85 85 85 85

Heatsink Undertemperature Warning Degrees C 0 0 0 0 0
Power Card Ambient Overtemperature Degrees C 60 60 60 60 60
Power Card Ambient Overtemperature Degrees C -20 -20 -20 -20 -20
Mains Phase Warning (5 sec delay) DC Bus Ripple VAC 70 70 70 70 70

Mains Phase Alarm (25 sec delay) DC Bus Ripple VAC 70 70 70 70 70


1 Model number FC102/202
FC302
P450
P355
P500
P400
P560 P630
P500 P560
MAX (60 sec) [A] (525550 V) 517 575 656 693
Nominal [A] (551690 V) 450 500 570 630
MAX (60 sec) [A] (551690 V) 495 550 627 693

Nominal [kVA] (575 V) 448 498 568 627
Nominal [kVA] (690 V) 538 598 681 753

[HP] (575 V) 450 500 600 650
[kW] (690 V) 450 500 560 630

MAX (60 sec) [A] (525550 V) 593 644 785 894
Nominal [A] (551690 V) 380 410 500 570
MAX (60 sec) [A] (551690 V) 570 615 750 855

Nominal [kVA] (575 V) 376 408 498 568
Nominal [kVA] (690 V) 454 490 598 681

[HP] (575 V) 400 400 500 600
[kW] (690 V) 355 400 500 560
Power loss Normal overload [W] 6449 7249 8727 9673

Power loss High overload [W] 5383 5818 7671 8715
Limits and Ranges

Overcurrent Warning VLT ARMSOut 824 824 989 1168
Overcurrent Alarm (1.5 sec delay) VLT ARMSOut 824 824 989 1168
Earth (Ground) Fault Alarm VLT ARMSOut 190 205 250 285
Short Circuit Alarm VLT ARMSOut 1046 1046 1255 1490
Heatsink Overtemperature Degrees C 85 85 85 85

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
Mains Phase Warning (5 sec delay) DC Bus Ripple VAC 70 70 70 70

Mains Phase Alarm (25 sec delay) DC Bus Ripple VAC 70 70 70 70

High Power Service Manual for VLT FC Series 2 Operator Interface and Frequency Converter
Frequency Converters Control
2 Operator Interface and Frequency Converter

Control
2
2.1 Introduction
Frequency converters are designed with self-diagnostic circuitry to isolate fault conditions and
activate display messages which greatly simplify troubleshooting and service. The operating status
of the frequency converter is displayed in real-time. Virtually every command given to the fre-
quency converter results in some indication on the local control panel LCP display. Fault logs are
maintained within the frequency converter for fault history.
The frequency converter monitors supply and output voltages along with the operational condition
of the motor and load. When the frequency converter issues a warning or alarm, it cannot be
assumed that the fault lies within the frequency converter itself. In fact, for most service calls, the
fault condition will be found outside of the frequency converter. Most of the warnings and alarms
that the frequency converter displays are generated by response to faults outside of the frequency
converter. This service manual provides techniques and test procedures to help isolate a fault
condition whether in the frequency converter or elsewhere.
Familiarity with the information provided on the display is important. Additional diagnostic data
can be accessed easily through the LCP.
2.2 User Interface

2.2.1 How to Operate the Graphic Local Control Panel (LCP)
The LCP is divided into four functional groups:
1. Graphical display with status lines.
2. Menu keys and indicator lights (LEDs) - selecting mode, changing parameters and
switching between display functions.
3. Navigation keys and indicator lights (LEDs).
4. Operation keys and indicator lights (LEDs).
Graphical display:
The LCD display is back lit with a total of 6 alpha-numeric lines. All data is displayed on the LCP
which can show up to five operating variables whilst in [Status] mode.

2 Operator Interface and Frequency Converter High Power Service Manual for VLT FC Series
Control Frequency Converters
Display lines:
a. Status line: Status messages dis-

playing icons and graphics.
2 b. Line 1-2: Operator data lines dis-
playing data and variables defined or
chosen by the user. By pressing the
[Status] key, up to one extra line can
be added.
c. Status line: Status messages dis-
playing text.
The display is divided into three sections:
Top section (a) shows the status when in status mode or up to two variables when not in status
mode and in the case of Alarm/Warning.
The number of the Active Set-up (selected as the Active Set-up in par. 0-10 Active Set-up) is
shown. When programming in another Set-up than the Active Set-up, the number of the Set-up
being programmed appears to the right in brackets.
The Middle section (b) shows up to 5 variables with related unit, regardless of status. In case
of alarm/warning, the warning is shown instead of the variables.
It is possible to toggle between three status readout displays by pressing the [Status] key.
Operating variables with different formatting are shown in each status screen - see below.
Several values or measurements can be linked to each of the displayed operating variables. The
values/measurements to be displayed can be defined via par. 0-20, 0-21, 0-22, 0-23, and 0-24,
which can be accessed via [QUICK MENU] Q3 Function Setups, Q3-1 General Settings, Q3-13
Display Settings.
Each value/measurement readout parameter selected in par. 0-20 Display Line 1.1 Small to par.
0-24 Display Line 3 Large has its own scale and number of digits after a possible decimal point.
Larger numeric values are displayed with few digits after the decimal point.
Ex.: Current readout
5.25 A; 15.2 A 105 A.

Status display I:
130BP041.10
This readout state is standard after start-up or
initialisation. 1.1
Use [INFO] to obtain information about the
value/measurement linked to the displayed
operating variables (1.1, 1.2, 1.3, 2, and 3).
1.2
2
See the operating variables shown in the dis- 2
play in this illustration. 1.1, 1.2 and 1.3 are
shown in small size. 2 and 3 are shown in me- 3 1.3
dium size.
Status display II:
130BP062.10
See the operating variables (1.1, 1.2, 1.3, and
2) shown in the display in this illustration.
In the example, Speed, Motor current, Motor
power and Frequency are selected as varia- 1.1
1.3
bles in the first and second lines.

1.1, 1.2 and 1.3 are shown in small size. 2 is 1.2
shown in large size.
2
Status display III:
130BP063.10
This state displays the event and action of the
Smart Logic Control.
The Bottom section always shows the state
130BP074.10
Top section
of the frequency converter in Status mode.
Middle section
Display contrast adjustment
Bottom section
Press [status] and [] for darker display
Press [status] and [] for brighter display

Indicator lights (LEDs):
If certain threshold values are exceeded, the alarm and/or warning LED lights up. A status and
alarm text appears on the control panel.
2 The On indicator lamp is activated when the frequency converter receives power from mains volt-
age, a DC bus terminal, or an external 24 V supply. At the same time, the back light is on.
Green LED/On: Control section is

working.
Yellow LED/Warn.: Indicates a warn-
ing.
Flashing Red LED/Alarm: Indicates
an alarm.
LCP keys
Menu keys
The menu keys are divided into functions. The
keys below the display and indicator lamps are 130BP045.10
used for parameter set-up, including choice of
display indication during normal operation.
[Status]
indicates the status of the frequency converter and/or the motor. Three different readouts can be
chosen by pressing the [Status] key:
5 line readouts, 4 line readouts or Smart Logic Control.
Use [Status] for selecting the mode of display or for changing back to Display mode from either
the Quick Menu mode, the Main Menu mode or Alarm mode. Also use the [Status] key to toggle
single or double readout mode.
[Quick Menu]
allows quick set-up of the frequency converter. The most common functions can be pro-
grammed here.
The [Quick Menu] consists of:
- My Personal Menu
- Quick Set-up
- Function set-up
- Changes Made
- Loggings
The Function set-up provides quick and easy access to all parameters required for the majority of
applications. Among other features it also includes parameters for selecting which variables to
display on the LCP.

[Main Menu]
is used for programming all parameters. The Main Menu parameters can be accessed immediately
unless a password has been created via par. 0-60, 0-61, 0-65 or 0-66.
Parameter shortcut can be carried out by pressing down the [Main Menu] key for 3 seconds.
The parameter shortcut allows direct access to any parameter.
2
[Alarm Log]
displays an Alarm list of the five latest alarms (numbered A1-A5). To obtain additional details about
an alarm, use the arrow keys to find the alarm number and press [OK]. Information is displayed
about the condition of the frequency converter before it enters the alarm mode.
The [Alarm log] button on the LCP allows access to both the Alarm log and Maintenance log.
[Back]
reverts to the previous step or layer in the navigation structure.
[Cancel]
last change or command will be cancelled as long as the display has not been changed.
[Info]
displays information about a command, parameter, or function in any display window. [Info] pro-
vides detailed information when needed.
Exit Info mode by pressing either [Info], [Back], or [Cancel].
Navigation keys
The four navigation arrows are used to navi-
gate between the different choices available
in [Quick Menu], [Main Menu] and
[Alarm Log]. Use the keys to move the cur-
sor.
[OK] is used for choosing a parameter

marked by the cursor and for enabling the
change of a parameter.
Operation keys for local control are found at

the bottom of the control panel.
130BP046.10

[Hand On]
Enables control of the frequency converter via the LCP. [Hand On] also starts the motor, and it is
now possible to enter the motor speed data by means of the arrow keys. The key can be selected
as Enable [1] or Disable [0] via par. 0-40 [Hand on] Key on LCP.
2 The following control signals will still be active when [Hand On] is activated:
[Hand On] - [Off] - [Auto On]
Reset
Coasting stop inverse
Reversing
Set-up select lsb - Set-up select msb
Stop command from serial communication
Quick stop
DC brake
NB!
External stop signals activated by means of control signals or a serial bus will over-
ride a start command via the LCP.
[Off]
stops the connected motor. The key can be selected as Enable [1] or Disable [0] via par.
0-41 [Off] Key on LCP. If no external stop function is selected and the [Off] key is inactive, the
motor can only be stopped by disconnecting the mains supply.
[Auto On]
enables the frequency converter to be controlled via the control terminals and/or serial commu-
nication. When a start signal is applied on the control terminals and/or the bus, the frequency
converter will start. The key can be selected as Enable [1] or Disable [0] via par. 0-42 [Auto on]
Key on LCP.
NB!
An active HAND-OFF-AUTO signal via the digital inputs has higher priority than the
control keys [Hand On] [Auto On].
[Reset]
is used for resetting the frequency converter after an alarm (trip). It can be selected as Enable
[1] or Disable [0] via par. 0-43 [Reset] Key on LCP.
The parameter shortcut can be carried out by holding down the [Main Menu] key for 3 seconds.
The parameter shortcut allows direct access to any parameter.

2.2.2 Numeric Local Control Panel (NLCP)

See the FC Series Operating Instructions for instructions for using the numeric LCP.
2
2.2.3 Tips and Tricks
* For the majority of applications the Quick Menu, Quick Set-up and Function Set-up provides the simplest
and quickest access to all the typical parameters required.
* Whenever possible, performing an AMA will ensure best shaft performance.
* Display contrast can be adjusted by pressing [Status] and [ ] for a darker display or by pressing [Status]

and [ ] for a brighter display.
* Under [Quick Menu] and [Changes Made], any parameter that has been changed from factory settings
is displayed.
* Press and hold the [Main Menu] key for 3 seconds to access any parameter
* For service purposes, it is recommended to copy all of the parameters to the LCP, see par. 0-50 LCP
Copy for further information.
Table 2.1: Tips and tricks

2.3 Status Messages

2 Status messages appear in the bottom of the display - see the example below.
The left part of the status line indicates the active operation model of the frequency converter.
The centre part of the status line indicates the references site.
The last part of the status line gives the operation status, e.g. Running, Stop or Stand by.
Other status messages may appear related to the software version and frequency converter type.
Operation Mode
130BP046.10
[Off] The FC does not react to any control signal until [Auto On] or [Hand On] on the LCP are
pressed.
[Auto On] The FC is controlled via the control terminals and/or the serial communication.
[Hand On] Only stop commands, alarm resets (Reset), reversing, DC brake, and set-up selection
signals can be applied to the control terminals.
For further information about the LCD display, please see the chapter How to programme in the
Programming Guide.

Reference Site
[Remote] The Reference is given via internal preset references (absolute or relative) and/or ex-
ternal signals (analog or digital) and/or via serial communication.
[Local] The FC uses the reference values set via the LCP.
For further information, please examine parameter 3-13. 2
Operation Status
AC Brake
AC Brake was selected in par. 2-10 Brake Function. The motor is slowed down via the active down
ramp and feeds the FC with generative energy. The AC Brake over-magnetizes the motor to ach-
ieve a controlled end of the active ramp.
AMA finish OK
Enable complete or reduced AMA was selected in par. 1-29 Automatic Motor Adaptation (AMA).
The Automatic Motor Adaptation was carried out successfully.
AMA ready
The Automatic Motor Adaptation is ready to start. Press [Hand On] on the LCP to start.
AMA running
The AMA process is in progress.
Braking
The brake chopper is in operation. Generative energy is absorbed by the brake resistor.
Braking max.
The brake chopper is in operation. The power limit for the brake resistor defined in par.
2-12 Brake Power Limit (kW) is reached.
Bus Jog 1
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The Jog 1 function is activated
via serial communication. The motor is running with par. 8-90 Bus Jog 1 Speed.
Bus Jog 2
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The Jog 2 function is activated
via serial communication. The motor is running with par. 8-91 Bus Jog 2 Speed.
Catch up
The output frequency is corrected by the value set in par. 3-12 Catch up/slow Down Value.
1. Catch up is selected as a function for a digital input (parameter group 5-1*). The corre-
sponding terminal is active.
2. Catch up was activated via serial communication.
Coast
1. Coast inverse has been selected as a function for a digital input (parameter group 5-1*).
The corresponding terminal (e.g. Terminal 27) is not connected.
2. Coast is on 0 on serial communication
Control ready
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The FC needs the second part
(e.g. 0x047F) of the two-part start command via serial communication to allow starting. Using a
terminal is not possible.
Ctrl. Ramp-down
A function with Ctrl. Ramp-down was selected in par. 14-10 Mains Failure. The Mains Voltage is
below the value set in par. 14-11 Mains Voltage at Mains Fault. The FC ramps down the motor
using a controlled ramp down.
Current High
In par. 4-51 Warning Current High, a current limit is set. The output current of the FC is above
this limit.

Current Low
In par. 4-52 Warning Speed Low, a current limit is set. The output current of the FC is below this
limit.
DC Hold
2 The motor is driven with a permanent DC current, par. 2-00 DC Hold Current. DC hold is selected
in par. 1-80 Function at Stop. A Stop command (e.g. Stop (inverse)) is active.
DC Stop
The motor is momentarily driven with a DC current, par. 2-01 DC Brake Current, for a specified
time, par. 2-02 DC Braking Time.
1. DC Brake is activated (OFF) in par. 2-03 DC Brake Cut In Speed [RPM] and a Stop com-
mand (e.g. Stop (inverse)) is active.
2. DC Brake (inverse) is selected as a function for a digital input (parameter group 5-1*).
The corresponding terminal is not active.
3. The DC Brake is activated via serial communication.
DC Voltage U0
In par. 1-01 Motor Control Principle U/f and in par. 1-80 Function at Stop DC Voltage U0 is selected.
A Stop command (e.g. Stop (inverse)) is activated. The voltage selected according to the par.
1-55 U/f Characteristic - U [0] (UF Characteristic U[V]) is applied to the motor.
Feedback high
In par. 4-57 Warning Feedback High, an upper feedback limit is set. The sum of all active feed-
backs is above the feedback limit.
Feedback low
In par. 4-56 Warning Feedback Low, a lower feedback limit is set. The sum of all active feedbacks
is below the feedback limit.
Flying start
In par. 1-73 Flying Start, the Flying start function is activated. The FC is testing if the connected
motor is running with a speed that is in the adjusted speed range. The process was started by
connecting a digital input (parameter group 5-1*) programmed as Coast inverse or by connecting
to mains.
Freeze output
The remote reference is active and the momentarily given speed is saved.
1. Freeze output was selected as a function for a digital input (Group 5-1*). The corre-
sponding terminal is active. Speed control is only possible via the terminal functions
Speed up and Speed down.
2. Hold ramp is activated via serial communication.
Freeze output request
A freeze output command has been given, but the motor will remain stopped until a Run permis-
sive signal is received via a digital input.
Freeze Ref.
Freeze Ref. was chosen as a function for a digital input (parameter group 5-1*). The corresponding
terminal is controlled. The FC saves the actual reference. Changing the reference is now only
possible via terminal functions Speed up and Speed down.
Jog request
A JOG command has been given, but the motor will be stopped until a Run permissive signal is
received via a digital input.
Jogging
The motor is running with par. 3-19 Jog Speed [RPM].
1. Jog was selected as function for a digital input (parameter group 5-1*). The correspond-
ing terminal (e.g. Terminal 29) is active.

2. The Jog function is activated via the serial communication.

3. The Jog function was selected as a reaction for a monitoring function (e.g. No signal).
The monitoring function is active.
Kinetic backup
In par. 14-10 Mains Failure, a function was set as kinetic backup. The Mains Voltage is below the 2
value set in par. 14-11 Mains Voltage at Mains Fault. The FC is running the motor momentarily
with kinetic energy from the inertia of the load.
Motor check (FC 100/200 only)
In par. 1-80 Function at Stop, the function Motor check was selected. A stop command (e.g. Stop
inverse) is active. To ensure that a motor is connected to the FC, a permanent test current is
applied to the motor.
Off1
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The OFF 1 function is activated
via serial communication. The motor is stopped via the ramp.
Off2
via serial communication. The output of the FC is disabled immediately and the motor coasted.
Off3
via serial communication. The motor is stopped via the ramp.
OVC control
Overvoltage Control is activated in par. 2-17 Over-voltage Control. The connected motor is sup-
plying the FC with generative energy. The Overvoltage Control adjusts the UF ratio to run the
motor in controlled mode and to prevent the FC from tripping.
PowerUnit Off
Only with frequency converters with installed option (ext. 24 V supply). The mains supply to the
frequency converter is cut off, but the control card is still supplied with 24 V.
Pre-magnetize
Pre-magnetization is selected in par. 1-80 Function at Stop. A stop command (e.g. Stop inverse)
is activated. A suitable constant magnetizing current is applied to the motor.
Protection md
The FC 100/200/300 has detected a critical status (e.g. an overcurrent, overvoltage). To avoid
tripping the frequency converter (alarm), protection mode is activated, which includes reducing
the switching frequency to 4 kHz. If possible, protection mode ends after approximately 10 s.
Activation of protection mode can be restricted by adjusting the par. 14-26 Trip Delay at Inverter
Fault.
QStop
The motor is stopped using a quick stop ramp par. 3-81 Quick Stop Ramp Time.
1. Quick stop inverse was chosen as a function for a digital input (parameter group 5-1*).
The corresponding terminal (e.g. Terminal 27) is not active.
2. The Quick stop function was activated via serial communication.
Ramping
The motor is accelerating/decelerating using the active Ramp Up/Down. The reference, a limit
value or a standstill is not yet reached.
Ref. high
In par. 4-55 Warning Reference High a reference high limit is set. The sum of all active references
is above the reference limit.
Ref. low
In par. 4-55 Warning Reference High a reference low limit is set. The sum of all active references
is below the reference limit.
Run on ref.

The FC is running in the reference range. The feedback value matches the set reference value.
Run request (FC 100/200 only)
A start command has been given, but the motor will be stopped until a Run permissive signal is
received via digital input.
2 Running
The motor is driven by the FC, the ramping phase is done and the motor revolutions are outside
the On Reference range. Occurs when one of the motor speed limits (Par. 4-11/4-12/4-13 or 4-14)
is set, but the maximum reference is outside this range.
Sleep Boost (FC 100/200 only)
The boost function in parameter 406Boost setpoint is enabled. This function is only possible in
Closed loop operation.
Sleep Mode (FC 100/200)
The energy saving function in parameter 403Sleep mode timer is enabled. This means that at
present the motor has stopped, but that it will restart automatically when required.
Speed down
The output frequency is corrected by the value set in par. 3-12 Catch up/slow Down Value.
1. Speed down was selected as a function for a digital input (parameter group 5-1*). The
corresponding terminal is active.
2. Speed down was activated via serial communication.
Speed high
In par. 4-53 Warning Speed High, a value is set. The speed of the motor is above this value.
Speed low
In par. 4-52 Warning Speed Low, a value is set. The speed of the motor is below this value.
Standby
[Auto On] The FC starts the motor using a start signal in a digital input (if the parameter is pro-
grammed accordingly) or via serial communication.
Start delay
In par. 1-71 Start Delay, the delay of the starting time was set. A Start command was activated
and the delay time is still running. The motor will start after the delay time has expired.
Start fwd/rev
Enable start forward and Enable start reverse were selected as functions for two different digital
inputs (parameter group 5-1*). To start the motor, a direction dependent start signal has to be
given and the corresponding terminal has to be active.
Start inhibit
PROFIDrive profile was selected in par. 8-10 Control Word Profile. The start inhibition is active.
The FC needs the first part (e.g. 0x047E) of the two-part start command via serial communication
to allow starting. See also operation status control ready.
Stop
[Off] was pressed on the LCP or Stop inverse was selected as a function for a digital input (Group
5-1*). The corresponding terminal is not active.
Trip
An alarm occurred. It is possible, provided the cause of the alarm is cleared, to reset the alarm
via a Reset signal ([Reset] key on the LCP, a control terminal or serial communication).
Trip lock
A serious alarm occurred. It is possible, provided the cause of the alarm was cleared, to reset the
alarm after the mains have been switched off and on again. This can be done via a reset signal
([Reset] on the LCP, a control terminal or serial communication).
Unit/Drive not ready
PROFIDrive profile was selected in par. 8-10 Control Word Profile. A control word is sent to the
FC via serial communication with Off 1, Off 2 and Off 3 active. Start inhibit is active. To enable
start, see operation status Start inhibit.

2.4 Service Functions

Service information for the frequency convert-
er can be shown on display lines 3 and 4. 2
Included in the data are counters that tabulate
operating hours, power ups and trips; fault
logs that store frequency converter status val-
ues present at the 20 most recent events that
stopped the frequency converter; and fre-
quency converter nameplate data. The service
information is accessed by displaying items in
the frequency converter's 15-** parameter
group.
Parameter settings are displayed by pressing

the [MAIN MENU] key on the LCP.
130BP045.10
Use the arrow keys [], [], [] and [] on

the LCP to scroll through parameters.
See the FC Series Operating Instructions for detailed information on accessing and displaying
parameters and for descriptions and procedures for service information available in the 15-**
parameter group.

2.5 Frequency Converter Inputs and Outputs

2 The frequency converter operates by receiving control input signals. The frequency converter can
also output status data or control auxiliary devices. Control input is connected to the frequency
converter in three possible ways. One way for frequency converter control is through the LCP on
the front of the frequency converter when operating in local (hand) mode. These inputs include
start, stop, reset, and speed reference.
Another control source is through serial communication from a serial bus. A serial communication
protocol supplies commands and references to the frequency converter, can program the fre-
quency converter, and reads status data from the frequency converter. The serial bus connects
to the frequency converter through the RS-485 serial port or through a communication option
card.
The third way is through signal wiring connected to the frequency converter control terminals (see
illustration below). The frequency converter control terminals are located below the frequency
converter LCP. Improperly connected control wiring can be the cause of a motor not operating or
the frequency converter not responding to a remote input.
Terminal Descriptions
1. Digital I/O terminals
2. RS-485 (EIA-485) terminal
3. Analog I/O terminals
4. USB connector
Illustration 2.1: Control Terminals

2.5.1 Input signals

The frequency converter can receive two types of remote input signals: digital or analog. Digital
inputs are wired to terminals 18, 19, 20 (common), 27, 29, 32, and 33. Analog or digital inputs
are wired to terminals 53 or 54 and 55 (common). The terminal functions are set by a switch found
by removing the LCP. Some options may include additional terminals.
2
Analog signals can be either voltage (0 to +10 VDC) or current (0 to 20 mA or 4 to 20 mA). Analog
signals can be varied like dialling a rheostat up and down. The frequency converter can be pro-
grammed to increase or decrease output in relation to the amount of current or voltage. For
example, a sensor or external controller may supply a variable current or voltage. The frequency
converter output, in turn, regulates the speed of the motor connected to the frequency converter
in response to the analog signal.
Digital signals are a simple binary 0 or 1 which, in effect, act as a switch. Digital signals are
controlled by a 0 to 24 VDC signal. A voltage signal lower than 5 VDC is a logic 0. A voltage higher
than 10 VDC is a logic 1. Zero is open, one is close. Digital inputs to the frequency converter are
switched commands such as start, stop, reverse, coast, reset, and so on. (Do not confuse these
digital inputs with serial communication formats where digital bytes are grouped into communi-
cation words and protocols.)
The RS-485 serial communication connector is wired to terminals (+) 68 and (-) 69. Terminal 61
is common and may be used for terminating screens only when the control cable run between
frequency converters, not between frequency converters and other devices. See Earthing
Screened Cables in this section for correct methods for terminating a screened control cable.
2.5.2 Output signals

The frequency converter also produces output signals that are carried through either the RS-485
serial bus or terminal 42. Output terminal 42 operates in the same manner as the inputs. The
terminal can be programmed for either a variable analog signal in mA or a digital signal (0 or 1)
in 24 VDC. In addition, a pulse reference can be provided on terminals 27 and 29. Output analog
signals generally indicate the frequency converter frequency, current, torque and so on to an
external controller or system. Digital outputs can be control signals used to open or close a damp-
er, for example, or send a start or stop command to auxiliary equipment.
Additional terminals are Form C relay outputs on terminals 01, 02, and 03, and terminals 04, 05,
and 06.
Terminals 12 and 13 provide 24 VDC low voltage power, often used to supply power to the digital
input terminals (18-33). Those terminals must be supplied with power from either terminal 12 or
13, or from a customer supplied external 24 VDC power source. Improperly connected control
wiring is a common service issue for a motor not operating or the frequency converter not re-
sponding to a remote input.

2.6 Control Terminals

2 Control terminals must be programmed. Each terminal has specific functions it is capable of per-
forming and a numbered parameter associated with it. See table below. The setting selected in
the parameter enables the function of the terminal.
It is important to confirm that the control terminal is programmed for the correct function.
Parameter settings are displayed by pressing

the [Status] key on the LCP.
130BP045.10
Use the arrow keys [], [], [] and [] on

the LCP to scroll through parameters.
See the Programming Guide for details on changing parameters and the functions available for
each control terminal.
In addition, the input terminal must be receiving a signal. Confirm that the control and power
sources are wired to the terminal. Then check the signal.
Signals can be checked in two ways. Digital input can be selected for display by pressing [status]
key as discussed previously, or a voltmeter may be used to check for voltage at the control ter-
minal. See procedure details at Input Terminal Test in Section 6.
In summary, for proper frequency converter functioning, the frequency converter in-
put control terminals must be:
1. wired properly
2. powered
3. programmed correctly for the intended function
4. receiving a signal

2.7 Control Terminal Functions

The following describes the functions of the control terminals. Many of these terminals have mul-
tiple functions determined by parameter settings. Some options provide additional terminals. See 2
Illustration 2-2.
Terminal No. Function

01, 02, 03 and 04, Two Form C output relays. Maximum 240 VAC, 2 A. Minimum 24 VDC,
05, 06 10 mA or 24 VAC, 100 mA. Can be used for indicating status and warn-
ings. Physically located on the power card.
12, 13 24 VDC power supply to digital inputs and external transducers. The
maximum output current is 200 mA.
18, 19, 27, 29, 32, Digital inputs for controlling the frequency converter. R = 2 kohm. Less
33 than 5 V = logic 0 (open). Greater than 10 V = logic 1 (closed). Terminals
27 and 29 are programmable as digital/pulse outputs.
20 Common for digital inputs.
37 024 VDC input for safety stop (some units).
39 Common for analog and digital outputs.
42 Analog and digital outputs for indicating values such as frequency, ref-
erence, current and torque. The analog signal is 0/4 to 20 mA at a
maximum of 500 . The digital signal is 24 VDC at a minimum of 500 .
50 10 VDC, 15 mA maximum analog supply voltage for potentiometer or
thermistor.
53, 54 Selectable for 0 to 10 VDC voltage input, R = 10 k, or analog signals
0/4 to 20 mA at a maximum of 200 . Used for reference or feedback
signals. A thermistor can be connected here.
55 Common for terminals 53 and 54.
61 RS-485 common.
68, 69 RS 485 interface and serial communication.
Term 18 19 27 29 32 33 37 53 54 42 1-3 4-6
Par. 5-10 5-11 5-12 5-13 5-14 5-15 5-19 6-1* 6-2* 6-5* 5-4* 5-4*
Table 2.2: Control Terminals and Associated Parameter
Control terminals must be programmed. Each terminal has specific functions it is capable of per-
forming and a numbered parameter associated with it. The setting selected in the parameter
enables the function of the terminal. See the FC Series Operating Instructions for details.

Illustration 2.2: Control Terminals Electrical Diagram

2.8 Earthing Screened Cables

It is recommended that screened control cables be connected with cable clamps at both ends to
the metal cabinet of the frequency converter. Table 2-3 shows earth cabling for optimal results. 2
Correct earthing Control cables and cables for serial communication must be fit-
ted with cable clamps at both ends to ensure the best possible electrical connection.
Incorrect earthing Do not use twisted cable ends (pigtails) since these increase
screen impedance at high frequencies.
Earth potential protection When the earth potential between the frequency
converter and the PLC or other interface device is different, electrical noise may
occur that can disturb the entire system. This can be resolved by fitting an equal-
izing cable next to the control cable. Minimum cable cross section is 8 AWG.
50/60 Hz earth loops When using very long control cables, 50/60 Hz earth loops
may occur that can disturb the entire system. This can be resolved by connecting
one end of the screen with a 100 nF capacitor and keeping the lead short.
Serial communication control cables Low frequency noise currents between

frequency converters can be eliminated by connecting one end of the screened
cable to frequency converter terminal 61. This terminal connects to earth through
an internal RC link. It is recommended to use twisted-pair cables to reduce the
differential mode interference between conductors.
Table 2.3: Earthing Screened Cables

3 Internal Frequency Converter Operation Frequency Converters

Frequency Converters 3 Internal Frequency Converter Operation
3 Internal Frequency Converter Operation
3.1 General
This section is intended to provide an operational overview of the frequency converters main
assemblies and circuitry. With this information, a repair technician should have a better under-
standing of the frequency converter's operation and aid in the troubleshooting process.
3
3.2 Description of Operation

A frequency converter is an electronic controller that supplies a regulated amount of AC power to
a three phase induction motor in order to control the speed of the motor. By supplying variable
frequency and voltage to the motor, the frequency converter controls the motor speed, or main-
tains a constant speed as the load on the motor changes. The frequency converter can also stop
and start a motor without the mechanical stress associated with a line start.
In its basic form, the frequency converter can be divided into four main sections: rectifier, inter-
mediate circuit, inverter, and control (see Illustration 3-1).
Illustration 3.1: Control Card Logic
To provide an overview, the main frequency converter components will be grouped into three
categories consisting of the control logic section, logic to power interface, and power section. In
the sequence of operation description, these three sections will be covered in greater detail while
describing how power and control signals move throughout the frequency converter.

3.2.1 Logic Section

The control card contains most of the logic section (see Illustration 3-2). The primary logic element
of the control card is a microprocessor, which supervises and controls all functions of frequency
converter operation. In addition, separate PROMs contain the parameters to provide the user with
programmable options. These parameters are programmed to enable the frequency converter to
meet specific application requirements. This data is then stored in an EEPROM which provides
3 security during power-down and also allows the flexibility to change the operational characteristics
of the frequency converter.
A custom integrated circuit generates a pulse width modulation (PWM) waveform which is then
sent to the interface circuitry located on the power card.
Illustration 3.2: Logic Section
The PWM waveform is created using an improved control scheme called VVCplus, a further devel-
opment of the earlier VVC (Voltage Vector Control) system. VVCplus provides a variable frequency
and voltage to the motor which matches the requirements of the motor. Also available is the
continuous pulsing SFAVM PWM. Selection can be made in parameter group 14-**. The dynamic
response of the system changes to meet the variable requirements of the load.
Another part of the logic section is the local control panel (LCP). This is a removable keypad/
display mounted on the front of the frequency converter. The LCPprovides the interface between
the frequency converter's internal digital logic and the operator.
All the frequency converter's programmable parameter settings can be uploaded into the EEPROM
of the LCP. This function is useful for maintaining a backup frequency converter profile and pa-
rameter set. It can also be used, through its download function, in programming other frequency
converters or to restore a program to a repaired unit. The LCP is removable during operation to
prevent undesired program changes. With the addition of a remote mounting kit, the LCP can be
mounted in a remote location of up to ten feet away.
Control terminals, with programmable functions, are provided for input commands such as run,
stop, forward, reverse and speed reference. Additional output terminals are provided to supply
signals to run peripheral devices or for monitoring and reporting status.

The control card logic is capable of communicating via serial link with outside devices such as
personal computers or programmable logic controllers (PLC).
The control card also provides two voltage supplies for use from the control terminals. The 24
VDC is used for switching functions such as start, stop and forward/reverse. The 24 VDC supply
is also capable of supplying 200 mA of power, part of which may be used to power external
encoders or other devices. A 10 VDC supply on terminal 50 is rated at 17 mA is also available for
use with speed reference circuitry. 3
The analog and digital output signals are powered through an internal frequency converter supply.
Two relays for monitoring the status of the frequency converter are located on the power card.
These are programmable through parameter group 5-4*. The relays are Form C, meaning it has
one normally open contact and one normally closed contact on a single throw. The contacts of
the relay are rated for a maximum load of 240 VAC at 2 Amps resistance.
The logic circuitry on the control card allow for the addition of option modules for synchronising
control, serial communications, additional relays, the cascade pump controller, or custom oper-
ating software.
3.2.2 Logic to Power Interface

The logic to power interface isolates the high voltage components of the power section from the
low voltage signals of the logic section. The interface section consists of the power card and gate
drive card.
Much of the fault processing for output short circuit and earth fault conditions is handled by the
control card. The power card provides conditioning of these signals. Scaling of current feedback
and voltage feedback is accomplished by the control card.
The power card contains a switch mode power supply (SMPS) which provides the unit with 24
VDC, +18 VDC, 18 VDC and 5 VDC operating voltage. The logic and interface circuitry is powered
by the SMPS. The SMPS is supplied by the DC bus voltage. The frequency converters can be
purchased with an optional secondary SMPS which is powered from a customer supplied 24 VDC
source. This secondary SMPS provides power to the logic circuitry with main input disconnected.
It can keep units with communication options live on a network when the frequency converter is
not powered from the mains.
Circuitry for controlling the speed of the cooling fans is also provided on the power card.
The gate frequency converter signals from the control card to the output transistors (IGBTs) are
isolated and buffered on the gate drive card. In units that have the dynamic brake option, the
driver circuits for the brake transistors are also located on this card.

3.2.3 Power Section

The high voltage power section consists of AC input terminals, AC and DC bus bars, fusing, har-
nessing, AC output, and optional components. The power section (see Illustration 3-3) also
contains circuitry for the soft charge and SCR/diode modules in the rectifier; the DC bus filter
circuitry containing the DC coils, often referred to as the intermediate or DC bus circuit; and the
output IGBT modules which make up the inverter section.
3 In conjunction with the SCR/diode modules, the soft charge circuit limits the inrush current when
power is first applied and the DC bus capacitors are charging. This is accomplished by the SCRs
in the modules being held off while charging current passes through the soft charge resistors,
thereby limiting the current. The DC bus circuitry smooths the pulsating DC voltage created by
the conversion from the AC supply.
The DC coil is a single unit with two coils wound on a common core. One coil resides in the positive
side of the DC bus and the other in the negative. The coil aids in the reduction of mains harmonics.
The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing cir-
cuitry. Due to the requirement for higher power capacity, some frequency converters have two
capacitor banks connected in parallel.
The inverter section is made up of six IGBTs, commonly referred to as switches. One switch is
necessary for each half phase of the three-phase power, for a total of six. The six IGBTs are
contained in a single module. Due to higher current handling requirements, some models contain
two or three larger six-pack style modules. In these units, each switch (half phase) is made up of
two or three IGBTs in parallel.
A Hall effect type current sensor is located on each phase of the output to measure motor current.
This type of device is used instead of more common current transformer (CT) devices in order to
reduce the amount of frequency and phase distortion that CTs introduce into the signal. With Hall
sensors, the average, peak, and earth leakage currents can be monitored.
Illustration 3.3: Typical Power Section

3.3 Sequence of Operation

3.3.1 Rectifier Section
When input power is first applied to the frequency converter, it enters through the input terminals
(L1, L2, L3) and on to the disconnect or/and RFI option, depending on the unit's configuration
(see Illustration 3-4). If equipped with optional fuses, these fuses (FU1, FU2, FU3) limit damage 3
caused by a short circuit in the power section. The SCRs, in the combined SCR/diode modules,
are not gated so current can travel to the rectifier on the soft charge card. In E frequency converter
models, the SCR and diode modules are separate. Additional fuses located on the soft charge card
provide protection in the event of a short in the soft charge or fan circuits. Three phase power is
also branched off and sent to the power card. It provides the power card with a reference of the
main supply voltage and provides a supply voltage for the cooling fans.
During the charging process, the top diodes of the soft charge rectifier conduct and rectify during
the positive half cycle. The diodes in the main rectifier conduct during the negative half cycle. The
DC voltage is applied to the bus capacitors through the soft charge resistor. The purpose of
charging the DC bus through this resistor is to limit the high inrush current that would otherwise
be present.
Positive temperature coefficient (PTC) resistors located on the soft charge card are in series with
the soft charge resistor. Frequent cycling of the input power or the DC bus charging over an
extended time can cause the PTC resistors to heat up due to the current flow. Resistance of the
PTC device increases with temperature, eventually adding enough resistance to the circuit to pre-
vent significant current flow. This protects the soft charge resistor from damage along with any
other components that could be damaged by continuous attempts to charge the DC bus.
The low voltage power supplies are activated when the DC bus reaches approximately 50 VDC
less than the alarm voltage low for the DC bus. After a short delay, an inrush enable signal is sent
from the control card to the power card SCR gating circuit. The SCRs are automatically gated when
forward biased, as a result acting similar to an uncontrolled rectifier.
When the DC bus capacitors are fully charged, the voltage on the DC bus will be equal to the peak
voltage of the input mains. Theoretically, this can be calculated by multiplying the mains value by
1.414 (VAC x 1.414). However, since AC ripple voltage is present on the DC bus, the actual DC
value will be closer to VAC x 1.38 under unloaded conditions and may drop to VAC x 1.32 while
running under load. For example, a frequency converter connected to a nominal 460 V line, while
sitting idle, the DC bus voltage will be approximately 635 VDC (460 x 1.38).
As long as power is applied to the frequency converter, this voltage is present in the intermediate
circuit and the inverter circuit. It is also fed to the Switch Mode Power Supply (SMPS) on the power
card and is used for generating all other low voltage supplies.

HS FAN ASSEMBLY
CBL8 175L9400
LEGEND: 190843
CN3 F1
90kW = FC-302 P90K T5 27651
FC-202 P100 T4 WHT 1 1 WHT
FC-102 P110 T4 (DISABLE MAINS RECTIFIER) BLK 2 2 BLU

EXTERNAL BRAKE 3 3 ORN
TEMP SWITCH GRN 4 4 GRN
110kW = FC-302 P110 T5 190835 190836 190836
FC-202 P132 T4 AUX FAN HEATSINK

FAN
FC-102 P132 T4
1 2 3 3 2 1 6 5 4 3 2 1 3 5 4 13 11 12 9 8 1 6 BLK C1
CBL9
5 5 BLK
190812
GND
AUX_S
AUX_T
TMP
AUX_S
AUX_T
L1 L2 L1 L2 L1 L1 HEATSINK
1
LCP1 FAN CAPACITOR
10 R' 6 6 BLK 10313
18 PULSE NTC
105 104 106 102 100 103 101
FANS X2 X1 R 5
44 1 C NC S
MAINS
MK103 NO AUX_S T AUX_T MK107 8 S'
MK106 S 3
FK102 FK103 CBL12 F2
6 T' TR1 CN4
T CN2 190817 27653
DISPLAY 1
16150 DOOR FAN
1 1
MK104
TEST CONNECTOR 3 3
3 IN FAN- NEMA 1,
FC-X02 CBL2 POWER CARD FU4 2 2 NEMA 12,
FAN+
MK110
2 2 IP 21,
OUT
FK102
2 3 3
CONTROL 130B0057 PCA3 GND IP 54
CBL1 UNITS ONLY.
CARD 130B6893 1 1 20203 COM
130B0096 1
PCA4 130B6895-COATED
IP54/NEMA12 PCA1 CBL5
HEATSINK/DOOR
90kW = 130B6805 190848 FAN TRANSFORMER CN5 F4
MK111
CURRENT 30
CONTROL SCALING 110kW = 130B6806 SENS 10
ASSY 175L9471
TOP FAN
1 44 CARD CUR 11
1 1
USED ON
PANEL DET FAN+
VPOS 1 2 2 CHASSIS AND
FAN- IP00 UNITS
IU' 2
IU1 3 3
ONLY.
VNEG 3
175L0109-GRAPHIC VPOS 4 ASSY 175L8314
CURRENT
SENSORS
IV' 5
IV1 CN6 F5
175L0110-NUMERIC MK102
RS-485 ANALOG I/O VNEG 6 TOP FAN
MK101 MK100 MK112 VPOS 7 1 1
MK103 FAN+ USED ON
3
61 68 69 SCR
IW' IW1 8 2 2 CHASSIS AND
39 42 50 53 54 55 VNEG 16 FAN- IP00 UNITS
S + - GATE DRIVER MK105 MK400 RELAY 1 RELAY 2
3 3 ONLY.
VDD 14
HF SW +
15 1 RL2 15 HF SWITCH
DIGITAL INPUTS R S T +DC -DC +DC -DC
C NO NC C NO NC ASSY 175L8314
MK109 CC FAN
VDD 12 -
MK102 FANO 13
3 6 2 5 1 4 A B A C 1 2 3 4 5 6
GND 9
12 13 18 19 27 29 32 33 20 37
CBL16
CBL15 190830 BRAKE OPTION
190820 MK101
6 4 1
GATE DRIVE CARD BRC E1/C2
1 6 5
CBL23 190834
3 2 1
MK105
BRK
BRK
MK106
MK1
+ VDD RFI SW PCA5 BRN E2 81 R-
RL2 130B6857 GBP G2 EXT BRAKE
CBL13 -
PRE TEST CBL22 190833 RESISTOR
CONTROL CARD VARIANTS 190847 130B6856 (COATED W/BRAKE) CBL21 82
R+
COL
RFI SWITCH MK250 MK350 MK450 MK550 MK650 MK750 MK850 MK100 BRAKE GATE
FC-302 - 130B7204 MK102 MK103 MK104
190832
FC-302 - 130B7205 COATED GUN GUP GVN GVP GWN GWP BRK U V W NTC RES CARD BRAKE IGBT TB3
IGBT4
GATE
GWN
292
GWP
EWN
GUN
GWN
GVN
GWP
EWP
GUP
EWN
GUN
EUN
GVP
TMP+
GUP
GBP
EVN
GVN
EWP
BRN
EUP
EUN
GVP
EVP
EVN
FC-102/202 - 130B7206 WITH SAFE STOP
EUP
TMP-
EVP
PCA13
FC-102/202 - 130B7207 COATED, WITH SAFE STOP 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 2 3 1 5 6 10 1 5 6 10 1 5 6 10 1 2 3 130B6865 ASSY 175L9421
EM
FC-102/202 - 130B7226 NO SAFE STOP FU5
CBL17 CBL18 CBL19
FC-102/202 - 130B7213 COATED, NO SAFE STOP 20203 3x190831 CBL20
190808
UDC- UDC+
4 5 8 1 4 5 8 1 4 5 8 1 1 2 3
NTC1
NTC2
GLO2
GUP2
EUP2
GLO3
GLO1
GUP3
EUP3
GUP1
EUP1
ELO2
ELO3
ELO1
U V W NTC
MK100 MK100 MK100 MK103
CBL14
190815 GATE RESISTOR CARD
PCA6 NTC
90kW=130B6858 110kW=130B6859
OUT
IN
CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3
CBANK1
HF CARD DC CAP BANK ASSY
90kW=16000 PCA8 90kW=175L9426
110kW=16001 130B6870 110kW=175L9427
L1 UDC+
DC INDUCTOR IU
SCR1 SCR2 SCR3 TB2
2379 2379 2379 L2
C3 C4 10312 16005
C2 96 U
10312 10312 NTC + M -
+
UP VP WP
DISC/FUSE OPTION RFI OPTION -
IV
R S T
L3
R
91 FU1 FK1 FK4
16005
L1 ECONOPACK+ MODULE 97 V
A + M -
S RFI CARD
MK1
92 FU2 FK2 FK5 B
L2
PCA12 C
T
L3 93 FU3 FK3 FK6
BAL CKT
PCA9 IW
GND 94 SW1 3x L4
130B6885
20202 20207
TB1 MK1 UN VN WN 16005 98 W
+
-
+
+ M -
-
3 2 1
95 GND
CBL15
3
IGBT1
MK100
190820 + 90kW=175L9433
2
110kW=175L9405
-
1
- UDC-
RFI SWITCH
+ LOAD SHARE OPTION
PCA 12: CBL9
130B6872-RFI ONLY CBL24 190812
190846 R' 89 +DC
130B6873-COATED, RFI ONLY S' TB4
130B6874-USED WITH DISC SW AND FUSES
T'
130B6875-COATED, USED WITH DISC SW AND FUSES 88 -DC
R' S' T' CBL25 CBL5

R +SCR A
190813 190848
MK2
MK3
MK1
S -SCR C +
HF SWITCH
-
T SOFTCHARGE BOARD
PCA11
RS+ A R1
130B6866
MK4
27 Ohms
130B6868 (Coated) RS- B Assy 175L9472
130BX187.10
No RFI relay on 525 - 690V

Units. E1 units have 2 RFI
cards
Illustration 3.4: Rectifier circuit

3.3.2 Intermediate Section

Following the rectifier section, voltage passes to the intermediate section. (see Illustration 3-5).
This rectified voltage is smoothed by an LC filter circuit consisting of the DC bus inductor and the
DC bus capacitor bank.
The DC bus inductor provides series impedance to changing current. This aids the filtering process
while reducing harmonic distortion to the input AC current waveform normally inherent in rectifier
circuits.
3
The DC capacitor bank assembly consists of up to eight capacitors arranged in series/parallel
configuration. Higher power units have two capacitor bank assemblies. Also contained within the
assembly is the bleeder/balance circuitry. This circuitry maintains equal voltage drops across each
capacitor and provides a current path for discharging the capacitors once power has been removed
from the frequency converter.
Also located in the intermediate section is the high frequency (HF) filter card. It contains a high
frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interfer-
ence with other sensitive equipment in the area. The circuit, as with other RFI filter circuitry, can
be sensitive to unbalanced phase-to-earth voltages in the three-phase AC input line. This can
occasionally result in nuisance overvoltage alarms. For this reason, the high frequency filter card
on 380500 V range frequency converters, contains a set of relay contacts in the earth connection
of the filter capacitors. The relay is tied into the RFI/HF switch, which can be switched on or off
in par. 14-50 RFI Filter. This disconnects the earth references to all filters should unbalanced
phase-to-earth voltages create nuisance overvoltage conditions.
For 525690 V frequency converters, there are no relay contacts that disconnect the earthing.

Illustration 3.5: Intermediate section

3.3.3 Inverter Section

In the inverter section (see Illustration 3-7), gate signals are delivered from the control card,
through the power card and gate frequency converter card to the gates of the IGBTs. The series
connection of each set of IGBTs is delivered to the output, first passing through the current sen-
sors.
Once a run command and speed reference are present, the IGBTs begin switching to create the
output waveform, as shown in Illustration 3-6. Looking at the phase-to-phase voltage waveform
3
with an oscilloscope, it can be seen that the Pulse Width Modulation (PWM) principal creates a
series of pulses which vary in width. Basically, the pulses are narrower as zero crossing is ap-
proached and wider the farther from zero crossing. The width is controlled by the pulse duration
of applied DC voltage. Although the voltage waveform is a consistent amplitude, the inductance
within the motor windings will serve to average the voltage delivered and so, as the pulse width
of the waveform varies, the average voltage seen by the motor varies as well. This then equates
to the resultant current waveform which takes on the sine wave shape that we expect to see in
an AC system. The frequency of the waveform is then determined by the rate at which the pulses
occur. By employing a sophisticated control scheme, the frequency converter is capable of deliv-
ering a current waveform that nearly replicates a true AC sine wave.
This waveform, as generated by the Danfoss VVCplus PWM principle at the control card, provides
optimal performance and minimal losses in the motor.
Hall effect current sensors monitor the output current and deliver proportional signals to the power
card where they are buffered and delivered to the control card. These current signals are used by
the control card logic to determine proper waveform compensations based on load conditions.
They further serve to detect overcurrent conditions, including earth faults and phase-to-phase
shorts on the output.
During normal operation, the power card and control card are monitoring various functions within
the frequency converter. The current sensors provide current feedback information. The DC bus
voltage and mains voltage are monitored as well as the voltage delivered to the motor. A thermal
sensor mounted inside one of IGBT modules provides heatsink temperature feedback.
130BX136.10
Illustration 3.6: Output Voltage and Current Waveforms

HS FAN ASSEMBLY
CBL8 175L9400
LEGEND: 190843
CN3 F1
90kW = FC-302 P90K T5 27651
FC-202 P100 T4 WHT 1 1 WHT

110kW = FC-302 P110 T5 190835 190836 190836

FAN
FC-102 P132 T4
1 2 3 3 2 1 6 5 4 3 2 1 3 5 4 13 11 12 9 8 1 6 BLK C1
CBL9
5 5 BLK
190812
GND
AUX_S
AUX_T
TMP
AUX_S
AUX_T
1
LCP1 FAN CAPACITOR
10 R' 6 6 BLK 10313
18 PULSE NTC
105 104 106 102 100 103 101
FANS X2 X1 R 5
44 1 C NC S
MAINS
MK106 S 3
6 T' TR1 CN4
T CN2 190817 27653
DISPLAY 1
16150 DOOR FAN
1 1
MK104
TEST CONNECTOR 3 3
3 IN FAN- NEMA 1,
FAN+
MK110
2 2 IP 21,
OUT
FK102
2 3 3
CBL1 UNITS ONLY.
CARD 130B6893 1 1 20203 COM
130B0096 1
HEATSINK/DOOR
MK111
CURRENT 30
ASSY 175L9471
TOP FAN
1 44 CARD CUR 11
1 1
USED ON
PANEL DET FAN+
FAN- IP00 UNITS
IU' 2
IU1 3 3
ONLY.
VNEG 3
CURRENT
SENSORS
IV' 5
IV1 CN6 F5
MK101 MK100 MK112 VPOS 7 1 1
MK103 FAN+ USED ON
61 68 69 SCR
IW' 8
IW1 2 2 CHASSIS AND
39 42 50 53 54 55 FAN- IP00 UNITS
S + - GATE DRIVER MK105 MK400 RELAY 1 RELAY 2 VNEG 16
3 3 ONLY.
VDD 14
HF SW +
MK109 CC FAN
VDD 12 -
MK102 FANO 13
3 6 2 5 1 4 A B A C 1 2 3 4 5 6
GND 9
12 13 18 19 27 29 32 33 20 37
CBL16
3
190820 MK101
6 4 1
GATE DRIVE CARD BRC E1/C2
1 6 5
CBL23 190834
3 2 1
MK105
BRK
BRK
MK106
MK1
CBL13 -
R+
COL
FC-302 - 130B7204 MK102 MK103 MK104
190832
IGBT4
GATE
GWN
292
GWP
EWN
GUN
GWN
GVN
GWP
EWP
GUP
EWN
GUN
EUN
GVP
TMP+
GUP
GBP
EVN
GVN
EWP
BRN
EUP
EUN
GVP
EVP
EVN
EUP
TMP-
EVP
PCA13
EM
CBL17 CBL18 CBL19
190808
UDC- UDC+
4 5 8 1 4 5 8 1 4 5 8 1 1 2 3
NTC1
NTC2
GLO2
GUP2
EUP2
GLO3
GLO1
GUP3
EUP3
GUP1
EUP1
ELO2
ELO3
ELO1
U V W NTC
MK100 MK100 MK100 MK103
CBL14
PCA6 NTC
90kW=130B6858 110kW=130B6859
OUT
IN
CBANK1
90kW=16000 PCA8 90kW=175L9426
110kW=16001 130B6870 110kW=175L9427
L1 UDC+
DC INDUCTOR IU
SCR1 SCR2 SCR3 TB2
2379 2379 2379 L2
C3 C4 10312 16005
C2 96 U
10312 10312 NTC + M -
+
UP VP WP
IV
R S T
L3
R
91 FU1 FK1 FK4
16005
A + M -
S RFI CARD
MK1
92 FU2 FK2 FK5 B
L2
PCA12 C
T
L3 93 FU3 FK3 FK6
BAL CKT
PCA9 IW
GND 94 SW1 3x L4
130B6885
20202 20207
+
-
+
+ M -
-
3 2 1
95 GND
CBL15
3
IGBT1
MK100
190820 + 90kW=175L9433
2
110kW=175L9405
-
1
- UDC-
RFI SWITCH
+ LOAD SHARE OPTION
PCA 12: CBL9
130B6872-RFI ONLY CBL24 190812
190846 R' 89 +DC
T'
R' S' T' CBL25 CBL5

R +SCR A
190813 190848
MK2
MK3
MK1
S -SCR C +
HF SWITCH
-
T SOFTCHARGE BOARD
PCA11
RS+ A R1
130B6866
MK4
27 Ohms
130BX186.10
Illustration 3.7: Inverter section

3.3.4 Brake Option

For frequency converters equipped with the dynamic brake option, a brake IGBT along with ter-
minals 81(R-) and 82(R+) is included for connecting an external brake resistor.
The function of the brake IGBT (see Illustration 3-8) is to limit the voltage in the intermediate
circuit, whenever the maximum voltage limit is exceeded. It does this by switching the externally
mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors.
Excess DC bus voltage is generally a result of an overhauling load causing regenerative energy to
3
be returned to the DC bus. This occurs, for example, when the load frequency converters the
motor causing the voltage to return to the DC bus circuit.
Placing the brake resistor externally has the advantages of selecting the resistor based on appli-
cation need, dissipating the energy outside of the control panel, and protecting the frequency
converter from overheating if the brake resistor is overloaded.
The Brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via
the power card and gate frequency converter card. Additionally, the power and control cards
monitor the brake IGBT and brake resistor connection for short circuits and overloads.
HS FAN ASSEMBLY
CBL8 175L9400
LEGEND: 190843
CN3 F1
90kW = FC-302 P90K T5 27651
FC-202 P100 T4 WHT 1 1 WHT

110kW = FC-302 P110 T5 190835 190836 190836

FAN
FC-102 P132 T4
1 2 3 3 2 1 6 5 4 3 2 1 3 5 4 13 11 12 9 8 1 6 BLK C1
CBL9
5 5 BLK
190812
GND
AUX_S
AUX_T
TMP
AUX_S
AUX_T
1
LCP1 FAN CAPACITOR
10 R' 6 6 BLK 10313
18 PULSE NTC
105 104 106 102 100 103 101
FANS X2 X1 R 5
44 1 C NC S
MAINS
MK106 S 3
6 T' TR1 CN4
T CN2 190817 27653
DISPLAY 1
16150 DOOR FAN
1 1
MK104
TEST CONNECTOR 3 3
3 IN FAN- NEMA 1,
FAN+
MK110
2 2 IP 21,
OUT
FK102
2 3 3
CBL1 UNITS ONLY.
CARD 130B6893 1 1 20203 COM
130B0096 1
HEATSINK/DOOR
MK111
CURRENT 30
ASSY 175L9471
TOP FAN
1 44 CARD CUR 11
1 1
USED ON
PANEL DET FAN+
FAN- IP00 UNITS
IU' 2
IU1 3 3
ONLY.
VNEG 3
CURRENT
SENSORS
IV' 5
IV1 CN6 F5
MK101 MK100 MK112 VPOS 7 1 1
MK103 FAN+ USED ON
61 68 69 SCR
IW' 8
IW1 2 2 CHASSIS AND
39 42 50 53 54 55 FAN- IP00 UNITS
S + - GATE DRIVER MK105 MK400 RELAY 1 RELAY 2 VNEG 16
3 3 ONLY.
VDD 14
HF SW +
MK109 CC FAN
VDD 12 -
MK102 FANO 13
3 6 2 5 1 4 A B A C 1 2 3 4 5 6
GND 9
12 13 18 19 27 29 32 33 20 37
CBL16
190820 MK101
GATE DRIVE CARD BRC
6 4 1 E1/C2
1 6 5
CBL23 190834
3 2 1
MK105
BRK
BRK
MK106
MK1
CBL13 -
R+
COL
FC-302 - 130B7204 MK102 MK103 MK104
190832
IGBT4
GATE
GWN
292
GWP
EWN
GUN
GWN
GVN
GWP
EWP
GUP
EWN
GUN
EUN
GVP
TMP+
GUP
GBP
EVN
BRN
GVN
EWP
EUP
EUN
GVP
EVP
EVN

EUP
TMP-
EVP
PCA13
EM
CBL17 CBL18 CBL19
190808
UDC- UDC+
4 5 8 1 4 5 8 1 4 5 8 1 1 2 3
NTC1
NTC2
GLO2
GUP2
EUP2
GLO3
GLO1
GUP3
EUP3
GUP1
EUP1
ELO2
ELO3
ELO1
U V W NTC
MK100 MK100 MK100 MK103
CBL14
PCA6 NTC
90kW=130B6858 110kW=130B6859
OUT
IN
CBANK1
90kW=16000 PCA8 90kW=175L9426
110kW=16001 130B6870 110kW=175L9427
L1 UDC+
DC INDUCTOR IU
SCR1 SCR2 SCR3 TB2
2379 2379 2379 L2
C3 C4 10312 16005
C2 96 U
10312 10312 NTC + M -
+
UP VP WP
IV
R S T
L3
R
91 FU1 FK1 FK4
16005
A + M -
S RFI CARD
MK1
92 FU2 FK2 FK5 B

L2
PCA12 C
T
L3 93 FU3 FK3 FK6
BAL CKT
PCA9 IW
GND 94 SW1 3x L4
130B6885
20202 20207
+
-
+
+ M -
-
3 2 1
95 GND
CBL15
3
IGBT1
MK100
190820 + 90kW=175L9433
2
110kW=175L9405
-
1
- UDC-
RFI SWITCH
+ LOAD SHARE OPTION
PCA 12: CBL9
130B6872-RFI ONLY CBL24 190812
190846 R' 89 +DC
T'
R' S' T' CBL25 CBL5

R +SCR A
190813 190848
MK2
MK3
MK1
S -SCR C +
HF SWITCH
-
T SOFTCHARGE BOARD
PCA11
RS+ A R1
130B6866
MK4
27 Ohms
130BX132.10
Illustration 3.8: Brake option

3.3.5 Cooling Fans

All frequency converters in this size range are equipped with cooling fans to provide airflow along
the heatsink. Units in NEMA 1 (IP21) and NEMA 12 (IP54) enclosures have a fan mounted in the
enclosure door to provide additional airflow to the unit. Chassis (IP00) enclosures have a fan or
fans mounted to the top of the unit for additional cooling. Some frequency converters in this size
range have a small 24 VDC fan mounted on the input plate. This fan is only mounted on E-frame
3 size units equipped with both an RFI filter and mains fuses. The fan provides air flow around the
main fuses. The fan operates anytime the frequency converter is powered.
All fans are powered by mains voltage which is stepped down by an autotransformer and regulated
to 200 or 230 VAC by circuitry provided on the power card. On/off and high/low speed control of
the fans is provided to reduce overall acoustical noise and extend the life of the fans.
Fans are activated by the following causes:
60% of nominal current exceeded

Specific heatsink temperature exceeded (power size dependent)
DC hold active
DC brake active
Pre-magnetization of the motor
Automatic motor adaptation in progress
Regardless of the heatsink temperature, the fans are started shortly after main input
power is applied to the frequency converter.
Once fans are started, they will run for a minimum of 10 minutes.
3.3.6 Fan Speed Control

The cooling fans are controlled with sensor feedback which regulates fan operation and speed
control as described below.
1. IGBT thermal sensor measured temperature. The fan can be off, low speed, or high
speed based on this temperature.
IGBT Thermal Sensor D Frame Units E Frame Units

Fan Turn On Low Speed 45 C 45 C
Fan Low Speed to High Speed 50 C 50 C
Fan High Speed to Low Speed 40 C 40 C
Fan Turn Off from Low Speed 30 C 30 C
Table 3.1: IGBT Thermal Sensor
2. Power card ambient temperature sensor measured temperature. The fan can be off or
high speed based on this temperature.
Power Card Ambient D Frame Units E Frame Units

Fan turn on to High Speed 35 C 45 C
Fan turn off from High Speed 30 C 40 C
Fan turn on to High Speed <10 C <10 C
Table 3.2: Power Card Ambient Temperature Sensor
3. Control card thermal sensor measured temperature. The fan can be off or low speed
based on this temperature.

Control Card Ambient D Frame Units E Frame Units

Fan turn on to Low Speed 55 C 55 C
Fan turn off from Low Speed 45 C 45 C
Table 3.3: Control Card Thermal Sensor
4. Output current value. If the output current is greater than 60% of rated current, the fan
will turn on low speed.
3
3.3.7 Load Sharing
Units with the built-in load sharing option contain terminals 89 (+) DC and 88 (-) DC. Within the
frequency converter, these terminals connect to the DC bus in front of the DC link reactor and bus
capacitors.
The use of the load sharing terminals can take on two different configurations.
In one method, the terminals are used to tie the DC bus circuits of multiple frequency converters
together. This allows for the possibility of one frequency converter that is in a regenerative mode
to share its excess bus voltage with another frequency converter that is in motoring mode. When
applied correctly, this can reduce the need for external dynamic brake resistors while also saving
energy. In theory, the number of frequency converters that can be connected in this way is infinite;
however, the frequency converters must be of the same voltage rating. In addition, depending
on the size and number of frequency converters, it may be necessary to install DC reactors and
DC fuses in the DC link connections and AC reactors on the mains. Attempting such a configuration
requires specific considerations and should not be attempted without first consulting Danfoss Ap-
plication Engineering.
In the second method, the frequency converter is powered exclusively from a DC source. This is
a bit more complicated. First, a DC source is required. Second, a means to soft charge the DC bus
at power up is required. Last, a mains voltage source is required to power the fans within the
frequency converter. Again such a configuration should not be attempted without first consulting
Danfoss Application Engineering.
3.3.8 Specific Card Connections

Connector FK102, terminals 104, 105 and 106 located on the power card, provide for the con-
nection of an external temperature switch. The input could be used to monitor the temperature
of an external brake resistor. Two input configurations are possible. A normally closed switch may
be connected between terminals 104 and 106 or a normally open switch between terminals 104
and 105. Should the input change states, the frequency converter would trip on an Alarm 29,
Overtemperature. The input SCRs would also be disabled to prevent further energy from being
supplied to the DC bus. If no such input is used, or the normally open configuration is selected,
a jumper must be installed between terminals 104 and 106.
Connector FK103, terminals 100, 101, 102, and 103 located on the power card, provide for the
connection of mains voltage to allow powering the AC cooling fans from an external source. This
is required when the frequency converter is used in a load sharing application where no AC power
is provided to the main input terminals. To make use of this provision, the jumpers would be
removed from terminals 100 and 102, 101 and 103. The auxiliary mains voltage power supply
would be connected to terminals 100 and 101.

The power card MK112, terminals 1, 2, and 3, and 4, 5, and 6 provide access to 2 auxiliary relays.
These are form C sets of contacts, meaning one normally open and one normally closed contact
on a single throw. The contacts are rated for a maximum of 240 VAC, 2 Amps and a minimum of
24 VDC, 10 mA or 24 VAC, 100 mA. The relay can be programmed via par. 5-40 Function Relay
to indicate frequency converter status.
Terminal positions on the power card labelled MK400 and MK103 are reserved for future use.
3

Frequency Converters 4 Troubleshooting
4 Troubleshooting
4.1 Troubleshooting Tips

Before attempting to repair a frequency converter, here are some tips to follow to make the job
easier and possibly prevent unnecessary damage to functional components.
1. Note all warnings concerning voltages present in the frequency converter. Always verify
the presence of AC input voltage and DC bus voltage before working on the unit. Some
points in the frequency converter are referenced to the negative DC bus and are at bus
4
potential even though it may appear on diagrams to be a neutral reference.
Remember that voltage may be present for as long as 40 minutes on E-frame
size frequency converters or 20 minutes on D-frame size frequency converters
after removing power from the unit. See the label on the front of the frequency
converter door for the specific discharge time.
2. Never apply power to a unit that is suspected of being faulty. Many faulty components
within the frequency converter can cause damage to other components when power is
applied. Always perform the procedure for testing the unit after repair as described in
Section 5, Test Procedures.
3. Never attempt to defeat any fault protection circuitry within the frequency converter.
That will result in unnecessary component damage and may cause personal injury.
4. Always use factory approved replacement parts. The frequency converter has been de-
signed to operate within certain specifications. Incorrect parts may affect tolerances and
result in further damage to the unit.
5. Read the instruction and service manuals. A thorough understanding of the unit is the
best approach. If ever in doubt, consult the factory or authorised repair centre for as-
sistance.
4.2 Exterior Fault Troubleshooting

There may be slight differences in servicing a frequency converter that has been operational for
some extended period of time compared to a new installation. When using proper troubleshooting
procedures, make no assumptions. To assume a motor is wired properly because the frequency
converter has been in service for some time may cause you to overlook loose connections, im-
proper programming, or added equipment, for example. It is best to develop a detailed approach,
beginning with a physical inspection of the system. See Table 4-1, Visual Inspection, for items to
examine.
4.3 Fault Symptom Troubleshooting

This troubleshooting section is divided into sections based on the symptom being experienced. To
start Table 4-1 provides a visual inspection check list. Many times the root cause of the problem
may be due to the way the frequency converter has been installed or wired. The check list provides
guidance through a variety of items to inspect during any frequency converter service process.
Next, symptoms are approached as the technician most commonly discovers them: reading an
unrecognised frequency converter display, problems with motor operation, or a warning or alarm
displayed by the frequency converter. Remember, the frequency converter processor monitors
inputs and outputs as well as internal frequency converter functions, so an alarm or warning does
not necessary indicate a problem within the frequency converter itself.

4 Troubleshooting Frequency Converters
Each incident has further descriptions on how to troubleshoot that particular symptom. When
necessary, further referrals are made to other parts of the manual for additional procedures. Sec-
tion 5, Frequency Converter and Motor Applications, presents detailed discussions on areas of
frequency converter and system troubleshooting that an experienced repair technician should
understand in order to make effective diagnoses.
Finally, a list of tests called After Repair Tests is provided. These tests should always be performed
when first starting a frequency converter, when approaching a frequency converter that is sus-
pected of being faulty, or anytime following a repair to the frequency converter.

4.4 Visual Inspection

The table below lists a variety of conditions that require visual inspection as part of any initial
troubleshooting procedure.
Inspect For Description

Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may
reside on the input power side of frequency converter or the output side to motor. Examine
the operation and condition of these items for possible causes of operational faults. Check
Cable routing
the function and installation of pressure sensors or encoders etc. that provide feedback to
the frequency converter.
Avoid routing motor wiring, mains wiring, and signal wiring in parallel. If parallel routing is
4
unavoidable, try to maintain a separation of 68 inches (150200 mm) between the cables
or separate them with an earthed conductive partition. Avoid routing cables through free
air.
Control wiring Check for broken or damaged wires and connections. Check the voltage source of the sig-
nals. Though not always necessary depending on the installation conditions, the use of
screened cable or a twisted pair is recommended. Ensure the screen is terminated correctly.
Refer to the section on earthing screened cables in Section 2.
Drive cooling Check the operational status of all cooling fans. Check the door filters on NEMA 12 (IP54)
units. Check for blockage or constrained air passages. Make sure the bottom gland plate is
installed.
Drive display Warnings, alarms, drive status, fault history and many other important items are available
via the local control panel display on the drive.
Drive interior The frequency converter interior must be free of dirt, metal chips, moisture, and corrosion.
Check for burnt or damaged power components or carbon deposits resulting from cata-
strophic component failure. Check for cracks or breaks in the housings of power semicon-
ductors, or pieces of broken component housings loose inside the unit.
EMC considerations Check for proper installation with regard to electromagnetic capability. Refer to the fre-
quency converter operating instructions and Section 5 of this manual for further details.
Environmental conditions Under specific conditions, these units can be operated within a maximum ambient of 50 C
(122 F). Humidity levels must be less than 95% noncondensing. Check for harmful airborne
contaminates such as sulphur based compounds.
Earthing The frequency converter requires a dedicated earth wire from its chassis to the building
earth. It is also suggested that the motor be earthed to the frequency converter chassis as
well. The use of a conduit or mounting the frequency converter onto a metal surface is not
considered a suitable earth. Check for good earth connections that are tight and free of
oxidation.
Input power wiring Check for loose connections. Check for proper fusing. Check for blown fuses.
Motor Check the nameplate ratings of the motor. Ensure that the motor ratings coincide with the
frequency converters. Make sure that the frequency converter's motor parameters (1-20
1-25) are set according to the motor ratings.
Output to motor wiring Check for loose connections. Check for switching components in the output circuit. Check
for faulty contacts in the switch gear.
Programming Make sure that the frequency converter parameter settings are correct according to motor,
application, and I/O configuration.
Proper clearance These frequency converters require adequate top and bottom clearance to ensure proper
air flow for cooling in accordance with the frequency converter size. Frequency converters
with exposed heatsinks out the back of the frequency converter must be mounted on a flat
solid surface.
Vibration Although this is a somewhat subjective procedure, look for any unusual amount of vibration
that the frecuency converter may be subjected to. The frequency converter should be
mounted solidly or the use of shock mounts employed.
Table 4.1: Visual Inspection

4.5 Fault Symptoms

4.5.1 No Display
The LCP display provides two display indica-
tions. One by means of the backlit LCD alpha-
numeric display. The other is three LED
indicators lights near the bottom of the LCP.
4 If the green power-on LED is illuminated but

the backlit display is dark, this indicates that
the LCP itself is defective and must be re-
placed.
Be certain, however, that the display is completely dark. Having a single character in the upper
corner of the LCP or just a dot indicates that communications may have failed with the control
card. This is typically seen when a serial bus communication option has been installed in the
frequency converter and is either not connected properly or is malfunctioning.
If neither indication is available, then the source of the problem may be elsewhere. Proceed to
the No Display test (6.3.1) to carry out further troubleshooting steps.
4.5.2 Intermittent Display

Cutting out or flashing of the entire display and power LED indicates that the power supply (SMPS)
is shutting down as a result of being overloaded. This may be due to improper control wiring or
a fault within the frequency converter itself.
The first step is to rule out a problem in the control wiring. To do this, disconnect all control wiring
by unplugging the control terminal blocks from the control card.
If the display stays lit, then the problem is in the control wiring (external to the frequency con-
verter). All control wiring should be checked for shorts or incorrect connections.
If the display continues to cut out, follow the procedure for No Display as though the display were
not lit at all.

4.5.3 Motor Will not Run

In the event that this symptom is detected, first verify that the unit is properly powered up (display
is lit) and that there are no warning or alarm messages displayed. The most common cause of
this is either incorrect control logic or an incorrectly programmed frequency converter. Such oc-
currences will result in one or more of the following status messages being displayed.
LCP Stop
The [OFF] key has been pressed. Line 2 of the display will also flash when this occurs.
4
Press the [AUTO ON] or [HAND ON] key.
Standby
This indicates that there is no start signal at terminal 18.
Ensure that a start command is present at terminal 18. Refer to the Input Terminal Signal Test
(6.3.16).
Unit ready
Terminal 27 is low (no signal).
Ensure that terminal 27 is logic 1. Refer to the Input Terminal Signal Test (6.3.16).
Run OK, 0 Hz
This indicates that a run command has been given to the frequency converter but the reference
(speed command) is zero or missing.
Check the control wiring to ensure that the proper reference signal is present at the frequency
converter input terminals and that the unit is properly programmed to accept the signal provided.
Refer to the Input Terminal Signal Test (6.3.16).
Off 1 (2 or 3)
This indicates that bit #1 (or #2, or #3) in the control word is logic 0. This will only occur when
the frequency converter is being controlled via the fieldbus.
A correct control word must be transmitted to the frequency converter over the communication
bus to correct this.
STOP
One of the digital input terminals 18, 19, 27, 29, 32, or 33 (parameter 5-1*) is programmed for
Stop Inverse and the corresponding terminal is low (logic 0).
Ensure that the above parameters are programmed correctly and that any digital input program-
med for Stop Inverse is high (logic 1).
Display Indication That the Unit is Functioning, but No Output
Make sure that par. 14-22 Operation Mode is not set to Run With Inverter Disabled.
If the unit is equipped with an external 24 VDC option, check that main power is applied to the
frequency converter.
Note: In this case, the display will alternately flash Warning 8.

4.5.4 Incorrect Motor Operation

Occasionally, a fault can occur where the motor will continue to run, but not in the correct manner.
The symptoms and causes may vary considerably. Many of the possible problems are listed below
by symptom along with recommended procedures for determining their causes.
Wrong speed/unit will not respond to

command
Possible incorrect reference (speed command).
4
Ensure that the unit is programmed correctly according to the reference signal being used, and
that all reference limits are set correctly as well. Perform Input Terminal Signal Test (6.3.16) to
check for faulty reference signals.
Motor speed unstable
Possible incorrect parameter settings, faulty current feedback circuit, loss of motor (output) phase.
Check the settings of all motor parameters, including all motor compensation settings (Slip Com-
pensation, Load Compensation, etc.) For Closed Loop operation, check PID settings. Perform Input
Terminal Signal Test (6.3.16) to check for faulty reference signals. Perform the Output Imbalance
of Supply Voltage Test (6.3.10) to check for loss of motor phase.
Motor runs rough
Possible over-magnetization (incorrect motor settings), or an IGBT misfiring. Note: Motor may
also stall when loaded or the frequency converter may trip occasionally on Alarm 13.
Check setting of all motor parameters. Perform the Output Imbalance of Supply Voltage Test
(6.3.10).
If output voltage is unbalanced, perform the Gate Drive Signal Test (6.3.11).
Motor draws high current but cannot
start
Possible open winding in motor or open phase in connection to motor.
Perform the Output Imbalance of Supply Voltage Test (6.3.10) to ensure the frequency converter
is providing correct output (see Motor Runs Rough above).
Run an AMA to check the motor for open windings and unbalanced resistance. Inspect all motor
wiring connections.
Motor will not brake
Possible fault in the brake circuit. Possible incorrect setting in the brake parameters. The ramp
down time too short. Note: May be accompanied by an alarm or warning message.
Check all brake parameters and ramp down time (parameters 2-0* and 3-4*).
Perform Brake Check (6.3.13).

4.6 Warning/Alarm Messages

4.6.1 Warning/Alarm Code List
A warning or an alarm is signalled by the LEDs on the front of the frequency converter and by a
code on the display.
A warning indicates a condition that may require attention or a trend that may eventually require
attention. A warning remains active until the cause is no longer present. Under some circumstan-
ces motor operation may continue.
4
A trip is the action when an alarm has appeared. The trip removes power to the motor and can
be reset after the condition has been cleared by pressing the [reset] button or through a digital
input (parameter 5-1*). The event that caused an alarm cannot damage the frequency converter
or cause a dangerous condition. Alarms must be reset to restart operation once their cause has
been rectified.
This may be done in three ways:
1. Pressing the [reset] button on the control panel LCP.
2. A digital reset input.
3. Serial communication/optional fieldbus reset signal.
NB!
After a manual reset using the [RESET] button on the LCP, the [AUTO ON] button
must be pressed to restart the motor.
A trip lock is an action when an alarm occurs which may cause damage to the frequency converter
or connected equipment. Power is removed from the motor. A trip lock can only be reset after the
condition is cleared by cycling power. Once the problem has been rectified, only the alarm con-
tinues flashing until the frequency converter is reset.
An X marked in the table below means that action occurs. A warning precedes an alarm.
No. Description Warning Alarm/Trip Alarm/Trip

Lock
1 10 volts low X
2 Live zero error (X) (X)
3 No motor (X)
4 Mains phase loss (X) (X) (X)
5 DC link voltage high X
6 DC link voltage low X
7 DC overvoltage X X
8 DC undervoltage X X
9 Inverter overloaded X X
10 Motor overtemperature (X) (X)
11 Motor thermistor overtemperature (X) (X)
12 Torque limit X X
13 Overcurrent X X X
14 Earth (ground) fault X X X
15 Hardware mismatch X X
16 Short circuit X X
17 Control word time-out (X) (X)
22 Hoist mechanical brake X
23 Internal fan fault X
24 External fan fault X
25 Brake resistor short circuit X
Table 4.2: Warning/alarm code list

No. Description Warning Alarm/Trip Alarm/Trip Lock

26 Brake resistor power limit (X) (X)
27 Brake chopper fault X X
28 Brake check failed (X) (X)
29 Heatsink temp X X X
30 Motor phase U missing (X) (X) (X)
31 Motor phase V missing (X) (X) (X)
32 Motor phase W missing (X) (X) (X)
33 Inrush fault X X
34 Fieldbus communication fault X X
36 Mains failure X X
38 Internal fault X X
39 Heatsink sensor X X
40 Overload of Digital Output Terminal 27 (X)
4 41
42
Overload of Digital Output Terminal 29
Overload of Digital Output on X30/6 or Overload of Digital
(X)
(X)
Output on X30/7
46 Power card supply X X
47 24 V supply low X X X
48 1.8 V supply low X X
49 Speed limit X
50 AMA calibration failed X
51 AMA check Unom and Inom X
52 AMA low Inom X
53 AMA motor too big X
54 AMA motor too small X
55 AMA parameter out of range X
56 AMA interrupted by user X
57 AMA time-out X
58 AMA internal fault X X
59 Current limit X
60 External interlock X
61 Encoder loss (X) (X)
62 Output frequency at maximum limit X X
63 Mechanical brake low (X)
64 Voltage limit X
65 Control board overtemperature X X X
66 Heatsink temperature low X
67 Option configuration has changed X
68 Safe stop activated (X) (X)1)
69 Power card temperature X X
70 Illegal FC configuration X
71 PTC 1 safe stop X X
72 Dangerous failure X X X
73 Safe stop auto restart X
79 Illegal PS config X X
80 Drive initialised to default value X
81 CSIV corrupt X
82 CSIV parameter error X
90 Encoder loss (X) (X)
91 Analog input 54 wrong settings X
92 No flow (X) (X)
93 Dry pump (X) (X)
94 End of curve (X) (X)
95 Broken belt (X) (X)
96 Start delayed (X)
97 Stop delayed (X)
98 Clock fault X
100-199 See Operating Instructions for MCO 305
200 Fire mode (X)
201 Fire mode was active (X)
202 Fire mode limits exceeded (X)
243 Brake IGBT X X
244 Heatsink temperature X X X
245 Heatsink sensor X X
246 Power card supply X X
247 Power card temperature X X
248 Illegal PS config X X
250 New spare part X
251 New type code X X
Table 4.3: Alarm/warning code list
(X) Programmable: dependent on parameter setting.

1) Cannot be auto reset via parameter selection.

LED indication
Warning yellow
Alarm flashing red
Trip locked yellow and red
WARNING 1, 10 volts low

The control card voltage is below 10 V from terminal 50.
Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or
minimum 590 .
This condition can be caused by a short in a connected potentiometer or improper wiring of the
potentiometer.
Troubleshooting: Remove the wiring from terminal 50. If the warning clears, the problem is
4
with the customer wiring. If the warning does not clear, replace the control card.
WARNING/ALARM 2, Live zero error
This warning or alarm will only appear if programmed by the user in par. 6-01 Live Zero Timeout
Function. The signal on one of the analog inputs is less than 50% of the minimum value pro-
grammed for that input. This condition can be caused by broken wiring or faulty device sending
the signal.
Troubleshooting:
Check the connections on all the analog input terminals. Control card terminals 53 and
54 for signals, terminal 55 common. MCB 101 terminals 11 and 12 for signals, terminal
10 common. MCB 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6 common).
Make sure that the frequency converter programming and switch settings match the
analog signal type.
Perform the Input Terminal Signal Test in Section 6.3.16.
WARNING/ALARM 3, No motor
No motor has been connected to the output of the frequency converter. This warning or alarm
will only appear if programmed by the user in par. 1-80 Function at Stop.
Troubleshooting: Check the connection between the frequency converter and the motor.
WARNING/ALARM 4, Mains phase loss
A phase is missing on the supply side, or the mains voltage imbalance is too high. This message
also appears for a fault in the input rectifier on the frequency converter. Options are programmed
at par. 14-12 Function at Mains Imbalance.
Troubleshooting: Check the supply voltage and supply currents to the frequency converter. See
Section 5.1.2 for troubleshooting details.
WARNING 5, DC link voltage high
The intermediate circuit voltage (DC) is higher than the high voltage warning limit. The limit is
dependent on the frequency converter voltage rating. The frequency converter is still active.
See ratings table in Section 1.9 for the voltage limits.
WARNING 6, DC link voltage low
The intermediate circuit voltage (DC) is lower than the low voltage warning limit. The limit is
dependent on the frequency converter voltage rating. The frequency converter is still active.
WARNING/ALARM 7, DC overvoltage
If the intermediate circuit voltage exceeds the limit, the frequency converter trips after a time.
Troubleshooting:
Connect a brake resistor
Extend the ramp time
Change the ramp type

Activate functions in par. 2-10 Brake Function

Increase par. 14-26 Trip Delay at Inverter Fault
See ratings table in Section 1.9 for the voltage limits. See Section 5.1.1 for troubleshooting details.
WARNING/ALARM 8, DC undervoltage
If the intermediate circuit voltage (DC) drops below the undervoltage limit, the frequency con-
verter checks if a 24 V backup supply is connected. If no 24 V backup supply is connected, the
frequency converter trips after a fixed time delay. The time delay varies with unit size.
4 Troubleshooting:
Make sure that the supply voltage matches the frequency converter voltage.
Perform Input voltage test (Section 6.3.2)
Perform soft charge and rectifier circuit test (Section 6.2.1 or 6.2.3)
WARNING/ALARM 9, Inverter overloaded
The frequency converter is about to cut out because of an overload (too high current for too long).
The counter for electronic, thermal inverter protection gives a warning at 98% and trips at 100%,
while giving an alarm. The frequency converter cannot be reset until the counter is below 90%.
The fault is that the frequency converter is overloaded by more than 100% for too long.
Troubleshooting:
Compare the output current shown on the LCP with the frequency converter rated cur-
rent.
Compare the output current shown on the LCP with measured motor current.
Display the Thermal Drive Load on the LCP and monitor the value. When running above
the frequency converter continuous current rating, the counter should increase. When
running below the frequency converter continuous current rating, the counter should
decrease.
Note: See the derating section in the Design Guide for more details if a high switch frequency is
required.
WARNING/ALARM 10, Motor overload temperature
According to the electronic thermal protection (ETR), the motor is too hot. Select whether the
frequency converter should give a warning or an alarm when the counter reaches 100% in par.
1-90 Motor Thermal Protection. The fault is that the motor is overloaded by more than 100% for
too long.
Troubleshooting:
Check if motor is overheating.
If the motor is mechanically overloaded
That the motor par. 1-24 Motor Current is set correctly.
Motor data in parameters 1-20 through 1-25 are set correctly.
The setting in par. 1-91 Motor External Fan.
Run AMA in par. 1-29 Automatic Motor Adaptation (AMA).
WARNING/ALARM 11, Motor thermistor overtemp
The thermistor or the thermistor connection is disconnected. Select whether the frequency con-
verter gives a warning or an alarm when the counter reaches 100% in par. 1-90 Motor Thermal
Protection.
Troubleshooting:
Check if motor is overheating.
Check if the motor is mechanically overloaded.

Check that the thermistor is connected correctly between terminal 53 or 54 (analog volt-
age input) and terminal 50 (+10 V supply), or between terminal 18 or 19 (digital input
PNP only) and terminal 50.
If a KTY sensor is used, check for correct connection between terminal 54 and 55.
If using a thermal switch or thermistor, check the programming of par. 1-93 Thermistor
Resource matches sensor wiring.
If using a KTY sensor, check the programming of parameters 1-95, 1-96, and 1-97 match
sensor wiring.
WARNING/ALARM 12, Torque limit
The torque is higher than the value in par. 4-16 Torque Limit Motor Mode (in motor operation) or 4
the torque is higher than the value in par. 4-17 Torque Limit Generator Mode (in regenerative
operation). par. 14-25 Trip Delay at Torque Limit can be used to change this from a warning only
condition to a warning followed by an alarm.
See section 5.1 for troubleshooting.
WARNING/ALARM 13, Overcurrent
The inverter peak current limit (approx. 200% of the rated current) is exceeded. The warning lasts
about 1.5 sec., then the frequency converter trips and issues an alarm. If extended mechanical
brake control is selected, trip can be reset externally.
Troubleshooting:
This fault may be caused by shock loading or fast acceleration with high inertia loads.
Turn off the frequency converter. Check if the motor shaft can be turned.
Make sure that the motor size matches the frequency converter.
Incorrect motor data in parameters 1-20 through 1-25.
See section 1.9 for current trip points.
ALARM 14, Earth (ground) fault
There is a discharge from the output phases to earth, either in the cable between the frequency
converter and the motor or in the motor itself.
See section 1.9 for trip levels.
Troubleshooting:
Turn off the frequency converter and remove the earth fault.
Measure the resistance to earth of the motor leads and the motor with a megohmmeter
to check for earth faults in the motor.
Perform the current sensor test (section 6.3.14).
See section 5.2 for more details.
ALARM 15, Hardware mismatch
A fitted option is not operational with the present control board hardware or software.
Record the value of the following parameters and contact your Danfoss supplier:
par. 15-40 FC Type
par. 15-41 Power Section
par. 15-42 Voltage
par. 15-43 Software Version
par. 15-45 Actual Typecode String
par. 15-49 SW ID Control Card
par. 15-50 SW ID Power Card
par. 15-60 Option Mounted
par. 15-61 Option SW Version (for each option slot)

ALARM 16, Short circuit

There is short-circuiting in the motor or on the motor terminals.
Turn off the frequency converter and remove the short-circuit.
See section 1.9 for trip levels.
WARNING/ALARM 17, Control word time-out
There is no communication to the frequency converter.
The warning will only be active when par. 8-04 Control Word Timeout Function is NOT set to OFF.
If par. 8-04 Control Word Timeout Function is set to Stop and Trip, a warning appears and the
frequency converter ramps down until it trips, while giving an alarm.
4 Troubleshooting:
Check connections on the serial communication cable.
Increasepar. 8-03 Control Word Timeout Time
Check the operation of the communication equipment.
Verify a proper installation based on EMC requirements. See section 5.
WARNING 22, Hoist mechanical brake
The report value will show what kind it is.
0 = The torque reference was not reached before time-out.
1 = There was no brake feedback before the time-out.
WARNING 23, Internal fan fault
The fan warning function is an extra protective function that checks if the fan is running/mounted.
The fan warning can be disabled in par. 14-53 Fan Monitor ([0] Disabled).
For the D, E, and F Frame frequency converters, the regulated voltage to the fans is monitored.
Troubleshooting:
Check fan resistance (see section 6.2.9 or 6.2.10).
Check soft charge fuses (see section 6.2.1 or 6.2.3).
WARNING 24, External fan fault
The fan warning function is an extra protective function that checks if the fan is running/mounted.
The fan warning can be disabled in par. 14-53 Fan Monitor ([0] Disabled).
For the D, E, and F Frame frequency converters, the regulated voltage to the fans is monitored.
Troubleshooting:
WARNING 25, Brake resistor short circuit
The brake resistor is monitored during operation. If it short circuits, the brake function is discon-
nected and the warning appears. The frequency converter still works, but without the brake
function. Turn off the frequency converter and replace the brake resistor (see par. 2-15 Brake
Check).
WARNING/ALARM 26, Brake resistor power limit
The power transmitted to the brake resistor is calculated: as a percentage, as a mean value over
the last 120 seconds, on the basis of the resistance value of the brake resistor, and the inter-
mediate circuit voltage. The warning is active when the dissipated braking power is higher than
90%. If Trip [2] has been selected in par. 2-13 Brake Power Monitoring, the frequency converter
cuts out and issues this alarm, when the dissipated braking power is higher than 100%.
Warning: There is a risk of substantial power being transmitted to the brake resistor
if the brake transistor is short-circuited.

WARNING/ALARM 27, Brake chopper fault

The brake transistor is monitored during operation and if it short-circuits, the brake function dis-
connects and issues a warning. The frequency converter is still able to run, but since the brake
transistor has short-circuited, substantial power is transmitted to the brake resistor, even if it is
inactive.
Turn off the frequency converter and remove the brake resistor.
This alarm/warning could also occur should the brake resistor overheat. Terminal 104 to 106 are
available as brake resistor. Klixon inputs, see section Brake Resistor Temperature Switch.
WARNING/ALARM 28, Brake check failed
Brake resistor fault: the brake resistor is not connected or not working.
Check par. 2-15 Brake Check. 4
ALARM 29, Heatsink temp
The maximum temperature of the heatsink has been exceeded. The temperature fault will not be
reset until the temperature falls below a defined heatsink temperature. The trip and reset point
are different based on the frequency converter power size.
Troubleshooting:
Ambient temperature too high.
Motor cable too long.
Incorrect clearance above and below the frequency converter.
Dirty heatsink.
Blocked air flow around the frequency converter.
Damaged heatsink fan.
For the D, E, and F Frame frequency converters, this alarm is based on the temperature measured
by the heatsink sensor mounted inside the IGBT modules. For the F Frame frequency converters,
this alarm can also be caused by the thermal sensor in the rectifier module. See the rating table
in Section 1.9 for the trip point.
Troubleshooting:
IGBT thermal sensor (see section 6.2.8).
ALARM 30, Motor phase U missing
Motor phase U between the frequency converter and the motor is missing.
Turn off the frequency converter and check motor phase U.
ALARM 31, Motor phase V missing
Motor phase V between the frequency converter and the motor is missing.
Turn off the frequency converter and check motor phase V.
ALARM 32, Motor phase W missing
Motor phase W between the frequency converter and the motor is missing.
Turn off the frequency converter and check motor phase W.
ALARM 33, Inrush fault
Too many power-ups have occurred within a short time period. Let the unit cool to operating
temperature.
WARNING/ALARM 34, Fieldbus communication fault
The fieldbus on the communication option card is not working.
WARNING/ALARM 35, Out of frequency range:
This warning is active if the output frequency has reached the high limit (set in parameter 4-53)
or low limit (set in parameter 4-52). In Process Control, Closed Loop, par. 1-00 Configuration
Mode this warning is displayed.

WARNING/ALARM 36, Mains failure

This warning/alarm is only active if the supply voltage to the frequency converter is lost and par.
14-10 Mains Failure is NOT set to OFF. Check the fuses to the frequency converter
ALARM 38, Internal fault
It may be necessary to contact your Danfoss supplier. Some typical alarm messages:
0 Serial port cannot be initialised. Serious 1792 DSP watchdog is active. Debugging of pow-
hardware failure er part data Motor Orientated Control data
256-25 Power EEPROM data is defect or too old not transferred correctly
8 2049 Power data restarted
2064-20 H081x: option in slot x has restarted
512 Control board EEPROM data is defect or too
4
72
old
2080-20 H082x: option in slot x has issued a power
513 Communication time out reading EEPROM 88 up-wait
data 2096-21 H083x: option in slot x has issued a legal
514 Communication time out reading EEPROM 04 power up-wait
data 2304 Could not read any data from power EE-
515 Application Orientated Control cannot rec- PROM
ognise the EEPROM data 2305 Missing SW version from power unit
516 Cannot write to the EEPROM because a write 2314 Missing power unit data from power unit
command is on progress 2315 Missing SW version from power unit
517 Write command is under time out 2316 Missing io_statepage from power unit
518 Failure in the EEPROM 2324 The power card configuration is deter-
519 Missing or invalid Barcode data in EEPROM mined to be incorrect at power up.
783 Parameter value outside of min/max limits 2325 A power card has stopped communicating
1024-1 A CAN telegram that must be sent, couldn't while main power is applied
279 be sent 2326 The power card configuration is deter-
1281 Digital Signal Processor flash time-out mined to be incorrect after the power card
1282 Power micro software version mismatch register delay.
1283 Power EEPROM data version mismatch 2327 Too many power card locations have been
1284 Cannot read Digital Signal Processor soft- registered as present.
ware version 2330 Power size information between the power
1299 Option SW in slot A is too old cards does not match.
1300 Option SW in slot B is too old 2561 No communication from DSP to ATACD
1301 Option SW in slot C0 is too old 2562 No communication from ATACD to DSP
1302 Option SW in slot C1 is too old (state running)
1315 Option SW in slot A is not supported (not al- 2816 Stack overflow of control board module
lowed) 2817 Scheduler slow tasks
1316 Option SW in slot B is not supported (not al- 2818 Fast tasks
lowed) 2819 Parameter thread
1317 Option SW in slot C0 is not supported (not 2820 LCP Stack overflow
allowed) 2821 Serial port overflow
1318 Option SW in slot C1 is not supported (not 2822 USB port overflow
allowed) 2836 cfListMempool to small
1379 Option A did not respond when calculating 3072-51 Parameter value is outside its limits
Platform Version. 22
1380 Option B did not respond when calculating 5123 Option in slot A: Hardware incompatible
Platform Version. with control board hardware
1381 Option C0 did not respond when calculating 5124 Option in slot B: Hardware incompatible
1382 Option C1 did not respond when calculating 5125 Option in slot C0: Hardware incompatible
1536 An exception in the Application Orientated 5126 Option in slot C1: Hardware incompatible
Control is registered. Debug information with control board hardware
written in LCP 5376-62 Out of memory
31
ALARM 39, Heatsink sensor

No feedback from the heatsink temperature sensor.
The signal from the IGBT thermal sensor is not available on the power card. The problem could
be on the power card, on the gate drive card, or the ribbon cable between the power card and
gate drive card.
WARNING 40, Overload of Digital Output Terminal 27
Check the load connected to terminal 27 or remove the short-circuit connection. Check par.
5-00 Digital I/O Mode and par. 5-01 Terminal 27 Mode.
WARNING 41, Overload of Digital Output Terminal 29
Check the load connected to terminal 29 or remove the short-circuit connection. Check par.
5-00 Digital I/O Mode and par. 5-02 Terminal 29 Mode.

WARNING 42, Overload of Digital Output on X30/6 or Overload of Digital Output on

X30/7
For X30/6, check the load connected to X30/6 or remove the short-circuit connection. Check par.
5-32 Term X30/6 Digi Out (MCB 101).
For X30/7, check the load connected to X30/7 or remove the short-circuit connection. Check par.
5-33 Term X30/7 Digi Out (MCB 101).
ALARM 46, Power card supply
The supply on the power card is out of range.
There are three power supplies generated by the switch mode power supply (SMPS) on the power
card: 24 V, 5V, +/- 18V. When powered with 24 VDC with the MCB 107 option, only the 24 V and
5 V supplies are monitored. When powered with three phase mains voltage, all three supplied are
4
monitored.
WARNING 47, 24 V supply low
The 24 VDC is measured on the control card. The external 24 VDC backup power supply may be
overloaded, otherwise contact your Danfoss supplier.
WARNING 48, 1.8 V supply low
The 1.8 Volt DC supply used on the control card is outside of allowable limits. The power supply
is measured on the control card.
WARNING 49, Speed limit
The speed is not within the specified range in par. 4-11 Motor Speed Low Limit [RPM] and par.
4-13 Motor Speed High Limit [RPM].
ALARM 50, AMA calibration failed
Contact your Danfoss supplier.
ALARM 51, AMA check Unom and Inom
The setting of motor voltage, motor current, and motor power is presumably wrong. Check the
settings.
ALARM 52, AMA low Inom
The motor current is too low. Check the settings.
ALARM 53, AMA motor too big
The motor is too big for the AMA to be carried out.
ALARM 54, AMA motor too small
The motor is too big for the AMA to be carried out.
ALARM 55, AMA parameter out of range
The parameter values found from the motor are outside acceptable range.
ALARM 56, AMA interrupted by user
The AMA has been interrupted by the user.
ALARM 57, AMA time-out
Try to start the AMA again a number of times, until the AMA is carried out. Please note that
repeated runs may heat the motor to a level where the resistances Rs and Rr are increased. In
most cases, however, this is not critical.
ALARM 58, AMA internal fault
Contact your Danfoss supplier.
WARNING 59, Current limit
The current is higher than the value in par. 4-18 Current Limit.
WARNING 60, External interlock
External interlock has been activated. To resume normal operation, apply 24 VDC to the terminal
programmed for external interlock and reset the frequency converter (via serial communication,
digital I/O, or by pressing the reset button on LCP).

WARNING 61, Tracking error

An error has been detected between the calculated motor speed and the speed measurement
from the feedback device. The function for Warning/Alarm/Disable is set in par. 4-30 Motor Feed-
back Loss Function, error setting in par. 4-31 Motor Feedback Speed Error, and the allowed error
time in par. 4-32 Motor Feedback Loss Timeout. During a commissioning procedure the function
may be effective.
WARNING 62, Output frequency at maximum limit
The output frequency is higher than the value set in par. 4-19 Max Output Frequency
ALARM 63, mechanical brake Low
4
The actual motor current has not exceeded the release-brake current within the start-delay time
window.
WARNING 64, Voltage limit
The load and speed combination demands a motor voltage higher than the actual DC link voltage.
WARNING/ALARM/TRIP 65, Control card overtemperature
Control card overtemperature: The cutout temperature of the control card is 80 C.
WARNING 66, Heatsink temperature low
This warning is based on the temperature sensor in the IGBT module. See the ratings table in
Section 1.9 for the temperature reading that will trigger this warning.
Troubleshooting:
The heatsink temperature measured as 0 C could indicate that the temperature sensor is defec-
tive, thereby causing the fan speed to increase to the maximum. If the sensor wire between the
IGBT and the gate drive card is disconnected, this warning is produced. Also, check the IGBT
thermal sensor (see section 6.2.8).
ALARM 67, Option module configuration has changed
One or more options have either been added or removed since the last power-down.
ALARM 68, Safe stop activated
Safe stop has been activated. To resume normal operation, apply 24 VDC to terminal 37, then
send a reset signal (via bus, digital I/O, or by pressing the reset key. See par. 5-19 Terminal 37
Safe Stop.
ALARM 69, Power card temperature
The temperature sensor on the power card is either too hot or too cold. See the ratings table in
Section 1.9 for the high and low temperatures that can cause this alarm.
Troubleshooting:
Check the operation of the door fans.
Make sure that the filters for the door fans are not blocked.
Make sure that the gland plate is properly installed on IP21 and IP54 (NEMA 1 and NEMA
12) frequency converters.
ALARM 70, Illegal FC Configuration
The current control board and power board combination is illegal.
WARNING/ALARM 71, PTC 1 safe stop
Safe Stop has been activated from the MCB 112 PTC thermistor card (motor too warm). Normal
operation can be resumed when the MCB 112 applies 24 V DC to T-37 again (when the motor
temperature reaches an acceptable level) and when the digital input from the MCB 112 is deac-
tivated. When this happens, a reset signal is sent (via serial communication, digital I/O, or by
pressing reset button on LCP). Note that if automatic restart is enabled, the motor may start when
the fault is cleared.
ALARM 72, Dangerous failure
Safe stop with trip lock. Unexpected signal levels on the safe stop and digital input from the MCB
112 PTC thermistor card.

Warning 73, Safe stop auto restart

Safe stopped. Note that with automatic restart enabled, the motor may start when the fault is
cleared.
ALARM 79, Illegal power section config-
uration
The scaling card is the incorrect part number or not installed. Also, the MK102 connector on the
power card is not installed.
ALARM 80, Drive initialised to default value
Parameter settings are initialised to default settings after a manual reset.
WARNING 81, CSIV corrupt
CSIV file has syntax errors.
4
WARNING 82, CSIV parameter error
CSIV has failed to record a parameter.
ALARM 91, Analog input 54 wrong settings
Switch S202 must be set in the position OFF (voltage input) when a KTY sensor is connected to
analog input terminal 54.
ALARM 92, No flow
A no-load situation has been detected in the system. See parameter group 22-2*.
ALARM 93, Dry pump
A no-flow situation and high speed indicate that the pump has run dry. See parameter group
22-2*.
ALARM 94, End of curve
Feedback stays lower than the setpoint which may indicate leakage in the pipe system. See pa-
rameter group 22-5*.
ALARM 95, Broken belt
Torque is below the torque level set for no load, indicating a broken belt. See parameter group
22-6*.
ALARM 96, Start delayed
Motor start has been delayed due to short-cycle protection active. See parameter group 22-7*.
WARNING 97, Stop delayed
Stopping the motor has been delayed due to short cycle protection is active. See parameter group
22-7*.
WARNING 98, Clock fault
Clock Fault. The time is not set or the RTC clock (if mounted) has failed. See parameter group
0-7*.
WARNING 200, Fire mode
The input command fire mode is active. See parameter group 24-0*.
WARNING 201, Fire mode was active
Fire mode has been active. See parameter group 0-7*.
WARNING 202, Fire mode limits exceeded
One or more warranty voiding alarms have been suppressed during fire mode operation. See
parameter group 0-7*.
ALARM 243, Brake IGBT
This alarm is only for F Frame frequency converters. It is equivalent to Alarm 27. The report value
in the alarm log indicates which power module generated the alarm:
1 = left most inverter module.
2 = middle inverter module in F2 or F4 drive.
2 = right inverter module in F1 or F3 drive.

5 = rectifier module.
ALARM 244, Heatsink temperature
4 5 = rectifier module.
ALARM 245, Heatsink sensor
ALARM 246, Power card supply
ALARM 247, Power card temperature
ALARM 248, Illegal power section configuration
This alarm is only for F frame frequency converters. It is equivalent to Alarm 79. The report value
ALARM 250, New spare part
The power or switch mode power supply has been exchanged. The frequency converter type code
must be restored in the EEPROM. Select the correct type code in par. 14-23 Typecode Setting
according to the label on the unit. Remember to select Save to EEPROM to complete.

ALARM 251, New type code

The frequency converter has a new type code.
4.7 After Repair Tests

Following any repair to a frequency converter or testing of a frequency converter suspected of
being faulty, the following procedure must be followed to ensure that all circuitry in the frequency
converter is functioning properly before putting the unit into operation.
1.
2.
Perform visual inspection procedures as described in Table 3-1.
Perform static test procedures 6.2.1., 6.2.2 and 6.2.5 for D-frame size units or 6.2.3,
4
6.2.4 and 6.2.5 for E-frame size units to ensure frequency converter is safe to start.
3. Disconnect the motor leads from the output terminals (U, V, W) of the frequency con-
verter.
4. Apply AC power to the frequency converter.
5. Give the frequency converter a run command and slowly increase the reference (speed
command) to approximately 40 Hz.
6. Using an analog voltmeter or a DVM capable of measuring true RMS, measure phase-to-
phase output voltage on all three phases: U to V, U to W, V to W. All voltages must be
balanced within 8 volts. If unbalanced voltage is measured, refer to Input Voltage Test
(6.3.2).
7. Stop the frequency converter and remove the input power. Allow 40 minutes for DC
capacitors to fully discharge for E-frame size frequency converters or 20 minutes for D-
frame size frequency converters.
8. Reconnect the motor leads to the frequency converter output terminals (U, V, W).
9. Reapply power and restart the frequency converter. Adjust the motor speed to a nominal
level.
10. Using a clamp-on style ammeter, measure the output current on each output phase. All
currents should be balanced. If unbalanced current is measured, refer to Current Sensor
Test (6.3.14).

5 Frequency Converter and Motor Applications Frequency Converters

Frequency Converters 5 Frequency Converter and Motor Applications
5 Frequency Converter and Motor Applications
5.1 Torque Limit, Current Limit, and Unstable Motor Op-

eration
Excessive loading of the frequency converter may result in warning or tripping on torque limit,
overcurrent, or inverter time. This is not a concern if the frequency converter is properly sized for
the application and intermittent load conditions cause anticipated operation in torque limit or an
occasional trip. However, nuisance or unexplained occurrences may be the result of improperly
setting specific parameters. The following parameters are important in matching the frequency
5
converter to the motor for optimum operation. These setting need careful attention.
par. 1-03 Torque Characteristics sets the mode in which the frequency converter will
operate.
Parameters 1-20 through 1-29 match the frequency converter to the motor and adapt to
the motor characteristics.
Parameters 4-17 and 14-25 set the torque control features of the frequency converter
for the application.
par. 1-00 Configuration Mode sets the frequency converter for open or closed loop operation or
torque mode operation. In a closed loop configuration, a feedback signal controls the frequency
converter speed. The settings for the PID controller play a key role for stable operation in closed
loop, as described in the Operating Instructions. In open loop, the frequency converter calculates
the torque requirement based on current measurements of the motor.
par. 1-03 Torque Characteristics sets the frequency converter for constant or variable torque op-
eration. It is imperative that the correct torque characteristic is selected, based on the application.
If, for example, the load type is constant torque, such as a conveyor, and variable torque is se-
lected, the frequency converter may have great difficulty starting the load, if started at all. Consult
the factory if uncertain about the torque characteristics of an application.
Parameters 1-20 through 1-25 configure the frequency converter for the connected motor. These
are motor power, voltage, frequency, current, and rated motor speed. Accurate setting of these
parameters is very important. Enter the motor data required as listed on the motor nameplate.
For effective and efficient load control, the frequency converter relies on this information for cal-
culating the output waveform in response to the changing demands of the application.
par. 1-29 Automatic Motor Adaptation (AMA) activates the automatic motor adaptation (AMA)
function. When AMA is performed, the frequency converter measures the electrical characteristics
of the motor and sets various frequency converter parameters based on the findings. Two key
parameter values set by this function are stator resistance and main reactance, parameters 1-30
and 1-35. If unstable motor operation is experienced and AMA has not been performed, it should
be done. AMA can only be performed on single motor applications within the programming range
of the frequency converter. Consult the Operating Instructions for more on this function.
Parameters 1-30 and 1-35, as stated, should be set by the AMA function, values supplied by the
motor manufacturer, or left at the factory default values. Never adjust these parameters to random
values even though it may seem to improve operation. Such adjustments can result in unpredict-
able operation under changing conditions.

par. 4-17 Torque Limit Generator Mode sets the limit for frequency converter torque. The factory
setting is 160% for FC 302 series and 110% for FC 102/202 series and will vary with motor power
setting. For example, a frequency converter programmed to operate a smaller rated motor will
yield a higher torque limit value than the same frequency converter programmed to operate a
larger size motor. It is important that this value not be set too low for the requirements of the
application. In some cases, it may be desirable to have a torque limit set at a lesser value. This
offers protection for the application in that the frequency converter will limit the torque. It may,
however, require higher torque at initial start up. Under these circumstances, nuisance tripping
may occur.
par. 14-25 Trip Delay at Torque Limit works in conjunction with torque limit. This parameter selects
the length of time the frequency converter operates in torque limit prior to a trip. The factory
default value is off. This means that the frequency converter will not trip on torque limit, but it
5 does not mean it will never trip from an overload condition. Built into the frequency converter is
an internal inverter thermal protection circuit. This circuit monitors the output load on the inverter.
If the load exceeds 100% of the continuous rating of the frequency converter, a timer is activated.
If the load remains excessive long enough, the frequency converter will trip on inverter time.
Adjustments cannot be made to alter this circuit. Improper parameter settings effecting load cur-
rent can result in premature trips of this type. The timer can be displayed.
5.1.1 Overvoltage Trips

This trip occurs when the DC bus voltage reaches its DC bus alarm voltage high (see ratings tables
in introductory section). Prior to the trip, the frequency converter will display a high voltage warn-
ing. Most times an over voltage condition is due to fast deceleration ramps with respect to the
inertia of the load. During deceleration of the load, inertia of the system acts to sustain the running
speed. Once the motor frequency drops below the running speed, the load begins overhauling the
motor. At this point the motor becomes a generator and starts returning energy to the frequency
converter. This is called regenerative energy. Regeneration occurs when the speed of the load is
greater than the commanded speed. This return voltage is rectified by the diodes in the IGBT
modules and raises the DC bus. If the amount of returned voltage is too high, the frequency
converter will trip.
There are a few ways to overcome this situation. One method is to reduce the deceleration rate
so it takes longer for the frequency converter to decelerate. A general rule of thumb is that the
frequency converter can only decelerate the load slightly faster than it would take for the load to
naturally coast to a stop. A second method is to allow the overvoltage control circuit to take care
of the deceleration ramp. When enabled the overvoltage control circuit regulates deceleration at
a rate that maintains the DC bus voltage at an acceptable level. One caution with overvoltage
control is that it will not make corrections to unrealistic ramp rates. For example, if the deceleration
ramp needs to be 100 seconds due to the inertia, and the ramp rate is set at 3 seconds, overvoltage
control will initially engage and then disengage and allow the frequency converter to trip. This is
purposely done so the units operation is not misinterpreted. A third method in controlling regen-
erated energy is with a dynamic brake. The frequency converter monitors the level of the DC bus.
Should the level become too high, the frequency converter switches the resistor across the DC
bus and dissipates the unwanted energy into the external resistor bank mounted outside of the
frequency converter. This will actually increase the rate of deceleration.
Less often is the case that the overvoltage condition is caused by the load while it is running at
speed. In this case the dynamic brake option can be used or the overvoltage control circuit. It
works with the load in this way. As stated earlier, regeneration occurs when the speed of the load
is greater than the commanded speed. Should the load become regenerative while the frequency
converter is running at a steady state speed, the overvoltage circuit will increase the frequency
to match the speed of the load. The same restriction on the amount of influence applies. The

frequency converter will add about 10% to the base speed before a trip occurs. Otherwise, the
speed could continue to rise to potentially unsafe levels.
5.1.2 Mains Phase Loss Trips

The frequency converter actually monitors phase loss by monitoring the amount of ripple voltage
on the DC bus. Ripple voltage on the DC bus is a product of a phase loss. The main concern is
that ripple voltage causes overheating in the DC bus capacitors and the DC coil. Left unchecked,
the lifetime of the capacitors and DC coil would be drastically reduced.
When the input voltage becomes unbalanced or a phase disappears completely, the ripple voltage
increases causing the frequency converter to trip and issue an Alarm 4. In addition to missing
phase voltage, increased bus ripple can be caused by a line disturbance or imbalance. Line dis-
turbances may be caused by line notching, defective transformers or other loads that may be
5
effecting the form factor of the AC waveform. Mains imbalances which exceed 3% cause sufficient
DC bus ripple to initiate a trip.
Output disturbances can have the same effect of increased ripple voltage on the DC bus. A missing
or lower than normal output voltage on one phase can cause increased ripple on the DC bus.
Should a mains imbalance trip occur, it is necessary to check both the input and output voltage
of the frequency converter.
Severe imbalance of supply voltage or phase loss can easily be detected with a voltmeter. Line
disturbances most likely need to be viewed on an oscilloscope. Conduct tests for input imbalance
of supply voltage, input waveform, and output imbalance of supply voltage as described in the
chapter Troubleshooting.
5.1.3 Control Logic Problems

Problems with control logic can often be difficult to diagnose, since there is usually no associated
fault indication. The typical complaint is simply that the frequency converter does not respond to
a given command. There are two basic commands that must be given to any frequency converter
in order to obtain an output. First, the frequency converter must be told to run (start command).
Second, the frequency converter must be told how fast to run (reference or speed command).
The frequency converters are designed to accept a variety of signals. First determine what types
of signals the frequency converter is receiving. There are six digital inputs (terminals 18, 19, 27,
29, 32, 33), two analog inputs (53 and 54), and the fieldbus (68, 69). The presence of a correct
reading will indicate that the desired signal has been detected by the microprocessor of the fre-
quency converter. See the chapter Frequency Converter Inputs and Outputs.
Using the status information displayed by the frequency converter is the best method of locating
problems of this nature. By selecting within parameter group 0-2* LCP Display, line 2 or 3 of the
display can be set to indicate the signals coming in. The presence of a correct reading indicates
that the desired signal is detected by the microprocessor of the frequency converter. This data
also may be read in parameter group 16-6*.
If there is not a correct indication, the next step is to determine whether the signal is present at
the input terminals of the frequency converter. This can be performed with a voltmeter or oscil-
loscope in accordance with the 6.3.16, Input Terminal Signal Test.

If the signal is present at the terminal, the control card is defective and must be replaced. If the
signal is not present, the problem is external to the frequency converter. The circuitry providing
the signal along with its associated wiring must then be checked.
5.1.4 Programming Problems

Difficulty with frequency converter operation can be a result of improper programming of the
frequency converter parameters. Three areas where programming errors may affect drive and
motor operation are motor settings, references and limits, and I/O configuration. See Drive Inputs
and Outputs in Section 2.
The frequency converter must be set up correctly for the motor(s) connected to it. Parameters
5 1-20 1-25 must have data from the motor nameplate entered into the frequency converter. This
enables the frequency converter processor to match the frequency converter to power charac-
teristics of the motor. The most common result of inaccurate motor data is the motor drawing
higher than normal amounts of current to perform the task expected of it. In such cases, setting
the correct values for these parameters and performing the automatic motor adaptation (AMA)
function will usually solve the problem.
Any references or limits set incorrectly will result in less than acceptable frequency converter
performance. For instance, if maximum reference is set too low, the motor will be unable to reach
full speed. These parameters must be set according to the requirements of the particular instal-
lation. References are set in the 3-0* parameter group.
Incorrectly set I/O configuration usually results in the frequency converter not responding to the
function as commanded. It must be remembered that for every control terminal input or output,
there are corresponding parameters settings. These determine how the frequency converter re-
sponds to an input signal or the type of signal present at that output. Utilising an I/O function
must be thought of as a two step process. The desired I/O terminal must be wired properly, and
the corresponding parameter must be set accordingly. Control terminals are programmed in the
5-0* and 6-0* parameter groups.
5.1.5 Motor/Load Problems

Problems with the motor, motor wiring or mechanical load on the motor can develop in a number
of ways. The motor or motor wiring can develop a phase-to-phase or phase-to-earth short re-
sulting in an alarm indication. Checks must be made to determine whether the problem is in the
motor wiring or the motor itself.
A motor with unbalanced, or non-symmetrical, impedances on all three phases can result in un-
even or rough operation, or unbalanced output currents. Measurements should be made with a
clamp-on style ammeter to determine whether the current is balanced on the three output phases.
See Output Imbalance of Supply Voltage Test procedure.
An incorrect mechanical load will usually be indicated by a torque limit alarm or warning. Discon-
necting the motor from the load, if possible, can determine if this is the case.
Quite often, the indications of motor problems are similar to those of a defect in the frequency
converter itself. To determine whether the problem is internal or external to the frequency con-
verter, disconnect the motor from the frequency converter output terminals. Perform the output
imbalance of supply voltage test procedure (6.3.10) on all three phases with an analog voltmeter.
If the three voltage measurements are balanced, the frequency converter is functioning correctly.
The problem therefore is external to the frequency converter.

If the voltage measurements are not balanced, the frequency converter is malfunctioning. This
typically means that one or more output IGBT is not switching on and off correctly. This can be a
result of a defective IGBT or gate signal from the gate drive card. Perform the IGBT gate signal
test (6.3.11).
5.2 Internal Frequency Converter Problems

The vast majority of problems related to failed frequency converter power components can be
identified by performing a visual inspection and the static tests as described in the test section.
There are, however, a number of possible problems that must be diagnosed in a different manner.
The following discusses many of the most common of these problems.
5.2.1 Overtemperature Faults 5

In the event that an overtemperature indication is displayed, determine whether this condition
actually exists within the frequency converter or whether the thermal sensor is defective. Of
course, this can easily be detected by feeling the outside of the unit, if the overtemperature con-
dition is still present. If not, the temperature sensor must be checked. This can be done with the
use of an ohmmeter in accordance with the thermal sensor test procedure.
5.2.2 Current Sensor Faults

When a current sensor fails, it is indicated sometimes by an overcurrent alarm that cannot be
reset, even with the motor leads disconnected. Most often, however, the frequency converter will
experience frequent false earth fault trips. This is due to the DC offset failure mode of the sensors.
To explain this it is necessary to investigate the internal makeup of a Hall effect type current
sensor. Included inside the device is an op-amp to amplify the signal to usable levels in the re-
ceiving circuitry. Like any op-amp, the output at zero input level (zero current flow being
measured) should be zero volts, exactly half way between the plus and minus power supply vol-
tages. A tolerance of +/- 15mv is acceptable. In a three phase system that is operating correctly,
the sum of the three output currents should always be zero.
When the sensor becomes defective, the output voltage level varies by more than the 15mv al-
lowed. The defective current sensor in that phase indicates current flow when there is none. This
results in the sum of the three output currents being a value other than zero, an indication of
leakage current flowing. If the deviation from zero (current amplitude) approaches a specific level,
the frequency converter assumes an earth fault and issues an alarm.
The simplest method of determining whether a current sensor is defective is to disconnect the
motor from the frequency converter, then observe the current in the display of the frequency
converter. With the motor disconnected, the current should, of course, be zero. A frequency con-
verter with a defective current sensor will indicate some current flow. Because the current sensors
for the higher horsepower frequency converters have less resolution, an indication of a fraction
of an amp on a frequency converter is tolerable. However, that value should be considerably less
than one amp. Therefore, if the display shows more than one amp of current, there is a defective
current sensor.
To determine which current sensor is defective, measure the voltage offset at zero current of each
current sensor. See the current sensor test procedure.

5.2.3 Signal and Power Wiring Considerations for Frequency Con-

verter Electromagnetic Compatibility
The following is an overview of general signal and power wiring considerations when addressing
the Electromagnetic Compatibility (EMC) concerns for typical commercial and industrial equip-
ment. Only certain high-frequency phenomena (RF emissions, RF immunity) are discussed. Low-
frequency phenomena (harmonics, mains voltage imbalance, notching) are not covered. Special
installations or compliance to the European CE EMC directives will require strict adherence to
relevant standards and are not discussed here.
5.2.4 Effect of EMI
5 While Electromagnetic Interference (EMI) related disturbances to frequency converter operation

are uncommon, the following detrimental EMI effects may be seen:
Motor speed fluctuations

Serial communication transmission errors
Drive CPU exception faults
Unexplained frequency converter trips
A disturbance resulting from other nearby equipment is more common. Generally, other industrial
control equipment has a high level of EMI immunity. However, non-industrial, commercial, and
consumer equipment is often susceptible to lower levels of EMI. Detrimental effects to these sys-
tems may include the following:
Pressure/flow/temperature signal transmitter signal distortion or aberrant behaviour

Radio and TV interference
Telephone interference
Computer network data loss
Digital control system faults
5.2.5 Sources of EMI

Modern frequency converters (see Illustration 5-1) utilise Insulated-Gate Bipolar Transistors
(IGBTs) to provide an efficient and cost effective means to create the Pulse Width Modulated
(PWM) output waveform necessary for accurate motor control. These devices rapidly switch the
fixed DC bus voltage creating a variable frequency, variable voltage PWM waveform. This high
rate of voltage change [dV/dt] is the primary source of the frequency converter generated EMI.
The high rate of voltage change caused by the IGBT switching creates high frequency EMI.

130BX137.10
Rectifier DC Bus Inverter
Filter reactor
AC Line Motor
IGBT
Filter capacitor
Sine wave PWM waveform

Illustration 5.1: Frequency Converter Functionality Diagram
5.2.6 EMI Propagation 5

Frequency converter generated EMI is both conducted to the mains and radiated to nearby con-
ductors. See Illustrations 5-2 and 5-3.
VFD
130BX138.11
Motor
AC Line Motor cable
Stray capacitance Stray capacitance
Ground Potential 1 Potential 2 Potential 3

Illustration 5.2: Earth Currents
Stray capacitance between the motor conductors, equipment earth, and other nearby conductors
results in induced high frequency currents.
High earth circuit impedance at high frequencies results in an instantaneous voltage at points
reputed to be at earth potential. This voltage can appear throughout a system as a common mode
signal that can interfere with control signals.
Theoretically, these currents will return to the frequency converters DC bus via the earth circuit
and a high frequency (HF) bypass network within the frequency converter itself. However, im-
perfections in the frequency converter earthing or the equipment earth system can cause some
of the currents to travel out to the power network.

Frequency
Converter
130BX139.12
Motor
A C Li ne Motor cable
Stray capacitance
Signal wiring to BMS

Illustration 5.3: Signal Conductor Currents
5
Unprotected or poorly routed signal conductors located close to or in parallel to motor and mains
conductors are susceptible to EMI.
Signal conductors are especially vulnerable when they are run parallel to the power conductors
for any distance. EMI coupled into these conductors can affect either the frequency converter or
the interconnected control device. See Illustration 5-4.
While these currents will tend to travel back to the frequency converter, imperfections in the
system will cause some current to flow in undesirable paths thus exposing other locations to the
EMI.
Frequency
130BX140.12
Converter
Motor
AC Line Motor cable
Stray capacitance
AC Line
Illustration 5.4: Alternate Signal Conductor Currents
High frequency currents can be coupled into the mains supplying the frequency converter when
the mains conductors are located close to the motor cables.

5.2.7 Preventive Measures

EMI related problems are more effectively alleviated during the design and installation phases
rather than after the system is in service. Many of the steps listed here can be implemented at a
relatively low cost when compared to the cost for identifying and fixing the problem later in the
field.
Earthing
The frequency converter and motor should be solidly earthed to the equipment frame. A good
high frequency connection is necessary to allow the high frequency currents to return back to the
frequency converter rather than to travel thorough the power network. The earth connection will
be ineffective if it has high impedance to high frequency currents, therefore it should be as short
and direct as practical. Flat braided cable has lower high frequency impedance than round cable.
Simply mounting the frequency converter or motor onto a painted surface will not create an ef-
fective earth connection. In addition, running a separate earth conductor directly between the
5
frequency converter and the running motor is recommended.
Cable routing
Avoid routing motor wiring, mains wiring, and signal wiring in parallel. If parallel routing is un-
avoidable, try to maintain a separation of 200 mm (68 inches) between the cables or separate
them with a earthed conductive partition. Avoid routing cables through free air.
Signal cable selection
Signal cable selection. Single conductor 600 volt rated wires provide the least protection from EMI.
Twisted-pair and screened twist-pair cables are available which are specifically designed to min-
imise the effects of EMI. While unscreened twisted-pair cables are often adequate, screened
twisted-pair cables provide another degree of protection. The signal cables screen should be ter-
minated in a manner that is appropriate for the connected equipment. Avoid terminating the
screen through a pigtail connection as this increases the high frequency impedance and spoils the
effectiveness of the screen. Refer to Section 2.8, Earthing Screened Cables.
A simple alternative is to twist the existing single conductors to provide a balanced capacitive and
inductive coupling thus cancelling out differential mode interference. While not as effective as true
twisted-pair cable, it can be implemented in the field using the materials on hand.
Motor cable selection
The management of the motor conductors has the greatest influence on the EMI characteristics
of the system. These conductors should receive the highest attention whenever EMI is a problem.
Single conductor wires provide the least protection from EMI emissions. Often if these conductors
are routed separately from the signal and mains wiring, then no further consideration is needed.
If the conductors are routed close to other susceptible conductors, or if the system is suspected
of causing EMI problems then alternate motor wiring methods should be considered.
Installing screened power cable is the most effective means to alleviate EMI problems. The cables
screen forces the noise current to flow directly back to the frequency converter before it gets back
into the power network or takes other undesirable and unpredictable high frequency paths. Unlike
most signal wiring, the screening on the motor cable should be terminated at both ends.
If screened motor cable is not available, then 3 phase conductors plus earth in a conduit will
provide some degree of protection. This technique will not be as effective as screened cable due
to the unavoidable contact of the conduit with various points within the equipment.
Serial communications cable selection
There are various serial communication interfaces and protocols on the market. Each of these
recommends one or more specific types of twisted-pair, screened twisted-pair, or proprietary ca-
bles. Refer to the manufacturers documentation when selecting these cables. Similar recommen-
dations apply to serial communication cables as to other signal cables. Using twisted-pair cables
and routing them away from power conductors is encouraged. While screened cable provides
additional EMI protection, the screen capacitance may reduce the maximum allowable cable length
at high data rates.

5.2.8 Proper EMC Installation

Shown in the illustration below is a correct installation with EMC considerations in mind. Although
most installations will not follow all the recommended practices the closer an installation resembles
this example the better immunity the network will have against EMI. Should EMI problems arise
in an installation, refer to this example. Attempt to replicate this installation recommendation as
closely as possible to alleviate such problems.
Illustration 5.5: Proper EMC Installation

Frequency Converters 6 Test Procedures
6 Test Procedures
6.1 Introduction
Touching electrical parts of frequency converter may be fatal even after equipment
has been disconnected from AC power. Wait 20 minutes for D-frame sizes or 40
minutes for E-frame sizes after power has been removed before touching any in-
ternal components to ensure that capacitors have fully discharged. See label on front
of frequency converter door for specific discharge time.
This section contains detailed procedures for testing frequency converters. Previous sections of
this manual provide symptoms, alarms and other conditions which require additional test proce-
dures to further diagnose the frequency converter. The results of these tests indicate the
6
appropriate repair actions. Again, because the frequency converter monitors input and output
signals, motor conditions, AC and DC power and other functions, the source of fault conditions
may exist outside of the frequency converter itself. Testing described here will isolate many of
these conditions as well. Sections 7 and 8, Disassembly and Assembly Instructions, describes
detailed procedures for removing and replacing frequency converter components, as required (D-
or E-sized frequency converters, respectively).
Frequency converter testing is divided into Static Tests, Dynamic Tests, and Initial Start Up or
After Repair Drive Tests. Static tests are conducted without power applied to the frequency con-
verter. Most frequency converter problems can be diagnosed simply with these tests. Static tests
are performed with little or no disassembly. The purpose of static testing is to check for shorted
power components. Perform these tests on any unit suspected of containing faulty power com-
ponents prior to applying power.
For dynamic test procedures, main input power is required. All devices and power
when conducting tests on a powered frequency converter. Contact with powered
Dynamic tests are performed with power applied to the frequency converter. Dynamic testing
traces signal circuitry to isolate faulty components.
Both D-frame and E-frame size frequency converters are covered here. Differences in the proce-
dures are noted, as required. However, the Soft Charge and Rectifier Circuit Test, Soft Charge
Rectifier Test, and Fan Continuity Test sections are independent for D-frame and E-frame fre-
quency converters.
Replace any defective component and retest the frequency converter with the new component
before applying power to the frequency converter as described in Initial Start Up or After Repair
Drive Tests.

6 Test Procedures Frequency Converters
6.1.1 Tools Required for Testing

Digital volt/ohm meter capable of reading real RMS
Analog volt meter
Oscilloscope
Clamp-on style ammeter
Signal test board p/n 176F8437
Test cable p/n 176F8439
6.1.2 Signal Test Board

The signal test board can be used to test circuitry within the frequency converter and provides
easy access to test points. The test board plugs into connector MK104 on the power card. Its use
6 is described in the procedures where called out. See Signal Test Board in Section 9, Special Test
Equipment, for detailed pin descriptions.
130BX66.10
Illustration 6.1: Signal Test Board

6.1.3 Test Cables

The test cables bypass the main DC bus capacitors and supply DC voltage to the power card from
the soft charge card. This provides voltage for testing the power card without the frequency con-
verter circuitry being powered. The SCR shorting plug ensures that the SCRs do not fire. There
are two cable types, the D-frame frequency converters use the 2-pin cable and the E-frame fre-
quency converters use the 3-pin cable (see the illustrations below). The D-frame cable connects
to the wire harness above the power card by the SMPS fuse to the power card connector MK105.
The E-frame connects between the soft charge connector MK3 and the power card connector
MK105.
130BX64.10
Illustration 6.2: SCR Shorting Plug
6
Illustration 6.3: Two-Pin D-frame Test Cable
Illustration 6.4: Three-Pin E-frame Test Cable

6.2 Static Test Procedures

All tests should be made with a meter capable of testing diodes. Use a digital volt/ohmmeter (VOM)
set on the diode scale or an analog ohmmeter set on Rx100 scale. Before making any checks
disconnect all input, motor and brake resistor connections.
Illustration 6-3 Power Card PCA Connector Identification is provided as a reference for finding the
appropriate connectors described in the test procedures in this section. Some connectors are op-
tional and not on all frequency converter configurations.
NB!
For best troubleshooting results, it is recommended that static test procedures de-
scribed in this section be performed in the order presented.
6 Diode Drop
A diode drop reading will vary depending on the model of ohmmeter. Whatever the ohmmeter
displays as a typical forward bias diode is defined as a diode drop in these procedures. With a
typical DVM, the voltage drop across most components will be around .300 to .500. The opposite
reading is referred to as infinity and most DMVs will display the value OL for overload.
3 4
2 5
16
6
15
14
12 10 8
13
11 9 7
130BX172.10
Illustration 6.5: Power Card, and Mounting Plate
380480/500V: Yellow tape on the main SMPS transformer in the upper right corner.
525690V: White tape on the main SMPS transformer in the upper right corner.
1 Power card PCA3 9 MK106

2 Mounting plate 10 MK100
3 MK110 11 MK109
4 MK102 12 FK102
5 MK104 13 MK112 terminals 4, 5, 6
6 MK105 14 MK112 terminals 1, 2, 3
7 MK107 15 Scaling card
8 FK103 16 Scaling card standoff

6.2.1 Soft Charge and Rectifier Circuits Test: D-frame Size

Both the rectifier and soft charge circuits are tested simultaneously. The soft charge circuit is made
up of the soft charge rectifier, fuses and the soft charge resistor. The rectifier circuit is made up
of the SCR/diode modules. The soft charge resistor limits the inrush current when power is applied
to the frequency converter. The soft charge circuit card also provides snubbing for the SCRs.
It is important to pay close attention to the polarity of the meter leads to ensure identification of
a faulty component should an incorrect reading appear.
Prior to performing the test, it is necessary to ensure the soft charge fuses, F1, F2, and F3, located
on the soft charge card, are good.
Illustration 6-4 shows the soft charge card and the location of the fuses. It is for reference only.
It is not necessary to remove the card to perform the tests.
Soft charge fuse test 6

Use a digital ohmmeter to test continuity on rectifier fuses F1, F2, and F3 at connector MK106 on
the power card.
NB!
If the unit has fused disconnect option, make test connections L1, L2, and L3 to the
output (drive) side of the disconnect. Do not unplug the connector.
1. Measure fuse F1 from the mains input L1 (R) to MK106 pin 10 on the power card.
2. Measure fuse F2 from the mains input L2 (S) to MK106 pin 8 on the power card.
3. Measure fuse F3 from the mains input L3 (T) to MK106 pin 6 on the power card.
A measurement of 0 ohms indicates good continuity. Replace any open fuse (infinite resistance).
To replace a soft charge fuse, follow the soft charge disassembly instructions in Section 7.
F1, F2, F3
130BX65.12
Illustration 6.6: Soft Charge Card Fuses
380480/500V: Blue MOV & 8 PTCs 525690V: Red MOV & 6 PTCs.

Main rectifier circuit test part I

1. Connect the positive (+) meter lead to the positive (+) DC bus connector MK105 (A) on
the power card.
2. Connect the negative () meter lead to terminals L1, L2, and L3 in sequence.
Each reading should show infinity. The meter will start at a low value and slowly climb towards
infinity due to capacitance within the frequency converter being charged by the meter.
Incorrect reading
With the Part I test connection, the SCRs in the SCR/diode modules are reverse biased so they
are blocking current flow. If a short circuit exists, it would be possible that either the SCRs or the
diodes in the soft charge rectifier are shorted. To isolate between SCRs or the soft charge rectifier,
perform the Soft Charge Rectifier Test.
Main rectifier circuit test part II
1. Reverse meter leads by connecting the negative () meter lead to the positive (+) DC
bus connector MK105 (A) on the power card.
6
2. Connect the positive (+) meter lead to L1, L2, and L3 in sequence. Each reading should
show a diode drop.
Incorrect reading
With the Part II test connection, even though the SCRs in the SCR/diode modules are forward
biased by the meter, current will not flow through the SCRs without providing a signal to their
gates. The upper diodes in the soft charge rectifier are forward biased so the meter reads the
voltage drop across those diodes.
If an open reading were present, it would indicate the upper diodes in the soft charge rectifier are
open. It could also indicate that one or more of the soft charge fuses are open. It could further
indicate that the soft charge resistor is open. To isolate between the three possibilities, perform
the Soft Charge Fuse Test and Soft Charge Rectifier Test.
A short circuit reading indicates either one or more of the upper soft charge rectifier diodes are
shorted or the SCRs are shorted in the SCR/diode module. To isolate between SCRs or the soft
charge rectifier, perform the Soft Charge Rectifier Test.
Main rectifier circuit test part III
1. Connect the positive (+) meter lead to the negative (-) DC bus connector MK105 (B) on
the power card.
2. Connect the negative () meter lead to terminals L1, L2 and L3 in sequence. Each reading
should show a diode drop.
Incorrect reading With the Part III test connection, the diodes in the SCR/diode modules are
forward biased as well as the lower diodes in the soft charge rectifier. The meter reads the diode
drops. If a short circuit exists, it would be possible that either the diodes in the SCR/diode modules
or the lower diodes in the soft charge rectifier are shorted. To isolate between SCRs or the soft
charge rectifier, perform the Soft Charge Rectifier Test.
Although an open reading is possible, it is unlikely since that indicates that both the diodes in the
SCR/diode modules and the lower diodes in the soft charge rectifier are open. Should that occur,
replace both diodes.
Main rectifier circuit test part IV

1. Reverse meter leads by connecting the negative () meter lead to the negative (-) DC
bus connector MK105 (B) on the power card.
2. Connect the positive (+) meter lead to L1, L2 and L3 in sequence. Each reading should
show infinity.
Each reading should show infinity. The meter will start at a low value and slowly climb toward

Incorrect reading
With the Part IV test connection, the diodes in the SCR/diode modules are reversed biased as well
as the lower diodes in the soft charge rectifier. If a short circuit exists, it would be possible that
either the diodes in the SCR/diode modules or the lower diodes in the soft charge rectifier are
shorted. To isolate between SCRs or the soft charge rectifier, perform the Soft Charge Rectifier
Test, 6.2.2.
6.2.2 Soft Charge Rectifier Test: D-frame Size

Testing the soft charge rectifier requires access to the soft charge card connectors. It requires
removing the control card and power card mounting plate. Refer to removal instructions for soft
charge card in Section 7.
Do not remove the soft charge card completely or unplug any connectors not called out. Doing so
will break the continuity path of these measurements and may result in a false interpretation of
a failure. Although an open reading is possible, it is unlikely since that indicates that both the
diodes in the SCR/diode modules and the lower diodes in the soft charge rectifier are open. Should
6
that occur, replace both diodes.
1. Extract the soft charge card far enough to access the connectors.
2. Disconnect the DC cable at the connector MK3.
Since the rectifier test requires the soft charge resistor to be in the circuit, verify the resistor is
good before proceeding.
3. Measure the resistance between pins A and B of connector MK4 on the soft charge
card. It should read 27 ohms (10%) for 380500V frequency converters and 68 ohms
(10%) for 525690V. A reading outside this range indicates a defective soft charge
resistor. Replace the resistor in accordance with disassembly procedures in Section 7.
Continue tests.
Should the resistor be defective and a replacement not readily available, the remainder of the
tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and
placing a temporary jumper across pins A and B. This provides a path for continuity for the re-
maining tests. Ensure any temporary jumpers are removed at the conclusion of the tests.
For the following tests, set the meter to diode check or Rx100 scale.
4. Connect the negative (-) meter lead to the positive (+) MK3 (A) (DC output to DC
bus), and connect the positive (+) meter lead to MK1 terminals R, S, and T in sequence.
Each reading should show a diode drop.
An incorrect reading here indicates the soft charge rectifier is shorted. The rectifier is not serviced
as a component. Replace the entire soft charge card in accordance with the disassembly proce-
dures in Section 7.
5. Reverse meter leads with the positive (+) meter lead to the positive (+) MK3 (A).
Connect the negative (-) lead to MK1 terminals R, S, and T in sequence. Each reading
should show open.
6. Connect the positive (+) meter lead to the negative (-) MK3 (C). Connect the negative
(-) meter lead to MK1 terminals R, S, and T in sequence. Each reading should show a
diode drop.
An incorrect reading here indicates the soft charge rectifier is shorted. The rectifier is not serviced
dures in Section 7.

7. Reverse the meter leads with the negative (-) meter lead to the negative (-) MK3 (C).
Connect the positive (+) meter lead to MK1 terminals R, S, and T in sequence. Each
reading should show open.
If all tests indicate correctly while isolating between the SCR/diode modules and the soft charge
card, the SCR/diode modules are suspect. Before reconnecting the cable at MK3, return to the
Main Rectifier tests and repeat those tests. Put the power card temporarily back in place to retest
the main rectifier. Replace any defective assemblies in accordance with the disassembly proce-
dures in Section 7.
1
6
4
130BX71.10
Illustration 6.7: Soft Charge Card Connectors
380480/500V: Blue MOV & 8 PTCs 525690V: Red MOV & 6 PTCs.
1 MK1 3 MK4
2 MK2 4 MK3

6.2.3 Soft Charge and Rectifier Circuits Test: E-frame Size

For E-frame size frequency converters, the rectifier and soft charge circuits are tested separately.
The soft charge circuit is made up of the soft charge rectifier, fuses and the soft charge resistor.
The rectifier circuit is made up of the SCR and diode modules. The soft charge resistor limits the
inrush current when power is applied to the frequency converter. The soft charge circuit card also
provides snubbing for the SCRs.
It is important to pay close attention to the polarity of the meter leads to ensure identification of
a faulty component should an incorrect reading appear.
Prior to performing the test, it is necessary to ensure the soft charge fuses, F1, F2, and F3, located
on the soft charge card, are good. An open fuse could indicate a problem in the soft charge circuit.
Continue test procedures.
Illustration 6-6 shows the soft charge card and the location of the fuses. It is for reference only.
It is not necessary to remove the card to perform the tests. 6
Disconnect the MK3 from the soft charge card and leave disconnected until completion of soft
charge and rectifier tests.
Soft charge fuse test

Use a digital ohmmeter to test continuity on rectifier fuses F1, F2, and F3 on the soft
charge card.
1. Measure F1 across fuse. Open reading indicates open (blown) fuse.
A measurement of 0 ohms indicates good continuity. Replace any open fuse (infinite resistance).
1
130BX78.10
Illustration 6.8: Soft Charge Card Fuse Location
380480/500V: Blue MOV and 8 PTCs. 525690V: Red MOV and 6 PTCs.
1 Fuses F1, F2 and F3 2 MK3 (disconnect for soft charge and rectifier tests)

Main rectifier circuit test E-frames part I

1. Connect the positive (+) meter lead to the positive (+) DC bus connector MK105 (A) on
the power card.
2. Connect the negative () meter lead to terminals L1, L2, and L3 in sequence. If a dis-
connect option is used, measure on top side of fuses.
Each reading should show infinity. The meter will start at a low value and slowly climb towards
Incorrect reading
With the Part I test connection, the SCR modules are blocking current flow. A short indicates a
shorted SCR module.
Main rectifier circuit test E-frames part II
1. Reverse meter leads by connecting the negative () meter lead to the positive (+) DC
bus connector MK105 (A) on the power card.
2. Connect the positive (+) meter lead to L1, L2, and L3 in sequence. Each reading should
6 show open.
Incorrect reading
With the Part II test connection, the SCR modules are blocking current flow. A short indicates a
shorted SCR module.
Main rectifier circuit test E-frames part III
the power card.
2. Connect the negative () meter lead to terminals L1, L2 and L3 in sequence. Each reading
Incorrect reading
With the Part III test connection, the diodes in the main rectifier diode modules are forward biased.
The meter reads the diode drops. If a short circuit or an open circuit exists, the diode module is
damaged.
Main rectifier circuit test E-frames part IV
1. Reverse meter leads by connecting the negative () meter lead to the negative (-) DC
bus connector MK105 (B) on the power card.
2. Connect the positive (+) meter lead to L1, L2 and L3 in sequence. Each reading should
show infinity.
Incorrect reading
With the Part IV test connection, the diodes in the main diode modules are reversed biased. If a
short circuit exists, the diode module is damaged.
Continue to Soft Charge Rectifier Tests: E-frames.

6.2.4 Soft Charge Rectifier Test: E-frame Size

The DC cable at connector MK3 remains disconnected for this procedure.
Since the rectifier test requires the soft charge resistor to be in the circuit, verify the resistor is
good before proceeding.
1. Measure the resistance between pins A and B of connector MK4 on the soft charge
card. It should read 27 ohms (10%) for 380500 V frequency converters or 68 ohms
(10%) for 525690 V frequency converters. A reading outside this range indicates a
defective soft charge resistor. Replace the resistor according to the disassembly proce-
dures in Section 8. Continue tests.
Should the resistor be defective and a replacement not readily available, the remainder of the
tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and
placing a temporary jumper across pins A and B. This provides a path for continuity for the re-
maining tests. Ensure any temporary jumpers are removed at the conclusion of the tests.
6
For the following tests, set the meter to diode check or Rx100 scale.
2. Connect the negative (-) meter lead to the positive (+) MK3 (A) (DC output to DC
bus), and connect the positive (+) meter lead to MK1 terminals R, S, and T in sequence.
Each reading should show a diode drop.
3. Reverse meter leads with the positive (+) meter lead to the positive (+) MK3 (A).
Connect the negative (-) lead to MK1 terminals R, S, and T in sequence. Each reading
should show open.
4. Connect the positive (+) meter lead to the negative (-) MK3 (C). Connect the negative
(-) meter lead to MK1 terminals R, S, and T in sequence. Each reading should show a
diode drop.
5. Reverse the meter leads with the negative (-) meter lead to the negative (-) MK3 (C).
Connect the positive (+) meter lead to MK1 terminals R, S, and T in sequence. Each
reading should show open.
An incorrect reading here indicates the soft charge rectifier is faulty. The rectifier is not serviced
dures in Section 8.
Reconnect the MK3 on the soft charge card after these tests.
4
3
2
1
130BX120.10
Illustration 6.9: Soft Charge Card Connectors
1 MK1 3 MK4
2 MK3 4 MK2

6.2.5 Inverter Section Tests

The inverter section is primarily made up of the IGBTs used for switching the DC bus voltage to
create the output to the motor. IGBTs are grouped into modules comprised of six IGBTs. De-
pending on the size of the unit, either one, two, or three IGBT modules are present. The frequency
converter also has 3 snubber capacitors on each IGBT module.
Disconnect motor leads when testing inverter section. With leads connected, a short
circuit in one phase will read in all phases, making isolation difficult.
Before starting tests, ensure that meter is set to diode scale. If removed previously, reinstall the
soft charge card and power cards. Do not disconnect the cable to connector MK105 on the power
6 card since the path for continuity would be broken.
Inverter test part

1. Connect the positive (+) meter lead to the (+) positive DC bus connector MK105 (A) on
the power card.
2. Connect the negative () meter lead to terminals U, V, and W in sequence.
Inverter test part II

1. Reverse the meter leads by connecting the negative () meter lead to the positive (+)
DC bus connector MK105 (A) on the power card.
2. Connect the positive (+) meter lead to U, V, and W in sequence. Each reading should
show a diode drop.
Incorrect reading
An incorrect reading in any inverter test indicates a failed IGBT module. Replace the IGBT module
according to the disassembly instructions in Section 7 or 8. It is further recommended for units
with two IGBT modules that both modules be replaced even if the second module tests correctly.
Inverter test part III
the power card.
2. Connect the negative () meter lead to terminals U, V, and W in sequence. Each reading
Inverter test part IV
1. Reverse the meter leads by connecting the negative () meter lead to the negative (-)
DC bus connector MK105 (B) on the power card.
2. Connect the positive (+) meter lead to U, V, and W in sequence.
Incorrect reading
An incorrect reading in any inverter test indicates a failed IGBT module. Replace the IGBT module
according to the disassembly instructions in Section 7 or 8. It is further recommended for units
with two IGBT modules that both modules be replaced even if the second module tests correctly.

Indications of a failure in this circuit

IGBT failures may be caused by the frequency converter being exposed to repeated short circuits
or earth faults, or by extended frequency converter operation outside of its normal operating
parameters. Following an IGBT failure, it is important to verify the gate frequency converter signals
are present and of the correct waveform. See the dynamic test section on checking IGBT gate
drive signals.
Gate resistor test
Mounted to each IGBT module is an IGBT gate resistor board containing, among other compo-
nents, the gate resistors for the IGBT transistors. Based on the nature of the failure, a defective
IGBT can produce good readings from the previous tests. In nearly all cases, the failure of an
IGBT will result in the failure of the gate resistors.
Located on the gate drive card near each of the gate signal leads is a 3 pin test connector (see
Illustration 6-17). These are labelled MK 250, 350, 450, 550, 650, 750, and, if the frequency
converter is equipped with a brake option, 850.
For the sake of clarity, refer to the 3 pins as one, two, and three, reading left to right. Pins 1 and
2 of each connector are in parallel with the gate drive signal sent to the IGBTs. Pin 1 is the signal
and Pin 2 is common. 6
1. With ohmmeter, measure pins 1 and 2 of each test connector. Reading should indicate
7.8K ohms for D1/D3 Frames, 3.9K ohms for D2/D4 Frames, and 2.6K ohms for E1/E2
frames.
Incorrect reading
An incorrect reading indicates that either the gate signal wires are not connected from the gate
drive card to the gate resistor board or the gate resistors are defective. Connect the gate signal
wires, or if the resistors are defective, the entire IGBT module assembly requires replacement.
Replace the IGBT module according to the disassembly procedures in Section 7 or 8.
6.2.6 Brake IGBT Test

This test can only be carried out on units equipped with a dynamic brake option. If a brake resistor
is connected to terminals 81 and 82, disconnect it before proceeding. Use an ohmmeter set on
diode check or Rx100 scale.
Brake IGBT test part I

1. Connect the positive (+) meter lead to the brake resistor terminal R+ (82).
2. Connect the negative (-) meter lead to the brake resistor terminal R- (81).
The reading should indicate infinity. The meter may start out at a value and climb toward infinity
as capacitance is charged within the frequency converter.
Brake IGBT test part II

1. Connect the positive (+) meter lead to the brake resistor terminal R- (81).
2. Connect the negative (-) meter lead to the brake resistor terminal R+ (82).
The reading should indicate a diode drop.
Brake IGBT test part III

1. Connect the positive (+) meter lead to the brake resistor terminal R- (81).
2. Connect the negative (-) meter lead to the negative (-) DC bus connector MK105 (B) on
the power card.
The reading should indicate infinity. The meter may start out at a value and climb toward infinity
as capacitance is charged within the frequency converter.

Incorrect reading
An incorrect reading on any of the above tests indicates that the brake IGBT is defective. Replace
the brake IGBT in accordance with the disassembly procedures in Section 7 or 8.
The failure of any IGBT may also lead to a failure of the gate drive circuit supplying that device.
Following the replacement of an IGBT, always ensure the gate drive signals are tested in accord-
ance with the procedures in the dynamic test section.
6.2.7 Intermediate Section Tests

The intermediate section of the frequency converter is made up of the DC bus capacitors, the DC
coils, and the balance circuit for the capacitors.
1. Test for short circuits with the ohmmeter set on Rx100 scale or, for a digital meter, select
diode.
2. Measure across the positive (+) DC terminal (A) and the negative () DC terminal (B) on
6 3.
connector MK105 on the power card. Observe the meter polarity.
The meter will start out with low ohms and then move towards infinity as the meter
charges the capacitors.
4. Reverse meter leads on connector MK105 on the power card.
5. The meter will peg at zero while the capacitors are discharged by the meter. The meter
then begins moving slowly toward two diode drops as the meter charges the capacitors
in the reverse direction. Although the test does not ensure the capacitors are fully func-
tional, it ensures that no short circuits exist in the intermediate circuit.
Incorrect reading
A short circuit could be caused by a short in the soft charge, rectifier, or inverter section. Be sure
that the tests for these circuits have already been performed successfully. A failure in one of these
sections could be read in the intermediate section since they are all routed via the DC bus.
If a short circuit is present, and the unit is equipped with a brake, perform the brake IGBT test
next.
The only other likely cause would be a defective capacitor within the capacitor bank.
There is not an effective test of the capacitor bank when it is fully assembled. Although it is unlikely
that a failure within the capacitor bank would not be indicated by a physically damaged capacitor,
if suspect, the entire capacitor bank must be replaced. Replace the capacitor bank in accordance
with the disassembly procedures in Section 7 or 8.

6.2.8 Heatsink Temperature Sensor Test

The temperature sensor is an NTC (negative temperature coefficient) device. As a result, high
resistance means low temperature. As temperature decreases, resistance increases. Each IGBT
module has a temperature sensor mounted internally. The sensor is wired from the IGBT module
to the gate drive card connector MK100. For frequency converters with two IGBTs, the sensor on
the right module is used. For frequency converters with three IGBT modules, the centre module
is used.
On the gate drive card, the resistance signal is converted to a frequency signal. The frequency
signal is sent to the power card for processing. The temperature data is used to regulate fan speed
and to monitor for over and undertemperature conditions.
1. Use ohmmeter set to read ohms.
2. Unplug connector MK100 on the gate drive card (see Illustration 6-17) and measure the
resistance across the cable leads.
The relationship between temperature and resistance is nonlinear. At 25C, the resistance will be
6
approximately 5k Ohms. At 0 C, the resistance will be approximately 13.7k Ohms. At 60 C, the
resistance will be approximately 1.5k Ohms. The higher the temperature, the lower the resistance.
6.2.9 Fan Continuity Tests: D-frame Size

Make all continuity checks using an ohmmeter set to Rx1 scale. Digital or analog ohmmeter can
be used.
To aid in making the measurements, unplug the connector CN2 from its mate. CN2 terminals
correspond to the terminal numbers labelled on the transformer. Connector CN2 is located near
the fan transformer on the input plate. See Illustration 6.10.
Fan Fuse test
1. Test the fan fuse on the input plate by checking the continuity across the fuse.
An open fuse could indicate additional faults. Replace the fuse and continue the fan checks.
Checking continuity of connections

For the following tests, read the plug end of connector CN2 that is not connected to the trans-
former.
1. Measure from L3 (T) to CN2 terminal 1. A reading of <1ohm should be indicated.
2. Measure from L2 (S) to CN2 terminal 3. A reading of <1 ohm should be indicated.
3. Measure from CN2 terminal 2 to terminal 12 on the power card connector MK107. A
reading of <1 ohm should be indicated.
Incorrect reading
An incorrect reading would indicate a faulty cable connection. Replace the cable assembly.
Ohm test of transformer (380500V)
For the following tests, read the plug end of connector CN2 that is connected to the transformer.
1. Measure between CN2 terminals 1 and 3. Approximately 15 ohms should be read.
Incorrect reading
An incorrect reading would indicate a defective fan transformer. Replace the fan transformer.

When finished, be sure to reconnect CN2.

Ohm test of transformer (525690V)
For the following tests, read the plug end of connector CN2 that is connected to the transformer.

Incorrect reading
When finished, be sure to reconnect CN2.
Ohm test of fans
1. Measure between terminals 11 and 13 of power card connector MK107. A reading of 20
ohms should be indicated.
2. On IP21 and IP 54 units: Disconnect the spade connectors from the door fan and repeat
6 the measurement. A reading of 21 ohms should be indicated.
3. On IP21 and IP 54 units: Read the door fan terminals with the wires disconnected. A
reading of 400 ohms should be indicated.
4. Reconnect the wires to the door fan.
Incorrect reading
An incorrect reading of one or both of the fans indicates a defective fan. Replace the defective
fan.
1 2 3
130BX80.10
Illustration 6.10: Fan Transformer and Fuse Location
380480/500V: White label on fan transformer.

525690V: Orange label on fan transformer.
1 Fan transformer 3 Fan fuse

2 CN2

6.2.10 Fan Continuity Tests: E-frame Size

Make all continuity checks using an ohmmeter set to Rx1 scale. A digital or analog ohmmeter can
be used. Some instability may result when measuring resistance of a transformer with a multi-
meter. This can be reduced by turning off the auto-ranging function and setting the measurement
manually.
To aid in making the measurements, unplug the MK107 from the power card.
Checking continuity of connections

For the following tests, read connector MK107 on the power card.
1. Measure from L3 (T) to MK107 terminal 8. Reading of <1ohm should be indicated.
2. Measure from L2 (S) to MK107 terminal 1. Reading of <1 ohm should be indicated.
Incorrect reading
An incorrect reading would indicate a faulty cable connection. Replace the cable assembly.
Fan fuse test 6
1. Test the fan fuses on the power card mounting plate by checking the continuity across
the fuse.
An open fuse could indicate additional faults. Replace the fuse and continue the fan checks.
Ohm test of transformer

For the following tests, read the plug end of the wire connected to MK107 on the
power card.
1. Measure between MK107 terminals 1 and 8. Should read approximately value A in Table
6-1.
2. Measure between MK107 terminals 8 and 12. Should read approximately value B in Table
6-1.
3. Measure between MK107 terminals 1 and 12. Should read approximately value C in Table
6-1.
AC Voltage Drive Resistance (in Ohms) Heatsink Fan Fan Inductor

FC 102 FC202 FC 302 A B C D
380-500 P315 P315 P250 15 12 4 21 no
380-500 P355 P355 P315 4 3 1 4 yes
380-500 P400 P400 P355 4 3 1 4 yes
380-500 P450 P450 P400 4 3 1 4 yes
525-690 P400 P400 P355 20 8 12 21 no
525-690 P500 P500 P400 20 8 12 21 no
525-690 P560 P560 P500 7.4 3.6 3.2 4 yes
525-690 P630 P630 P560 7.4 3.6 3.2 4 yes
Table 6.1: Fan transformer resistance
Incorrect reading
When finished, reconnect the MK107.

Ohm test of fans

1. Measure between terminals 3 and 5 of power card connector MK107. It should read
approximately value D in Table 6-1.
Incorrect reading
For fans without an inductor, replace the fan. For frequency converters with
a fan and inductor, isolate the fault between the fan and the inductor as fol-
lows.
1a Disconnect CN3 and measure the resistance between pins 1 and 2 on the fan
side of the connector. Reading should be approx 4 ohms. If incorrect, replace
fan.
1b Disconnect CN4 and CN5. Measure the resistance across the inductor. Reading
should be less than 1 ohm. If incorrect, replace the inductor.
2. Measure between terminals 11 and 13 of power card connector MK107. For units with
one top mounted fan, a reading of 400 ohms is expected. For units with two door moun-
ted fans, a reading of 200 ohms is expected.
6 Incorrect reading
For units with one top mounted fan, replace the fan. For units with two door mounted fans, isolate
the faulty fan as follows.
a. Disconnect the wiring from the fan terminals.
b. Read across the fan terminals on each fan. A reading of 400 ohms is expected. Replace
any defective fans.
Illustration 6.11: Fan and DC Bus Fuse Locations
1 Power card 4 Mounting plate

2 DC bus fuse 5 MK107
3 Fan fuse

6.3 Dynamic Test Procedures

Refer to the terminal locations in Illustration 6-10 for performing dynamic test procedures.
NB!
Test procedures in this section are numbered for reference only. Tests do not need
to be performed in this order. Perform tests only as necessary.
Never disconnect the input cabling to the frequency converter with power applied
due to danger of severe injury or death.
Take all the necessary safety precautions for system start up prior to applying power
6
to the frequency converter.
2 130BX79.10
3 4
Illustration 6.12: Drive Power Terminals (D-size Frames)
1 Main 3-phase AC power to frequency converter 3 Brake resistor connection

2 DC bus/load sharing connections 4 3-phase output to motor

6.3.1 No Display Test

A frequency converter with no display can be the result of several causes. Verify first that there
is no display whatsoever. A single character in the display or a dot in the upper corner of the
display indicates a communication error and is typically caused by an option card not properly
installed. When this condition occurs, the green power-on LED is illuminated.
If the LCD display is completely dark and the green power-on LED is not lit, proceed with the
following tests.
First test for proper input voltage.
6.3.2 Input Voltage Test

1. Apply power to frequency converter.
6 2. Use the DVM to measure the input mains voltage between the frequency converter input
terminals in sequence:
L1 to L2
L1 to L3
L2 to L3
For 380500 V frequency converters, all measurements must be within the range of 342550 VAC.
Readings of less than 342 VAC indicate problems with the input mains voltage. For 525690 V
frequency converters, all measurements must be within the range of 446759 VAC. Readings of
less than 446 VAC indicate problems with the input mains voltage.
In addition to the actual voltage reading, the balance of the voltage between the phases is also
important. The frequency converter can operate within specifications as long as the imbalance of
supply voltage is not more than 3%.
Danfoss calculates mains imbalance per an IEC specification.

Imbalance = 0.67 X (Vmax Vmin)/Vavg
For example, if three phase readings were taken and the results were 500 VAC, 478.5 VAC, and
478.5 VAC; then 500 VAC is Vmax, 478.5 VAC is Vmin, and 485.7 VAC is Vavg, resulting in an
imbalance of 3%.
Although the frequency converter can operate at higher mains imbalances, the lifetime of com-
ponents, such as DC bus capacitors, will be shortened.

Incorrect reading
Open (blown) input fuses or tripped circuit breakers usually indicate a more serious
problem. Prior to replacing fuses or resetting breakers, perform static tests described
in section 6.2.
An incorrect reading here requires that the main supply be investigated further. Typical items to
check would be:
Open (blown) input fuses or tripped circuit breakers
Open disconnects or line side contactors
Problems with the power distribution system
If the Input Voltage Test was successful check for voltage to the control card.
6
6.3.3 Basic Control Card Voltage Test
1. Measure the control voltage at terminal 12 with respect to terminal 20. The meter
should read between 21 and 27 VDC.
An incorrect reading here could indicate the supply is being loaded down by a fault in the customer
connections. Unplug the terminal strip and repeat the test. If this test is successful, then continue.
Remember to check the customer connections. If still unsuccessful, proceed to the Switch Mode
Power Supply (SMPS) test.
2. Measure the 10 V DC control voltage at terminal 50 with respect to terminal 55. The
meter should read between 9.2 and 11.2 VDC.
An incorrect reading here could indicate the supply is being loaded down by a fault in the customer
connections. Unplug the terminal strip and repeat the test. If this test is successful, then continue.
Remember to check the customer connections. If still unsuccessful, proceed to the SMPS test.
A correct reading of both control card voltages would indicate the LCP or the control card is de-
fective. Replace the LCP with a known good one. If the problem persists, replace the control card
in accordance with the disassembly procedures in Section 7 or 8.
6.3.4 Switch Mode Power Supply (SMPS) Test

The SMPS derives its power from the DC bus. The first indication that the DC bus is charged is
the DC bus charge indicator light located on the power card being lit. This LED however can be
lit at a voltage still to low to enable the power supplies.
First test for the presence of the DC bus.

1. Using a voltmeter, read DC bus voltage at power card connector MK105 (A) with respect
to MK105 (B). The meter should indicate approximately 1.35 x AC input voltage to the
2. If the voltage is correct, proceed to set 3. If voltage is present but out of range, proceed
to DC Undervoltage test. If voltage is at zero, proceed to Zero DC Bus Voltage test.
3. Test the remaining power supplies. Insert the signal test board into the power card con-
nector MK104.

4. Connect the negative (-) meter lead to terminal 4 (common) of the signal board. With a
positive (+) meter lead, check the following terminals on the signal board.
Terminal Supply Voltage Range
11 +18V 16.519.5 VDC

12 -18V -16.5-19.5 VDC
23 +24V 2325 VDC
24 +5V 4.755.25 VDC
In addition, the signal test board contains three LED indicators that indicate the presence of volt-
age as follows:
Red LED +/- 18VDC supplies present
Yellow LED +24VDC supply present
Green LED +5VDC supply present
6 The lack of any one of these power supplies indicates the low voltage supplies on the power card
are defective. This assumes of course that the proper DC bus voltage was read at power card
connector MK105 (A) and (B). Replace the power card in accordance with the disassembly pro-
cedures in Section 7 or 8.
6.3.5 Zero DC Bus Voltage Test

If no voltage is present at power card connector MK105 (A) and (B), check the condition of the
DC power supply fuse. The fuse is located on the power card mounting plate next to the power
card. It can be tested without disassembling the unit.
1. Remove power to the frequency converter and make sure the DC bus is fully discharged
by measuring the voltage at the power card connector MK105 (A) with respect to MK105
(B).
If the DC power supply fuse is open (blown), it is not possible to detect the presence
of bus voltage at these terminals. If uncertain, wait 20 minutes for D-frame sizes or
40 minutes for E-frame sizes to allow the DC bus to fully discharge. See label on
front of frequency converter door for specific discharge time.
2. With the ohmmeter set on a diode scale or Rx100, measure from power card connector
MK105 (A) to any bus bars coming from the DC inductor. Bus bars are visible at the lower
edge and beneath the power card mounting bracket. Depending on the bus bar readout,
look for a diode drop or a complete short. In either case, this indicates a fuse is in the
circuit providing a path for continuity. An open reading indicates an open fuse.
If the fuse is open, it indicates a failure of the power supplies on the power card. The power card
and fuse require replacement. If the fuse checks good, there may be a problem with the soft
charge circuitry. Proceed to the static checks of the soft charge and rectifier circuits earlier in this
section.

6.3.6 DC Undervoltage Test

The initial charge of the DC bus is accomplished by the soft charge circuit. If the DC bus voltage
is below normal it would indicate that either the mains voltage is out of tolerance or the soft charge
circuit is restricting the DC bus from charging. Conduct the input voltage test (6.3.2) to ensure
the mains voltage is correct.
If excessive input power cycling has occurred, the PTC resistors on the soft charge card may be
restricting the bus from charging. If this is the case, expect to read a DC bus voltage in the area
of 50 VDC.
1. Check DC bus voltage by reading power card connector MK105 (A) with respect to MK105
(B). If verified, disconnect the power from the frequency converter and allow it to cool
for approximately 20 minutes.
2. Reapply power to the frequency converter after 20 minutes and recheck the DC bus
voltage. If voltage remains, a short circuit may exist within the intermediate circuit pre-
venting it from charging. Proceed to static checks (6.2) earlier in this section.
6
6.3.7 Input Imbalance of Supply Voltage Test
Theoretically, the current drawn on all three input phases should be equal. Some imbalance may
be seen, however, due to variations in the phase to phase input voltage and, to some degree,
single phase loads within the frequency converter itself.
A current measurement of each phase will reveal the balanced condition of the line. To obtain an
accurate reading, it will be necessary for the frequency converter to run at its rated load or or at
a load of not less than 40%.
1. Perform the input voltage test prior to checking the current, in accordance with proce-
dure. Voltage imbalances will automatically result in a corresponding current imbalance.
2. Apply power to the frequency converter and place it in run.
3. Using a clamp-on amp meter (analog preferred), read the current on each of three input
lines at L1(R), L2(S), and L3(T).
Typically, the current should not vary from phase to phase by more than 5%. Should a
greater current variation exist, it would indicate a possible problem with the mains supply
to the frequency converter or a problem within the frequency converter itself.
One way to determine if the mains supply is at fault is to swap two of the incoming
phases. This assumes that two phases read one current while the third deviates by more
than 5%. If all three phases are different from one another, swap the phase with the
highest current with the phase with the lowest current.
4. Remove power to frequency converter.
5. Swap the phase that appears to be incorrect with one of other two phases.
6. Reapply power to the frequency converter and place it in run.
7. Repeat the current measurements.
If the imbalance of supply voltage moves with swapping the leads, then the mains supply is sus-
pect. Otherwise, it may indicate a problem with the gating of the SCR. This may be due to a
defective SCR or in the gate signals from the power card to the module, including the possibility
of the wire harness from the power card to the SCR gates. Further tests on the proper gating of
the SCRs require an oscilloscope equipped with current probes. Proceed to testing the input
waveform and input SCR in accordance with their procedures.

6.3.8 Input Waveform Test

Testing the current waveform on the input of the frequency converter can assist in troubleshooting
mains phase loss conditions or suspected problems with the SCR/diode modules. Phase loss
caused by the mains supply can be easily detected. In addition, the rectifier section is controlled
by SCR/diode modules. Should one of the SCR/diode modules become defective or the gate signal
to the SCR lost, the frequency converter will respond the same as loss of one of the phases.
The following measurements require an oscilloscope with voltage and current probes.
Under normal operating conditions, the waveform of a single phase of input AC voltage to the
frequency converter appears as in Illustration 6-13.
Illustration 6.13: Normal AC Input Voltage Waveform
The waveform shown in Illustration 6-14 represents the input current waveform for the same
phase as Illustration 6-13 while the frequency converter is running at 40% load. The two positive
and two negative jumps are typical of any 6 diode bridge. It is the same for frequency converters
with SCR/diode modules.
Illustration 6.14: AC Input Current Waveform with Diode Bridge

With a phase loss, the current waveform of the remaining phases would take on the appearance
shown in Illustration 6-15.
Illustration 6.15: Input Current Waveform with Phase Loss.
6
Always verify the condition of the input voltage waveform before forming a conclusion. The current
waveform will follow the voltage waveform. If the voltage waveform is incorrect proceed to in-
vestigate the reason for the AC supply problem. If the voltage waveform on all three phases is
correct but the current waveform is not then the input rectifier circuit in the frequency converter
is suspect. Perform the static soft charge and rectifier tests and also the dynamic SCR/diode mod-
ule test.
6.3.9 Input SCR Test

The SCR can be disabled by the frequency converter for various reasons. Check the following
before making more complicated tests.
The SCRs can be disabled as a result of an input, or lack of input, at power card connector FK102,
the external brake temperature switch. Unless used as an input, a jumper must be placed between
terminals 104 and 106 of FK102
The SCRs are gated in sequence with the main supply. Verify that the voltage reference signal is
correct as follows.
1. Using a voltmeter, measure phase to phase mains voltage at Terminals R, S, and T of

power card connector MK106.
2. Measurements should correspond with measurements called out in the Input Voltage
Test (6.3.2).
An incorrect reading at MK106 with a correct input voltage may indicate a problem in the soft
charge card or the connecting cable.
If the above tests reveal no abnormalities, it is further possible that the inrush signal has not been
enabled by the control card. Using the signal test card, verify the inrush signal is present and the
SCR disable signal is at the correct voltage level as follows.
3. Insert the signal test board into power card connector MK104.
4. Check the SCR disable signal.
5. Using a voltmeter, connect the negative (-) meter lead to terminal 4 (common) of the
test board.
6. Connect the positive (+) meter lead to terminal 19 of the signal board.

A reading of 0 VDC indicates the SCRs have been disabled. A reading of 0.6 to 0.8 VDC indicates
the SCRs are active and should be gated.
With a reading of 0 VDC and proper mains applied to the frequency converter, it would be likely
that the input at power card terminal FK102 has caused the SCRs to be disabled. Given the con-
nection at FK102 has been verified the control card would be suspect. Check the inrush signal as
follows.
7. Connect the positive (+) meter lead to terminal 7 of the signal board.
A reading of 0 VDC indicates the inrush signal is active and the SCRs are being gated. A reading
of 5 VDC indicates the inrush signal is inactive and the SCRs are not gated.
With a reading of 5 VDC and proper mains applied to the frequency converter, it would be likely
that the control card is defective.
6 If the control card is suspect, replace it in accordance with the disassembly procedures in Section
7 or 8.
Should the above tests check correctly, proceed to testing the SCR gate signals.
To view the gate signals, an oscilloscope and a current probe are required.
8. Run the frequency converter while under some degree of load. At least a 30% load
may be required to consistently see gate signals produced since SCRs are only gated
when the DC bus falls below the peak of line.
9. Connect the current probe, in sequence, to each (+) positive SCR gate wire (white
leads) marked R, S, and T at power card connector MK100.
The waveform should appear as in Illustration 6-16.
Illustration 6.16: SCR Gate Signal
The current pulse should have a waveform as shown.

A1 > 1.1 A
A2 > 0.40 A
T1> 300 s
Given all the other tests above were successful, a missing gate signal indicates the power card is
defective. Replace the power card in accordance with the disassembly procedures in Section 7 or
8.
A distorted signal may be due to a defective gate on that particular SCR that is loading down the
supply. Replace the SCR module which corresponds to the incorrect gate signal reading.

6.3.10 Output Imbalance of Supply Voltage Test

Checking the balance of the frequency converter output voltage and current measures the elec-
trical functioning between the frequency converter and the motor. In testing the phase-to-phase
output, both voltage and current are monitored. It is recommended that static tests on the inverter
section of the frequency converter be conducted prior to this procedure.
If the voltage is balanced but the current is not, this indicates the motor is drawing an uneven
load. This could be the result of a defective motor, a poor connection in the wiring between the
frequency converter and the motor, or, if applicable, a defective motor overload.
If the output current is unbalanced as well as the voltage, the frequency converter is not gating
the output properly. This could be the result of a defective power card, gate drive, connections
between the gate drive card and IGBTs, or the output circuitry of the drive improperly connected.
6
NB!
Use an analog voltmeter for monitoring output voltage. Digital voltmeters are sen-
sitive to waveform and switching frequencies and commonly return erroneous
readings.
The initial test can be made with the motor connected and running its load. If suspect readings
are recorded then the motor leads may have to be disconnected to further isolate the problem.
1. Using a voltmeter, measure AC output voltage at frequency converter motor terminals

96 (U), 97 (V), and 98 (W). Measure phase to phase checking U to V, then U to W, and
then V to W.
All three readings should be within 8 VAC of each other. The actual value of the voltage depends
on the speed at which the frequency converter is running. The volts/hertz ratio is relatively linear
(except in VT mode) so at 60Hz the voltage should be approximately equal to the mains voltage
applied. At 30 Hz, it is about half of that and so on for any other speed selected. The exact voltage
reading is less important than balance between phases.
2. Next, monitor three output phases at frequency converter motor terminals 96 (U), 97
(V), and 98 (W) with the clamp on the ammeter. An analog device is preferred. To achieve
an accurate reading, run the frequency converter above 40Hz as this is normally the
frequency limitation of such meters.
The output current should be balanced from phase to phase and no phase should be more than
2 to 3% different from another. If the above tests are successful, the frequency converter is
operating normally.
3. If a greater imbalance exists than described above, disconnect the motor leads and
repeat the voltage balance test.
Since the current will follow the voltage, it is necessary to differentiate between a load problem
and a frequency converter problem. Should a voltage imbalance in the output be detected with
the motor disconnected, it is necessary to test the gate drive circuits for proper firing. Proceed to
the gate drive signals test (6.3.11).
If the voltage was balanced but the current imbalanced when the motor was connected, then the
load is suspect. There could be a faulty connection between the frequency converter and motor
or a defect in the motor itself. Look for bad connections at any junctions of the output wires
including connections made to contactors and overloads. Also, check for burned or open contacts
in such devices.

6.3.11 IGBT Gate Drive Signals Test

This procedure tests the gate drive signals at the output of the gate drive card just prior to them
being delivered to the IGBTs.
A simple test to check for the presence of the gate signals can be performed with a DVM, however,
to actually check the waveforms, an oscilloscope is required.
Disable the DC bus when performing this test with Test Cable p/n 176F8437. Failure
to do so could result in damage to the frequency converter if the probe is inadver-
tently connected to the wrong pins. Additionally, AC mains bus bars are in close
proximity to these test points. Exercise caution when working close to high voltage
components.
6 Prior to beginning the tests, ensure that power is removed from the unit and that the DC Bus
capacitors have been discharged.
Check for the presence of DC bus voltage by measuring power card connector MK105 (A) with
respect to MK105 (B). The voltage should be zero (0) before proceeding.
1. For D-frame size units, follow the procedure in Section 7 for soft charge card removal
and disengage the soft charge card far enough to disconnect the cable plugged into the
MK3.
2. Disconnect the cable from the MK3 connector on the soft charge card and connect one
end of the test cable into the MK3.
3. For D-frame size units, reinstall the soft charge card.
4. Disconnect connectors MK100 and MK105 on the power card.
5. Connect the free end of test cable into MK105.
6. Connect the SCR gate shorting plug (included with test cable 176F8437) into the cable
that was removed from MK100.
A 3 pin test connector is located on the gate drive card near each gate signal lead. These are
labelled MK250, MK350, MK450, MK550, MK650, MK750, and, if the frequency converter is equip-
ped with a brake option, MK850 (see Illustration 6-17).
For the sake of clarity, refer to the 3 pins as one, two, and three, reading left to right. Pins 1 and
2 of each connector are in parallel with the gate drive signal sent to the IGBTs. Pin 1 is the signal
and pin 2 is common.
7. Reconnect AC power to the frequency converter.

8. In stop mode, apply power to the frequency converter.
9. Measure pins 1 and 2 of each test connector. Each reading should be approximately -9
VDC, indicating all IGBTs are turned off.
10. Apply the run command to the frequency converter and 30 Hz reference.
11. If using a DVM, measure pins 1 and 2 of each connector. Waveform to IGBTs is a square
wave that goes positive to 14 VDC and negative to -9 VDC. Average voltage read by DVM
should be 2.2 to 2.5 VDC.

130BX75.10
1 2 3 4 5 6 7 8 9 10 11 12 6
Illustration 6.17: Gate Drive Card Test Connectors
1 Pin 1 7 MK450
2 MK850 (brake) 8 MK103 (V)
3 MK105 (brake option) 9 MK550
4 MK250 10 MK650
5 MK102 (U) 11 MK104 (W)
6 MK350 12 MK750
When using an oscilloscope, the readings should appear as in Illustration 6-18.
Illustration 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.
An incorrect reading of a gate signal indicates the gate drive card is defective or the signal has
been lost prior to it arriving at the gate card. The gate signals can then be checked with the signal
test board to verify their presence from the control card to the power card as follows.
12. Insert the signal test board into power card connector MK104.
13. With scope probe earth connected to terminal 4 (common) of signal board, measure six
gate signals at signal board terminals 25 through 30.
14. Place the frequency converter in run at 30 Hz.
The waveform should appear as in Illustration 6-19.

Illustration 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
15. Using a DVM, again check these same signal board terminals. DVM should read 2.2 to
2.5 VDC.
An incorrect reading of a gate signal indicates either the power card is defective or the signal has
been lost prior to arriving at the power card. There is no test to verify the signals directly out of
the control card. The power card would be suspect if a single gate signal is incorrect. The control
card would be suspect if all six signals are incorrect. Replace the corresponding card in accordance
with the disassembly procedures in Section 7 or 8.
6.3.12 IGBT Switching Test

Using the test cable 176F8439 while the frequency converter is powered and the DC bus is disa-
bled, a simple test can be made to determine if the IGBTs are actually turning on.
Before proceeding, verify that the DC bus is in fact disabled.

1. Disconnect the cable from connector MK105 on the power card. With a voltmeter, meas-
ure between white lead of the cable disconnected from MK105 and output terminals U,
V, and W in sequence. Switch between AC and DC scales. Voltage should read nearly
zero.
2. Measure between the black lead of the same cable and the output terminals U, V, and
W in sequence. Voltage should read nearly zero.
With the DC bus disabled, proceed using a DVM set on a diode scale.
1. With the frequency converter in stop mode, connect the positive (+) meter lead to the
black lead of MK105 cable disconnected from the power card.
2. In sequence, connect the negative (-) meter lead to the frequency converter output ter-
minals U, V, and W. The meter should indicate a diode drop.
3. Leave the positive meter lead connected to cable MK105, and run the frequency con-
verter at 30 Hz.
4. In sequence, again connect the negative (-) meter lead to the frequency converter output
terminals U, V, and W. The meter should effectively indicate a short circuit or around a
0.035 diode drop which indicates lower IGBTs are turned on and shorting the meter to
a negative bus.

NB!
Some voltage leakage within the unit may cause the meter to indicate a small neg-
ative voltage drop.
5. Repeat the test for positive (+) or upper IGBTs.

6. With the frequency converter in stop mode, connect the negative (-) meter lead to the
white lead of MK105 cable disconnected from the power card.
7. In sequence, connect the positive (+) meter lead to the frequency converter output ter-
minals U, V, and W. The meter should indicate a diode drop.
8. Leave the negative meter lead connected to cable MK105, and run the frequency con-
verter at 30 Hz.
9. In sequence, again connect the positive (+) meter lead to the frequency converter output
terminals U, V, and W. The meter should effectively indicate a short circuit or around a
0.035 diode drop which indicates upper IGBTs are turned on and shorting the meter to
a positive bus. 6
NB!
Some voltage leakage within the unit may cause the meter to indicate a small neg-
ative voltage drop.
Incorrect Reading
An incorrect reading indicates some of the IGBTs are not turning on. Replace the IGBT module
according to the disassembly instructions in Section 7 or 8.
6.3.13 Brake IGBT Test

Use the signal test board to test the operation of the dynamic brake IGBT and gate drive circuitry.
The following procedure can be used to force the brake circuit to activate for testing.
1. Connect the signal test board to connector MK104 on the control card.
2. Set the voltage test switch labelled Over V to the ON position.
3. Turn the potentiometer on the test board until the brake circuit activates. This causes
the brake IGBT to turn on and off at approximately 1.2 KHz. Duty cycle (pulse width)
increases as the potentiometer is increased.
4. Using an oscilloscope or DVM, measure at terminal 13. Terminal 13 represents the gate
signal to the brake IGBT. This should be 4.04 VDC when brake is OFF and drop to zero
when brake is ON.
5. Use an oscilloscope or DVM at terminal 14. Terminal 14 is a logic level (5V) signal rep-
resenting voltage across brake IGBT. This should measure 5.1 VDC when brake is OFF
and drop to zero when brake is ON.
Incorrect Reading
If the signal on terminal 13 is not correct, first check that the frequency converter is correctly
programmed for dynamic braking (parameter 2-10). If the programming is correct, replace the
control card in accordance with procedures in Section 7 or 8.
If the signal on terminal 13 is correct but the signal on terminal 14 is not, the brake IGBT gate
signal must be checked to determine whether the fault lies in the IGBT or the gate drive card. See
Gate Drive Signal Tests.

6.3.14 Current Sensors Test

The current sensors are Hall effect devices that send a signal proportional to the actual output
current waveform to the power card. The current scaling card, attached to the power card, scales
the signals from the current sensors to the proper level for monitoring and processing motor
control data. A defective current sensor can cause erroneous earth faults and overcurrent trips.
In such instances, the fault will usually only occur at higher loads. If the incorrect current scaling
card is installed, the current signals will be improperly scaled. This could cause erroneous over-
current trips. If the current scaling card is not installed, the frequency converter will trip.
A couple of simple checks can be made to determine the status of the sensors.
1. Apply power to the frequency converter.

2. Ensure that motor check, pre-magnetizing, DC hold, DC brake, or other parameter setups
are disabled that create a holding torque while at zero speed. Current displayed will
6
exceed 1 to 2 amps if such parameters are not disabled.
3. Run the frequency converter with a zero speed reference. Note the output current read-
ing in the display. The display should indicate approximately 1 to 2 amps.
If the current is greater than 1 to 2 amps and a current producing parameter is not active, the
test will need to be made again with the motor leads disconnected.
4. Remove power from the frequency converter. Monitor the DC bus voltage at power card
connector MK105 (A) and (B) to ensure the bus is fully discharged.
5. Remove the output motor leads from terminals U, V, and W.
6. Apply power to the frequency converter.
7. Run the frequency converter with a zero speed reference. Note the output current read-
ing in the display. The display should indicate less than 1 amp.
If an incorrect reading was obtained from the above tests, further tests of the current feedback
signals are required using the signal test board.
Testing current feedback with the signal test board.
8. Remove power to frequency converter. Make sure the DC bus is fully discharged.
9. Install the signal test board into power card connector MK104.
10. Using a DVM, measure the resistance between terminals 1 and 4, 2 and 4, and 3 and
4 of the signal test board. Resistance should be the same for all three readings. Table
6-2 shows approximate resistance readings based on frequency converter power and
voltage rating. Note that values listed are values at the current scaling card. When
measuring with a signal test board, the actual reading may be higher due to meter lead
resistance. Absence of resistance indicates a missing scaling card.
11. Reapply power to the frequency converter.
12. Using a DVM, connect the negative (-) meter lead to terminal 4 (common) of the
signal test board.
13. Run the frequency converter with a zero speed reference.
14. Measure the AC voltage at terminals 1, 2, and 3 of the signal test board in sequence.
These terminals correspond with current sensor outputs U, V, and W, respectively. Expect
a reading near zero volts but no greater than 15 mv.
If the control card parameters are set up to provide holding torque while at zero speed, the current
displayed will be greater than expected. To perform this test, disable such parameters.

The current sensor feedback signal at this point in the circuit will read approximately 400 mv at
a 100% frequency converter load so any reading above 15 mv while the frequency converter is
at zero speed has a negative effect on the way the frequency converter interprets the feedback
signal.
A reading of greater than 15 mv suggests that the corresponding current sensor be replaced. See
the disassembly instructions in Section 7 or 8.
Resistance
Voltage (AC) FC 102 FC202 FC 302 (Ohms)
380-500 P110 P110 P90K 4.5
380-500 P132 P132 P110 3.8
380-500 P160 P160 P132 3.1
380-500 P200 P200 P160 2.6
380-500 P250 P250 P200 5.1
6
380-500 P315 P315 P250 4.2
380-500 P355 P355 P315 2.6
380-500 P400 P400 P355 2.6
380-500 P450 P450 P400 2.3
525-690 P45K P45K P37K 5.9
525-690 P55K P55K P45K 5.9
525-690 P75K P75K P55K 5.9
525-690 P90K P90K P75K 5.9
525-690 P110 P110 P90K 5.9
525-690 P132 P132 P110 5.9
525-690 P160 P160 P132 4.5
525-690 P200 P200 P160 3.1
525-690 P250 P250 P200 3.1
525-690 P315 P315 P250 2.6
525-690 P400 P400 P315 5.1
525-690 P450 P450 P355 4.5
525-690 P500 P500 P400 4.5
525-690 P560 P560 P500 3.8
525-690 P630 P630 P560 2.6
Table 6.2: Scaling Card Resistance Values
6.3.15 Fan Tests

The fan control circuit is made up of the fan transformer and the control circuitry located on the
power card along with control signals for ON, OFF, and speed control from the control card. Since
the fans do not necessarily run at all times, see the description for cooling fan operation under
sequence of operation in Section 3.3.5.
Supply voltage
Supply voltage for the fans is from the soft charge card to power card connector
MK106. First, verify the supply voltage is present as follows.
1. Use a voltmeter to measure the AC phase to phase voltage at R, S, and T of power card
connector MK106. It should equal main supply voltage applied to frequency converter.
2. If voltage is not present, ensure proper mains voltage is applied to frequency converter.
Conduct Input Voltage test (6.3.2).
3. If mains voltage is present at the input of the frequency converter but not at MK106 of
the power card, conduct a static test of the soft charge fuses (6.2.1).

4. If voltage is present at MK106, check the voltage at the fan transformer read from con-
nector CN2 located near the transformer. With a voltmeter, read the AC voltage at CN2
pins 1 and 3. The voltage should correspond to the main mains voltage applied to the
5. If voltage is not present, ensure jumpers are in place at power card connector FK103.
Otherwise, connect an external source of power to terminal FK103 for fan supply voltage.
If the jumpers are in place or an auxiliary supply is connected and powered but no voltage is
present at the fan transformer connector CN2, the power card is likely defective. Replace the
power card in accordance with the disassembly instructions in Section 7 or 8.
Transformer output
If the appropriate voltage is present at CN2 pins 1 and 3, next check the output of the transformer.
Prior to making this test, ensure the fan transformer fuse is good.
1. With a voltmeter, measure mains voltage from CN2 terminal 1 to terminal 2. Voltage
should equal 66% of main AC supply voltage (48% for frequency converters 525690
6 VAC) applied to frequency converter (or that of the auxiliary supply). If the voltage is
incorrect, replace the fan transformer.
2. If the voltage is correct, check the fan voltage supplied to the fans themselves. The
voltage can be read at power card connector MK107 pins 8 and 11 with respect to pin
1. The voltage at pins 8 and 11 correspond to the fan's commanded speed: 200 VAC for
low speed and 230 VAC for high speed.
If the correct voltage is available but the fan is not running, that fan is defective. If no voltage is
available, verify that the fans should be running. If so, the power card is defective. Replace the
fan or power card in accordance with the disassembly instructions in Section 7 or 8.
Fan control circuit

To verify that the fan control circuit is receiving appropriate commands from the control card, the
signal test board can be used to verify those signals.
1. Remove power from the frequency converter and allow the DC bus to fully discharge.
2. Install the signal test board into power connector MK104.
3. Reapply power to the frequency converter.
4. Connect the negative (-) meter lead of a voltmeter to signal board terminal 4 (common).
5. With a positive (+) meter lead, check the signal at terminal 6 of the signal board. The
meter should read zero (0) volts with the fans set to run, 5 VDC if the control card has
the fans set to off.
6. Verify sequence of operation of the cooling fans to ensure they should be running. In
addition, the signal board contains a fan test switch. When switched on, fans should start
and run at high speed.
The signals at terminals 5 and 10 of the signal board determine fan speed. See Section 9 for more
on those signals. In addition, if a heatsink overtemperature trip has occurred, the fans will auto-
matically be switched to high speed.
Given the fact that the fans should be running, if the signal at terminal 6 is correct and the fan
test switch activates the fan, the control card is defective. Otherwise, the power card is defective.
Replace the appropriate assembly in accordance with the disassembly instructions in Section 7 or
8.

6.3.16 Input Terminal Signal Tests

The presence of signals on either the digital or analog input terminals of the frequency converter
can be verified on the frequency converter display. Digital or analog input status can be selected
or read in parameters 16-60 through 16-64.
Digital inputs
With digital inputs displayed, control terminals 18, 19, 27, 29, 32, and 33 are shown left to right,
with a 1 indicating the presence of a signal.
If the desired signal is not present in the display, the problem may be either in the external control
wiring to the frequency converter or a faulty control card. To determine the fault location, use a
voltmeter to test for voltage at the control terminals.
6
Verify the control voltage power supply is correct as follows.
1. With a voltmeter measure voltage at control card terminal 12 and 13 with respect to
terminal 20. The meter should read between 21 and 27 VDC.
If the 24 V supply voltage is not present, conduct the Control Card Test (6.3.17) later in this
section.
If 24 V is present, proceed with checking the individual inputs as follows

2. Connect the (-) negative meter lead to reference terminal 20.
3. Connect the (+) positive meter lead to the terminals in sequence.
The presence of a signal at the desired terminal should correspond to the digital input display
readout. A reading of 24 VDC indicates the presence of a signal. A reading of 0 VDC indicates no
signal is present.
Analog inputs
The value of signals on analog input terminals 53 and 54 can also be displayed. The voltage or
current in mA, depending on the switch setting, is shown in line 2 of the display.
If the desired signal is not present in the display, the problem may be either in the external control
wiring to the frequency converter or a faulty control card. To determine the fault location, use a
voltmeter to test for a signal at the control terminals.
Verify the reference voltage power supply is correct as follows.

1. With a voltmeter, measure the voltage at control card terminal 50 with respect to terminal
55. The meter should read between 9.2 and 11.2 VDC.
If the 10 V supply voltage is not present, conduct the Control Card Voltage Test earlier in this
section.

If the 10 volts is present proceed with checking the individual inputs as follows.
2. Connect the (-) negative meter lead to reference terminal 55.
3. Connect the (+) positive meter lead to desired terminal 53 or 54.
For analog input terminals 53 and 54, a DC voltage between 0 and +10 VDC should be read to
match the analog signal being sent to the frequency converter. Or a reading of 0.9 to 4.8 VDC
corresponds to a 4 to 20 mA signal
Note that a (-) minus sign preceding any reading above indicates a reversed polarity. In this case,
reverse the wiring to the analog terminals.
6.4 Initial Start Up or After Repair Drive Tests

Following any repair to a frequency converter or testing of a frequency converter suspected of
being faulty, the following procedure must be followed to ensure that all circuitry in the frequency
converter is functioning properly before putting the unit into operation.
6
1. Perform visual inspection procedures as described in Table 4-1.
2. Perform static test procedures 6.2.1, 6.2.2 and 6.2.5 for D-frame size units or 6.2.3, 6.2.4
and 6.2.5 for E-frame size units to ensure the frequency converter is safe to start.
3. Disconnect the motor leads from the output terminals (U, V, W) of the frequency con-
verter.
4. Apply AC power to the frequency converter.
5. Give the frequency converter a run command and slowly increase the reference (speed
command) to approximately 40 Hz.
6. Using an analog voltmeter or a DVM capable of measuring true RMS, measure phase-to-
phase output voltage on all three phases: U to V, U to W, V to W. All voltages must be
balanced within 8 volts. If unbalanced voltage is measured, refer to Input Voltage Test
(6.3.2).
7. Stop the frequency converter and remove the input power. Allow 40 minutes for DC
capacitors to fully discharge for E-frame size frequency converters or 20 minutes for D-
frame size frequency converters.
8. Reconnect the motor leads to the frequency converter output terminals (U, V, W).
9. Reapply power and restart the frequency converter. Adjust the motor speed to a nominal
level.
10. Using a clamp-on style ammeter, measure the output current on each output phase. All
currents should be balanced. If unbalanced current is measured, refer to Current Sensor
Test (6.3.14).

High Power Service Manual for VLT FC Series 7 D-Frame Sizes Disassembly and Assembly
Frequency Converters Instructions
7 D-Frame Sizes Disassembly and Assembly In-

structions

Frequency converters contain dangerous voltages when connected to mains voltage.
No disassembly should be attempted with power applied. Remove power to the fre-
quency converter and wait at least 20 minutes to let the frequency converter
capacitors fully discharge. Only a competent technician should carry out service.
ELECTROSTATIC DISCHARGE (ESD)

Use proper electrostatic discharge (ESD) procedures to prevent damage to sensitive 7

components when servicing the frequency converter.
NB!
Frame size is used throughout this manual where ever procedures or components
differ between frequency converters based upon the unit's physical size. Refer to
the tables in the Introduction Section to determine frame size definitions. See Sec-
tion 8 for E-frame sizes disassembly and assembly instructions.
7.2 Instructions
7.2.1 Control Card and Control Card Mounting Plate
1. Open the front panel door or remove the front cover, depending on the unit type.
2. (See Illustration 7-1) Unplug the LCP ribbon cable (not shown) from the control card or
remove LCP, depending on unit type. LCP can be removed by hand.
3. Remove the LCP cradle. LCP cradle can be removed by hand.
4. Remove any customer control wiring from the control card terminal blocks.
5. Remove the 4 screws (T20 Torx) securing the control card mounting plate to the control
assembly support bracket.
6. Unplug the ribbon cable from the back of the control card.
Reinstall in reverse order of this procedure. The red conductor on the ribbon cable between the
control card and the power card should be on the bottom of the connector. Tighten the control
card mounting plate screws to 1 Nm (8 in-lb).

7 D-Frame Sizes Disassembly and Assembly High Power Service Manual for VLT FC Series
Instructions Frequency Converters
Illustration 7.1: Control Card Access
380480/500V: Yellow tape on the main SMPS transformer in the upper right corner.
525690V: White tape on the main SMPS transformer in the upper right corner.
1 Local control panel (LCP) (Step 2) 8 Power card PCA3

2 LCP cradle (Step 3) 9 MK102 ring lug connection
3 C-option (if installed) 10 DC bus fuse
4 Mounting screws (Step 5) 11 Control card mounting plate
5 Control assembly support bracket 12 Control card terminal block
6 Attaching hardware 13 Control card (under LCP)
7 Power card mounting plate
7.2.2 Control Assembly Support Bracket

1. Remove the control card mounting plate in accordance with procedure.
2. Remove the 6 mounting nuts (10 mm), see Illustration 7-1.
3. Remove the control assembly support bracket.
Reinstall in reverse order of this procedure. Tighten the mounting screws to 4 Nm (35 in-lbs).

7.2.3 Power Card

1. Remove the control assembly support bracket in accordance with procedure.
2. Unplug power card connectors MK100, MK102, MK105, MK106, MK107 and MK109.
3. If customer connections are present, unplug connectors FK102, FK103, and MK112.
4. Remove the 7 mounting screws (T25 Torx) from the power card.
5. Remove the power card from the plastic standoff at the top right of the power card.
6. Remove the current scaling card from the power card by pushing in the retaining clips
on the standoffs. KEEP THIS SCALING CARD FOR FUTURE REINSTALLATION OF ANY
REPLACEMENT POWER CARD. The scaling card controls signals operating with this spe-
cific frequency converter. The scaling card is not part of the replacement power card.
Reinstall in reverse order of this procedure. When installing the power card, ensure that the in-
sulator sheet is installed behind the power card. Tighten the mounting screws to 2.3 Nm (20 in-
lbs).
3 4
7
5
2
1
16
6
15
14
12 10
13 8
11 9 7
130BX172.10
380480/500V: Yellow tape on the main SMPS 525690V: White tape on the main SMPS
transformer in the upper right corner. transformer in the upper right corner.

3 MK110 11 MK109
4 MK102 12 FK102
5 MK104 13 MK112 terminals 4,5,6
7 MK107 15 Current scaling card PCA4
8 FK103 16 Current scaling card standoff

7.2.4 Power Card Mounting Plate

1. Remove the control assembly mounting bracket in accordance with procedure.
2. The power card mounting plate (see Illustration 7-1) can be removed with the power
card still mounted, if so desired. If the power card is to be removed, remove it in ac-
cordance with the power card procedure.
3. To remove the power card mounting plate with the power card attached, unplug con-
nectors MK100, MK102, MK105, MK106, MK107, and MK109 (see Illustration 7-2).
5. Remove the nut (7 mm) attaching the MK102 ring lug to the power card mounting plate.
6. Remove the 2 connectors, one on each end of the DC bus fuse holder.
7. Remove the 2 nuts (10 mm) on the right side of the power card mounting plate. (Two
nuts that secure the control assembly mounting bracket also secure the left side of the
power card mounting bracket.)
Reinstall in reverse order of this procedure. The ring lug for the wire assembly that connects to
power card connector MK102 attaches to the right mounting stud on the top of the power card
mounting plate. The white wire from the DC bus connects to the left end of the DC bus fuse holder.
7 The white wire from the power card connector MK105 connects to the right end of the DC bus
fuse holder. Tighten the 10 mm mounting nuts to 4 Nm (35 in-lbs) and the 7 mm nut to 1 Nm (8
in-lbs).
7.2.5 Soft Charge Card

1. Remove the power card mounting plate in accordance with procedure.
2. Remove the 2 retaining nuts from the soft charge card assembly (10 mm).
3. Slide the assembly part way out to access the cable glands on the card.
4. Disconnect MK1, MK2, MK3, and MK4.
5. Remove the soft charge card assembly.
Reinstall by aligning the soft charge card with fastening clips on the side of the chassis. Reattach
the connectors. Slide into place and tighten the mounting screws to 4 Nm (35 in-lbs).

2
3
130BX122.10
Illustration 7.1: Soft Charge Card Assy
7
1 MK1
2 Retaining screw (Step 2)
3 MK2
4 MK4
5 MK3

7.2.6 Gate Drive Card

1. Disconnect the cables from the connectors on gate drive card MK100, MK102, MK103,
MK104, MK106, and, if the unit has a brake option, MK105, and, for 380-500 V units with
an RFI filter, MK101.
2. Remove the gate drive card by removing the 6 mounting screws (T25 Torx) from the
standoffs.
Reinstall in reverse order of this procedure. Tighten the mounting screws to 2.3 Nm (20 in-lbs).
1 2 3
130BX160.10
7
4 5 6 7
Illustration 7.1: Gate Drive Card
1 MK100 (temperature sensor)

2 MK101 (RFI filter)
3 MK106
4 MK105 (brake option)
5 MK102 (U)
6 MK103 (V)
7 MK104 (W)

7.2.7 Capacitor Bank(s)
Some D2/D4 size units have 2 capacitor bank assemblies mounted one above the
other. Separate disassembly instructions are given for upper and lower capacitor
banks. For units with one capacitor bank assembly only, disassemble in accordance
with instructions for Single capacitor bank D1/D3 units.
Upper capacitor bank D2/D4 units

1. Remove the control assembly support bracket in accordance with instructions.
2. Capacitor bank connection to DC bus bars can be seen recessed in the gap between
upper and lower cap banks. Remove the 2 nuts (10 mm) furthest from the DC bus bars.
A minimum 100 mm (4 in) extension is required.
3. Remove the 4 retaining nuts (10 mm) from the cap bank cover plate and remove the
cover plate.
4. Note that the weight of the cap bank is approximately 9 kg (20 lbs). Remove the cap
bank by pulling it free from the mounting studs.
7
1 2 3
130BX73.10
4 5 6
Illustration 7.1: D2/D4 Upper and Lower Capacitor Bank Assemblies
380480/500V: Blue DC Link Capacitors. 525690V: Black DC Link Capacitors
1 Upper cap bank assy retaining nuts (step 2) 4 Lower cover plate retaining nut (step 3)
2 Upper cover plate 5 Gate drive card
3 Upper cover plate retaining nut (step 3) 6 Lower cap bank assy retaining nuts (step 1)

Lower capacitor bank D2/D4 units

1. Capacitor bank connection to DC bus bars can be seen recessed in the gap between
upper and lower cap banks. Remove the 2 cap bank retaining nuts (10 mm) furthest to
the right from the DC bus bars. A minimum 100 mm (4 in) extension is required.
2. Note that the IGBT gate drive card can remain attached to the cap bank cover plate.
Disconnect MK100, MK102, MK103, MK104, and MK106 from the gate drive card. Also
remove the MK105, for units with a brake, and MK101 for units with an RFI filter.
3. Remove the 4 retaining nuts (10 mm) from the cap bank cover plate, and remove the
plate.
Single capacitor bank D1/D3 units

1. Remove the control assembly support bracket in accordance with instructions.
2. Remove the 2 capacitor bank retaining nuts (10 mm) from the DC bus bars. A minimum
100 mm (4 in) extension is required.
7 3. Note that the IGBT gate drive card can remain attached to the cap bank cover plate.
Disconnect MK100, MK102, MK103, MK104, and MK106 from the gate drive card. Also
remove the MK105, for units with a brake, and MK101 for units with an RFI filter.
4. Remove the 4 retaining nuts (10 mm) from the cap bank cover plate, and remove the
plate.
1
130BX72.10
2 3
Illustration 7.1: D1/D3 Single Capacitor Bank Assembly
380480/500V: Blue DC Link Capacitors. 525690V: Black DC Link Capacitors.
1 Retaining nuts (step 2)

2 Retaining nuts (step 4)
3 Gate drive card (step 3)

7.2.8 Soft Charge (SC) Resistors D2/D4 Units

1. Remove the upper capacitor bank assembly in accordance with procedure.
NB!
On D2/D4 units, only the upper cap bank assembly is removed.
2. The MK4 connector on the soft charge card must be disconnected. Disengage the soft
charge card far enough to access the MK4 (see Illustration 7-3) in accordance with steps
1-3 in the soft charge card disassembly procedure.
3. Note that the soft charge resistor is located under the bus bars and held in place by 2
retaining nuts. Bus bars do not need to be removed. Loosen the retaining nut (8 mm)
furthest to the right.
4. Remove the 8 mm retaining nut furthest to the left.
5. Lift the left side of the SC resistor and remove the resistor by sliding it to the left and out
from under the bus bars.
Reinstall in reverse order of this procedure. Tighten the 8 mm mounting nuts to 2.3 Nm (20 in-
lbs). Tighten 10 mm mounting nuts to 4 Nm (35 in-lbs).
7
1
2 3
130BX77.10
Illustration 7.1: D2/D4 Soft Charge Resistor
380480/500V: Clear wire leads. 525690V: Black wire leads.
1 Bus bars BB27 (do not remove)

2 Soft charge resistor
3 Retaining nut (loosen) (Step 3)

7.2.9 Soft Charge (SC) Resistors D1/D3 Units

1. Remove the capacitor bank per instructions.
2. Remove the input terminal mounting plate per instructions.
3. Note the colour coding for each of three wires attached to terminal 1 for each SCR/diode
module. Ensure that the correct wire is attached to the applicable stud during reassembly.
Remove the wiring from the studs. Remove the retaining screw (T25) from terminal 1 of
each of 3 SCR/diode modules and remove the bus bar.
CONTINUED ON NEXT PAGE
130BX87.10
7 2
Illustration 7.1: D2/D4 Soft Charge Resistor (1 of 3)

2 Bus bar BB2 (Step 3)

4. Remove the six retaining screws (T25) from the SCR/diode modules, terminals 2 and 3
in each module.
5. Remove the 4 (10 mm) retaining nuts from the DC inductor input bus bars and the 4
retaining nuts (not shown) from the side mounted bus bars. (Side mounted bus bars are
only present on units with load sharing.) Remove the DC input bus assembly.
130BX85.10
1 Retaining screws (Step 4)

2 DC input bus assembly BB3
3 Retaining nuts (Step 5)

6. Remove the soft charge resistor by removing the two mounting screws.
130BX83.10
7

2 Mounting screws (Step 6)
Reassembly
1. Clean the heatsink surface with a mild solvent or alcohol solution.
2. Reassemble the remaining parts in reverse order of their removal. Tighten the T25 and
8 mm mounting screws to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs).

7.2.10 Input Terminal Mounting Plate Assembly

1. Disconnect the input power wiring from L1, L2, L3, and earth connection.
2. Remove the upper most bus bar retaining nuts (13 mm) from the AC power input bus
bars L1, L2, and L3.
3. Disconnect the fan autotransformer cable at the in-line connector.
4. Remove the 4 or 5 (10 mm) retaining nuts (varies with size) from the mounting plate.
The input terminal mounting plate weighs approximately 727 kg (1560 lbs) de-
pending on the mounted options.
5. Remove the entire assembly from the mounting studs.

Reinstall in reverse order of this procedure. Tighten the 10 mm mounting nuts to 4 Nm (35 in-lbs)
and the 13 mm nuts to 9.5 Nm (85 in-lb).
1 7
130BX81.10
3
4
Illustration 7.1: Input Terminal Mounting Plate Assembly (no options shown)
380480/500V: White label on fan transform- 525690V: Orange label on fan transformer.
er.
1 Input power connector (Step 1)

2 Bus bar retaining nuts (shown removed) (Step 2)
3 Transformer connector (Step 3)

7.2.11 SCR/Diode Module D2/D4 Units

1. Remove the lower DC capacitor bank per instructions.
2. Remove the input terminal plate per instructions.
3. Remove the retaining nuts (8 mm) from the SCR input bus bars, one for each input phase.
4. Note the colour coding for each of the three wires attached to the retaining studs. Ensure
that the correct wire is attached to the applicable stud during reassembly. Remove the
wiring from the studs.
5. Remove screw (T30) from terminal 1 of each SCR/diode module by accessing the screw
through access hole in the SCR/diode input bus bar. Remove the SCR input bus bars.
6. Remove each IGBT output bus bar by removing the nut (13 mm) from the stud. Also
remove the retaining screw (T40) at other end of the IGBT output bus bars (not shown).
CONTINUED NEXT PAGE
130BX161.10
1
2
6
Illustration 7.1: D2/D4 SCR/Diode Module (1 of 4)
1 SRC/diode input bus bar retaining nut and stud (Steps 3 & 4) 4 IGBT output bus bar retaining nut (Step 6)
2 SRC/diode terminal screw (Step 5) 5 SRC/diode terminal screw (Step 5)
3 SRC/diode input bus bar BB21 or BB22 per drive power rating 6 IGBT output bus bar BB32 (Step 6)

7. Remove twelve (T30) screws from the output (lower) side of the IGBT modules.
8. Remove the retaining nut (8 mm) from each intermediate IGBT output bus bar. Remove
the intermediate IGBT bus bars.
9. Remove 4 nuts (10 mm), two on either side, connecting the rectifier DC bus bars to the
main DC bus bars. These are located to either side of the SCR/diode modules.
CONTINUED NEXT PAGE
4
5
130BX84.10
2
1 6 7
9
11
10
1 Retaining screws (Step 9) 7 IGBT output retaining screws (Step 7)

2 Retaining nut (Step 8) 8 Retaining screws (Step 9)
3 IGBT module 9 Intermediate IGBT output bus bar BB30 (Step 8)
4 Main DC bus bar BB25 (Step 9) 10 Bus bar BB31
5 Bus bar BB27 11 Bus bar BB30
6 Bus bar BB26

NB!
Note which gate leads are attached to which module to ensure that the leads are
reconnected to the correct modules upon reassembly.
10. Remove the rectifier DC bus bars by removing the 3 screws (T25) connecting each rec-
tifier DC bus bar to standoffs on the SCR/diode modules.
1 Bus bar BB27

2 Bus bar BB28
4 Rectifier DC bus bars BB23 or BB24 per drive power rating (Step 10)

11. Remove the SCR gate lead connectors from the modules.
12. Remove the SCR/diode module retaining screws on each module (T30) and remove the
SCR/diode modules.
130BX163.10
1
2
1 SCR/diode module (Step 12)

2 SCR gate lead connectors (Step 11)
3 SCR/diode module mounting screws (Step 12)
REASSEMBLY
1. To replace SCR/diode modules, follow the instructions included with the replacement
module.
2. Reassemble in reverse order. Tighten the remaining T25 and 8 mm screws to 2.3 Nm
(20 in-lbs) and T30 to 4 Nm (35 in-lbs).
3. Be sure to cross the tighten replacement unit with the spare part per instructions.

7.2.12 SCR/Diode Module D1/D3 Units

1. Remove the capacitor bank per instructions.
3. Remove the retaining screw (T25) from terminal 1 of each SCR/diode module.
4. Remove the 8 mm retaining nut from the bus bar holding bracket and remove the bus
bar, one for each input phase.
CONTINUED ON NEXT PAGES
130BX165.10
1
2
7
3
4
1 Bus bar BB2 (Step 4)

2 Retaining screw access (Step 3)
3 Retaining nut (Step 4)
4 Bus bar BB1
5 SCR/diode module

5. Remove the six retaining screws (T25) from the SCR/diode modules, terminals 2 and 3
in each module.
6. Remove the 4 (10 mm) retaining nuts from the DC inductor input bus bars and the 4
retaining nuts (not shown) from the side mounted bus bars. (Side mounted bus bars are
only present on units with load sharing.) Remove the DC input bus assembly.
1
130BX93.10
3
5
7
1 Bus bar BB4

3 DC input bus assembly BB3 (Step 6)
5 SCR/diode module

7. Note which gate leads attach to which module for reassembly. Remove the SCR/diode
gate lead connectors from the modules (not shown).
8. If the unit is equipped with a brake option, remove the two bus bars attaching the brake
IGBT module to the IGBT bus assy. Remove the SCR/diode mounting screws.
7
130BX92.10
1 SCR/diode module
2 Mounting screws (Step 8)
REASSEMBLY
1. To replace SCR/diode modules, follow the instructions included with the replacement
module.
2. Reinstall the module and mounting screws. Tighten the remaining T25 and 8 mm screws
to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs).
3. Reassemble the remaining parts in reverse order of their removal.

7.2.13 Current Sensor

1. Remove the motor cabling, as required.
2. Remove the input terminal mounting plate assembly per instructions.
3. Remove terminals U, V, and W by removing the 3 mounting screws. The terminal slides
out from under the current sensor.
4. Disconnect the current sensor cable from the current sensor.
5. Note which cables attach to which sensor for reassembly. Remove the 2 (8 mm) retaining
nuts from the stud on the chassis base plate and remove the sensor.
Reinstall in reverse order of this procedure. Tighten the 8 mm mounting nuts to 2.3 Nm (20 in-
lbs).
Illustration 7.1: Current Sensors
1 Terminal 4 Current sensor mounting screws (2)

2 Current sensor 5 Terminal mounting screws (2)
3 Terminal mounting screw 6 Output motor cable connection screws (2)

7.2.14 Heatsink Fan Assembly

1. Remove the input terminal mounting plate assembly per instructions.
2. Remove the 3 IGBT output bus bars (see Illustration 7-19) by removing the 6 retaining
nuts (8 mm), one from each end, of the IGBT output bus bars. Remove the bus bars.
NB!
Omit steps 3 and 4 for D2/D4 units.
3. Use a 100 mm (4 in) minimum extension and remove terminal 1 from the SCR/diode
module.
AC power lead to the intermediate SCR input bus bar by removing the nut 8 mm) and
remove the bus bar.
7 1 2 3
130BX88.10
Illustration 7.1: Fan Assembly (1 of 2)
1 Terminal (Step 3)
2 Intermediate SCR input bus bar (Step 3)
5 IGBT output bus bar (Step 2)

5. Disconnect the in-line Molex connector.

6. Remove the fan assy by removing the 6 (8 mm) retaining nuts from the stud. Note
that the fan assembly weighs approximately 8 kg (18 lbs).
Reinstall in reverse order of this procedure. Tighten mounting nuts to 2.3 Nm (20 in-lbs).
130BX89.10
2 7
Illustration 7.1: Fan Assembly (2 of 2)
1 Inline Molex connector (Step 5)


7.2.15 AC Input Terminals

1. Remove the AC input power cabling, as required.
2. Remove the R/L1, S/L2, T/L3 terminals by removing the 3 retaining screws.
Reinstall in reverse order of this procedure. Tighten the mounting nuts per specifications in the
unit's instruction manual.
4
3
130BX125.10
7 1
Illustration 7.1: AC Input Terminals (no options shown)
380480V: White label on fan transformer.
525690V: Orange label on fan transformer.
1 AC input terminal
2 AC input cable gland (Step 1)

7.2.16 IGBT Modules D2/D4 Units

1. Remove the capacitor banks per instructions.
2. Note the IGBT gate signal cables connected between gate drive card connectors MK100
(temperature sensor), MK102 (U), MK103 (V), and MK104 (W) and IGBTs. These will
need to be reconnected in the same locations during reassembly. Units with a brake
option will have brake cabling from MK105 in addition. Disconnect the cables at the con-
nectors on the IGBT modules.
3. Remove the retaining nuts (8 mm) from the SCR input bus bars.
wiring from the studs.
5. Remove screw (T25) from terminal 1 of each SCR/diode module by accessing the screw
through the access hole in the SCR/diode input bus bar. Remove the SCR input bus bars.
6. Remove each IGBT output bus bar by removing the nut (10 mm) from the stud. Also
remove retaining screw (T30) at the other end of the IGBT output bus bars (not shown).
7
5
130BX91.10
3
2 1
6
1
Illustration 7.1: D2/D4 IGBT Modules (1 of 3)
1 SCR/diode input bus bar BB21 or BB22 per drive power rating 5 Snubber capacitor
2 SCR/diode terminal screw (Step 5) 6 IGBT output bus bar retaining nut (Step 6)
3 SCR/diode input bus bar retaining nut and stud (Steps 3 & 4) 7 SCR/diode terminal screw (Step 5)
4 IGBT gate signal input terminal (Step 2) 8 IGBT output bus bar BB32 (Step 6)

7. Remove the 4 (10 mm) retaining nuts at the top of the IGBT bus bar assy.
8. Remove the 12 retaining screws (6 on each module) on the upper portion of the IGBT
modules. These screws also attach the snubber capacitors to the IGBT modules (see
Illustration 7-22, item 5 for snubber capacitor location). Remove the snubber capacitors.
9. Remove the 10 mm retaining nut from the IGBT bus bar assy.
10. Remove the IGBT bus bar assy.
11. At the bottom end of the IGBT module, remove the 12 retaining screws (4 each for U,
V, and W intermediate IGBT output bus bars).
12. Remove the retaining nut (8 mm) from the 3 intermediate IGBT output bus bars. Remove
the intermediate IGBT output bus bars.
7
5
130BX98.10
4
8
2
10
11
1 Intermediate IGBT output bus bar BB30 (Step 12) 7 IGBT bus bar assembly BB29 (Steps 7 & 10)
2 Retaining nut (Step 12) 8 Retaining nut (Step 7)
3 Retaining screws (Step 11) 9 IGBT module
4 IGBT module 10 BB30
5 Retaining screws (shown removed) (Step 8) 11 BB31

13. Remove the 2 IGBT modules by removing the 16 retaining screws (8 per module) and
sliding the modules free from under the bus bars.
130BX126.10
1
1 IGBT module
REASSEMBLY
1. Replace the IGBT module in accordance with the instructions provided with the replace-
ment unit.
2. Reassemble the remaining parts in reverse order of their removal.
3. Reinstall the module and mounting screws. Tighten the remaining T25 and 8 mm screws
to 2.3 Nm (20 in-lbs) and T30 and 10 mm to 4 Nm (35 in-lbs).

7.2.17 IGBT Modules D1/D3 Units

1. Remove the control card cassette per instructions.
3. Note the IGBT gate signal cables connected between the gate drive card connectors
MK100 (temperature sensor), MK102 (U), MK103 (V), and MK104 (W) and the IGBT
module connectors. These will need to be reconnected in the same locations during re-
assembly. Units with a brake option will have brake cabling from MK105 in addition.
Remove the capacitor bank per instructions.
4. Disconnect the gate drive cables at the connectors on the IGBT modules.
5. Disconnect the cable connected to connector MK100 on the high frequency card.
6. Remove the high frequency card by removing 2 retaining screws and 1 retaining nut.
6a For units with a brake option, the DC input bus assembly must be removed to
access and remove the bus bars between the IGBT bus bar assembly and the
brake IGBT. Remove the DC input bus bar assembly per steps 35 of SCR/Diode
Module Removal (D1 units).
6b For units with brake option, remove the bus bars between the IGBT bus bar
7 assembly and brake IGBT by removing two T25 retaining screws on brake IGBT
(not shown) and two 8 mm retaining nuts on the IGBT bus bar assembly (not
shown).
7. Remove the 3 IGBT output bus bars by removing the nut (10 mm) from the stud. Also
remove retaining screw (T30) at the other end of the IGBT output bus bars (not shown).
3 4 5
130BX90.10
2
1
7
10
Illustration 7.1: D1/D3 IGBT Module (1 of 2)
1 IGBT output bus bar BB9 (Step 7) 6 Retaining nut (Step 6)

2 DC input bus bar assembly BB3 (Step 6A) 7 Do not remove (Step 6)
3 Retaining screw (Step 6) 8 Gate drive cable glands (Steps 3 & 4)
4 High frequency card 9 IGBT module
5 Connector MK100 (Step 5) 10 IGBT output bus bar retaining nut (Step 7)

8. Remove the 4 (10 mm) retaining nuts at the top of the IGBT bus bar assy.
9. Remove the 6 retaining screws on the upper portion of the IGBT modules. These
screws also attach the snubber capacitors to the IGBT modules. Remove the 3 snubber
capacitors.
10. Remove the IGBT bus bar assy.
11. At the bottom end of a IGBT module, remove the 6 retaining screws (2 each for U,
V, and W intermediate IGBT output bus bars).
12. Remove the retaining nut (8 mm) from the 3 intermediate IGBT output bus bars.
Remove the intermediate IGBT output bus bars.
13. Remove the IGBT module.
REASSEMBLY
1. Replace the IGBT module in accordance with the instructions enclosed with the replace-
ment module.
2. Tighten the remaining T25 and 8 mm screws to 2.3 Nm (20 in-lbs) and T30 and 10 mm
to 4 Nm (35 in-lbs).
3. Reassemble the frequency converter in reverse order of disassembly and tighten the
attachment hardware in accordance with the torque tables.
7
130BX159.10
2
1
4
7
Illustration 7.1: D1/D3 IGBT Module (2 of 2)
1 IGBT module 5 Retaining screw (Step 9)

2 Snubber capacitor (Step 9) 6 Retaining nut (Step 11)
3 IGBT bus bar assembly (Step 8) 7 Intermediate IGBT output bus bar (Step 11)

8 E-Frame Sizes Disassembly and Assembly High Power Service Manual for VLT FC Series

High Power Service Manual for VLT FC Series 8 E-Frame Sizes Disassembly and Assembly
8 E-Frame Sizes Disassembly and Assembly In-

structions

Frequency converters contain dangerous voltages when connected to mains voltage.
No disassembly should be attempted with power applied. Remove power to the fre-
quency converter and wait at least 40 minutes to let the frequency converter
capacitors fully discharge. Only a competent technician should carry out service.
ELECTROSTATIC DISCHARGE (ESD)

Use proper electrostatic discharge (ESD) procedures to prevent damage to sensitive

components when servicing the frequency converter.
NB!
8
Frame size is used throughout this manual where ever procedures or components
differ between frequency converters based upon the unit's physical size. Refer to
the tables in the Introduction section to determine E-frame size definitions.
8.2 Instructions
8.2.1 Control Card and Control Card Mounting Plate
1. Open the front panel door or remove the front cover, depending on the unit type.
2. (See Illustration 8-1) Unplug the LCP ribbon cable (not shown) from the control card or
remove the LCP, depending on the unit type. The LCP can be removed by hand.
3. Remove the LCP cradle. LCP cradle can be removed by hand.
4. Remove any customer control wiring from the control card terminal blocks.
5. Remove the 4 screws (T20 Torx) securing the control card mounting plate to the control
assembly support bracket.
6. Unplug the ribbon cable from the back of the control card.
Reinstall in reverse order of this procedure. The red conductor on the ribbon cable between the
control card and the power card should be on the bottom of the connector. Tighten the control
card mounting plate screws to 1 Nm (8 in-lb).

Illustration 8.1: Control Card Access
1 Local control panel (LCP) (Step 2) 8 Power card PCA3

2 LCP cradle (Step 3) 9 MK102 ring lug connection
3 C-option (if installed) 10 DC bus fuse
4 Mounting screws (Step 5) 11 Control card mounting plate
5 Control assembly support bracket 12 Control card terminal block
6 Attaching hardware 13 Control card (under LCP)
7 Power card mounting plate
8.2.2 Control Assembly Support Bracket

1. Remove the control card mounting plate in accordance with procedure.
2. Remove the 6 mounting nuts (10 mm), see Illustration 8-1.
3. Remove the control assembly support bracket.

8.2.3 Power Card

1. Remove the control assembly support bracket in accordance with procedure.
2. Unplug power card connectors MK100, MK102, MK105, MK106, MK107 and MK109.
4. Remove the 7 mounting screws (T25 Torx) from the power card.
5. Remove the power card from the plastic standoff at the top right of the power card.
6. Remove the current scaling card from the power card by pushing in the retaining clips
on the standoffs. KEEP THIS SCALING CARD FOR FUTURE REINSTALLATION OF ANY
REPLACEMENT POWER CARD. The scaling card controls signals operating with this spe-
cific frequency converter. The scaling card is not part of the replacement power card.
Reinstall in reverse order of this procedure. When installing the power card, ensure that the in-
sulator sheet is installed behind the power card. Tighten the mounting screws to 2.3 Nm (20 in-
lbs).
3 4
5
2
1
16
6
15
14
12 10
13 8
11 9 7
130BX172.10

3 MK110 11 MK109
4 MK102 12 FK102
7 MK107 15 Current scaling card PCA4
8 FK103 16 Current scaling card standoff

8.2.4 Soft Charge Card

1. Disconnect MK1, MK2, MK3, and MK4.
2. Remove the 4 mounting screws (T25) from the standoffs.
3. Remove the soft charge card. Note the insulation sheet below the soft charge card. Re-
move and keep the insulation with the card for reinstallation.
Reinstall by mounting the insulation onto the standoffs. Mount the soft charge card and tighten
the mounting screws to 2.3 Nm (20 in-lbs).
5
4
3
2
130BX155.10
1
8
Illustration 8.1: Soft Charge Card
1 MK3 4 MK4
2 Mounting screw (Step 2) 5 MK2
3 MK1

8.2.5 Gate Drive Card

1. Disconnect the cables from connectors on the gate drive card MK100, MK102, MK103,
MK104, MK106, and, if unit has a brake option, MK105, and, for 380500 V units with
an RFI filter, MK101.
2. Remove the gate drive card by removing the 6 mounting screws (T25 Torx) from the
standoffs.
Reinstall in reverse order of this procedure. Tighten the mounting screws to 2.3 Nm (20 in-lbs).
1 2 3
130BX160.10
8
4 5 6 7
Illustration 8.1: Gate Drive Card.
1 MK100 5 MK102 (U)

2 MK101 (RFI filter) 6 MK103 (V)
3 MK106 7 MK104 (W)
4 MK105 (brake option)

8.2.6 Capacitor Banks

Upper Capacitor Banks
1. Remove the control assembly support bracket and the gate drive card in accordance with
the instructions.
2. The capacitor bank connection to the DC bus bars can be seen recessed in the gap be-
tween the upper and the lower capacitor banks. A minimum extension of 6 inches (150
mm) is required. Remove the 6 electrical connection nuts (8 mm) for the upper capacitor
bank on the DC bus bars.
3. Remove the 4 retaining nuts (10 mm) from the capacitor bank and remove the air dam.
4. Note that the weight of the capacitor bank is approximately 20 pounds (9 kg). Remove
the capacitor bank by pulling free from the mounting studs.
Reinstall in reverse order of this procedure. Tighten the electrical connection nuts (8 mm) to 2.3
Nm (20 in-lbs) and the mechanical connection nuts (10 mm) to 4 Nm (35 in-lbs).
Lower Capacitor Banks

1. Remove the soft charge card in accordance with procedures.
2. The capacitor bank connection to the DC bus bars can be seen recessed in the gap be-
tween the upper and the lower capacitor banks. A minimum extension of 150 mm (6 in)
is required. Remove the 6 electrical connection nuts (8 mm) for the lower capacitor bank
8 3.
from the DC bus bars.
Remove the 4 retaining nuts (10 mm) from the capacitor bank.
4. Note that the weight of the capacitor bank is approximately 9 kg (20 lbs). Remove the
capacitor bank by pulling free from the mounting studs.
Reinstall in reverse order of this procedure. Note: DO NOT overtorque. Tighten the electrical con-
nection nuts (8 mm) to 2.3 Nm (20 in-lbs) and the mechanical connection nuts (10 mm) to 4 Nm
(35 in-lbs).

Illustration 8.1: Upper and Lower Capacitor Bank Assemblies
8
1* Upper capacitor bank assy 5* Lower capacitor bank assy
2 Upper cap bank assy electrical connection nuts (Step 6 Gate drive card
2)
3 Lower cap bank assy electrical connection nuts (Step 7 Upper cap bank assy retaining nut (Step 4)
2)
4 Lower cap bank assy retaining nut (Step 3) 8** Soft charge card
*380480/500V: Blue DC Link Capacitors.
525690V: Black DC Link Capacitors.
**380480/500V: Blue MOV and 8 PTCs.
525690V: Red MOV and 6 PTCs.

8.2.7 Input Terminal Mounting Plate Assy Option

The frequency converter has component options that can be mounted on the input mounting plate.
This results in differing unit configurations. These options include input terminal blocks, input
disconnect, RFI filter, input fuses, and an additional cooling fan. These options may need to be
removed from the mounting plate assembly to reduce the weight of the assembly for ease of
removal.
1. Disconnect the input power wiring from terminals L1, L2, L3, and earth connector.
2. Remove the upper most bus bar retaining nut (17 mm) from each of three terminals.
3. If a disconnect (not shown) is mounted, remove the disconnect from the terminal plate
assembly to reduce the weight of the terminal plate as follows.
3a Loosen the connection nut (17 mm) between the fuse and disconnect.
3b Remove the 4 mounting screws (T40) from the disconnect.
3c Note that the weight of the disconnect can be up to 16 kg (35 lbs). Slide dis-
connect down to clear fuses and remove.
4. If a cooling fan is mounted, disconnect the fan cable.
5. If an RFI filter is mounted, disconnect the RFI cable.
6. Note that the weight of the terminal plate without the disconnect can be up to 20 kg (44
8 lbs). To remove the terminal plate, remove the 8 retaining nuts (10 mm) from the ter-
minal plate and lift the entire assembly from the mounting studs.
Reinstall in reverse order of this procedure. Tighten the 10 mm mounting nuts to 4 Nm (35 in-
lbs), 17 mm connection nuts to 19 Nm (170 in-lbs) and T40 mounting screws to 9.5 Nm (85 in-
lbs).
4
5
2
1
130BX97.10
Illustration 8.1: Input Terminal Mounting Plate Assy (shown with RFI and mains fuse options)
1 Input terminals (Step 1) 5 Retaining nut (Step 2)

2 Connection nut (Step 3a) 6 Cooling fan (Step 4)
3 Fuse 7 Input terminal mounting plate
4 RFI filter assembly

8.2.8 Soft Charge Resistor

1. Remove the input terminal plate assembly in accordance with procedure.
2. Disconnect the MK4 connector on the soft charge card.
3. Loosen top retaining nut (8 mm) on soft charge resistor.
4. Remove bottom retaining nut (8 mm) on the soft charge resistor.
5. Lift the bottom of the soft charge resistor and remove the resistor by sliding it down.
Reinstall in reverse order of this procedure. Tighten the 8 mm retaining nuts to 2.3 Nm (20 in-
lbs).
1 2
130BX101.10
8
3
5
Illustration 8.1: Soft Charge Resistor
1 Soft charge card 4* Soft charge resistor

2 MK4 connector (Step 2) 5 Bottom retaining nut (Step 4)
3 Top retaining nut (Step 3)
*380480/500V: Clear wire leads.
525690V: Black wire leads.

8.2.9 SCR and Diode Modules

1. Remove the lower DC capacitor bank in accordance with procedure.
2. Remove the input terminal plate in accordance with procedure.
3. Remove the wire retaining nut (10 mm) from each of the 3 SCR input bus bars (BB41).
4. Note colour coding for each of the 3 wires attached to the retaining studs. Ensure that
the correct wire is attached to the applicable stud upon reassembly. Remove the wiring
from the studs.
5. Remove the wire retaining nut (8 mm) from the SCR output bus bars (BB42). One from
the (+) DC bus bar and one from the () DC bus bar.
6. Note colour coding for each wire attached to the retaining studs. Ensure that the correct
wire is attached to the applicable stud upon reassembly. Remove the wiring from the
studs.
7. Remove the 4 retaining nuts (13 mm) on the side of the bus bars, 2 on each bus bar.
130BX105.10
3
8
4
1
Illustration 8.1: SCR and Diode Modules (1 of 3)
1 Retaining nuts (Step 7) 4 Diode module

2 Wire retaining nut on bus bar BB41 (Step 3) 5 Wire retaining nuts for output bus bars BB42
(Steps 5 & 6)
3 SCR module

8. If the unit is not equipped with the load sharing option, proceed to step 9. If the unit is
equipped with load sharing, the load share minus (-) bus bar must be removed as follows.
8a. Remove the 2 retaining nuts (13 mm) connecting the load share bus bar to
the SCR output bus bar.
8b. Remove the retaining nut (17 mm) connecting the load share bus bar to the
load share terminal on the opposite end of the bus bar (not shown).
8c. Remove the load share bus bar.
9. Remove both positive (+) and negative (-) SCR output bus bars by removing the 6 con-
nection screws (T50). There are 3 screws per bus bar.
10. Remove the three SCR and diode input bus bars by removing the 6 connection screws
(T50). There are 2 screws per bus bar.
CONTINUED NEXT PAGE
130BX129.10
8
1 3
2 6
1 Load sharing option retaining stud (Step 8) 4 Positive (+) output bus bar connecting
screw (Step 9)
2 SCR and diode input bus bar BB41 (Step 10) 5 Negative (-) output bus bar BB42 (Step 9)
3 Positive (+) output bus bar BB42 (Step 9) 6 Negative (-) output bus bar connecting
screw (Step 9)

11. Note which gate lead connects to which SCR module. Ensure that the correct wire is
attached to the applicable SCR upon reassembly. Remove the wiring from each SCR
module. The connector is keyed for proper reinstallation. DO NOT force the connection.
12. Remove the SCR or diode module by removing the 4 retaining screws (T25) from
each module.
5 6 7
130BX107.10
4
3
8
2
1
8
1 SCR module SCR2 5 Diode module D1
2 Retaining screw (Step 12) 6 Diode module D2
3 SCR module SCR1 7 Diode module D3
4 SCR gate lead connection (Step 11) 8 SCR module SCR3
REASSEMBLY
Equipment Damage!
Do not reverse the SCR and diode modules during installation. Reversing the SCR
and diode modules can result in equipment damage.
NB!
For each AC input phase, there is one SCR module and one diode module. The SCR
is on the left, the diode on the right (as seen facing the upright unit). There are three
pairs. Only the SCR module has a connection pin for the gate signals.
1. Replace SCR and diode modules in accordance with the instructions included with the
replacement modules.
2. Reassemble in reverse order.
Attaching Hardware Tightening Torque

T50 Per spare part instruction
T25 Per spare part instruction
17 mm 19 Nm (170 in-lbs)
13 mm 9.5 Nm (85 in-lbs)
10 mm 4 Nm (35 in-lbs)
8 mm 2.3 Nm (20 in-lbs)

8.2.10 Current Sensor

2. Remove the retaining nut (17 mm) connecting the current sensor bus bar to the motor
terminal bus bar.
3. Remove the retaining nut (17 mm) or T50 screw, depending on unit type, connecting
the current sensor bus bar to the IGBT via the fan bus bar.
4. Note which cable is attached to the current sensor. Ensure that the correct cable is at-
tached upon reassembly. Unplug the cable from the current sensor being removed.
5. Remove the 2 retaining nuts (size varies with model) from the stud on the base plate,
and remove the sensor.
Reinstall in reverse order of this procedure. Tighten the 17 mm retaining nuts or T50 screw to 19
Nm (170 in-lbs).
1 2
3
8
4
130BX102.10
Illustration 8.1: Current Sensors
1 Current sensor 3 Current sensor mounting screws (2) (Step 5)

2 IGBT terminal bus bar mounting screw (Step 3) 4 Output motor terminal bus bar retaining nut (Step 2)

8.2.11 Heatsink Fan Assembly

2. Remove the retaining nut (17 mm) or T50 Torx screw, depending on the unit type, con-
necting each of the 3 IGBT over-fan bus bars to the 3 current sensor bus bars.
3. Remove the retaining nut (17 mm) connecting each of three IGBT over-fan bus bars to
three IGBT output bus bars.
4. Disconnect the in-line Molex connector in the fan wiring. Cut the tie wrap to free the
wiring from frame.
5. Remove the fan assembly by removing the 6 retaining nuts (10 mm). Note that the fan
assembly weighs approximately 11 kg (25 pounds).
Reinstall in reverse order of this procedure. Tighten the 10 mm retaining nuts to 4 Nm (35 in-lbs)
and the 17 mm connecting nuts or T50 screw to 19 Nm (170 in-lbs).
130BX103.10
3
4
8
5
2
Illustration 8.1: Fan Assembly
1 IGBT output bus bar BB49 4 Retaining nut (Step 3)

2 Fan housing 5 Molex connector (Step 4)
3 Retaining nut (Step 5) 6 Retaining nut (Step 2)

8.2.12 AC Input, Motor, Load Sharing or Regen Terminals

1. Remove the external wiring from the terminals as required.
2. Remove the retaining nut (17 mm) connecting the terminal bus bar to other bus bar
assemblies.
3. Remove the 2 retaining nuts (13 mm) attaching the terminal bus bar to the terminal block
insulation. Slide the terminal bus bar out.
4. If the terminal block is attached to the input terminal plate (not shown), remove the
retaining screw (T40) attaching the terminal block insulation, otherwise go to step 5.
5. If the terminal block is not attached to the input terminal plate, remove the retaining nut
(13 mm) attaching the terminal block insulation.
Reinstall in reverse order of this procedure. Tighten the 17 mm connecting nuts to 19 Nm (170
in-lbs) and the 13 mm or T40 Torx screw to 9.5 Nm (85 in-lbs).
130BX106.10
2
3 8
1
Illustration 8.1: Terminal Blocks
1 Retaining nuts (Step 3) 3 Terminal block insulation (Step 4 or 5)


8.2.13 IGBT Modules

1. Remove both DC capacitor banks in accordance with the procedure.
2. Remove the Input Terminal Plate in accordance with procedure.
3. Remove the wire retaining nut (10 mm) from each of the 3 SCR input bus bars.
4. Note colour coding for each of the 3 wires attached to the retaining studs. Ensure that
the correct wire is attached to the applicable stud upon reassembly. Remove the wiring
from the studs.
5. Remove the wire retaining nut (8 mm) from the SCR output bus bars. One from the (+)
DC bus bar and one from the () DC bus bar.
6. Note colour coding for each wire attached to the retaining studs. Ensure that the correct
wire is attached to the applicable stud upon reassembly. Remove the wiring from the
studs.
7. Remove the 4 retaining nuts (13 mm) on the side of the bus bars, 2 on each bus bar.
CONTINUED NEXT PAGE
130BX130.10
8
3
Illustration 8.1: IGBT Modules (1 of 4)
1 Retaining nuts (Step 7) 3 IGBT board

2 Wire retaining nut on bus bar BB41 (Step 3) 4 Wire retaining nuts for output bus bars BB42
(Steps 5 & 6)

8. If the unit is not equipped with the load sharing option, proceed to step 9. If the unit is
equipped with load sharing, the load share minus (-) bus bar must be removed as follows.
8a. Remove the 2 retaining nuts (13 mm) connecting the load share bus bar to
the SCR output bus bar.
8b. Remove the retaining nut (17 mm) connecting the load share bus bar to the
load share terminal on the opposite end of the bus bar (not shown).
8c. Remove the load share bus bar.
9. Remove both positive (+) and negative (-) SCR output bus bars by removing the 6 con-
nection screws (T50). There are 3 screws per bus bar.
10. Remove the three SCR and diode input bus bars by removing the 6 connection screws
(T50). There are 2 screws per bus bar.
CONTINUED NEXT PAGE
130BX129.10
8
1 3
2 6
1 Load sharing option retaining studs (Step 8) 4 Positive (+) output bus bar connecting screw (Step 9)
2 SCR and diode input bus bar BB41 (Step 10) 5 Negative (-) output bus bar BB42 (Step 9)
3 Positive (+) output bus bar BB42 (Step 9) 6 Negative (-) output bus bar connecting screw (Step 9)

11. Remove the 6 retaining screws (T30) connecting each IGBT module output to the IGBT
output bus bars.
12. Remove the retaining nut (17 mm) connecting the IGBT output bus bar to IGBT over-
fan bus bar. Note that there is one for each of three phases.
13. Remove the retaining nut (17 mm) or T50 Torx screw, depending on the unit type, con-
necting to IGBT over-fan bus bar to current sensor bus bar.
14. Remove the 3 retaining nuts (17 mm) at top and one retaining nut (8 mm) at bottom
attaching IGBT output bus bar to standoffs. Remove the IGBT output bus bar.
CONTINUED NEXT PAGE
130BX104.10
1
8
2
1 Retaining screw (Step 11) 5 Retaining nut (Step 12)

2 Retaining nut (Step 14) 6 Over-fan bus bar
3 Output bus bar 7 Retaining nut (Step 13)

15. Remove the 18 retaining screws (T30) on the IGBT input terminals. Note snubber ca-
pacitors come off when screws are removed. There are 6 screws for each IGBT module.
16. Remove the 2 retaining nuts (8 mm) connecting each IGBT-cap bus bar assembly to the
IGBT-Ind bus bar assembly and remove the IGBT-cap bus bar assembly. There are three
IGBT-cap bus bar assemblies.
17. Remove the retaining nut (8 mm) from the high frequency board.
18. Remove the 2 retaining screws (T25) from the high frequency board.
19. Disconnect the wire assembly from the high frequency board and remove the board.
20. If the unit has Brake IGBTs, remove the 4 retaining screws (T30) connecting the IGBT-
Ind bus bar assembly to the Brake IGBT. Note that there are 2 screws per Brake IGBT
module.
21. Remove the 4 retaining nuts (13 mm) connecting the IGBT-Ind bus bar assembly to two
DC bus bars from the inductor. Remove the IGBT-Ind bus bar assembly.
22. Remove the 8 retaining screws (T25) mounting each IGBT module.
2 4
1 5 8
10
11
130BX131.10
1 Snubber capacitor 7 Retaining screw (Step 16)

2 Retaining screw (Brake IGBT option) (Step 20) 8 Retaining screw (Step 15)
3 Retaining nut (Step 17) 9 IGBT-Cap bus bar BB47
4 Retaining nut (Step 21) 10 IGBT board
5 High Frequency board 11 IGBT retaining screw (Step 22)

REASSEMBLY
1. Replace the IGBT modules in accordance with instructions included with the replacement
modules.
2. Reassemble in reverse order.
Attaching Hardware Tightening Torque

8 mm/T25 2.3 Nm (20 in-lbs)
10 mm/T30 4 Nm (35 in-lbs)
13 mm 9.5 Nm (85 in-lbs)
17 mm/T50 19 Nm (170 in-lbs)

Frequency Converters 9 Special Test Equipment
9 Special Test Equipment
9.1 Test Equipment

Test tools have been developed to aid in troubleshooting these products. It is highly recommended
for repair and servicing this equipment that these tools be available to the technician. Without
them, some troubleshooting procedures described in this manual cannot be carried out. Although
some test points can be found inside the frequency converter to probe for similar signals, the test
tools provide a safe and sure location for making necessary measurements. Test equipment de-
scribed in this section is available from Danfoss.
Using the test cable allows powering the frequency converter without having to
charge DC bus capacitors. Main input power is required and all devices and power
when conducting tests on a powered frequency converter. Contact with powered
9.1.1 Test Cables and SCR Shorting Plug Kit p/n 176F8439
This tool provides the ability to power up the
Switch Mode Power Supplies (SMPS) and ac-
9
130BX64.10
tivate all the control functions of the frequen-
cy converter without having the DC bus
capacitors charged. It provides protection for
Illustration 9.1: SCR Shorting Plug
troubleshooting gate drive signals and other
important control signals within the frequency
converter.
The test kit includes the shorting plug and Illustration 9.2: Two-pin D-frame Test Cable
connector cables. The cable is connected be-
tween the soft charge card and the power
card. The SCR shorting plug shorts the gates
of the SCRs to ensure they do not fire and add
a charge to the DC bus. Illustration 9.3: Three-pin E-frame Test Cable

9 Special Test Equipment Frequency Converters
To install the cable, first make sure the frequency converter is powered down and the
DC bus is fully discharged.
1. For D-frame size units, follow the procedure in Section 7 for soft charge card removal
and disengage the soft charge card far enough to disconnect the cable plugged into the
MK3.
2. For all frame sizes, disconnect the cable from the MK3 connector on the soft charge card
and connect one end of the test cable into the MK3.
3. For D-frame size units, reinstall the soft charge card.
4. For all frame sizes, disconnect connectors MK100 and MK105 on the power card.
5. For all frame sizes, connect the free end of the test cable into MK105.
6. For all frame sizes, connect the SCR gate shorting plug into the cable that was removed
from MK100.
When reapplying main input power to the frequency converter, the soft charge rectifier provides
DC power to the power card. Testing with the use of the gate signal board and the signal test
board can now be carried out without the presence of DC bus voltage.
9.1.2 Signal Test Board (p/n 176F8437)

The signal test board provides access to a va-
riety of signals that can be helpful in trouble-
shooting the frequency converter.
9 The signal test board is plugged into power

card connector MK104. Points on the signal
test board can be monitored with or without
the DC bus disabled. In some cases, the fre-
quency converter will need the DC bus ena-
bled and operating a load to verify some test 130BX66.10
signals.
Illustration 9.4: Signal Test Board

The following is a description of the signals
available on the signal test board. Section 6 of
this manual describes when these tests would
be called for and what the signal should be at
that given test point.
9.1.3 Signal Test Board Pin Outs: Description and Voltage Levels
The tables on the following pages list the pins located on the signal test board. For each pin, its
function, description, and voltage levels are provided. Details on performing tests using the test
fixture are provided in Section 6 of this manual. Other than power supply measurements, most of
the signals being measured are made up of waveforms.
Although in some cases, a digital voltmeter can be used to verify the presence of such signals, it
cannot be relied upon to verify that the waveform is correct. An oscilloscope is the instrument
prefered. However, when similar signals are being measured at multiple points, a digital voltmeter
can be used with some degree of confidence. By comparing several signals to each other, such
as gate drive signals, and obtaining similar readings, it can be concluded each of the waveforms
match one another and are therefore correct. Values are provided for using a digital voltmeter for
testing as well.

Frequency Converters 9 Special Test Equipment
Pin Sche- Function Description Reading Using a Digital Voltmeter

No. matic
Acro-
nym
1 IU1 Current sensed, .937 VACpeak @ 165% of CT current
U phase, not con- rating. AC waveform @ output frequen-
ditioned cy of the frequency converter.
Approx 400 mv RMS @100% load

2 IV1 Current sensed, .937 VACpeak @ 165% of CT current
V phase, not con- rating. AC waveform @ output frequen-

3 IW1 Current sensed, .937 VACpeak @ 165% of CT current
W phase, not con- rating. AC waveform @ output frequen-

4 COM- Logic common This common is for all signals.
MON
5 AMBT Ambient temp. Used to control FAN high and low fan 1 VDC approximately equal to 25C
speeds.
6 FANO Control Card sig- Signal from the control card to turn the 0 VDC ON command
nal fans on and off. 5 VDC OFF command
7 INRUSH Control Card sig- Signal from the control card to start gating 3.3 VDC SCRs disabled
8 RL1
nal the SCR front end
Control Card sig- Signal from Control Card to provide status
0 VDC SCRs enabled
0 VDC Relay active
9
nal of Relay 01 0.7 VDC inactive
9 Not used
10 Not used
11 VPOS +18 VDC regula- The red LED indicates voltage is present +18 VDC regulated supply +16.5 to
ted supply +16.5 between VPOS and VNEG terminals. 19.5 VDC
to 19.5 VDC
12 VNEG -18 VDC regulated The red LED indicates voltage is present -18 VDC regulated supply
supply between VPOS and VNEG terminals. -16.5 to 19.5 VDC
-16.5 to 19.5 VDC
13 DBGATE Brake IGBT gate Voltage drops to zero when brake is
pulse train turned off. Voltage increases to 4.04
VDC as brake duty cycle reaches max.
Varies w/ brake duty cycle

14 BRT_O Brake IGBT 5V 5.10 VDC level with the brake turned
N logic level signal. off. Voltage decreases to zero as brake
duty cycle reaches max.
Varies w/ brake duty cycle

15 Not used
16 FAN_TS Control signal for Indicates Fan Test switch is activated to +5VDC disabled
T fans force the fans on high 0VDC fans on high
17 FAN_ON Pulse train to gate 5VDC - fans off
SCRs for fan volt-
age control. In
sync with line freq.
7 trigger pulses at 3Khz

9 Special Test Equipment Frequency Converters
Pin Sche- Function Description Reading Using a Digital Voltmeter

No. matic
Acro-
nym
18 HI_LOW Control signal Signal to switch fan speeds between high +5VDC = fans on high,
from Power Card and low Otherwise, 0VDC.
19 SCR_DI Control signal for Indicates SCR front end is enabled or dis- 0.6 to 0.8 VDC SCRs enabled
S SCR front end abled. 0VDC SCR disabled
20 INV_DI Control signal Disables IGBT gate voltages 5VDC inverter disabled
S from Power Card 0VDC inverter enabled
21 Not used
22 UINVEX Bus Voltage scaled Signal proportional to UDC OV switch must be off
down - 1 VDC = 450 VDC [T4/T5]
- 1 VDC = 610 VDC [T7]
23 VDD +24 VDC power Yellow LED indicates voltage is present. +24 VDC regulated supply
supply +23 to 25 VDC
24 VCC +5.0 VDC regula- The green LED indicates voltage is +5.0 VDC regulated supply +4.75 to
ted supply. present. 5.25 VDC
+4.75-5.25 VDC
25 GUP_T IGBT gate signal, 2.22.5 VDC
buffered, U phase, Equal on all phases
positive. Signal TP25-TP30
originates on Con-
trol Card.
2v/div 100us/div Run@10Hz

26 GUN_T IGBT gate signal, 2.22.5 VDC
buffered, U phase, Equal on all phases
negative. Signal TP25-TP30
originates on Con-
trol Card.
9 27 GVP_T IGBT gate signal,

buffered, V phase,
2.22.5 VDC
Equal on all phases
positive. Signal TP25-TP30
originates on Con-
trol Card.

28 GVN_T IGBT gate signal, 2.22.5 VDC
buffered, V phase, Equal on all phases
negative. Signal TP25-TP30
originates on Con-
trol Card.

29 GWP_T IGBT gate signal, 2.22.5 VDC
buffered, W Equal on all phases
phase, positive. TP25-TP30
Signal originates
on Control Card.

30 GWN_T IGBT gate signal, 2.22.5 VDC
buffered, W Equal on all phases TP25-TP30
phase, negative.
Signal originates
on Control Card.

Frequency Converters 10 Spare Parts List
10 Spare Parts List
10.1 Spare Parts List

10.1.1 General Notes
General Notes:
All spare parts are suitable for conformal coated frequency converters and can be used in either
coated or non-conformal coated frequency converters.
Bus bars used in some units are aluminum. Spare part bus bars are always plated copper. Plated
copper bus bars are useable for all units.
For the latest spare parts list, visit the Danfoss website at www.danfossdrives.com
10

10
178
10.1.2 Spare Parts Lists
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Dia- Spare FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
10 Spare Parts List
gram Des- Part Spare Part Name Comments FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
ignator Number FC 302 P90K P110 P132 P160 P200 P250 P315 P355 P400
PCA
PCA3 176F8652 Spare, power card, pdefc-xxxP110T4xxxxxUxC Power card, conformal coated, does not include scaling card 102 --- --- --- --- --- --- --- ---
PCA3 176F8653 Spare, power card, pdefc-xxxP132T4xxxxxUxC Power card, conformal coated, does not include scaling card --- 102 --- --- --- --- --- --- ---
PCA3 176F8654 Spare, power card, pdefc-xxxP160T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- 102 --- --- --- --- --- ---
PCA3 176F8655 Spare, power card, pdefc-xxxP200T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- 102 --- --- --- --- ---
PCA3 176F8656 Spare, power card, pdefc-xxxP250T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- 102 --- --- --- ---
PCA3 176F8657 Spare, power card, pdefc-xxxP315T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- 102 --- --- ---
PCA3 176F8658 Spare, power card, pdefc-xxxP355T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- 102 --- ---
PCA3 176F8659 Spare, power card, pdefc-xxxP400T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- --- 102 ---
PCA3 176F8660 Spare, power card, pdefc-xxxP450T4xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- --- --- 102
MG.90.L1.02 - VLT is a registered Danfoss trademark

PCA4 176F8308 Spare, Current Scaling PCA, 4.54 Ohm Installs on the Power Card 1 --- --- --- --- --- --- --- ---
PCA4 176F8309 Spare, Current Scaling PCA, 3.79 Ohm Installs on the Power Card --- 1 --- --- --- --- --- --- ---
PCA4 176F8310 Spare, Current Scaling PCA, 3.10 Ohm Installs on the Power Card --- --- 1 --- --- --- --- --- ---
PCA4 176F8311 Spare, Current Scaling PCA, 2.56 Ohm Installs on the Power Card --- --- --- 1 --- --- 1 1 ---
PCA4 176F8312 Spare, Current Scaling PCA, 5.10 Ohm Installs on the Power Card --- --- --- --- 1 --- --- --- ---
PCA4 176F8554 Spare, Current Scaling PCA, 4.21 Ohm Installs on the Power Card --- --- --- --- --- 1 --- --- ---
PCA4 176F8627 Spare, Current Scaling PCA, 2.32 Ohm Installs on the Power Card --- --- --- --- --- --- --- --- 1
PCA5 176F8626 Spare, FC Gate Drive PCA, CC, D&E Frame Gate Drive Board 1 1 1 1 1 1 1 1 1
PCA8 176F8307 Spare, HF PCA, T5, D&E Frame High Frequency Board 1 1 1 1 1 1 1 1 1
PCA11 176F8306 Spare, Soft charge PCA, CC, T5, D Frame Soft charge Board, Includes mounting bracket 1 1 1 1 1 --- --- --- ---
PCA11 176F8555 Spare, Soft charge PCA, CC, T5, E Frame Soft charge Board --- --- --- --- --- 1 1 1 1
PCA9 176F8510 Spare, Balance PCA, T5, D&E Frame Capacitor Bank Balance Card, included with spare Cap Bank 1 1 1 2 2 2 2 2 2
Table 10.1: Spare Parts List PCA3, PCA4, PCA5, PCA8 and PCA11
Frequency Converters
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
FC 302 P90K P110 P132 P160 P200 P250 P315 P355 P400
Semiconductors
IGBT1, 2 176F8628 Spare, FC IGBT kit, 300A, T5, D Frame 1 IGBT per kit 1 --- 2 2 --- --- --- --- ---
IGBT1,2 176F8629 Spare, FC IGBT kit, 450A, T5, D Frame 1 IGBT per kit --- 1 --- --- 2 --- --- --- ---
IGBT1,2 3 176F8630 Spare, FC IGBT kit, 300A, T5, E Frame 1 IGBT per kit --- --- --- --- --- 3 --- --- ---
IGBT1,2 3 176F8631 Spare, FC IGBT kit, 450A, T5, E Frame 1 IGBT per kit --- --- --- --- --- --- 3 3 3
IGBT4,5 176F8316 Spare, Brake IGBT kit, D&E Frame 1 IGBT per kit 1 1 2 2 2 2 2 2 2
SCR1,2,3 176F8317 Spare, SCR/diode kit, 160A, T5, D Frame 1 SCR and diode per kit 3 3 --- --- --- --- --- --- ---
SCR1,2,3 176F8318 Spare, SCR/diode kit, 175A, T5, D Frame 1 SCR and diode per kit --- --- 3 --- --- --- --- --- ---
SCR1,2,3 176F8319 Spare, SCR/diode kit, 250A, T5, D Frame 1 SCR and diode per kit --- --- --- 3 --- --- --- --- ---
SCR1,2,3 176F8320 Spare, SCR/diode kit, 330A,T5, D Frame 1 SCR and diode per kit --- --- --- --- 3 --- --- --- ---
SCR1,2,3 176F8558 Spare, SCR kit, 500A, T5, E Frame 1 SCR per kit --- --- --- --- --- 3 3 3 3
D1,2,3 176F8559 Spare, diode kit, 600A, T5, E Frame 1 diode per kit --- --- --- --- --- 3 3 3 3
Resistors
R1 176F8322 Spare, Soft charge Resistor, 27 Ohm, 110W Soft charge resistor assembly 1 1 1 1 1 --- --- --- ---
R1 176F8560 Spare, Soft charge Resistor, 27 Ohm, 155W Soft charge resistor assembly --- --- --- --- --- 1 1 1 1
Capacitors
C2, 3, 4, 5, 176F8323 Spare, CAP, IGBT Snubber, 1000V, 1.5uF IGBT snubber caps mounted on the IGBT modules 3 3 6 6 6 9 9 9 9
6, 7, 8, 9,
10
CBANK1,2 176F8324 Spare, CAP Bank, D Frame, 4cap, T5 Capacitor bank, includes balance card 1 --- --- 2 1 --- --- --- ---
CBANK1,2 176F8325 Spare, CAP Bank, D Frame, 6cap, T5 Capacitor bank, includes balance card --- 1 1 --- 1 --- --- --- ---
CBANK1,2 176F8636 Spare, CAP Bank, E Frame, 6cap, T5 Capacitor bank, includes balance card --- --- --- --- --- 2 1 --- ---

CBANK1,2 176F8637 Spare, CAP Bank, E Frame, 8cap, T5 Capacitor bank, includes balance card --- --- --- --- --- --- 1 2 2
Fans
F1+C1 176F8329 Spare, Heatsink Fan Assy, D Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables 1 1 1 1 1 --- --- --- ---
F1+C1 176F8578 Spare, Heatsink Fan Assy, small E Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables --- --- --- --- --- 1 --- --- ---
F1+C1 176F8579 Spare, Heatsink Fan Assy, large E Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables --- --- --- --- --- --- 1 1 1
F2,3 176F8330 Spare, Door Fan Kit, D&E Frame Door Fan Kit. Includes fan, grills, support, fasteners (1 fan per 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54
kit)
176F8331 Spare, Door Vent Kit, D&E Frame Door Vent Kit. Includes grill, support, fasteners (1 vent per kit) 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54
176F8332 Spare, Door Fan Filter, PKG10, D&E Frame Door Filters, Package of 10 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54
F4 176F8639 Spare, FC DC Top Fan, IP00 D Frame IP00 Top Fan, Fan Only (1 fan per kit) IP00 IP00 IP00 IP00 IP00 --- --- --- ---
F2 176F8333 Spare, Door/Top AC Fan, D&E Frame IP00 Top Fan, Fan Only (1 fan per kit) --- --- --- --- --- IP00 IP00 IP00 IP00
F2,3 176F8333 Spare, Door/Top AC Fan, D&E Frame IP21/IP54 Door Fan, Fan Only (1 fan per kit) 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54 21/54
F5 176F8612 Spare, Fuse Fan, Input Plate, E Frame Input fuse fan for units with RFI and Mains Fuse --- --- --- --- --- 1 1 1 1
Table 10.2: Spare Parts List Semiconductors, Resistors, Capacitors and Fans
10 Spare Parts List
179
10
10
180
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
Block Diagram Spare Part
Spare Part Name Comments FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
Designator Number
FC 302 P90K P110 P132 P160 P200 P250 P315 P355 P400
10 Spare Parts List
Fuses
FU1,2,3 176F8334 Spare, Fuse, Main, 350A Mains Fuse. 1 fuse per kit 3 3 --- --- --- --- --- --- ---
FU1,2,3 176F8335 Spare, Fuse, Main, 630A Mains Fuse. 1 fuse per kit --- --- 3 3 3 --- --- --- ---
FU1,2,3 176F8591 Spare, Fuse, Main, 700A Mains Fuse. 1 fuse per kit --- --- --- --- --- 3 --- --- ---
FU1,2,3 176F8592 Spare, Fuse, Main, 900A Mains Fuse. 1 fuse per kit --- --- --- --- --- --- 3 3 3
176F8336 Spare, Fuse, Soft charge, 20A, PKG3, D&E Frame Soft charge fuse. Package of 3 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg
FU5 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Power Card Fuse, 4 amp. Package of 3 1 1 1 1 1 1 1 1 1
FU4 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Fan Transformer Fuse, 4 amp. Package of 3 1 1 1 1 1 1 --- --- ---
FU4 176F8609 Spare, Fuse, 15A, PKG3, Fan, E Frame Fan Transformer Fuse, 15 amp. Package of 3 --- --- --- --- --- --- 1 1 1
Inductors and Current Sensors

L1 176F8337 Spare, Bus Inductor, 200uH DC Link Coil, Small D Frame 1 --- --- --- --- --- --- --- ---
L1 176F8338 Spare, Bus Inductor, 157uH DC Link Coil, Small D Frame --- 1 --- --- --- --- --- --- ---
L1 176F8339 Spare, Bus Inductor, 136uH DC Link Coil, Large D Frame --- --- 1 --- --- --- --- --- ---
L1 176F8340 Spare, Bus Inductor, 109uH DC Link Coil, Large D Frame --- --- --- 1 --- --- --- --- ---
L1 176F8341 Spare, Bus Inductor, 87uH DC Link Coil, Large D Frame --- --- --- --- 1 --- --- --- ---
L1 176F8564 Spare, Bus Inductor, 62uH, E Frame DC Link Coil, E Frame --- --- --- --- --- 1 --- --- ---
L1 176F8565 Spare, Bus Inductor, 51uH, E Frame DC Link Coil, E Frame --- --- --- --- --- --- 1 1 1
L2,3,4 176F8342 Spare, Current Sensor, 300A Motor Current Sensor, 1 sensor per kit 3 3 3 3 --- --- --- --- ---
L2,3,4 176F8343 Spare, Current Sensor, 500A Motor Current Sensor, 1 sensor per kit --- --- --- --- 3 3 --- --- ---
L2,3,4 176F8563 Spare, Current Sensor, 1000A Motor Current Sensor, 1 sensor per kit --- --- --- --- --- --- 3 3 3
TR1 176F8344 Spare, Fan Transformer Assy, 500V Fan Transformer. Includes cables and plug 1 1 1 1 1 --- --- --- ---
TR1 176F8566 Spare, Fan Transformer Assy, 5352T5 Fan Transformer. Includes cables and plug --- --- --- --- --- 1 --- --- ---
TR1 176F8567 Spare, Fan Transformer Assy, 1500VA Fan Transformer. Includes cables and plug --- --- --- --- --- --- 1 1 1
L5 176F8577 Spare, Heatsink Fan Inductor, E Frame Fan Inductor --- --- --- --- --- --- 1 1 1
Disconnects
SW1 176F8345 Spare, Disconnect SW,200A, D Frame Disconnect Switch 1 1 --- --- --- --- --- --- ---
SW1 176F8347 Spare, Disconnect SW, 400A, D Frame Disconnect Switch --- --- 1 1 1 --- --- --- ---
SW1 176F8593 Spare, Disconnect SW, 600A, E Frame Disconnect Switch --- --- --- --- --- 1 --- --- ---

SW1 176F8594 Spare, Disconnect SW, 800A, E Frame Disconnect Switch --- --- --- --- --- --- 1 1 1
176F8346 Spare, Disconnect Handle, Rod, D Frame Disconnect Handle 1 1 --- --- --- --- --- --- ---
176F8348 Spare, Disconnect Handle, Rod, D2&E Frame Disconnect Handle --- --- 1 1 1 1 1 1 1
Table 10.3: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Di- Spare FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
agram Desig- Parts Spare Parts Name Comments FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
nator Number FC 302 P90K P110 P132 P160 P200 P250 P315 P355 P400
Cables
CBL1 176F8640 Spare, Cable, FC LCP, D Frame, IP54 ribbon cable from the LCP to the control card, IP54 enclosure IP54 IP54 IP54 IP54 IP54 --- --- --- ---
CBL1 176F85861 Spare, Cable, LCP, E Frame ribbon cable from LCP to control card --- --- --- --- --- 1 1 1 1
76F8586
CBL2 176F8641 Spare, Cable, Control PCA, 44pin, D&E Frame ribbon cable from control card to power card 1 1 1 1 1 1 1 1 1
CBL5 176F8541 Spare, Cable, FC Current Sensor, D2 Frame wire harness from power card to current sensors 1 1 --- --- --- --- --- --- ---
CBL5 176F8349 Spare, Cable, FC Current Sensor, D Frame wire harness from power card to current sensors --- --- 1 1 1 --- --- --- ---
CBL5 176F8568 Spare, Cable, FC I-Sensor, small E Frame wire harness from power card to current sensors --- --- --- --- --- 1 --- --- ---
CBL5 176F8569 Spare, Cable, FC I-Sensor, large E Frame wire harness from power card to current sensors --- --- --- --- --- --- 1 1 1
CBL8 176F8542 Spare, Cable, HS Fan, D1 Frame wire harness from the power card to the fan transformer 1 1 --- --- --- --- --- --- ---
CBL8 176F8359 Spare, Cable, HS Fan, D2 Frame wire harness from the power card to the fan transformer --- --- 1 1 1 --- --- --- ---
CBL8 176F8571 Spare, Cable, Fan, IP00, small E Frame wire harness for all AC fans on IP00 units --- --- --- --- --- IP00 --- --- ---
CBL8 176F8572 Spare, Cable, Fan, IP21/54, small E Frame wire harness for all AC fans on IP21 and IP54 units --- --- --- --- --- 21/54 --- --- ---
CBL8 176F8573 Spare, Cable, Fan, IP00, large E Frame wire harness for all AC fans on IP00 units --- --- --- --- --- --- IP00 IP00 IP00
CBL8 176F8574 Spare, Cable, Fan, IP21/54, large E Frame wire harness for all AC fans on IP21 and IP54 units --- --- --- --- --- --- 21/54 21/54 21/54
CBL9 176F8354 Spare, Cable, Softchg RST prime, D Frame wire harness from soft charge to power card 1 1 1 1 1 --- --- --- ---
CBL9 176F8570 Spare, Cable, Softchg RST prime, E Frame wire harness from soft charge to power card --- --- --- --- --- 1 1 1 1
CBL12 176F8358 Spare, Cable, Door Fan, D Frame wire harness for AC door fans 21/54 21/54 21/54 21/54 21/54 --- --- --- ---
CBL13 176F8544 Spare, Cable, FC SCR, D1 Frame wire harness from power card to SCR 1 1 --- --- --- --- --- --- ---
CBL13 176F8357 Spare, Cable, FC SCR, D2 Frame wire harness from power card to SCR --- --- 1 1 1 --- --- --- ---
CBL13 176F8575 Spare, Cable, FC SCR, E Frame wire harness from power card to SCR --- --- --- --- --- 1 1 1 1
CBL14 176F8356 Spare, Cable, DC to Power PCA, DFrame voltage from DC bus to power card 1 1 1 1 1 --- --- --- ---
CBL14 176F85761 Spare, Cable, DC to Power PCA, E Frame voltage from DC bus to power card --- --- --- --- --- 1 1 1 1
76F8576

CBL15 176F8830 Spare, Cable, RFI Switch, D Frame wire from gate drive card to RFI filter 1 1 1 1 1 --- --- --- ---
CBL15 176F8580 Spare, Cable, RFI Switch, E Frame wire from gate drive card to RFI filter --- --- --- --- --- 1 1 1 1
CBL16 176F8363 Spare, Cable, FC Gate Drive, 16pin, D1 Frame ribbon cable from power card to gate drive card 1 1 --- --- --- --- --- --- ---
CBL16 176F8350 Spare, Cable, FC Gate Drive, 16pin, D2 Frame ribbon cable from power card to gate drive card --- --- 1 1 1 --- --- --- ---
CBL16 176F8581 Spare, Cable, FC Gate Drive, 16pin, E Frame ribbon cable from power card to gate drive card --- --- --- --- --- 1 1 1 1
CBL17,18,19 176F8364 Spare, Cable, IGBT Gate, D1 Frame wire harness from gate drive card to IGBT module (1 per kit) 3 3 --- --- --- --- --- --- ---
CBL17,18,19 176F8351 Spare, Cable, IGBT Gate, D2 Frame wire harness from gate drive card to IGBT module (1 per kit) --- --- 3 3 3 --- --- --- ---
CBL17,18,19 176F8582 Spare, Cable, IGBT Gate, E1 Frame wire harness from gate drive card to IGBT module (1 per kit) --- --- --- --- --- 3 3 3 3
CBL20 176F8352 Spare, Cable, IGBT Temperature temperature connection from IGBT module to gate drive card 1 1 1 1 1 1 1 1 1
CBL21 176F8365 Spare, Cable, Brake IGBT, D2 Frame wire harness from gate drive card to brake IGBT module 1 1 --- --- --- --- --- --- ---
CBL21 176F8368 Spare, Cable, Brake IGBT, D Frame wire harness from gate drive card to brake IGBT module --- --- 1 1 1 --- --- --- ---
CBL21 176F8583 Spare, Cable, Brake IGBT, E Frame wire harness from gate drive card to brake IGBT module --- --- --- --- --- 1 1 1 1
Table 10.4: Spare Parts List Cables

10 Spare Parts List
181
10
10
182
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Spare FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
Block Diagram
Parts Spare Parts Name Comments FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
Designator
Number FC 302 P90K P110 P132 P160 P200 P250 P315 P355 P400
10 Spare Parts List
Cables
CBL22 176F8366 Spare, Cable, Brake Power Plus, D1 Frame cable from brake IGBT to brake plus terminal 1 1 --- --- --- --- --- --- ---
CBL22 176F8369 Spare, Cable, Brake Power Plus, D2 Frame cable from brake IGBT to brake plus terminal --- --- 1 1 1 --- --- --- ---
CBL23 176F8367 Spare, Cable, Brake Power Minus, D1 Frame cable from brake IGBT to brake minus terminal 1 1 --- --- --- --- --- --- ---
CBL23 176F8370 Spare, Cable, Brake Power Minus, D2 Frame cable from brake IGBT to brake minus terminal --- --- 1 1 1 --- --- --- ---
CBL24 176F8543 Spare, Cable, Softchg RST, D1 Frame wire harness from input power to soft charge board 1 1 --- --- --- --- --- --- ---
CBL24 176F8353 Spare, Cable, Softchg RST, D2 Frame wire harness from input power to soft charge board --- --- 1 1 1 --- --- --- ---
CBL24 176F8584 Spare, Cable, Softchg RST, E Frame wire harness from input power to soft charge board --- --- --- --- --- 1 1 1 1
CBL25 176F8355 Spare, Cable, Softchg to DC bus, D Frame wire harness from soft charge to DC bus 1 1 1 1 1 --- --- --- ---
CBL25 176F8585 Spare, Cable, Softchg to DC bus, E Frame wire harness from soft charge to DC bus --- --- --- --- --- 1 1 1 1
CBL26 176F8613 Spare, Cable, FC Fuse Fan, E Frame cable from power card to fan fuse --- --- --- --- --- 1 1 1 1

380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Diagram
Designator
Terminals, Labels, Insulators
TB1 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame mains terminal bus bar (1 per kit) 3 3 --- --- --- --- --- --- ---
TB1 176F8375 Spare, BB, Terminals, Mains, Motor, D Frame mains terminal bus bar (1 per kit) --- --- 3 3 3 --- --- --- ---
TB1 176F8587 Spare, BB, Terminal Block, E Frame mains terminal stepped bus bar (1 per kit) --- --- --- --- --- 3 3 3 3
TB2 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame motor terminal bus bar (1 per kit) 3 3 --- --- --- --- --- --- ---
TB2 176F8375 Spare, BB, Terminals, Mains, Motor, D Frame motor terminal bus bar (1 per kit) --- --- 3 3 3 --- --- --- ---
TB2 176F8587 Spare, BB, Terminal Block, E Frame motor terminal stepped bus bar (1 per kit) --- --- --- --- --- 3 3 3 3
TB3 176F83956 Spare, BB, Terminal, LS, BK, D Frame brake terminal bus bar (1 per kit) 2 2 2 2 2 --- --- --- ---
KAF6H8395
TB3 176F8399 Spare, BB, Terminal, LS, LT, D Frame left brake terminal bus bar --- --- --- --- --- 1 1 1 1
TB3 176F8404 Spare, BB, Load Share, 2, D Frame right brake terminal bus bar --- --- --- --- --- 1 1 1 1
TB4 176F8395 Spare, BB, Terminal, LS, BK, D Frame load share terminal bus bar (1 per kit) 2 2 --- --- --- --- --- --- ---
TB4 176F8399 Spare, BB, Terminal, LS, LT, D Frame left load share terminal bus bar --- --- 1 1 1 --- --- --- ---
TB4 176F8404 Spare, BB, Load Share, 2, D Frame right load share terminal bus bar --- --- 1 1 1 --- --- --- ---
TB4 176F8587 Spare, BB, Terminal Block, E Frame load share terminal stepped bus bar (1 per kit) --- --- --- --- --- 2 2 2 2
TB1 176F8371 Spare, Terminal Insul, mains, motor, D Frame mains terminal insulation block 1 1 1 1 1 --- --- --- ---
TB1 176F8588 Spare, Insul, Terminal Block, E Frame mains terminal insulation block (1 per kit) --- --- --- --- --- 3 3 3 3
TB2 176F8371 Spare, Terminal Insul, mains, motor, D Frame motor terminal insulation block 1 1 1 1 1 --- --- --- ---
TB2 176F8588 Spare, Insul, Terminal Block, E Frame motor terminal insulation block (1 per kit) --- --- --- --- --- 3 3 3 3
TB3 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame brake terminal insulation block 1 1 1 1 1 1 1 1 1
TB4 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame load share terminal insulation block 1 1 1 1 1 --- --- --- ---
TB4 176F8588 Spare, Insul, Terminal Block, E Frame load share terminal insulation block (1 per kit) --- --- --- --- --- 2 2 2 2

176F8373 Spare, Label Set, Terminal Blk, D Frame terminal block label set includes mains, motor, brake, load share 1 1 1 1 1 --- --- --- ---
176F85896 Spare, Label Set, Terminal, EFrame terminal block label set includes mains, motor, brake, load share --- --- --- --- --- 1 1 1 1
KAF6H8589
176F8545 Spare, Insul, Mylar, IGBT, Bus, D1 Frame insulation under IGBT input bus bar assemblies 1 1 --- --- --- --- --- --- ---
176F8421 Spare, Insul, Mylar, IGBT, Bus, D2 Frame insulation under IGBT input bus bar assemblies --- --- 1 1 1 --- --- --- ---
176F8590 Spare, Insul, IGBT-Chassis, E Frame insulation under IGBT input bus bar assemblies --- --- --- --- --- 1 1 1 1
176F8547 Spare, Insul, IGBT snubber cap support mounts between IGBT and snubber capacitors (1 per kit) 1 1 2 2 2 --- --- --- ---
176F8546 Spare, Insul, between mains fuse, T6/7 insulator between mains fuses --- --- --- --- --- --- --- --- ---
176F8410 Spare, BB Stand Off, PKG10 bus bar mounting standoff (10 per kit) 12 12 17 17 17 11 11 11 11
176F8610 Spare, IGBT Output Standoff, PKG9, E Frame IGBT output bus bar mounting standoff (9 per kit) --- --- --- --- --- 9 9 9 9
Table 10.6: Spare parts list: Terminals, Labels, Insulators

10 Spare Parts List
183
10
10
184
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Dia- Spare FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
gram Desig- Parts Spare Parts Name Comments FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
10 Spare Parts List
Bus Bars
176F8380 Spare, BB, SCR, R\S\T, D Frame connects input plate bus bar to SCR input (1 per kit) 3 3 --- --- --- --- --- --- ---
176F8548 Spare, Brkt, SCR BB Support, D Frame SCR input bus bar support 1 1 --- --- --- --- --- --- ---
176F8394 Spare, BB, SCR, Input, D Frame connects input plate bus bar to SCR input (1 per kit) --- --- 3 --- --- --- --- --- ---
176F8387 Spare, BB, SCR, Plus, 1, E Frame connects input plate bus bar to SCR input (1 per kit) --- --- --- 3 3 --- --- --- ---
176F8595 Spare, BB, SCR/Di Input, D Frame from input plate to SCR and diode (1 per kit) --- --- --- --- --- 3 3 3 3
176F8379 Spare, BB Assy, SCR, D Frame connects to SCR outputs, sandwich assembly 1 1 --- --- --- --- --- --- ---
176F8381 Spare, BB, SCR, Minus, D Frame connects DC coil inputs to SCR output bus bar assembly (1 per kit) 2 2 --- --- --- --- --- --- ---
176F8393 Spare, BB, SCR, DC, VLT5202 connects to SCR outputs (1 per kit) --- --- 2 --- --- --- --- --- ---
176F8385 Spare, BB, SCR, Minus, 1, D Frame connects to SCR outputs (1 per kit) --- --- --- 2 2 --- --- --- ---
176F83861 Spare, BB, SCR, Minus, 2, D Frame connects to DC coil + input, left side of frequency converter --- --- 1 1 1 --- --- --- ---
76F8386
176F8388 Spare, BB, SCR, Plus, 2, D Frame connects to DC coil - input, right side of frequency converter --- --- 1 1 1 --- --- --- ---
176F8596 Spare, BB, SCR/Di Output, E Frame attaches to the SCR and diode on the DC side (1 per kit) --- --- --- --- --- 2 2 2 2
176F8597 Spare, BB, DC Bus Plus, Before Coil, E Frame DC Plus to DC Coils --- --- --- --- --- 1 1 1 1
176F8598 Spare, BB, DC Bus Minus, Before Coil, E Frame DC Minus to DC Coils --- --- --- --- --- 1 1 1 1
176F8549 Spare, BB, DC Link, Plus, D Frame connects DC Plus coil output to IGBT input bus bar assembly 1 1 --- --- --- --- --- --- ---
176F8391 Spare, BB, DC Link, Plus, D Frame connects DC Minus coil output to IGBT input bus bar assembly 1 1 --- --- --- --- --- --- ---
176F8382 Spare, BB, DC Link, Minus, D Frame connects DC coil output to IGBT input bus bar assembly (1 per kit) --- --- 2 2 2 --- --- --- ---
176F8599 Space, BB, DC Bus, After Coil, E Frame from DC Coil output to IGBT sandwich (1 per kit) --- --- --- --- --- 2 2 2 2
176F83761 Spare, BB Assy, IGBT, D Frame connects capacitor bank and IGBT inputs, sandwich assembly 1 1 --- --- --- --- --- --- ---
76F8376
176F8377 Spare, BB Assy, IGBT-Ind, D Frame lower IGBT input bus bar sandwich assembly --- --- 1 1 1 --- --- --- ---
176F8378 Spare, BB Assy, IGBT-Cap, D Frame upper IGBT input bus bar sandwich assembly --- --- 1 1 1 --- --- --- ---
176F8600 Spare, BB Assy, IGBT-Ind, E Frame DC Bus sandwich, connects to the IGBT input --- --- --- --- --- 1 1 1 1
176F8601 Spare, BB Assy, IGBT-Cap, D Frame connects the capacitor bank to the IGBT input (1 per kit) --- --- --- --- --- 3 3 3 3
176F8390 Spare, BB, IGBT, U\V\W, E Frame connects IGBT output to long bus bar over the fan (1 per kit) 3 3 --- --- --- --- --- --- ---
176F8392 Spare, BB, Motor, 2, D Frame long output bus bar over the fan (1 per kit) 3 3 --- --- --- --- --- --- ---
176F8383 Spare, BB, Motor, U/W, D Frame connects to IGBT output, for phase U or W (1 per kit) --- --- 2 2 2 --- --- --- ---
176F8384 Spare, BB, Motor, V, D Frame connects to IGBT output, for phase V (1 per kit) --- --- 1 1 1 --- --- --- ---

176F8389 Spare, BB, I-Sensor, D Frame long output bus bar over the fan (1 per kit) --- 3 3 3 --- --- --- ---
176F8602 Spare, BB, IGBT Output, E Frame from IGBT output between SCR and diode (1 per kit) --- --- --- --- --- 3 3 3 3
176F8603 Spare, BB, Over Fan Box, E Frame output over the fan box (1 per kit) --- --- --- --- --- 3 3 3 3
176F8604 Spare, BB, Current Sensor 5352, E goes through the current sensor (1 per kit) --- --- --- --- --- 3 --- --- ---
176F8605 Spare, BB, Current Sensor 5452-5502, E goes through the current sensor (1 per kit) --- --- --- --- --- --- 3 3 3
176F8397 Spare, BB, Brake, Plus, D Frame connects DC Plus to brake IGBT 1 1 --- --- --- --- --- --- ---
176F8398 Spare, BB, Brake, Minus, D Frame connects DC Minus to brake IGBT 1 1 --- --- --- --- --- --- ---
176F8396 Spare, BB, Brake, D Frame connects the two brake IGBT together --- --- 1 1 1 --- --- --- ---
176F8606 Spare, BB, Brake Assy, E Frame collection of brake bus bars, does not include terminal bus bars --- --- --- --- --- 1 1 1 1
Table 10.7: Spare parts lists: Bus Bars (tabel 1)

380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Diagram
Designator
Bus Bars
176F8401 Spare, BB, LS, Plus, D Frame connects plus load share terminal to SCR output bus bar assembly 1 1 --- --- --- --- --- --- ---
176F8400 Spare, BB, LS, Minus, D Frame connects minus load share terminal to SCR output bus bar assembly 1 1 --- --- --- --- --- --- ---
176F8403 Spare, BB, LS, Plus, D Frame connects SCR bus bar to plus load share terminal --- --- 1 1 1 --- --- --- ---
176F8402 Spare, BB, LS, Minus, D Frame connects SCR bus bar to minus load share terminal --- --- 1 1 1 --- --- --- ---
176F8607 Spare, BB, Load Share Plus, E Frame load share plus bus bar --- --- --- --- --- 1 1 1 1
176F8608 Spare, BB, Load Share Minus, E Frame load share minus bus bar --- --- --- --- --- 1 1 1 1
176F8405 Spare, BB, SCR, Input 2, D Frame located on input plate (1 per kit) 3 3 --- --- --- --- --- --- ---
176F8406 Spare, BB, SCR, T, 1, D Frame located on input plate (1 per kit) --- --- 3 3 3 --- --- --- ---
176F8407 Spare, BB, Disc, D Frame located on input plate (1 per kit) 3 3 --- --- --- --- --- --- ---
176F8408 Spare, BB, Disc, R, S, D Frame located on input plate (1 per kit) --- --- 2 2 2 --- --- --- ---
176F8409 Spare, BB, Disc, T, D Frame located on input plate (1 per kit) --- --- 1 1 1 --- --- --- ---
Table 10.8: Spare parts list: Bus Bars (table 2)

10 Spare Parts List
185
10
10
186
380480 VAC/380500 VAC
D1/D3 D2/D4 E1/E2
Block Dia- Spare Spare Parts Name Comments FC 102 P110 P132 P160 P200 P250 P315 P355 P400 P450
gram Desig- Parts FC 202 P110 P132 P160 P200 P250 P315 P355 P400 P450
10 Spare Parts List
Enclosure
176F8430 Spare, Cable Clamp, 60 mm 60 mm power cable clamp --- --- --- --- --- --- --- --- ---
176F8490 Spare, Brkt, HF, board, gnd, D Frame mounting bracket for high frequency board 1 1 --- --- --- --- --- --- ---
176F8491 Spare, Brkt, HF, board, gnd, D Frame mounting bracket for high frequency board --- --- 1 1 1 --- --- --- ---
176F8427 IP00, D3, Side Panel IP00 IP00
176F84286 IP00, D4, Side Panel IP00 IP00 IP00
KAF6H8428
Table 10.9: Spare parts list: Enclosure

525690 VAC
D1/D3 D2/D4 E1/E2
Block FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Dia- Spare 550

gram Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Desig- Number 550
nator FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
PCA
PCA3 176F8680 Spare, power card, pdefc-xxxP132T7xxxxxUxC Power card, conformal coated, does not include scaling card 102 --- --- --- --- --- --- --- --- ---
PCA3 176F8681 Spare, power card, pdefc-xxxP160T7xxxxxUxC Power card, conformal coated, does not include scaling card --- 102 --- --- --- --- --- --- --- ---
PCA3 176F8682 Spare, power card, pdefc-xxxP200T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- 102 --- --- --- --- --- --- ---
PCA3 176F8683 Spare, power card, pdefc-xxxP250T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- 102 --- --- --- --- --- ---
PCA3 176F8684 Spare, power card, pdefc-xxxP315T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- 102 --- --- --- --- ---
PCA3 176F8685 Spare, power card, pdefc-xxxP400T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- 102 --- --- --- ---
PCA3 176F8686 Spare, power card, pdefc-xxxP450T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- 102 --- --- ---
PCA3 176F8687 Spare, power card, pdefc-xxxP500T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- --- 102 --- ---
PCA3 176F8688 Spare, power card, pdefc-xxxP560T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- --- --- 102 ---
PCA3 176F8689 Spare, power card, pdefc-xxxP630T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- --- --- --- --- --- 102

10 Spare Parts List
187
10
10
188
525690 VAC
D1/D3 D2/D4 E1/E2
Block FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Dia- Spare 550
gram Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
10 Spare Parts List
Desig- Number 550

PCA
PCA4 176F8308 Spare, Current Scaling PCA, 4.54 Ohm Installs on the Power Card --- 1 --- --- --- --- 1 1 --- ---
PCA4 176F8309 Spare, Current Scaling PCA, 3.79 Ohm Installs on the Power Card --- --- --- --- --- --- --- --- 1 ---
PCA4 176F8310 Spare, Current Scaling PCA, 3.10 Ohm Installs on the Power Card --- --- 1 1 --- --- --- --- --- ---
PCA4 176F8311 Spare, Current Scaling PCA, 2.56 Ohm Installs on the Power Card --- --- --- --- 1 --- --- --- --- 1
PCA4 176F8312 Spare, Current Scaling PCA, 5.10 Ohm Installs on the Power Card --- --- --- --- --- 1 --- --- --- ---
PCA4 176F8525 Spare, Current Scaling PCA, 5.85 Ohm Installs on the Power Card 1 --- --- --- --- --- --- --- --- ---
PCA5 176F8626 Spare, FC Gate Drive PCA, CC, D&E Frame Gate Drive Board 1 1 1 1 1 1 1 1 1 1
PCA8 176F8523 Spare, HF PCA, T7, D&E Frame High Frequency Board 1 1 1 1 1 1 1 1 1 1
PCA11 176F8522 Spare, Soft charge PCA, CC, T7, D Frame Soft charge Board, Includes mounting bracket 1 1 1 1 1 1 --- --- --- ---
PCA11 176F8466 Spare, Soft charge PCA, CC, T7, E Frame Soft charge Board --- --- --- --- --- --- 1 1 1 1
PCA9 176F8526 Spare, Balance, PCA, T7, D&E Frame Capacitor Bank Balance Card, included with spare Cap Bank 1 1 2 2 2 2 2 2 2 2
Table 10.10: Spare Parts List PCA3-11

525690 VAC
D1/D3 D2/D4 E1/E2
Block Dia- Spare FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
gram Desig- Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
nator Number FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
Semiconductors
IGBT1,2 176F8632 Spare, FC IGBT kit, 300A, T7, D Frame 1 IGBT per kit 1 --- 2 2 --- --- --- --- --- ---
IGBT1,2 176F8633 Spare, FC IGBT kit, 450A, T7, D Frame 1 IGBT per kit --- 1 --- --- 2 2 --- --- --- ---
IGBT1,2 ,3 176F8634 Spare, FC IGBT kit, 300A, T7, E Frame 1 IGBT per kit --- --- --- --- --- --- 3 3 --- ---
IGBT1,2 ,3 176F8635 Spare, FC IGBT kit, 450A, T7, E Frame 1 IGBT per kit --- --- --- --- --- --- --- --- 3 3
IGBT4,5 176F8316 Spare, Brake IGBT kit, D&E Frame 1 IGBT per kit 1 1 2 2 2 2 2 2 2 2
SCR1,2,3 176F8529 Spare, SCR/diode kit, 160A, T7, D Frame 1 SCR and diode per kit 3 3 3 --- --- --- --- --- --- ---
SCR1,2,3 176F8530 Spare, SCR/diode kit, 280A, T7, D Frame 1 SCR and diode per kit --- --- --- 3 3 3 --- --- --- ---
SCR1,2,3 176F8434 Spare, SCR kit, 430A, T7, E Frame 1 SCR per kit --- --- --- --- --- --- 3 3 3 3
D1,2,3 176F8435 Spare, diode kit, 540A, T7, E Frame 1 diode per kit --- --- --- --- --- --- 3 3 3 3
Resistors
R1 176F8531 Spare, Soft charge Resistor, 68 Ohm, 110W Soft charge resistor assembly 1 1 1 1 1 1 --- --- --- ---
R1 176F8467 Spare, Soft charge Resistor, 68 Ohm, 155W Soft charge resistor assembly --- --- --- --- --- --- 1 1 1 1
Capacitors
C2, 3, 4, 5, 6, 176F8534 Spare, CAP, IGBT Snubber, 1250V, 1uF IGBT snubber caps mounted on the IGBT modules 3 3 6 6 6 6 9 9 9 9
7, 8, 9, 10
CBANK1,2 176F8532 Spare, CAP Bank, D Frame, 4cap, T7 Capacitor bank, includes balance card 1 --- 2 2 1 --- --- --- --- ---
CBANK1,2 176F8533 Spare, CAP Bank, D Frame, 6cap, T7 Capacitor bank, includes balance card --- 1 --- --- 1 2 --- --- --- ---
CBANK1,2 176F8638 Spare, CAP Bank, E Frame, 8cap, T7 Capacitor bank, includes balance card --- --- --- --- --- --- 2 2 2 2
Fans
F1+C1 176F8329 Spare, Heatsink Fan Assy, D Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables 1 1 1 1 1 1 --- ---
--- ---

F1+C1 176F8578 Spare, Heatsink Fan Assy, small E Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables --- --- --- --- --- --- 1 1
--- ---
F1+C1 176F8579 Spare, Heatsink Fan Assy, large E Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables --- --- --- --- --- --- --- 1 --- 1
F2,3 176F8330 Spare, Door Fan Kit, D&E Frame Door Fan Kit. Includes fan, grills, support, fasteners (1 fan per kit) 21/54 21/54
21/5 21/54 21/54 21/54 21/54 21/54
21/5 21/54
4 4
176F8331 Spare, Door Vent Kit, D&E Frame Door Vent Kit. Includes grill, support, fasteners (1 vent per kit) 21/54 21/54 21/5 21/54 21/54 21/54 21/54 21/54 21/5 21/54
4 4
176F8332 Spare, Door Fan Filter, PKG10, D&E Frame Door Filters, Package of 10 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54 IP54
F4 176F8639 Spare, FC DC Top Fan, IP00 D Frame IP00 Top Fan, Fan Only (1 fan per kit) IP00 IP00 IP00 IP00 IP00 IP00 --- --- --- ---
F2 176F8333 Spare, Door/Top AC Fan, D&E Frame IP00 Top Fan, Fan Only (1 fan per kit) --- --- --- --- --- --- IP00 IP00 IP00 IP00
F2,3 176F8333 Spare, Door/Top AC Fan, D&E Frame IP21/IP54 Door Fan, Fan Only (1 fan per kit) 21/54 21/54 21/5 21/54 21/54 21/54 21/54 21/54 21/5 21/54
4 4
Table 10.11: Spare Parts List Semiconductors, Resistors, Capacitors and Fans
10 Spare Parts List
189
10
10
190
525690 VAC
D1/D3 D2/D4 E1/E2
Spare FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Block Diagram
Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Designator
Number FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
10 Spare Parts List
Fuses
FU1,2,3 176F8334 Spare, Fuse, Main, 350A Mains Fuse. 1 fuse per kit 3 3 --- --- --- --- --- --- --- ---
FU1,2,3 176F8591 Spare, Fuse, Main, 700A Mains Fuse. 1 fuse per kit --- --- --- --- --- --- 3 3 3 ---
FU1,2,3 176F8592 Spare, Fuse, Main, 900A Mains Fuse. 1 fuse per kit --- --- --- --- --- --- --- --- --- 3
FU1,2,3 176F8540 Spare, Fuse, Main, 550A Mains Fuse. 1 fuse per kit --- --- 3 3 3 3 --- --- --- ---
176F8336 Spare, Fuse, Soft charge, 20A, PKG3, D&E Frame Soft charge fuse. Package of 3 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg
FU5 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Power Card Fuse, 4 amp. Package of 3 1 1 1 1 1 1 1 1 1 1
FU4 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Fan Transformer Fuse, 4 amp. Package of 3 1 1 1 1 1 1 1 1 --- ---
FU4 176F8609 Spare, Fuse, 15A, PKG3, Fan, E Frame Fan Transformer Fuse, 15 amp. Package of 3 --- --- --- --- --- --- --- --- 1 1

L1 176F8339 Spare, Bus Inductor, 136uH DC Link Coil, Large D Frame --- --- --- --- 1 --- --- --- --- ---
L1 176F8340 Spare, Bus Inductor, 109uH DC Link Coil, Large D Frame --- --- --- --- --- 1 --- --- --- ---
L1 176F8536 Spare, Bus Inductor, 350uH DC Link Coil, Small D Frame 1 --- --- --- --- --- --- --- --- ---
L1 176F8537 Spare, Bus Inductor, 250uH DC Link Coil, Small D Frame --- 1 --- --- --- --- --- --- --- ---
L1 176F8538 Spare, Bus Inductor, 195uH DC Link Coil, Large D Frame --- --- 1 1 --- --- --- --- --- ---
L1 176F8469 Spare, Bus Inductor, 73uH, E Frame DC Link Coil, E Frame --- --- --- --- --- --- 1 1 1 1
L2,3,4 176F8342 Spare, Current Sensor, 300A Motor Current Sensor, 1 sensor per kit 3 3 3 3 3 --- --- --- --- ---
L2,3,4 176F8343 Spare, Current Sensor, 500A Motor Current Sensor, 1 sensor per kit --- --- --- --- --- 3 3 3 3 ---
L2,3,4 176F8563 Spare, Current Sensor, 1000A Motor Current Sensor, 1 sensor per kit --- --- --- --- --- --- --- --- --- 3
TR1 176F8535 Spare, Fan Transformer Assy, 690V, 400VA Fan Transformer. Includes cables and plug 1 1 1 1 1 1 1 1 --- ---
TR1 176F8471 Spare, Fan Transformer Assy, E1, T7 Fan Transformer. Includes cables and plug --- --- --- --- --- --- --- --- 1 1
L5 176F8577 Spare, Heatsink Fan Inductor, E Frame Fan Inductor --- --- --- --- --- --- --- --- 1 1
Disconnects
SW1 176F8345 Spare, Disconnect SW,200A, D Frame Disconnect Switch 1 1 --- --- --- --- --- --- --- ---
SW1 176F8347 Spare, Disconnect SW, 400A, D Frame Disconnect Switch --- --- 1 1 1 1 --- --- --- ---
SW1 176F8593 Spare, Disconnect SW, 600A, E Frame Disconnect Switch --- --- --- --- --- --- 1 1 1 1
176F8346 Spare, Disconnect Handle, Rod, D Frame Disconnect Handle 1 1 --- --- --- --- --- --- --- ---
176F8348 Spare, Disconnect Handle, Rod, D&E Frame Disconnect Handle --- --- 1 1 1 1 1 1 1 1

Table 10.12: Spare Parts List Fuses, Inductors & Current Sensors and Disconnects
525690 VAC
D1/D3 D2/D4 E1/E2
Block Dia- Spare FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
gram Des- Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
ignator Number FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
Cables
CBL1 176F8640 Spare, Cable, FC LCP, D Frame, IP54 ribbon cable from LCP to control card, IP 54 enclosure IP54 IP54 IP54 IP54 IP54 IP54 --- --- --- ---
CBL1 176F8586 Spare, Cable, LCP, E Frame ribbon cable from LCP to control card --- --- --- --- --- --- 1 1 1 1
CBL2 176F8641 Spare, Cable, Control PCA, 44pin, D&E Frame ribbon cable from control card to power card 1 1 1 1 1 1 1 1 1 1
CBL5 176F8541 Spare, Cable, FC Current Sensor, D Frame wire harness from power card to current sensors 1 1 --- --- --- --- --- --- --- ---
CBL5 176F8349 Spare, Cable, FC Current Sensor, D2 Frame wire harness from power card to current sensors --- --- 1 1 1 1 --- --- --- ---
CBL5 176F8568 Spare, Cable, FC I-Sensor, small E Frame wire harness from power card to current sensors --- --- --- --- --- --- 1 1 1 ---
CBL5 176F8569 Spare, Cable, FC I-Sensor, large E Frame wire harness from power card to current sensors --- --- --- --- --- --- --- --- --- 1
CBL8 176F8542 Spare, Cable, HS Fan, D1 Frame wire harness from the power card to the fan transformer 1 1 --- --- --- --- --- --- --- ---
CBL8 176F8359 Spare, Cable, HS Fan, D2 Frame wire harness from the power card to the fan transformer --- --- 1 1 1 1 --- --- --- ---
CBL8 176F8571 Spare, Cable, Fan, IP00, small E Frame wire harness for all AC fans on IP00 units --- --- --- --- --- --- IP00 IP00 --- ---
CBL8 176F8572 Spare, Cable, Fan, IP21/54, small E Frame wire harness for all AC fans on IP21 and IP54 units --- --- --- --- --- --- 21/54 21/54 --- ---
CBL8 176F8573 Spare, Cable, Fan, IP00, large E Frame wire harness for all AC fans on IP00 units --- --- --- --- --- --- --- --- IP00 IP00
CBL8 176F8574 Spare, Cable, Fan, IP21/54, large E Frame wire harness for all AC fans on IP21 and IP54 units --- --- --- --- --- --- --- --- 21/54 21/54
CBL9 176F8354 Spare, Cable, Softchg RST prime, D Frame wire harness from soft charge to power card 1 1 1 1 1 1 --- --- --- ---
CBL9 176F8570 Spare, Cable, Softchg RST prime, E Frame wire harness from soft charge to power card --- --- --- --- --- --- 1 1 1 1
CBL12 176F8358 Spare, Cable, Door Fan, D Frame wire harness for AC door fans 21/54 21/54 21/54 21/54 21/54 21/54 --- --- --- ---
CBL13 176F8544 Spare, Cable, FC SCR, D1 Frame wire harness from power card to SCR 1 1 --- --- --- --- --- --- --- ---
CBL13 176F8357 Spare, Cable, FC SCR, D2 Frame wire harness from power card to SCR --- --- 1 1 1 1 --- --- --- ---
CBL13 176F8575 Spare, Cable, FC SCR, E Frame wire harness from power card to SCR --- --- --- --- --- --- 1 1 1 1
CBL14 176F8356 Spare, Cable, DC to Power PCA, D Frame voltage from DC bus to power card 1 1 1 1 1 1 --- --- --- ---
CBL14 176F8576 Spare, Cable, DC to Power PCA, E Frame voltage from DC bus to power card --- --- --- --- --- --- 1 1 1 1
CBL16 176F8363 Spare, Cable, FC Gate Drive, 16pin, D1 Frame ribbon cable from power card to gate drive card 1 1 --- --- --- --- --- --- --- ---
CBL16 176F8350 Spare, Cable, FC Gate Drive, 16pin, D2 Frame ribbon cable from power card to gate drive card --- --- 1 1 1 1 --- --- --- ---

CBL16 176F8581 Spare, Cable, FC Gate Drive, 16pin, E Frame ribbon cable from power card to gate drive card --- --- --- --- --- --- 1 1 1 1
CBL17,18,19 176F8364 Spare, Cable, IGBT Gate, D1 Frame wire harness from gate drive card to IGBT module (1 per kit) 3 3 --- --- --- --- --- --- --- ---
CBL17,18,19 176F8351 Spare, Cable, IGBT Gate, D2 Frame wire harness from gate drive card to IGBT module (1 per kit) --- --- 3 3 3 3 --- --- --- ---
CBL17,18,19 176F8582 Spare, Cable, IGBT Gate, E1 Frame wire harness from gate drive card to IGBT module (1 per kit) --- --- --- --- --- --- 3 3 3 3
CBL20 176F8352 Spare, Cable, IGBT Temperature temperature connection from IGBT module to gate drive card 1 1 1 1 1 1 1 1 1 1
CBL21 176F8365 Spare, Cable, Brake IGBT, D1 Frame wire harness from gate drive card to brake IGBT module 1 1 --- --- --- --- --- --- --- ---
CBL21 176F8368 Spare, Cable, Brake IGBT, D2 Frame wire harness from gate drive card to brake IGBT module --- --- 1 1 1 1 --- --- --- ---
CBL21 176F8583 Spare, Cable, Brake IGBT, E Frame wire harness from gate drive card to brake IGBT module --- --- --- --- --- --- 1 1 1 1
CBL22 176F8366 Spare, Cable, Brake Power Plus, D1 Frame cable from brake IGBT to brake plus terminal 1 1 --- --- --- --- --- --- --- ---
CBL22 176F8369 Spare, Cable, Brake Power Plus, D2 Frame cable from brake IGBT to brake plus terminal --- --- 1 1 1 1 --- --- --- ---
CBL23 176F8367 Spare, Cable, Brake Power Minus, D1 Frame cable from brake IGBT to brake minus terminal 1 1 --- --- --- --- --- --- --- ---
CBL23 176F8370 Spare, Cable, Brake Power Minus, D2 Frame cable from brake IGBT to brake minus terminal --- --- 1 1 1 1 --- --- --- ---
CBL24 176F8543 Spare, Cable, Softchg RST, D1 Frame wire harness from input power to soft charge board 1 1 --- --- --- --- --- --- --- ---
CBL24 176F8353 Spare, Cable, Softchg RST, D2 Frame wire harness from input power to soft charge board --- --- 1 1 1 1 --- --- --- ---
CBL24 176F8584 Spare, Cable, Softchg RST, E Frame wire harness from input power to soft charge board --- --- --- --- --- --- 1 1 1 1
CBL25 176F8355 Spare, Cable, Softchg to DC bus, D Frame wire harness from soft charge to DC bus 1 1 1 1 1 1 --- --- --- ---
CBL25 176F8585 Spare, Cable, Softchg to DC bus, E Frame wire harness from soft charge to DC bus --- --- --- --- --- --- 1 1 1 1
CBL26 176F8613 Spare, Cable, FC Fuse Fan, E Frame cable from power card to fan fuse --- --- --- --- --- --- 1 1 1 1

10 Spare Parts List
191
10
10
192
525690 VAC
D1/D3 D2/D4 E1/E2
Block Di- FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
agram Spare Part FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Spare Part Name Comments
Designa- Number FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
10 Spare Parts List
tor
TB1 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame mains terminal bus bar (1 per kit) 3 3 --- --- --- --- --- --- --- ---
TB1 176F8375 Spare, BB, Terminals, Mains, Motor, D Frame mains terminal bus bar (1 per kit) --- --- 3 3 3 3 --- --- --- ---
TB1 176F8587 Spare, BB, Terminal Block, E Frame mains terminal stepped bus bar (1 per kit) --- --- --- --- --- --- 3 3 3 3
TB2 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame motor terminal bus bar (1 per kit) 3 3 --- --- --- --- --- --- --- ---
TB2 176F8375 Spare, BB, Terminals, Mains, Motor, D Frame motor terminal bus bar (1 per kit) --- --- 3 3 3 3 --- --- --- ---
TB2 176F8587 Spare, BB, Terminal Block, E Frame motor terminal stepped bus bar (1 per kit) --- --- --- --- --- --- 3 3 3 3
TB3 176F8395 Spare, BB, Terminal, LS, BK, D Frame brake terminal bus bar (1 per kit) 2 2 2 2 2 2 --- --- --- ---
TB3 176F8399 Spare, BB, Terminal, LS, LT, D Frame left brake terminal bus bar --- --- --- --- --- 1 1 1 1
TB3 176F8404 Spare, BB, Load Share, 2, D Frame right brake terminal bus bar --- --- --- --- --- 1 1 1 1
TB4 176F8395 Spare, BB, Terminal, LS, BK, D Frame load share terminal bus bar (1 per kit) 2 2 --- --- --- --- --- --- --- ---
TB4 176F8399 Spare, BB, Terminal, LS, LT, D Frame left load share terminal bus bar --- --- 1 1 1 1 --- --- --- ---
TB4 176F8404 Spare, BB, Load Share, 2, D Frame right load share terminal bus bar --- --- 1 1 1 1 --- --- --- ---
TB4 176F8587 Spare, BB, Terminal Block, E Frame load share terminal stepped bus bar (1 per kit) --- --- --- --- --- --- 2 2 2 2
TB1 176F8371 Spare, Terminal Insul, mains, motor, D Frame mains terminal insulation block 1 1 1 1 1 1 --- --- --- ---
TB1 176F8588 Spare, Insul, Terminal Block, E Frame mains terminal insulation block (1 per kit) --- --- --- --- --- --- 3 3 3 3
TB2 176F8371 Spare, Terminal Insul, mains, motor, D Frame motor terminal insulation block 1 1 1 1 1 1 --- --- --- ---
TB2 176F8588 Spare, Insul, Terminal Block, E Frame motor terminal insulation block (1 per kit) --- --- --- --- --- --- 3 3 3 3
TB3 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame brake terminal insulation block 1 1 1 1 1 1 1 1 1 1
TB4 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame load share terminal insulation block 1 1 1 1 1 1 --- --- --- ---
TB4 176F8588 Spare, Insul, Terminal Block, E Frame load share terminal insulation block (1 per kit) --- --- --- --- --- --- 2 2 2 2
176F8373 Spare, Label Set, Terminal Blk, D Frame terminal block label set includes mains, motor, brake, load share 1 1 1 1 1 1 --- --- --- ---
176F8589 Spare, Label Set, Terminal, E Frame terminal block label set includes mains, motor, brake, load share --- --- --- --- --- --- 1 1 1 1
176F8545 Spare, Insul, Mylar, IGBT, Bus, D1 Frame insulation under IGBT input bus bar assemblies 1 1 --- --- --- --- --- --- --- ---
176F8421 Spare, Insul, Mylar, IGBT, Bus, D2 Frame insulation under IGBT input bus bar assemblies --- --- 1 1 1 1 --- --- --- ---
176F8590 Spare, Insul, IGBT-Chassis, E Frame insulation under IGBT input bus bar assemblies --- --- --- --- --- --- 1 1 1 1
176F8547 Spare, Insul, IGBT snubber cap support mounts between IGBT and snubber capacitors (1 per kit) 1 1 2 2 2 2 --- --- --- ---
176F8546 Spare, Insul, between mains fuse, T6/7 insulator between mains fuses --- --- 1 1 1 1 --- --- --- ---
176F8410 Spare, BB Stand Off, PKG10 bus bar mounting standoff (10 per kit) 12 12 17 17 17 17 11 11 11 11

176F8610 Spare, IGBT Output Standoff, PKG9, E Frame IGBT output bus bar mounting standoff (9 per kit) --- --- --- --- --- --- 9 9 9 9
Table 10.14: Spare Parts List terminals, Labels, Insulators

525690 VAC
D1/D3 D2/D4 E1/E2
Block Spare Part FC 102 P132 P160 P200 P250 P315 P400 P450 P50 P560 P630
Dia- Number 0
gram FC 202 P132 P160 P200 P250 P315 P400 P450 P50 P560 P630
Desig- 0
0
Bus Bars
176F8380 Spare, BB, SCR, R\S\T, D Frame connects input plate bus bar to SCR input (1 per kit) 3 3 --- --- --- --- --- --- --- ---
176F8548 Spare, Brkt, SCR BB Support, D Frame SCR input bus bar support 1 1 --- --- --- --- --- --- --- ---
176F8394 Spare, BB, SCR, Input, D Frame connects input plate bus bar to SCR input (1 per kit) --- --- 3 --- --- --- --- --- --- ---
176F8387 Spare, BB, SCR, Plus, 1, D Frame connects input plate bus bar to SCR input (1 per kit) --- --- --- 3 3 3 --- --- --- ---
176F8700 Spare, BB, SCR/Di Input, T7, E Frame from input plate to SCR and diode (1 per kit) --- --- --- --- --- --- 3 3 3 3
176F8379 Spare, BB Assy, SCR, D Frame connects to SCR outputs, sandwich assembly 1 1 --- --- --- --- --- --- --- ---
176F8381 Spare, BB, SCR, Minus, D Frame connects DC coil inputs to SCR output bus bar assembly (1 per kit) 2 2 --- --- --- --- --- --- --- ---
176F8393 Spare, BB, SCR, DC, VLT5202 connects to SCR outputs (1 per kit) --- --- 2 --- --- --- --- --- --- ---
176F8385 Spare, BB, SCR, Minus, 1, D Frame connects to SCR outputs (1 per kit) --- --- --- 2 2 2 --- --- --- ---
176F8386 Spare, BB, SCR, Minus, 2, D Frame connects to DC coil + input, left side of frequency converter --- --- 1 1 1 1 --- --- --- ---
176F8388 Spare, BB, SCR, Plus, 2, D Frame connects to DC coil - input, right side of frequency converter --- --- 1 1 1 1 --- --- --- ---
176F8701 Spare, BB, SCR/Di Output, T7, E Frame attaches to the SCR and diode on the DC side (1 per kit) --- --- --- --- --- --- 2 2 2 2
176F8597 Spare, BB, DC Bus Plus, Before Coil, E Frame DC Plus to DC Coils --- --- --- --- --- --- 1 1 1 1
176F8598 Spare, BB, DC Bus Minus, Before Coil, E Frame DC Minus to DC Coils --- --- --- --- --- --- 1 1 1 1
176F8549 Spare, BB, DC Link, Plus, D Frame connects DC Plus coil output to IGBT input bus bar assembly 1 1 --- --- --- --- --- --- --- ---
176F8391 Spare, BB, DC Link, Plus, D Frame connects DC Minus coil output to IGBT input bus bar assembly 1 1 --- --- --- --- --- --- --- ---
176F8382 Spare, BB, DC Link, Minus, D Frame connects DC coil output to IGBT input bus bar assembly (1 per kit) --- --- 2 2 2 2 --- --- --- ---
176F8599 Space, BB, DC Bus, After Coil, E Frame from DC Coil output to IGBT sandwich (1 per kit) --- --- --- --- --- --- 2 2 2 2
176F8376 Spare, BB Assy, IGBT, D Frame connects capacitor bank and IGBT inputs, sandwich assembly 1 1 --- --- --- --- --- --- --- ---
176F8377 Spare, BB Assy, IGBT-Ind, D Frame lower IGBT input bus bar sandwich assembly --- --- 1 1 1 1 --- --- --- ---

176F8378 Spare, BB Assy, IGBT-Cap, D Frame upper IGBT input bus bar sandwich assembly --- --- 1 1 1 1 --- --- --- ---
176F8600 Spare, BB Assy, IGBT-Ind, E Frame DC Bus sandwich, connects to the IGBT input --- --- --- --- --- --- 1 1 1 1
176F8601 Spare, BB Assy, IGBT-Cap, E Frame connects the capacitor bank to the IGBT input (1 per kit) --- --- --- --- --- --- 3 3 3 3
176F8390 Spare, BB, IGBT, U\V\W, D Frame connects IGBT output to long bus bar over the fan (1 per kit) 3 3 --- --- --- --- --- --- --- ---
176F8392 Spare, BB, Motor, 2, D Frame long output bus bar over the fan (1 per kit) 3 3 --- --- --- --- --- --- --- ---
176F8383 Spare, BB, Motor, U/W, D Frame connects to IGBT output, for phase U or W (1 per kit) --- --- 2 2 2 2 --- --- --- ---
176F8384 Spare, BB, Motor, V, D Frame connects to IGBT output, for phase V (1 per kit) --- --- 1 1 1 1 --- --- --- ---
176F8389 Spare, BB, I-Sensor, D Frame long output bus bar over the fan (1 per kit) --- --- 3 3 3 3 --- --- --- ---
176F8602 Spare, BB, IGBT Output, E Frame from IGBT output between SCR and diode (1 per kit) --- --- --- --- --- --- 3 3 3 3
176F8603 Spare, BB, Over Fan Box, E Frame output over the fan box (1 per kit) --- --- --- --- --- --- 3 3 3 3
176F8604 Spare, BB, Current Sensor 5352, E goes through the current sensor (1 per kit) --- --- --- --- --- --- 3 3 3 ---
176F8605 Spare, BB, Current Sensor 5452-5502, E goes through the current sensor (1 per kit) --- --- --- --- --- --- --- --- --- 3
176F8397 Spare, BB, Brake, Plus, D Frame connects DC Plus to brake IGBT 1 1 --- --- --- --- --- --- --- ---
176F8398 Spare, BB, Brake, Minus, D Frame connects DC Minus to brake IGBT 1 1 --- --- --- --- --- --- --- ---
176F8396 Spare, BB, Brake, D Frame connects the two brake IGBT together --- --- 1 1 1 1 --- --- --- ---
176F8606 Spare, BB, Brake Assy, E Frame collection of brake bus bars, does not include terminal bus bars --- --- --- --- --- --- 1 1 1 1
10 Spare Parts List
193
10
10
194
525690 VAC
D1/D3 D2/D4 E1/E2
Block Spare Part FC 102 P132 P160 P200 P250 P315 P400 P450 P50 P560 P630
Dia- Number 0
gram FC 202 P132 P160 P200 P250 P315 P400 P450 P50 P560 P630
10 Spare Parts List
Desig- 0
0
Bus Bars
176F8401 Spare, BB, LS, Plus, D Frame connects plus load share terminal to SCR output bus bar assembly 1 1 --- --- --- --- --- --- --- ---
176F8400 Spare, BB, LS, Minus, D Frame connects minus load share terminal to SCR output bus bar assembly 1 1 --- --- --- --- --- --- --- ---
176F8403 Spare, BB, LS, Plus, D Frame connects SCR bus bar to plus load share terminal --- --- 1 1 1 1 --- --- --- ---
176F8402 Spare, BB, LS, Minus, D Frame connects SCR bus bar to minus load share terminal --- --- 1 1 1 1 --- --- --- ---
176F8607 Spare, BB, Load Share Plus, E Frame load share plus bus bar --- --- --- --- --- --- 1 1 1 1
176F8702 Spare, BB, Load Share Minus, T7, E Frame load share minus bus bar --- --- --- --- --- --- 1 1 1 1
176F8405 Spare, BB, SCR, Input 2, D Frame located on input plate (1 per kit) 3 3 --- --- --- --- --- --- --- ---
176F8406 Spare, BB, SCR, T, 1, D Frame located on input plate (1 per kit) --- --- 3 3 3 3 --- --- --- ---
176F8407 Spare, BB, Disc, D Frame located on input plate (1 per kit) 3 3 --- --- --- --- --- --- --- ---
176F8408 Spare, BB, Disc, R, S, D Frame located on input plate (1 per kit) --- --- 2 2 2 2 --- --- --- ---
176F8409 Spare, BB, Disc, T, D Frame located on input plate (1 per kit) --- --- 1 1 1 1 --- --- --- ---
Table 10.15: Spare Parts List Bus Bars

525690 VAC
D1/D3 D2/D4 E1/E2
Spare FC 102 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Block Diagram
Part Spare Part Name Comments FC 202 P132 P160 P200 P250 P315 P400 P450 P500 P560 P630
Designator
Number FC 302 P110 P132 P160 P200 P250 P315 P355 P400 P500 P560
Enclosure
176F8430 Spare, Cable Clamp, 60 mm 60 mm power cable clamp --- --- --- --- --- --- --- --- --- ---
176F8490 Spare, Brkt, HF, board, gnd, D Frame mounting bracket for high frequency board 1 1 --- --- --- --- --- --- --- ---
176F8491 Spare, Brkt, HF, board, gnd, D Frame mounting bracket for high frequency board --- --- 1 1 1 1 --- --- --- ---
176F8427 IP00, D3, Side Panel IP00 IP00
176F8428 IP00, D4, Side Panel IP00 IP00 IP00 IP00
Table 10.16: Spare Parts List Enclosure


10 Spare Parts List
195
10
10
196
525690 VAC
D1/D3
FC 102 P45K P55K P75K P90K P110
Block Diagram Des- Spare Part
Spare Part Name Comments FC 202 P45K P55K P75K P90K P110
ignator Number
FC 302 P37K P45K P55K P75K P90K
10 Spare Parts List
PCA
PCA3 176F8692 Spare, power card, pdefc-xxxP45kT7xxxxxUxC Power card, conformal coated, does not include scaling card 102 --- --- --- ---
PCA3 176F8693 Spare, power card, pdefc-xxxP55kT7xxxxxUxC Power card, conformal coated, does not include scaling card --- 102 --- --- ---
PCA3 176F8694 Spare, power card, pdefc-xxxP75kT7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- 102 --- ---
PCA3 176F8695 Spare, power card, pdefc-xxxP90kT7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- 102 ---
PCA3 176F8696 Spare, power card, pdefc-xxxP110T7xxxxxUxC Power card, conformal coated, does not include scaling card --- --- --- --- 102
PCA4 176F8525 Spare, Current Scaling PCA, 5.85 Ohm Installs on the Power Card 1 1 1 1 1
PCA5 176F8626 Spare, FC Gate Drive PCA, CC, D&E Frame Gate Drive Board 1 1 1 1 1
PCA8 176F8523 Spare, HF PCA, T7, D&E Frame High Frequency Board 1 1 1 1 1
PCA11 176F8522 Spare, Soft charge PCA, CC, T7, D Frame Soft charge Board, Includes mounting bracket 1 1 1 1 1
PCA9 176F8526 Spare, Balance, PCA, T7, D&E Frame Capacitor Bank Balance Card, included with spare Cap Bank 1 1 1 1 1
Semiconductors
IGBT1,2 176F8632 Spare, FC IGBT kit, 300A, T7, D Frame 1 IGBT per kit 1 1 1 1 1
IGBT4,5 176F8316 Spare, Brake IGBT kit, D&E Frame 1 IGBT per kit 1 1 1 1 1
SCR1,2,3 176F8529 Spare, SCR/diode kit, 160A, T7, D Frame 1 SCR and diode per kit 3 3 3 3 3
Resistors
R1 176F8531 Spare, Soft charge Resistor, 68 Ohm, 110W Soft charge resistor assembly 1 1 1 1 1

Table 10.17: Spare Parts List PCA, Semiconductors and Resistors
525690 VAC
D1/D3
FC 102 P45K P55K P75K P90K P110

ignator Number
FC 302 P37K P45K P55K P75K P90K
Capacitors
C2, 3, 4, 5, 6, 7, 8, 9, 176F8534 Spare, CAP, IGBT Snubber, 1250V, 1uF IGBT snubber caps mounted on the IGBT modules 3 3 3 3 3
10
CBANK1,2 176F8532 Spare, CAP Bank, D Frame, 4cap, T7 Capacitor bank, includes balance card 1 1 1 1 1
Fans
F1+C1 176F8329 Spare, Heatsink Fan Assy, D Frame Heatsink Fan. Includes fan, fan box, capacitor, gasket, cables 1 1 1 1 1
F2,3 176F8330 Spare, Door Fan Kit, D&E Frame Door Fan Kit. Includes fan, grills, support, fasteners (1 fan per kit) 21/54 21/54 21/54 21/54 21/54
176F8331 Spare, Door Vent Kit, D%E Frame Door Vent Kit. Includes grill, support, fasteners (1 vent per kit) 21/54 21/54 21/54 21/54 21/54
176F8332 Spare, Door Fan Filter, PKG10, D&E Frame Door Filters, Package of 10 IP54 IP54 IP54 IP54 IP54
F4 176F8639 Spare, FC DC Top Fan, IP00 D Frame IP00 Top Fan, Fan Only (1 fan per kit) IP00 IP00 IP00 IP00 IP00
F2,3 176F8333 Spare, Door/Top AC Fan, D&E Frame IP21/IP54 Door Fan, Fan Only (1 fan per kit) 21/54 21/54 21/54 21/54 21/54
Fuses
FU1,2,3 176F8334 Spare, Fuse, Main, 350A Mains Fuse. 1 fuse per kit --- --- --- --- 3
FU1,2,3 176F8539 Spare, Fuse, Main, 200A Mains Fuse. 1 fuse per kit 3 3 3 3 ---
176F8336 Spare, Fuse, Soft charge, 20A, PKG3, D&E Frame Soft charge fuse. Package of 3 1 pkg 1 pkg 1 pkg 1 pkg 1 pkg
FU5 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Power Card Fuse, 4 amp. Package of 3 1 1 1 1 1
FU4 176F8440 Spare, Fuse, 4A, PKG3, Power PCA, Fan Fan Transformer Fuse, 4 amp. Package of 3 1 1 1 1 1

L1 176F8536 Spare, Bus Inductor, 350uH DC Link Coil, Small D Frame 1 1 1 1 1
L2,3,4 176F8342 Spare, Current Sensor, 300A Motor Current Sensor, 1 sensor per kit 3 3 3 3 3
TR1 176F8535 Spare, Fan Transformer Assy, 690V, 400VA Fan Transformer. Includes cables and plug 1 1 1 1 1

Table 10.18: Spare Parts List Capacitors, Fans, Fuses and Inductors & Current Sensors
10 Spare Parts List
197
10
10
198
525690 VAC
D1/D3
FC 102 P45K P55K P75K P90K P110
ignator Number
FC 302 P37K P45K P55K P75K P90K
10 Spare Parts List
Disconnects
SW1 176F8345 Spare, Disconnect SW,200A, D Frame Disconnect Switch 1 1 1 1 1
176F8346 Spare, Disconnect Handle, Rod, D Frame Disconnect Handle 1 1 1 1 1
Cables
CBL1 176F8640 Spare, Cable, FC LCP, D Frame, IP54 ribbon cable from LCP to control card, IP 54 enclosure IP54 IP54 IP54 IP54 IP54
CBL2 176F8641 Spare, Cable, Control PCA, 44pin, D&E Frame ribbon cable from control card to power card 1 1 1 1 1
CBL5 176F8541 Spare, Cable, FC Current Sensor, D Frame wire harness from power card to current sensors 1 1 1 1 1
CBL8 176F8542 Spare, Cable, HS Fan, D1 Frame wire harness from the power card to the fan transformer 1 1 1 1 1
CBL9 176F8354 Spare, Cable, Softchg RST prime, D Frame wire harness from soft charge to power card 1 1 1 1 1
CBL12 176F8358 Spare, Cable, Door Fan, D Frame wire harness for AC door fans 21/54 21/54 21/54 21/54 21/54
CBL13 176F8544 Spare, Cable, FC SCR, D1 Frame wire harness from power card to SCR 1 1 1 1 1
CBL14 176F8356 Spare, Cable, DC to Power PCA, D Frame voltage from DC bus to power card 1 1 1 1 1
CBL16 176F8363 Spare, Cable, FC Gate Drive, 16pin, D1 Frame ribbon cable from power card to gate drive card 1 1 1 1 1
CBL17,18,19 176F8364 Spare, Cable, IGBT Gate, D1 Frame wire harness from gate drive card to IGBT module (1 per kit) 3 3 3 3 3
CBL20 176F8352 Spare, Cable, IGBT Temperature temperature connection from IGBT module to gate drive card 1 1 1 1 1
CBL21 176F8365 Spare, Cable, Brake IGBT, D1 Frame wire harness from gate drive card to brake IGBT module 1 1 1 1 1
CBL22 176F8366 Spare, Cable, Brake Power Plus, D1 Frame cable from brake IGBT to brake plus terminal 1 1 1 1 1
CBL23 176F8367 Spare, Cable, Brake Power Minus, D1 Frame cable from brake IGBT to brake minus terminal 1 1 1 1 1
CBL24 176F8543 Spare, Cable, Softchg RST, D1 Frame wire harness from input power to soft charge board 1 1 1 1 1
CBL25 176F8355 Spare, Cable, Softchg to DC bus, D Frame wire harness from soft charge to DC bus 1 1 1 1 1
Table 10.19: Spare Parts List Disconnects and Cables

525690 VAC
D1/D3
FC 102 P45K P55K P75K P90K P110

ignator Number
FC 302 P37K P45K P55K P75K P90K
TB1 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame mains terminal bus bar (1 per kit) 3 3 3 3 3
TB2 176F8374 Spare, BB, Terminals, Mains, Motor, D Frame motor terminal bus bar (1 per kit) 3 3 3 3 3
TB3 176F8395 Spare, BB, Terminal, LS, BK, D Frame brake terminal bus bar (1 per kit) 2 2 2 2 2
TB4 176F8395 Spare, BB, Terminal, LS, BK, D Frame load share terminal bus bar (1 per kit) 2 2 2 2 2
TB1 176F8371 Spare, Terminal Insul, mains, motor, D Frame mains terminal insulation block 1 1 1 1 1
TB2 176F8371 Spare, Terminal Insul, mains, motor, D Frame motor terminal insulation block 1 1 1 1 1
TB3 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame brake terminal insulation block 1 1 1 1 1
TB4 176F8372 Spare, Terminal Insul, Brk, LD Shr, D Frame load share terminal insulation block 1 1 1 1 1
176F8373 Spare, Label Set, Terminal Blk, D Frame terminal block label set includes mains, motor, brake, load share 1 1 1 1 1
176F8545 Spare, Insul, Mylar, IGBT, Bus, D1 Frame insulation under IGBT input bus bar assemblies 1 1 1 1 1
176F8547 Spare, Insul, IGBT snubber cap support mounts between IGBT and snubber capacitors (1 per kit) 1 1 1 1 1
176F8410 Spare, BB Stand Off, PKG10 bus bar mounting standoff (10 per kit) 12 12 12 12 12
Table 10.20: Spare Parts List Terminals, Labels & Insulators

10 Spare Parts List
199
10
10
200
525690 VAC
D1/D3
FC 102 P45K P55K P75K P90K P110
Block Diagram Spare Part
Designator Number
FC 302 P37K P45K P55K P75K P90K
10 Spare Parts List
Bus Bars
176F8380 Spare, BB, SCR, R\S\T, D Frame connects input plate bus bar to SCR input (1 per kit) 3 3 3 3 3
176F8548 Spare, Brkt, SCR BB Support, D Frame SCR input bus bar support 1 1 1 1 1
176F8379 Spare, BB Assy, SCR, D Frame connects to SCR outputs, sandwich assembly 1 1 1 1 1
176F8381 Spare, BB, SCR, Minus, D Frame connects DC coil inputs to SCR output bus bar assembly (1 per kit) 2 2 2 2 2
176F8549 Spare, BB, DC Link, Plus, D Frame connects DC Plus coil output to IGBT input bus bar assembly 1 1 1 1 1
176F8391 Spare, BB, DC Link, Plus, D Frame connects DC Minus coil output to IGBT input bus bar assembly 1 1 1 1 1
176F8376 Spare, BB Assy, IGBT, D Frame connects capacitor bank and IGBT inputs, sandwich assembly 1 1 1 1 1
176F8390 Spare, BB, IGBT, U\V\W, D Frame connects IGBT output to long bus bar over the fan (1 per kit) 3 3 3 3 3
176F8392 Spare, BB, Motor, 2, D Frame long output bus bar over the fan (1 per kit) 3 3 3 3 3
176F8397 Spare, BB, Brake, Plus, D Frame connects DC Plus to brake IGBT 1 1 1 1 1
176F8398 Spare, BB, Brake, Minus, D Frame connects DC Minus to brake IGBT 1 1 1 1 1
176F8401 Spare, BB, LS, Plus, D Frame connects plus load share terminal to SCR output bus bar assembly 1 1 1 1 1
176F8400 Spare, BB, LS, Minus, D Frame connects minus load share terminal to SCR output bus bar assembly 1 1 1 1 1
176F8405 Spare, BB, SCR, Input 2, D Frame located on input plate (1 per kit) 3 3 3 3 3
176F8407 Spare, BB, Disc, D Frame located on input plate (1 per kit) 3 3 3 3 3
Enclosure
176F8430 Spare, Cable Clamp, 60 mm 60 mm power cable clamp --- --- --- --- ---
176F8490 Spare, Brkt, HF, board, gnd, D Frame mounting bracket for high frequency board 1 1 1 1 1
Table 10.21: Spare Parts List Bus Bars and Enclosure

Frequency Converters 11 Block Diagrams
11 Block Diagrams
11.1 Block Diagrams for D-Frames

11.1.1 D1/D3 380500 VAC
11

11 Block Diagrams Frequency Converters
11

11.1.2 D2/D4 380500 VAC
11

11

11.1.3 D1/D3 525690 VAC
11

11

11.1.4 D2/D4 525690 VAC
11

11.2 Block Diagrams for E-Frames

11.2.1 E1/E2 380500 VAC
11

11.2.2 E1/E2 525690 VAC
11

FC100 ServiceManual MG90L102

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High Power Service Manual for VLT FC Series

Frequency Converters Contents

2 Operator Interface and Frequency Converter Control 23

3 Internal Frequency Converter Operation 43

MG.90.L1.02 - VLT is a registered Danfoss trademark 1

Specific Card Connections 55

5 Frequency Converter and Motor Applications 77

2 MG.90.L1.02 - VLT is a registered Danfoss trademark

Soft Charge and Rectifier Circuits Test: E-frame Size 95

7 D-Frame Sizes Disassembly and Assembly Instructions 123

MG.90.L1.02 - VLT is a registered Danfoss trademark 3

SCR/Diode Module D2/D4 Units 136

8 E-Frame Sizes Disassembly and Assembly Instructions 153

9 Special Test Equipment 173

10 Spare Parts List 177

11 Block Diagrams 201

4 MG.90.L1.02 - VLT is a registered Danfoss trademark

Block Diagrams for E-Frames 208

MG.90.L1.02 - VLT is a registered Danfoss trademark 5

6 MG.90.L1.02 - VLT is a registered Danfoss trademark

MG.90.L1.02 - VLT is a registered Danfoss trademark 7

Illustration 8.1: Fan Assembly 166

8 MG.90.L1.02 - VLT is a registered Danfoss trademark

MG.90.L1.02 - VLT is a registered Danfoss trademark 9

10 MG.90.L1.02 - VLT is a registered Danfoss trademark

1.2 VLT FC Product Overview

1.3 For Your Safety

Frequency converters contain dangerous voltages when connected to mains. Only

MG.90.L1.02 - VLT is a registered Danfoss trademark 11

1.4 Electrostatic Discharge (ESD)

1.5 Frame Size Definitions

Table 1.1: FC 102 and FC 202 380-480 VAC

380-500 VAC Power

kW @400 VAC HP @460 VAC kW @500 VAC Frame Size

Table 1.2: FC 302 380-500 VAC

12 MG.90.L1.02 - VLT is a registered Danfoss trademark

525-690 VAC Power

Table 1.3: FC 102 and FC 202 525-690 VAC

525-690 VAC Power

kW @550 VAC HP @575 VAC kW @690 VAC Frame Size

Table 1.5: FC 302 AF-650 GP 525-690 VAC

1.6 Tools Required

Metric socket set 719 mm

Additional Tools Recommended for Testing

MG.90.L1.02 - VLT is a registered Danfoss trademark 13

1 1.7 General Torque Tightening Values

Table 1.7: Torque Values Table

14 MG.90.L1.02 - VLT is a registered Danfoss trademark

1.8 Exploded Views 1

Illustration 1.1: Exploded view D3 Frame size, D1 frame is similar.

1 Control card PCA1 14 SCR/Diode module SCR 1, 2, 3

MG.90.L1.02 - VLT is a registered Danfoss trademark 15

Illustration 1.2: Exploded view D4 frame size, D2 frame is similar.

1 Control card PCA1 15 IGBT module IGBT1, 2

16 MG.90.L1.02 - VLT is a registered Danfoss trademark

Illustration 1.3: Exploded view E2 frame size, E1 frame is similar.

2 Control input terminals 15 Fan inductor (not on all units)

MG.90.L1.02 - VLT is a registered Danfoss trademark 17

1 1.9 Ratings Tables