Contents VLT® HVAC Basic Drive FC 101 Service Manual

Contents

1 Introduction 6
1.1 Purpose 6
1.2 Product Overview 6
1.3 Safety 6
1.4 Electrostatic Discharge (ESD) 6
1.5 Tools Required 9
1.6 Electrical Installation in General 10
1.7 Exploded Views – H Frame Size 11
1.8 Exploded Views - I Frame Size 14
1.9 Ratings 17
1.9.1 Short Circuit and Over-current Trips 17
1.9.2 DC Voltage Levels 17

2 Frequency Converter Control 18

2.1 Introduction 18
2.2 Status Messages 18
2.3 Frequency Converter Inputs and Outputs 18
2.3.1 Input signals 18
2.3.2 Output Signals 19
2.4 Service Functions 19
2.5 Control Terminals 19
2.6 Control Terminal Functions 20
2.7 Grounding Shielded Cables 22

3 Internal Frequency Converter Operation 23

3.1 General 23
3.2 Description of Operation 23
3.2.1 Logic Section 23
3.2.2 Logic to Power Interface 24
3.2.3 Power Section 24
3.3 Sequence of Operation 24
3.3.1 Rectifier Section 24
3.3.2 Intermediate Section 26
3.3.3 Inverter Section 28
3.3.4 Fan Speed Control 30

4 Troubleshooting 31
4.1 Troubleshooting Tips 31
4.2 Exterior Fault Troubleshooting 31
4.3 Fault Symptom Troubleshooting 31

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4.4 Visual Inspection 32

4.5 Fault Symptoms 33
4.5.1 No Display 33
4.5.2 Intermittent Display 33
4.5.3 Display (Line2) Flashing 33
4.5.4 WRONG or WRONG LCP Displayed 33
4.5.5 Motor Will Not Run 33
4.5.6 Incorrect Motor Operation 34
4.6 Warnings and Alarms 34
4.6.1 Alarms 34
4.6.2 Warnings 35
4.6.3 Warning And Alarm Messages 35
4.7 After Repair Tests 40

5 Frequency Converter and Motor Applications 41

5.1 Torque Limit, Current Limit, and Unstable Motor Operation 41
5.1.1 Overvoltage Trips 41
5.1.2 Mains Phase Loss Trips 42
5.1.3 Control Logic Problems 42
5.1.4 Programming Problems 42
5.1.5 Motor/Load Problems 43
5.2 Internal Frequency Converter Problems 43
5.2.1 Current Sensor Faults 43
5.2.2 Signal and Power Wiring Considerations for Electromagnetic Compatibility 43
5.2.3 Effects of EMI 44
5.2.4 Sources of EMI 44
5.2.5 EMI Propagation 44
5.2.6 Preventive Measures 45

6 Test Procedures 47
6.1 Non-repairable Units 47
6.2 Introduction 49
6.3 Static Test Procedures 49
6.3.1 Pre-test Precautions 49
6.3.2 Rectifier Circuit Test 50
6.3.3 Inverter Section Tests 50
6.3.4 Intermediate Section Tests 50
6.3.5 Location of UDC Terminals 51
6.4 Dynamic Test Procedures 53
6.4.1 No Display Test (Display is Optional) 54
6.4.2 Input Voltage Test 54

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6.4.3 Basic Control Card Voltage Test 55

6.4.4 Input Imbalance of Supply Voltage Test 55
6.4.5 Input Waveform Test 55
6.4.6 Output Imbalance of Motor Supply Voltage Test 56
6.4.7 Input Terminal Signal Tests 57
6.5 Initial Start Up Or After Repair Drive Tests 57

7 H-Frame Size Disassembly and Assembly Instructions 59

7.1 Electrostatic Discharge (ESD) 59
7.2 General Disassembly Procedure 59
7.3 H6 Frame Size Disassembly and Assembly Instructions 59
7.3.1 Control Card and Control Card Mounting Plate 59
7.3.2 Heatsink Fan Assembly 60
7.3.3 DC Coil 61
7.3.4 DC Link Card 61
7.3.5 RFI Filter 62
7.3.6 Power Card 62
7.4 H7 Frame Size Disassembly and Assembly Instructions 63
7.4.1 Control Card and Control Card Mounting Plate 63
7.4.2 Power Card 64
7.4.3 Inrush Card 64
7.4.4 RFI Filter 65
7.4.5 Relay Transducer Card 65
7.4.6 Rectifier Modules 66
7.4.7 IGBT 66
7.4.8 Heatsink Fan Assembly 67
7.4.9 DC Coil 67
7.4.10 Capacitor Bank 68
7.5 H8 Frame Size Disassembly and Assembly Instructions 68
7.5.1 Control Card and Control Card Mounting Plate 68
7.5.2 Power Card 69
7.5.3 Inrush Card 70
7.5.4 Rectifier Modules 70
7.5.5 RFI Filter 71
7.5.6 Relay Transducer Card 72
7.5.7 IGBT 72
7.5.8 Heatsink Fan Assembly 73
7.5.9 DC Coil 74
7.5.10 Capacitor Bank 74
7.6 H10 Frame Size Disassembly and Assembly Instructions 75
7.6.1 Control Card and Control Card Mounting Plate 75

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7.6.2 Power Card Cover 75

7.6.3 Power Card 76
7.6.4 Heatsink and DC Coils 76
7.6.5 Heatsink Fan Assembly 77

8 I-Frame Size Disassembly and Assembly Procedures 78

8.1 General Disassembly Procedure 78
8.2 I6 Frame Size Disassembly and Assembly Instructions 78
8.2.1 Control Card and Control Card Mounting Plate 78
8.2.2 Cable Mounting Plate 79
8.2.3 Heatsink Fan Assembly 79
8.2.4 SMPS Card 80
8.2.5 Bus Bar Unit 80
8.2.6 Power Card 81
8.2.7 DC Coil 81
8.2.8 RFI Filter 82
8.3 I7 Frame Size Disassembly and Assembly Instructions 82
8.3.1 Control Card and Control Card Mounting Plate 82
8.3.2 Power Card 83
8.3.3 Power Card Mounting Plate 84
8.3.4 Inrush Card 84
8.3.5 Bus Bar 85
8.3.6 RFI Filter 85
8.3.7 Relay Transducer Card 86
8.3.8 Fan 86
8.3.9 Terminal Plate 87
8.3.10 DC Bus Bar Assembly 87
8.3.11 Heatsink Fan Assembly 88
8.3.12 Capacitor Bank 88
8.3.13 DC Coil 89
8.3.14 IGBT 89
8.3.15 Thyristor 90
8.4 I8 Frame Size Disassembly and Assembly Procedure 90
8.4.1 Control Card and Control Card Mounting Plate 90
8.4.2 Power Card 91
8.4.3 Power Card Mounting Plate 92
8.4.4 Inrush Card 92
8.4.5 Bus Bar 93
8.4.6 RFI Filter 93
8.4.7 Relay Transducer Card 94
8.4.8 Terminal Plate 94

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8.4.9 DC Bus Bar Assembly 95

8.4.10 Heatsink Fan Assembly 95
8.4.11 Capacitor Bank 96
8.4.12 DC Coil 96
8.4.13 IGBT 97
8.4.14 Thyristor 97

9 Block Diagrams 98
9.1 Block Diagrams, Frame Sizes H and 9 98
9.1.1 H6 Frame Size 98
9.1.2 I6 Frame Size 99
9.1.3 H7, H8, I7, I8 Frame Size 100
9.1.4 H9 Frame Size 101
9.1.5 H10 Frame Size 102

Index 103

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 Introduction VLT® HVAC Basic Drive FC 101 Service Manual

1 1 1 Introduction

1. DO NOT touch electrical parts of the frequency

converter when connected to mains. Also make
1.1 Purpose sure that other voltage inputs have been discon-
This manual provides the technical information and nected (linkage of DC intermediate circuit). Be
instructions required, for a qualified technician to identify aware that there may be high voltage on the DC-
faults and perform repairs and maintenance on the link even when the LEDs are turned off. Before
frequency converter: touching any potentially live parts of the
frequency converter, wait at least as stated in
Table 1.1.
• data for the different enclosure sizes
2. Before conducting repair or inspection,
• description of user interfaces and internal
disconnect mains.
processing
3. [Off] on the LCP does not disconnect mains.
• troubleshooting and test instructions
4. During operation and while programming
• assembly and disassembly instructions
parameters, the motor may start without warning.
The manual applies to frequency converter models and Press [Stop] when changing data.
voltage ranges described in Table 1.2 to Table 1.4.
5. When operating on a PM motor, disconnect
motor cable.
1.2 Product Overview
Minimum waiting
Voltage [V] Power Range [kW]
VLT® HVAC Basic Drive FC 101 frequency converters are time [min]
designed for the Heating, Ventilation, and Air-Conditioning 3x200 0.25–3.7 4
(HVAC) markets. They operate in variable torque mode, 3x200 5.5–11 15
and include features suited for fan and pump applications 3x400 0.37–7.5 4
within the HVAC market. 3x400 11–90 15
3x600 2.2–7.5 4
3x600 11–90 15
1.3 Safety
Table 1.1 Discharge Time
CAUTION
Frequency converters contain dangerous voltages when
connected to mains. Only a trained technician should
1.4 Electrostatic Discharge (ESD)
carry out the service. See also 2.1 Introduction.
NOTICE
When performing service, use proper electrostatic
CAUTION discharge (ESD) procedures to prevent damage to
For dynamic test procedures, main input power is sensitive components. Many electronic components
required and all devices and power supplies connected within the frequency converter are sensitive to static
to mains are energised at rated voltage. Take extreme electricity. Voltages so low that they cannot be felt, seen,
caution when conducting tests in a powered frequency or heard can reduce the life, affect performance, or
converter. Contact with powered components could completely destroy sensitive electronic components.
result in electrical shock and personal injury.
• Do not touch components on the circuit boards.

• Hold circuit boards by the edges or corners

only.

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1.4.1 Frame Size Definitions 1 1

Model HP @200–240 V AC kW @200–240 V AC Frame Size IP Rating Repairable Yes/No
PK25 0.33 0.25 H1 IP20 No
PK37 0.5 0.37 H1 IP20 No
PK75 1.0 0.75 H1 IP20 No
P1K5 2.0 1.5 H1 IP20 No
P2K2 3.0 2.2 H2 IP20 No
P3K7 5.0 3.7 H3 IP20 No
P5K5 7.5 5.5 H4 IP20 No
P7K5 10.0 7.5 H4 IP20 No
P11K 15.0 11.0 H5 IP20 No
P15K 20.0 15.0 H6 IP20 Yes
P18K 25.0 18.5 H6 IP20 Yes
P22K 30.0 22.0 H7 IP20 Yes
P30K 40.0 30.0 H7 IP20 Yes
P37K 50.0 37.0 H8 IP20 Yes
P45K 60.0 45.0 H8 IP20 Yes

Table 1.2 FC 101 Frequency Converters 200-240 V AC

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1 1 Model HP @380–480 V AC kW @380–480 V AC Frame Size IP Rating Repairable Yes/No

PK37 0.5 0.37 H1 IP20 No
PK75 1.0 0.75 H1 IP20 No
P1K5 2.0 1.5 H1 IP20 No
P2K2 3.0 2.2 H2 IP20 No
P3K0 4.0 3.0 H2 IP20 No
P4K0 5.0 4.0 H2 IP20 No
P5K5 7.5 5.5 H3 IP20 No
P7K5 10.0 7.5 H3 IP20 No
P11K 15.0 11.0 H4 IP20 No
P15K 20.0 15.0 H4 IP20 No
P18K 25.0 18.0 H5 IP20 No
P22K 30.0 22.0 H5 IP20 No
P30K 40.0 30.0 H6 IP20 Yes
P37K 50.0 37.0 H6 IP20 Yes
P45K 60.0 45.0 H6 IP20 Yes
P55K 70.0 55.0 H7 IP20 Yes
P75K 100.0 75.0 H7 IP20 Yes
P90K 125.0 90.0 H8 IP20 Yes
PK75 1.0 0.75 I2 IP54 No
P1K5 2.0 1.5 I2 IP54 No
P2K2 3.0 2.2 I2 IP54 No
P3K3 4.0 3.3 I2 IP54 No
P4K0 5.0 4.0 I2 IP54 No
P5K5 7.5 5.5 I3 IP54 No
P7K5 10.0 7.5 I3 IP54 No
P11K 15.0 11.0 I4 IP54 No
P15K 20.0 15.0 I4 IP54 No
P22K 25.0 18.0 I4 IP54 No
P11K 15.0 11.0 I5 IP54 No
P15K 20.0 15.0 I5 IP54 No
P22K 25.0 18.0 I5 IP54 No
P22K 30.0 22.0 I6 IP54 Yes
P30K 40.0 30.0 I6 IP54 Yes
P37K 50.0 37.0 I6 IP54 Yes
P45K 60.0 45.0 I7 IP54 Yes
P55K 70.0 55.0 I7 IP54 Yes
P75K 100.0 75.0 I8 IP54 Yes
P90K 125.0 90.0 I8 IP54 Yes

Table 1.3 FC 101 Frequency Converters 380-480 V AC

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Model HP @525–600 V AC kW @525–600 V AC Frame Size IP Rating Repairable Yes/No 1 1

P2K2 3.0 2.2 H9 IP20 No
P3K0 4.0 3.0 H9 IP20 No
P5K5 7.5 5.5 H9 IP20 No
P7K5 10.0 7.5 H9 IP20 No
P11K 15.0 11.0 H10 IP20 Yes
P15K 20.0 15.0 H10 IP20 Yes
P22K 30.0 22.0 H6 IP20 Yes
P30K 40.0 30.0 H6 IP20 Yes
P45K 60.0 45.0 H7 IP20 Yes
P55K 70.0 55.0 H7 IP20 Yes
P75K 100.0 75.0 H8 IP20 Yes
P90K 125.0 90.0 H8 IP20 Yes

Table 1.4 FC 101 Frequency Converters 525–600 V AC

1.5 Tools Required

Quick Guide for VLT® HVAC Basic Drive FC 101.

ESD Protection Kit Wrist strap and Mat

Metric socket set 7 to 19 mm
Torque wrench 0.5 Nm to 19 Nm
Socket extensions 100 to 150 mm (4 in and 6 in)
Torx driver set T10-T50
Needle nose pliers
Magnetic sockets
Ratchet
Screwdrivers Standard and Philips

Table 1.5 Required Tools

Additional Tools Recommended for Testing

• Digital voltmeter/ohmmeter (must be rated for
1000 V DC for 600 V units)

• Analog voltmeter

• Oscilloscope

• Clamp-on style ammeter

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1 1 1.6 Electrical Installation in General

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper
conductors required, (75 °C) recommended.

Power [kW] Torque [Nm]

Frame IP class 3x200-240 V 3x380-480 V Line Motor DC Control Ground Relay
connection terminals
H1 IP20 0.25-1.5 0.37-1.5 1.4 0.8 0.8 0.5 0.8 0.5
H2 IP20 2.2 2.2-4 1.4 0.8 0.8 0.5 0.8 0.5
H3 IP20 3.7 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
H4 IP20 5.5-7.5 11-15 1.2 1.2 1.2 0.5 0.8 0.5
H5 IP20 11 18.5-22 1.2 1.2 1.2 0.5 0.8 0.5
H6 IP20 15-18 30-45 4.5 4.5 - 0.5 3 0.5
H7 IP20 22-30 55 10 10 - 0.5 3 0.5
H7 IP20 - 75 14 14 - 0.5 3 0.5
H8 IP20 37-45 90 242 242 - 0.5 3 0.5

Table 1.6 Enclosure H1-H8

Power [kW] Torque [Nm]

Frame IP class 3x380-480 V Line Motor DC Control Ground Relay
connection terminals
I2 IP54 0.75-4.0 1.4 0.8 0.8 0.5 0.8 0.5
I3 IP54 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
I4 IP54 11-18.5 1.4 0.8 0.8 0.5 0.8 0.5
I6 IP54 22-37 4.5 4.5 - 0.5 3 0.6
I7 IP54 45-55 10 10 - 0.5 3 0.6
I8 IP54 75-90 14/241 14/241 - 0.5 3 0.6

Table 1.7 Enclosure I1-I8

Power [kW] Torque [Nm]

Frame IP class 3x525-600 V Line Motor DC Control Ground Relay
connection terminals
H9 IP20 2.2-7.5 1.8 1.8 not 0.5 3 0.6
recommended
H10 IP20 11-15 1.8 1.8 not 0.5 3 0.6
recommended
H6 IP20 18.5-30 4.5 4.5 - 0.5 3 0.5
H7 IP20 37-55 10 10 - 0.5 3 0.5
H8 IP20 75-90 14/241 14/241 - 0.5 3 0.5

Table 1.8 Details of Tightening Torques

1 Cable dimensions ≤95 mm2
2 Cable dimensions >95 mm2

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1.7 Exploded Views – H Frame Size 1 1

NOTICE
Non-repairable units are not shown with exploded views.

130BC341.10
13 14

12

11

10
9

7 15
3

4
2
6
5

16

17
1 18

Illustration 1.1 Exploded View - H6 Frame Size

1 Blind cover 10 Filter protection cover

2 Front cover LCP 11 RFI filter
3 Cradle 12 EMC shield
4 Control card 13 Bus bar unit
5 Control card mounting plate 14 Heatsink fan assembly
6 DC coils 15 Connector
7 Coil mounting plate 16 DC coil cover
8 Coil mounting plate 17 Capacitor bank metal cover
9 DC link card 18 Capacitor vibration support

Table 1.9 Legend to Illustration 1.1

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1 1 17 18

130BC342.10
14 16
15
12 19

13

11
9 10 20

8
7
3 5 22
21
6

4
2

23

24

Illustration 1.2 Exploded View - H7 Frame Size

1 Blind cover 13 Relay/transducer card mounting plate

2 LCP 14 DC coil cover plate
3 Front cover 15 Bus bar
4 EMC shield 16 Plastic cover
5 Cradle 17 Rectifier modules
6 Control card 18 Heatsink fan assembly
7 Control card mounting plate 19 DC coils
8 Power card 20 Capacitors
9 Power card mounting plate 21 Bottom plate
10 RFI filter 22 Relay/transducer card
11 EMC shield 23 IGBT
12 Inrush card 24 Cable mounting plate

Table 1.10 Legend to Illustration 1.2

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1 1

130BC214.11
19

18
20
17

16
15

14

21
13

12

11

22

10

7
6
5
2

3
1
4

Illustration 1.3 Exploded View - H8 Frame Size

1 LCP 12 SMPS card

2 Front cover 13 Cable mounting plate
3 Cradle, control card and mounting plate 14 IGBT
4 EMC shield 15 Relay/transducer card mounting plate
5 Power card 16 Relay/transducer card
6 Power card mounting plate 17 Bus bar
7 Support bracket 18 Rectifier modules
8 Plastic cover 19 Heatsink fan assembly
9 RFI filter 20 Capacitors
10 DC coil cover plate 21 Bottom cover
11 Bus bar unit 22 Connection terminals

Table 1.11 Legend to Illustration 1.3

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1 1
1.8 Exploded Views - I Frame Size

130BC046.11
10
7 9
8

5
6
4
2 3

13

14 12

15

11

16

Illustration 1.4 Exploded View - I6 Frame Size

1 Local Control Panel (LCP) 9 DC coil

2 Front cover 10 Heatsink
3 Cradle 11 Fan assembly
4 Control card 12 Cable mounting plate
5 Control card mounting plate 13 RFI filter
6 Fan 14 Connectors
7 Bus bar unit 15 EMC shield
8 Power card 16 Cable entry

Table 1.12 Legend to Illustration 1.4

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1 1

130BC215.11
16

15

14

13

12
17
11
10

9 18

8
19
7

20

6 21

5
4
3

22
2

1
23

24

25

Illustration 1.5 Exploded View - I7 Frame Size

1 Local Control Panel (LCP) 14 DC coil

2 Front door 15 Thyristors
3 Cradle 16 Back plate
4 Control card 17 IGBT
5 Control card mounting plate 18 Capacitor
6 Terminal plates 19 Heatsink fan
7 Support bracket 20 Bus bar unit
8 RFI filter 21 Relay/transducer card
9 Inrush card 22 Relay card mounting plate
10 Terminal connectors 23 Power card
11 Cable mounting plate 24 Power card mounting plate
12 Bus bar 25 Cable entry
13 Bracket

Table 1.13 Legend to Illustration 1.5

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1 1

130BC216.11
11

10

6 7 8
2 4 5
3 12
1

14
13

18

16 15

17

19

Illustration 1.6 Exploded View - I8 Frame Size

1 LCP 11 DC coil
2 Front cover 12 Rectifier modules
3 Cradle 13 IGBTs
4 LCP gasket 14 Capacitors
5 Control card 15 Heatsink fan assembly
6 Control card mounting plate 16 Fan
7 Support bracket 17 Cable mounting plate
8 RFI filter 18 Relay/transducer card with mounting plate
9 Power Card 19 Cable entry
10 Power card mounting plate

Table 1.14 Legend to Illustration 1.6

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1.9 Ratings 1 1
1.9.1 Short Circuit and Over-current Trips

The frequency converter is protected against short circuits with current measurement in each of the 3 motor phases or in
the DC link. A short circuit between 2 output phases causes an over current in the inverter. The inverter turns off the IGBTs
individually when the short circuit current exceeds the permitted value (Alarm 16 Trip Lock).

1.9.2 DC Voltage Levels

200-240 V AC 380-480 V AC 525-600 V AC

H1–H5 H6–H8 H1–H5 H6–H8 H6–H10
I2–I3–I4 I6–I8
Inrush circuit enabled
Inrush circuit disabled 202 184 314 372 532
Under voltage 202 184 314 372 532
Under voltage re-enable 202+15 184+16 314+30 372+24 532+20
Over voltage 410 412 800 800 976
Over voltage re-enable 410-15 412-16 800-30 800-24 976-20
IT-Grid Turn on 410+25 412+25 800+35 800+35 976+35

Table 1.15 DC Voltage Levels

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2 Frequency Converter Control

2 2 when operating in local (hand on) mode. These inputs
include start, stop, reset, and speed reference.
2.1 Introduction
Frequency converters are designed with self-diagnostic Another control source is through serial communication
circuitry to isolate fault conditions and activate display from a serial bus. A serial communication protocol that
messages which greatly simplify troubleshooting and supplies commands and references to the frequency
service. The operating status of the frequency converter is converter, can program the frequency converter, and read
displayed in real time. Virtually, every command given to status data from the frequency converter. The serial bus
the frequency converter results in some indication on the connects to the frequency converter through the RS-485
Local Control Panel (LCP) display. Fault logs are maintained serial port or through a communication option card.
within the frequency converter for fault history.
The third way is through signal wiring connected to the
The frequency converter monitors supply and output frequency converter control terminals. The frequency
voltages along with the operational condition of the motor converter control terminals are located below the LCP.
and load. When the frequency converter issues a warning Improperly connected control wiring can cause a motor
or alarm, it cannot be assumed that the fault lies within not to operate or the frequency converter not to respond
the frequency converter itself. In fact, for most service calls, to a remote input.
the fault condition is found outside of the frequency
converter. It is often faults outside of the frequency 2.3.1 Input signals
converter that generates most of the warnings and alarms
that the frequency converter displays. This service manual The frequency converter can receive 2 types of remote
provides techniques and test procedures to help isolate a input signals: digital or analog. Digital inputs are wired to
fault condition whether in the frequency converter or terminals 18, 19, 20 (common), 27, 29. Analog or digital
elsewhere. inputs are wired to terminals 53 or 54 and 55 (common). A
switch placed under the LCP sets the terminal functions.
Familiarity with the information provided on the display is Some options include additional terminals.
important. Additional diagnostic data can be accessed
easily through the LCP. Analog signals can be either voltage (0 V to +10 V DC) or
current (0-20 mA or 4-20 mA). Analog signals can be varied
like dialing a rheostat up and down. The frequency
2.2 Status Messages
converter can be programmed to increase or decrease
Status messages appear in the bottom of the display. The output in relation to the amount of current or voltage. For
left part of the status line indicates the active operation example, a sensor or external controller may supply a
model of the frequency converter. variable current or voltage. The frequency converter
output, in turn, regulates the speed of the motor
The centre part of the status line indicates the references connected to the frequency converter in response to the
site. The last part of the status line gives the operation analog signal.
status, for example, Running, Stop, or Stand by. Other
status messages may appear related to the software Digital signals are a simple binary 0 or 1 acting as a switch.
version and frequency converter type. A 0-24 V DC signal controls the digital signals. A voltage
signal lower than 5 V DC is a logic 0. A voltage higher
than 10 V DC is a logic 1. 0 is open, 1 is close. Digital
2.3 Frequency Converter Inputs and inputs to the frequency converter are switched commands
Outputs such as start, stop, reverse, coast, reset, and so on. (Do not
confuse these digital inputs with serial communication
The frequency converter operates by receiving control formats where digital bytes are grouped into communi-
input signals. The frequency converter can also output cation words and protocols).
status data or control auxiliary devices. Control input is
connected to the frequency converter in three possible
The RS-485 serial communication connector is wired to
ways. One way for the frequency converter control is
terminals (+) 68 and (-) 69. Terminal 61 is a common
through the LCP on the front of the frequency converter,
terminal. It is used for terminating screens only when the

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control cable is run between frequency converters, and not 14-28 Production Settings and 14-29 Service Code, are the
between frequency converters and other devices. relevant service parameters.

Parameters for configuring the input and output using Parameter settings are displayed by pressing [Main Menu]. 2 2
NPN and PNP.
Press [▲], [▼], [►] and [◄] to scroll through parameters.
These parameters cannot be changed while the motor is
running. See the Quick Guide for detailed information on accessing
and displaying parameters, and for descriptions and
2.3.2 Output Signals procedures for service information available in parameter
group 6-** Analog In/Out.
The frequency converter also produces output signals that
are carried either through the RS-485 serial bus or terminal
42. Output terminal 42 operates in the same manner as
2.5 Control Terminals
the inputs. The terminal can be programmed for either a Control terminals must be programmed. Each terminal has
variable analog signal in mA or a digital signal (0 or 1) in specific functions and a numbered parameter associated
24 V DC. In addition, a pulse reference can be provided on with it. The setting selected in the parameter enables the
terminals 27 and 29. Output analog signals generally function of the terminal.
indicate the frequency, current, torque, and so on, to an
external controller or system. Digital outputs can be
It is important to confirm that the control terminal is
control signals used to open or close a damper, or send a
programmed for the correct function.
start or stop command to auxiliary equipment.

Parameter settings are displayed by pressing [Main Menu].

Additional terminals are Form C relay outputs on terminals
01, 02, and 03, and terminals 04, 05, and 06.
Press [▲], [▼], [►] and [Back] to scroll through parameters.

Terminals 12 and 13 provide 24 V DC low voltage power,

often used to supply power to the digital input terminals See the Quick Guide for details on changing parameters
(18-33). Those terminals must be supplied with power from and the functions available for each control terminal.
either terminal 12 or 13, or from a customer supplied
external 24 V DC power source. Improperly connected In addition, the input terminal must be receiving a signal.
control wiring is a common service issue for a motor not Confirm that the control and power sources are wired to
operating or the frequency converter not responding to a the terminal. Then check the signal.
remote input.
Signals can be checked in 2 ways. Digital Input can be
Number of digital outputs 2 selected for display by pressing [Display Mode], or a
Terminal number 42, 451) voltmeter can be used to check for voltage at the control
Voltage level at digital output 17 V terminal.
Max. output current at digital output 20 mA
Max. load at digital output 1 kΩ In summary, for proper frequency converter functioning,
the frequency converter input control terminals must be
Table 2.1 Digital Output
1) Terminals 42 and 45 can also be programmed as analog output. • wired properly

• powered
2.4 Service Functions • programmed correctly for the intended function

Service information for the frequency converter can be

shown in display lines 1 and 2. 24 different items can be
accessed. Included in the data are

• counters that tabulate operating hours, etc.

• fault logs that store frequency converter status

values present at the ten most recent events that
stopped the frequency converter

• frequency converter nameplate data

MG90X302 - Rev. 2013-10-08 19

 Frequency Converter Control VLT® HVAC Basic Drive FC 101 Service Manual

2.6 Control Terminal Functions Terminal Function

No.
Table 2.2 describes the functions of the control terminals.
2 2
42, 45 Analog and digital outputs for indicating values
Many of these terminals have multiple functions such as frequency, reference, current and torque.
determined by parameter settings. See Illustration 2.1. The analog signal is 0 to 20 mA, or 4 to 20 mA at
a maximum of 500 Ω. The digital signal is 24 V DC
Terminal Function at a minimum of 600 Ω.
No. 50 10 V DC, 17 mA maximum analog supply voltage
01, 02, 03 Form C relay output on control card. Maximum for potentiometer or thermistor.
240 V AC, 2 A. Minimum 24 V DC, 10 mA or 24 V 53, 54 0 to 10 V DC voltage input, R = 10 kΩ Used for
AC, 100 mA. Can be used for indicating status and reference or feedback signals. A thermistor can be
warnings. Physically located on power card. connected here.
04, 05 Form A relay output on control card. 30 V AC, 42.5 55 Common for analog inputs. This common is
V DC. Can be used for indicating status and isolated from the common of all other power
warnings. supplies. If, for example, the frequency converter’s
12, 13 Voltage supply to digital inputs and external 24 V DC power supply is used to power an
transducers. For the 24 V DC to be used for digital external transducer, which provides an analog
inputs, switch 4 on the control card must be input signal, terminal 55 must be wired to terminal
closed (ON position). The maximum output current 39.
is 200 mA. 60 Programmable 0 to 20 mA or 4 to 20 mA, analog
16 - 33 Programmable digital inputs for controlling the current input, Resistance=approx. 200 Ω. Used for
frequency converter. R=2 kΩ. Less than 5 V=logic 0 reference or feedback signals.
(open). Greater than 10 V=logic 1 (closed). 61 RS-485 common.
20 Common for digital inputs. 68, 69 RS-485 interface and serial communication.
39 Common for analog and digital outputs.
Table 2.2 Terminal Functions

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Frequency Converter Control VLT® HVAC Basic Drive FC 101 Service Manual

130BB626.10
L1 U

2 2
L2 V
3 Phase
power L3 W
input
PE PE
Motor

UDC-
Not present on all power sizes

UDC+

50 (+10V OUT) relay2

+10Vdc
06
0-10Vdc- 53 (A IN) 240V AC 3A
0/4-20 mA 05

0-10Vdc- 54 (A IN) 04
0/4-20 mA
55 (COM A IN/OUT) relay1
42 0/4-20mA A OUT / DIG OUT 03
240V AC 3A
45 0/4-20mA A OUT / DIG OUT 02

Bus ter. 01
12 (+24V OUT) ON=Terminated
ON
1 2

OFF=Unterminated
18 (DIGI IN)
24V (NPN)
OV (PNP)
19 (DIGI IN)
24V (NPN)
20 (COM D IN) OV (PNP)
Bus ter.
27 (DIGI IN)
24V (NPN) RS-485 (N PS-485) 69
OV (PNP) RS-485
29 (DIGI IN) Interface
24V (NPN) (P RS-485) 68
OV (PNP) Do not connect shield to
(Com RS-485 ) 61 61 on 116,117 and 118 unites

(PNP)-Source
(NPN)-Sink

Illustration 2.1 Control Terminal Electrical Overview

Control terminals must be programmed. Each terminal has specific functions and a numbered parameter associated with it.
The setting selected in the parameter enables the function of the terminal. See the VLT® HVAC Basic Drive FC 101 Quick
Guide for details.

MG90X302 - Rev. 2013-10-08 21

 Frequency Converter Control VLT® HVAC Basic Drive FC 101 Service Manual

2.7 Grounding Shielded Cables Serial communication control cables

Low frequency noise currents between frequency
Connect the shielded control cables to the metal cabinet converters can be eliminated by connecting one end of
2 2 of the frequency converter with cable camps at both ends. the screened cable to frequency converter terminal 61.
Illustration 2.3 shows ground cabling for optimal results. This terminal connects to ground through an internal RC
link. Use twisted-pair cables to reduce the differential
Correct grounding mode interference between conductors.
Control cables and cables for serial communication must

130BB611.11
FC FC
be fitted with cable clamps at both ends to ensure the - 69
+68
best possible electrical connection.
61 (PE) PE
PLC FC 130BB610.11
Illustration 2.5 Serial Communication Control Cables

PE PE
Illustration 2.2 Correct Grounding

Incorrect grounding
Do not use twisted cable ends (pigtails) since they increase
screen impedance at high frequencies.
Ground potential protection
When the ground potential between the frequency
converter and the PLC or other interface device is different,
electrical noise may occur that can disturb the entire
system. Resolve the electrical noise by fitting an equalizing
cable next to the control cable. Minimum cable cross
section is 8 AWG.
PLC FC
130BB922.12

PE PE <10 mm
PE PE
1
2
Illustration 2.3 Ground Potential Protection

1 Min. 16 mm2
2 Equalizing cable

Table 2.3 Legend to Illustration 2.3

50/60 Hz ground loops

When using very long control cables, 50/60 Hz ground
loops may occur that can disturb the entire system.
Resolve the ground loops by connecting one end of the
screen with a 100 nF capacitor and keeping the lead short.
130BB609.12

PLC FC

PE
100nF PE <10 mm

Illustration 2.4 50/60 Hz Ground Loops

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Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

3 Internal Frequency Converter Operation

A custom integrated circuit generates a pulse width

modulation (PWM) waveform, which is then sent to the
3.1 General interface circuitry located on the power card. 3 3
This section provides an operational overview of the main
assemblies and circuitry in the frequency converter.

130BC343.10
Control Card Power

3.2 Description of Operation

PWM
MCP
A frequency converter is an electronic controller that Motor Control Processor ADC
supplies a regulated amount of AC power to a 3-phase CAN CAN MCU
UART
induction motor to control the motor speed. By supplying 1 mbps
variable frequency and voltage to the motor, the frequency Processor
Interface
converter controls the motor speed, also when the load on UART
the motor changes. The frequency converter can also stop ACP Supply
and start the motor without the mechanical stress Application Control Processor
associated with the line start.

In its basic form, the frequency converter can be divided

Standard I/O
into 4 main sections.
Digital Analog
LCP RS485
Input I/O
1. Rectifier
2. Intermediate Circuit Illustration 3.1 Logic Section
3. Inverter
4. Control and Regulation
The PWM waveform is improved through the Voltage
The main frequency converter components are grouped Vector Control Scheme, VVCplus. VVCplus provides variable
into three categories. They are: frequency and voltage to the motor matching the motor
requirements. Also available is the continuous pulsing
1. Control Logic Section SFAVM PWM. The dynamic response of the system
2. Logic to Power Interface changes to meet the variable requirements of the load.

3. Power Section
Another part of the logic section is the removable LCP or
In 3.3 Sequence of Operation, these 3 sections are covered display mounted on the front of the frequency converter.
in greater detail while describing how power and control The LCP provides the interface between the internal digital
signals move throughout the frequency converter. logic and the operator.

3.2.1 Logic Section All programmable parameter settings can be uploaded into
the EEPROM of the LCP. This function helps in maintaining
The control card includes most of the logic section (see a back-up frequency converter profile and parameter set.
Illustration 3.2). The primary logic element of the control Its download function can be used in programming other
card is a microprocessor, which supervises and controls all frequency converters or restoring a program to a repaired
functions of frequency converter operation. In addition, a unit. The LCP is removable during operation to prevent
separate PROM contains the parameters to provide the undesired program changes. With the addition of a remote
user with programmable options. These parameters are mounting kit, the LCP can be mounted in a remote
programmed to enable the frequency converter to meet location.
specific application requirements. This data is stored in an
EEPROM providing security during power-down and also Control terminals, with programmable functions, are
allows the flexibility to change the operational character- provided for input commands such as run, stop, forward,
istics of the frequency converter. reverse and speed reference. Additional output terminals
are provided to supply signals to run peripheral devices or
for monitoring and reporting status.

MG90X302 - Rev. 2013-10-08 23

 Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

The control card logic 7 V DC, 6 V DC, and 3.3 V DC operating voltage. SMPS
powers the logic and interface circuitry. SMPS is supplied
• communicates via serial link with outside devices by the DC bus voltage. The secondary SMPS provides
such as personal computers or Programmable power to the logic circuitry with main input disconnected.
Logic Controllers (PLC). It can keep units with communication options live on a
network when the frequency converter is not powered
3 3 • provides 2 voltage supplies for use from the
control terminals.
from the mains.

24 V DC is used for switching functions such as start, stop, Circuitry for controlling speed of the cooling fans is also
and forward/reverse. The 24 V DC supply also supplies 200 provided on the power card.
mA of power, which can partly be used to power external
encoders or other devices. A 10 V DC supply rated at 17
mA is also available for use with speed reference circuitry.
3.2.3 Power Section

The DC coil is a single unit 2 two coils wound on a

The analog and digital output signals are powered through
common core. One coil resides in the positive side of the
an internal frequency converter supply. The 3 power
DC bus and the other in the negative. The coil aids in the
supplies are isolated from one another to eliminate ground
reduction of mains harmonics.
loop conditions in the control input circuitry.

The DC bus capacitors are arranged into a capacitor bank

2 relays for monitoring the status of the frequency
along with bleeder and balancing circuitry.
converter are located on the power card. These relays are
programmable through parameter group 5-4* Relays. The
The inverter section is made up of six IGBTs, commonly
relays are Form C. These relays have one normally open
referred to as switches. One switch is necessary for each
contact, and one normally closed contact on a single
half phase of the 3-phase power, for a total of 6. The 6
throw. The contacts of the relay are rated for a maximum
IGBTs are contained in 3 dual modules.
load of 240 V AC at 2 Amps resistance.

A Hall effect type current sensor is located on each phase

The logic circuitry on the control card allows for adding:
of the output to measure motor current.

• option modules for synchronizing control

130BC330.10
• serial communications Rectifier Intermediate
(SCR/Diodes) circuit
Inverter
section (IGBTs)
• additional relays

• cascade pump controller

L1 T1
• custom operating software L2 T2
L3 T3

3.2.2 Logic to Power Interface

The logic to power interface isolates the high voltage Illustration 3.2 Typical Power Section
components of the power section from the low voltage
signals of the logic section. The interface consists of two
sections.
3.3 Sequence of Operation
• Power Card
3.3.1 Rectifier Section
• Gate Driver
The control card handles much of the fault processing for Depending on the rating of the frequency converter, the
output short circuit and ground fault conditions. The rectifier section is built on either 6 or 3 diodes and 3
power card provides conditioning of these signals. Scaling thyristors.
of current feedback and voltage feedback is accomplished
on the interface sections before processing by the control Inrush current in units with a normal 6-diode rectifier is
card. limited with a simple PTC and relay circuit.

The power card contains a Switch Mode Power Supply Phase controlling the thyristors (active inrush control)
(SMPS). The SMPS provides the unit with 24 V DC, 16 V DC, limits the inrush current in units with diodes and thyristors.

24 MG90X302 - Rev. 2013-10-08

Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

The low voltage power supplies are activated when the DC ripple voltage is present on the DC bus, the actual DC
bus reaches approximately 50 V DC less than the alarm value is closer to V ACx1.38 under unloaded conditions
voltage low for the DC bus (see 1.9.2 DC Voltage Levels). and may drop to V ACx1.32 while running under load. For
After a short delay, an inrush enable signal is sent from the example, a frequency converter connected to a nominal
control card to the power card SCR gating circuit. The SCRs 460 V line, while sitting idle, the DC bus voltage is approxi-
are automatically gated when forward biased, as a result mately 635 V DC (460x1.38).
acting similar to an uncontrolled rectifier. 3 3
As long as power is applied to the frequency converter,
When the DC bus capacitors are fully charged, the voltage this voltage is present in the intermediate circuit and the
on the DC bus is equal to the peak voltage of the input AC inverter circuit. It is also fed to the Switch Mode Power
line. Theoretically, this can be calculated by multiplying the Supply (SMPS) on the power card and is used for
AC line value by 1.414 (V ACx1.414). However, since AC generating all other low voltage supplies.

130BC134.10
Brake not connected to terminal on FC 101

AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS

Motor
L2 x3 RFI _ RL 2 x3 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1 Tmp_ VGDS

P_BRF
7 xGD
RL 2

SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
Control Card UINV_P SAFE _ FB
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
VGD +/- 15 /UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”

Illustration 3.3 Example of H6 Power and Control Section

MG90X302 - Rev. 2013-10-08 25

 Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

130BC135.10
Thyristor x3 AC / DC Brake not connected to terminal on FC 101
BR DC /AC
RFI (variations)
A
U

Motor
L1
3 3
x3
V
MAINS

A
L2 W
A
L3 o
C

RFI _RL 1 BR BR INV Temp.

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1

uC+ RL 1

Tmp_VGDS
P _BRF
7 xGD
EEP RL 2
RL 2

RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

VDD (GND) 24V Imax 2 comp.

E _FAN Level
E _FFB Shift

LCP ACP MCP Ext.

Display CAN
fans
”Internal Communication”
control ”Internal supply bus”
panel

Illustration 3.4 Example of H7, H8, I7, I8 Power and Control Section

3.3.2 Intermediate Section capacitor. It also provides a current path for discharging
the capacitors once power has been removed from the
Following the rectifier section, voltage passes to the frequency converter.
intermediate section. An LC filter circuit consisting of the
DC bus inductor and the DC bus capacitor bank smooths Also located in the intermediate section is the High
the rectified voltage. Frequency (HF) filter film capacitors. These capacitors
reduce the common mode noise caused by switching into
The DC bus inductor provides series impedance to stray capacitors to ground in cable and motor.
changing current. This impedance aids the filtering process
while reducing harmonic distortion to the input AC current In some units, RFI relay 2 can be opened to minimise
waveform normally inherent in rectifier circuits. voltage charge up.

The DC capacitor bank assembly consists of up to six If DC-link increases above a certain level specified in EE-
capacitors arranged in series/parallel configuration. A prom for each unit, RFI relay 2 opens automatically.
bleeder circuit maintains equal voltage drops across each

26 MG90X302 - Rev. 2013-10-08

Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

130BC335.10
Brake not connected to terminal on FC 101

3 3
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS

Motor
L2 x3 RFI _ RL 2 x3 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1

Tmp_ VGDS
P_BRF
7 xGD
RL 2

SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
Control Card UINV_P SAFE _ FB
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
VGD +/- 15 /UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”

Illustration 3.5 Example of H6 Intermediate Section

130BC336.10
Thyristor x3 AC / DC Brake not connected to terminal on FC 101
BR DC /AC
RFI (variations)
A
U

Motor
L1 x3
V
MAINS

A
L2 W
A
L3 o
C

RFI _RL 1 BR BR INV Temp.

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1

uC+ RL 1
Tmp_VGDS
P _BRF
7 xGD

EEP RL 2
RL 2

RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

VDD (GND) 24V Imax 2 comp.

E _FAN Level
E _FFB Shift

LCP ACP MCP Ext.

Display CAN
fans
”Internal Communication”
control ”Internal supply bus”
panel

Illustration 3.6 Example of H7, H8, I7, I8 Intermediate Section

MG90X302 - Rev. 2013-10-08 27

 Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

3.3.3 Inverter Section Hall effect current sensors monitor the output current and
deliver proportional signals to the power card where they
In the inverter section (see Illustration 3.8), gate signals are are buffered and delivered to the control card. The control
delivered from the control card, through the power card to card logic uses these current signals to determine proper
the gates of the IGBTs. The series connection of each set of waveform compensations based on load conditions. They
IGBTs is delivered to the output, first passing through the further serve to detect over current conditions, including
3 3 current sensors. ground faults and phase-to-phase shorts on the output.

Once a run command and speed reference are present, the During normal operation, the power card and control card
IGBTs begin switching to create the output waveform, as are monitoring various functions within the frequency
shown in Illustration 3.8. Looking at the phase-to-phase converter. The current sensors provide current feedback
voltage waveform with an oscilloscope shows that the information. The DC bus voltage and mains voltage are
Pulse Width Modulation (PWM) principal creates a series of monitored as well as the voltage delivered to the motor. A
pulses which vary in width. Basically, the pulses are thermal sensor mounted inside the sixpack IGBT module
narrower as zero crossing is approached and wider the provides heatsink temp feedback for the inverter. This
farther from zero crossing. The pulse duration of applied applies to unit up to and including H6 and I6 frame sizes.
DC voltage controls the width. Although the voltage For H7-H8 and I7-I8 frame sizes, the inverter consists of 3
waveform is a consistent amplitude, the inductance within dual IGBT modules and the thermal sensor is mounted
the motor windings serve to average the voltage delivered separately on the heatsink.
and so. As the pulse width of the waveform varies, the
average voltage seen by the motor varies as well. This then

130BX136.10
equates to the resultant current waveform which takes on
the sine wave shape expected in an AC system. The pulse
rate determines the waveform frequency waveform. By
employing a sophisticated control scheme, the frequency
converter can deliver a current waveform that nearly
replicates a true AC sine wave.
Illustration 3.7 Output Voltage and Current Waveforms
This waveform, as generated by the Danfoss VVCplus PWM
principle at the control card, provides optimal performance
and minimal losses in the motor.

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Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

130BC337.10
Brake not connected to terminal on FC 101

3 3
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS

Motor
L2 x3 RFI _ RL 2 x3 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1

Tmp_ VGDS
P_BRF
7 xGD
RL 2

SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
Control Card UINV_P SAFE _ FB
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
VGD +/- 15 /UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”

Illustration 3.8 Example of H6 Inverter Section

130BC338.10
Thyristor x3 AC / DC Brake not connected to terminal on FC 101
BR DC /AC
RFI (variations)
A
U

Motor
L1 x3
V
MAINS

A
L2 W
A
L3 o
C

RFI _RL 1 BR BR INV Temp.

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1

uC+ RL 1
Tmp_VGDS
P _BRF
7 xGD

EEP RL 2
RL 2

RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

VDD (GND) 24V Imax 2 comp.

E _FAN Level
E _FFB Shift

LCP ACP MCP Ext.

Display CAN
fans
”Internal Communication”
control ”Internal supply bus”
panel

Illustration 3.9 Example of H7, H8, I7, I8 Inverter Section

MG90X302 - Rev. 2013-10-08 29

 Internal Frequency Converte... VLT® HVAC Basic Drive FC 101 Service Manual

3.3.4 Fan Speed Control

IP20 IP20
Enclosure H6 H7 H8 Enclosure H9 H10 H6 H7 H8
Voltage T2 T2 T2 T2 T2 T2 Voltage T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6

3 3 Power Rating
[kW]
15 18. 5 22 30 37 45
Power
Rating 2.2 3.0 5.5 7.5 11 15 22 30 45 55 75 90
FAN start [kW]
45 45 45 45 45 45
temperature °C FAN start
FAN max speed tempera- 35 35 35 35 45 45 45 45 40 40 40 40
60 60 60 60 60 60
temperature °C ture °C
FAN stop FAN max
36 36 36 36 36 36
temperature °C speed
55 55 55 55 60 60 60 60 55 55 55 55
tempera-
Table 3.1 Fan Speed Control, IP20, H6-H8, T2 ture °C
FAN stop
IP20 tempera- 31 31 31 31 36 41 41 41 30 30 30 30
Enclosure H6 H7 H8 ture °C
Voltage T4 T4 T4 T4 T4 T4
Power Rating Table 3.4 Fan Speed Control, IP20, H9-H10 and H6-H8, T6
30 37 45 55 75 90
[kW]
FAN start
45 45 45 40 40 40
temperature °C
FAN max speed
60 60 60 55 55 55
temperature °C
FAN stop
41 41 41 30 30 30
temperature °C

Table 3.2 Fan Speed Control, IP20, H6-H8, T4

IP54
Enclosure I6 I7 I8
Voltage T4 T4 T4 T4 T4 T4 T4
Power Rating
22 30 37 45 55 75 90
[kW]
FAN start
45 45 45 40 40 40 40
temperature °C
FAN max speed
60 60 60 55 55 55 55
temperature °C
FAN stop
35 35 35 30 30 30 30
temperature °C

Table 3.3 Fan Speed Control, IP54, I6-I8

30 MG90X302 - Rev. 2013-10-08

Troubleshooting VLT® HVAC Basic Drive FC 101 Service Manual

4 Troubleshooting

CAUTION
4.1 Troubleshooting Tips Never assume that a motor is wired properly after a
service of the frequency converter. There is a risk of
Before repairing a frequency converter, read and overlooking for example,
understand the following instructions.
• loose connections
4 4
1. Note all warnings concerning voltages present in • improper programming
the frequency converter. Always verify the
• added equipment
presence of AC input voltage and DC bus voltage
before working on the unit. Some points in the
frequency converter are referenced to the It is best to develop a detailed approach, beginning with a
negative DC bus. They are at bus potential even physical inspection of the system. See Table 4.1 for items
though it sometimes appears on diagrams to be to examine.
a neutral reference.

CAUTION 4.3 Fault Symptom Troubleshooting

Voltage can be present for as long as 20 minutes on This troubleshooting section is divided into sections based
frequency converters after removing power from the on the symptom being experienced. To start, Table 4.1,
unit. See the label on the front of the frequency provides a visual inspection check list. Often, wrong instal-
converter door for the specific discharge time. lation or wiring of the frequency converter cause the
2. Never apply power to a unit that is suspected of problem. The check list provides guidance through various
being faulty. Many faulty components within the items to inspect during any frequency converter service
frequency converter can damage other process.
components when power is applied. Always
perform the procedure for testing the unit after Next, symptoms are approached as the technician most
repair as described in 4.7 After Repair Tests. commonly discovers them: reading an unrecognized
3. Never attempt to defeat any fault protection frequency converter display, problems with motor
circuitry within the frequency converter, as this operation, or a warning or alarm displayed by the
results in unnecessary component damage and frequency converter. Remember, the frequency converter
can cause personal injury. processor monitors inputs and outputs as well as internal
frequency converter functions. Thus, an alarm or warning
4. Always use factory approved replacement parts.
does not necessarily indicate a problem within the
The frequency converter is designed to operate
frequency converter itself.
within certain specifications. Incorrect parts can
affect tolerances and result in further damage to
the unit. Each incident has further descriptions on how to
troubleshoot that particular symptom. When necessary,
5. Read the instruction manual. A thorough further referrals are made to other parts of the manual for
understanding of the unit is the best approach. If more procedures. 5 Frequency Converter and Motor
ever in doubt, consult the factory or authorised Applications presents detailed discussions on areas of
repair centre for assistance. frequency converter and system troubleshooting that an
experienced repair technician must understand for
4.2 Exterior Fault Troubleshooting effective analysis.

There may be slight differences in servicing a frequency Finally, a list of tests, 4.7 After Repair Tests is provided.
converter that has been operational for some extended Always perform these tests under the following conditions:
time compared to a new installation. When using proper
troubleshooting procedures, make no assumptions.
• Starting a frequency converter for the first time.

• Approaching a frequency converter that is

suspected of being faulty.

• After a repair to the frequency converter.

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4.4 Visual Inspection

Visually inspect the conditions in Table 4.1 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
input power side of frequency converter or output side to motor. Examine operation and condition of
these items as possible causes for operational faults. Check function and installation of pressure sensors
or encoders (etc.) used for feedback to frequency converter.
4 4 Cable routing Avoid routing motor wiring, AC line wiring, and signal wiring in parallel. If parallel routing is
unavoidable, try to maintain a separation of 150–200 mm (6-8 inches) between the cables or separate
them with a grounded conductive partition. Avoid routing cables through free air.
Control wiring Check for broken or damaged wires and connections. Check the voltage source of the signals. Though
not always necessary depending on the installation conditions, the use of shielded cable or a twisted
pair is recommended. Ensure the shield is terminated correctly.
Frequency converter cooling Check operational status of all cooling fans. Check door filters on NEMA 12 (IP54) units. Check for
blockage or constrained air passages. Verify bottom gland plate is installed.
Frequency converter display Warnings, alarms, frequency converter status, fault history and many other important items are available
through the display on the local control panel of frequency converter.
Frequency converter interior Frequency converter interior must be free of dirt, metal chips, moisture, and corrosion. Check for burnt
or damaged power components or carbon deposits that were the result of a catastrophic component
failure. Check for cracks or breaks in the housings of power semiconductors, or pieces of broken
component housings loose inside the unit.
EMC considerations Check for proper installation with regard to electromagnetic capability. Refer to the frequency converter
instruction manual and this chapter 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% non-condensing. Check for harmful airborne contaminates such
as sulfur based compounds.
Grounding The frequency converter requires a dedicated ground wire from its chassis to the building ground. It is
also suggested that the motor be grounded to the frequency converter chassis as well. The use of
conduit or mounting of the frequency converter to a metal surface is not considered a suitable ground.
Check for good ground 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 nameplate ratings of motor. Ensure that motor ratings coincide with frequency converters. Ensure
frequency converter's motor parameters (1-20 Motor Power to 1-25 Motor Nominal Speed) are set
according to motor ratings.
Output to motor wiring Check for loose connections. Check for switching components in output circuit. Check for faulty contacts
in switch gear.
Programming Ensure frequency converter parameter settings are correct according to motor, application, and I/O
configuration.
Proper clearance These frequency converters require top and bottom clearance adequate to ensure proper air flow for
cooling in accordance with the frequency converter size. frequency converters with exposed heat sinks
out the back of the frequency converter must be mounted on a flat solid surface.
Vibration Though somewhat subjective look for an unusual amount of vibration that the frequency converter may
be subjected to. The frequency converter should be mounted solidly or the use of shock mounts
employed.

Table 4.1 Visual Inspection

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4.5 Fault Symptoms 4.5.3 Display (Line2) Flashing

4.5.1 No Display This indicates that a local stop command has been given
by pressing [Off/Reset]. The frequency converter cannot
The LCP display provides 2 display indications. One with accept any further run command until the local stop is
the backlit LCD alphanumeric display. The other is 3 LED cleared. Press [Auto On] or [Hand On] to clear the local
indicator lights near the bottom of the LCP. If the green stop.
power-on LED is illuminated but the backlit display is dark,
it indicates that the LCP is defective and must be replaced.
CAUTION 4 4
The frequency converter may start immediately. If the
frequency converter is being operated in local control, or
130BP044.10

remote control with a maintained run signal, the

frequency converter starts immediately.
On
4.5.4 WRONG or WRONG LCP Displayed
Warn. The message WRONG or WRONG LCP appears due to a
faulty LCP or the use of an incorrect LCP.
Alarm
Illustration 4.1 LED Indicator Lights Replace the LCP with a correct and functioning one.

Be certain, however, that the display is dark. Having a

NOTICE
single character in the upper corner of the LCP or just a Error 84 appears when the LCP cannot
dot indicates that communications may have failed with communicate with the frequency converter.
the control card. This situation typically appears when a
serial bus communication option has been installed in the 4.5.5 Motor Will Not Run
frequency converter and is either not connected properly
or is malfunctioning. If this symptom is detected, verify that the unit is properly
powered up (display is lit) and that there are no warning
If neither indication is available, then the source of the or alarm messages displayed. The most common cause of
problem is elsewhere. Proceed to 6.4.1 No Display Test this problem is either incorrect control logic or an
(Display is Optional) to carry out further troubleshooting incorrectly programmed frequency converter. Such
steps. occurrences result in one or more of the following status
messages being displayed.
4.5.2 Intermittent Display
LCP Stop
Cutting out or flashing of the entire display and power [Off] has been pressed. Line 2 of the display also flashes
LED indicates that the power supply (SMPS) is shutting when this situation occurs.
down as a result of being overloaded. The overload may Press [Auto On] or [Hand On]. Refer to the Input Terminal
be due to improper control wiring or a fault within the Signal Test.
frequency converter itself.
Standby
This message indicates that there is no start signal at
The first step is to rule out a problem in the control wiring.
terminal 18.
To do so, disconnect all control wiring by unplugging the
control terminal blocks from the control card. Ensure that a start command is present at terminal 18.
Refer to the Input Terminal Signal Test.
If the display stays lit, the problem is in the control wiring Unit ready
(external to the frequency converter). Check all control Terminal 27 is low (no signal).
wiring for shorts or incorrect connections. Ensure that terminal 27 is logic “1”. Refer to the Input
Terminal Signal Test.
If the display continues to cut out, follow the procedure
Run OK, 0 Hz
for 4.5.1 No Display as though the display was not lit at all.
This message indicates that a run command has been
given to the frequency converter but the reference (speed
command) is zero or missing.

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Check control wiring to ensure that the proper reference NOTICE

signal is present at the input terminals. Also check that the
Motor may also stall when loaded or the frequency
unit is properly programmed to accept the signal provided.
converter may trip occasionally on Alarm 13.
Refer to the Input Terminal Signal Test.
Off 1 (2 or 3) Check setting of all motor parameters, see 6.4.6 Output
This message indicates that bit #1 (or #2, or #3) in the Imbalance of Motor Supply Voltage Test.
control word is logic “0”. This situation only occurs when
the frequency converter is being controlled via the
If output voltage is unbalanced, see 6.4.6 Output Imbalance
4 4 fieldbus.
A correct control word must be transmitted to the
of Motor Supply Voltage Test.

frequency converter over the communication bus. Motor draws high current but cannot start
STOP Possible open winding in motor or open connection to
One of the digital input terminals 16, 17, 27, 29, 32, or 33 motor.
is programmed for “Stop Inverse” and the corresponding Perform 6.4.6 Output Imbalance of Motor Supply Voltage Test
terminal is low (logic “0”). to ensure that frequency converter is providing correct
Ensure that the above parameters are programmed output (see Motor Runs Rough above).
correctly and that any digital input programmed for “Stop Check motor for open windings. Check all motor wiring
Inverse” is high (logic “1”). connections.
Display Indication that the unit is functioning, but there Run an AMA to check the motor for open windings and
is no output. unbalanced resistance. Inspect all motor wiring
If the unit is equipped with external 24 V DC option, check connections.
that the main power is applied to the frequency converter.

NOTICE 4.6 Warnings and Alarms

In this case, the display alternately flashes Warning 8.
When the frequency converter fault circuitry detects a fault
condition, or a pending fault, a warning, or alarm is issued.
4.5.6 Incorrect Motor Operation A flashing display on the LCP indicates an alarm or
warning condition and the associated number code on line
Occasionally, a fault can occur where the motor continues
2. Sometimes a warning precedes an alarm. Table 4.2
to run, but not in the correct manner. The symptoms and
defines whether a warning precedes an alarm and whether
causes may vary considerably. Many of the possible
the frequency converter suspends operations (trips).
problems are listed below by symptom along with
recommended procedures for determining their causes.
4.6.1 Alarms
Wrong speed/unit does not respond to command
An alarm causes the frequency converter to trip (suspend
Possible incorrect reference (speed command).
operation). The frequency converter has 3 trip conditions
Ensure that the unit is programmed correctly according to which are displayed on line 1:
the reference signal being used, and that all reference
limits are set correctly as well. Perform 6.4.7 Input Terminal
TRIP (AUTO RESTART)
Signal Tests to check for faulty reference signals. The frequency converter is programmed to restart
Motor speed unstable automatically after the fault is removed. The number of
Possible incorrect parameter settings, faulty current automatic reset attempts can be continuous or limited to a
feedback circuit, loss of motor (output) phase. programmed number of attempts. If the selected number
of automatic reset attempts is exceeded, the trip condition
Check settings of all motor parameters, including all motor
changes to TRIP (RESET).
compensation settings (Slip Compensation, Load Compen-
sation, etc.). For Closed Loop operation, check PID settings. TRIP (RESET)
Perform 6.4.7 Input Terminal Signal Tests to check for faulty Requires resetting of the frequency converter before
reference signals. Perform Output Phase Imbalance Test to operation after a fault is cleared. The frequency converter
check for loss of motor phase. can be reset manually by pressing [Reset], a digital input,
or a serial bus command. For FC 101 frequency converters,
Motor runs rough
stop and reset are the same key. If [Off/Reset] is used to
Possible over magnetization (incorrect motor settings), or
reset the frequency converter, [Start] must be pressed to
an IGBT misfiring.
initiate a run command in either local or remote.

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TRIPLOCK (DISC> MAINS) A warning indicates a condition that may require attention
Requires that the main AC input power to the frequency or a trend that may eventually require attention. A
converter must be disconnected long enough for the warning remains active until the cause is no longer
display to go blank. The fault condition must be removed present. Under some circumstances, motor operation may
and power reapplied. Following power up, the fault continue.
indication changes to TRIP (RESET) and allow for manual,
digital, or serial bus reset. A trip is the action when an alarm has appeared. The trip
Line 2 displays alarm and the associated number while line removes power to the motor. It can be reset after the
condition has been cleared by pressing [Reset], or through
3 identifies the alarm in plain language.
a digital input (parameter group 5-1* Digital Inputs). The 4 4
event that caused an alarm cannot damage the frequency
NOTICE converter or cause a dangerous condition. Alarms must be
When exchanging the unit which requires fire mode reset to restart operation once their cause has been
activation, carefully check that the Fire Mode parameters rectified.
• 24-00 FM Function
The reset can be done in 3 ways:
• 24-05 FM Preset Reference

• 24-09 FM Alarm Handling

• Press [Reset]
are correctly transferred into the exchange unit.
• A digital reset input

4.6.2 Warnings • Serial communication/optional fieldbus reset

signal

During a warning, the frequency converter remains NOTICE

operational, although the warning flashes for as long as After a manual reset pressing [Reset] on the LCP,
the condition exists. The frequency converter may, press [Auto On] to restart the motor.
however, reduce the warning condition. For example, if the
warning displayed were Torque Limit (Warning 12), the
An (X) marked in Table 4.2 means that action occurs. A
frequency converter would be reducing speed to
warning precedes an alarm.
compensate for the over-current condition. In some cases,
if the condition is not corrected or worsens, an alarm
condition is activated and the frequency converter output If a situation occurs that can damage the frequency
to the motor terminated. Line 1 identifies the warning in converter or connected equipment, an alarm triggers a trip
plain language and line 2 identifies the warning number. lock. Power is removed from the motor. A trip lock can
only be reset after a cycling power has cleared the
condition. Once the problem has been rectified, only the
4.6.3 Warning And Alarm Messages alarm continues flashing until the frequency converter is
reset.
The LEDs on the front of the frequency converter and a
code in the display signal a warning or an alarm.

No. Description Warning Alarm Trip Lock Parameter

Reference
2 Live zero error (X) (X) 6–01
3 No motor (X) 1–80
4 Mains phase loss (X) (X) (X) 14–12
7 DC over voltage (X) (X)
8 DC under voltage (X) (X)
9 Inverter overloaded (X) (X)
10 Motor ETR over (X) (X) 1–90
temperature
11 Motor thermistor over (X) (X) 1–90
temperature
13 Over Current (X) (X) (X)
14 Ground fault (X) (X) (X)
16 Short Circuit (X) (X)
17 Control word timeout (X) 8–04

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No. Description Warning Alarm Trip Lock Parameter

Reference
24 Fan Fault (Only on 400 V (X) 14–53
30-90 kW)
30 Motor phase U missing (X) (X) 4–58
31 Motor phase V missing (X) (X) 4–58
32 Motor phase W missing (X) (X) 4–58
38 Internal fault (X) (X)

4 4 44
47
Ground fault 2
Control Voltage Fault
(X)
(X)
(X)
(X)
48 VDD1 Supply Low (X) (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 (X)
range
56 AMA interrupted by user (X)
57 AMA timeout (X)
58 AMA internal fault (X) (X)
59 Current limit (X)
60 External Interlock (X)
66 Heat sink Temperature Low (X)
69 Pwr Card Temperature (X) (X) (X)
79 Illegal PS config (X) (X)
80 Drive Initialised to Default (X)
Value
84 LCP Error X
87 Auto DC Braking (X)
95 Broken Belt (X) (X) 22–6*
201 Fire Mode (X)
202 Fire M Limits Exceeded (X)
250 New spare parts (X) (X)
251 New Type Code (X) (X)

Table 4.2 Alarm/Warning Code List

(X) Dependent on parameter. A trip is the action when an WARNING/ALARM 2, Live zero error
alarm has appeared. The trip coasts the motor and can be This warning or alarm only appears if programmed in
reset by pressing [Reset] or make a reset by a digital input 6-01 Live Zero Timeout Function. The signal on one of the
(parameter group 5-1* Digital Inputs [1]). The original event analog inputs is less than 50% of the minimum value
that caused an alarm cannot damage the frequency programmed for that input. Broken wiring or faulty device
converter or cause dangerous conditions. A trip lock is an sending the signal can cause this condition.
action when an alarm occurs, which can damage the Troubleshooting
frequency converter or connected parts. A trip lock Check connections on all the analog input
situation can only be reset by a power cycling. terminals. Control card terminals 53 and 54 for
signals, terminal 55 common. MCB 101 terminals
Warning Yellow 11 and 12 for signals, terminal 10 common. MCB
Alarm Flashing red 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6
common).
Table 4.3 LED Indication
Check that the frequency converter programming
The alarm words, warning words and extended status and switch settings match the analog signal type.
words can be read out via serial bus or optional fieldbus Perform Input Terminal Signal Test.
for diagnosis.

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WARNING/ALARM 4, Mains phase loss 100% in 1-90 Motor Thermal Protection. The fault occurs
A phase is missing on the supply side, or the mains when the motor runs with more than 100% overload for
voltage imbalance is too high. This message also appears too long.
for a fault in the input rectifier on the frequency converter.
Troubleshooting
Options are programmed at 14-12 Function at Mains Check for motor overheating.
Imbalance.
Check if the motor is mechanically overloaded
Troubleshooting
Check the supply voltage and supply currents to Check that the motor current set in 1-24 Motor
Current is correct.
the frequency converter.
Ensure that Motor data in parameters 1-20 to 4 4
1-25 are set correctly.
WARNING/ALARM 7, DC overvoltage
If the intermediate circuit voltage exceeds the limit, the If an external fan is in use, check in 1-91 Motor
frequency converter trips after a time. External Fan that it is selected.

Troubleshooting Running AMA in 1-29 Automatic Motor Adaptation

Extend the ramp time (AMA) tunes the frequency converter to the
motor more accurately and reduces thermal
Change the ramp type
loading.
Increase 14-26 Trip Delay at Inverter Fault
WARNING/ALARM 11, Motor thermistor over temp
WARNING/ALARM 8, DC undervoltage Check whether the thermistor is disconnected. Select
If the intermediate circuit voltage (DC link) drops below whether the frequency converter issues a warning or an
the under voltage limit, the frequency converter checks if a alarm in 1-90 Motor Thermal Protection.
24 V DC back-up supply is connected. If no 24 V DC back-
Troubleshooting
up supply is connected, the frequency converter trips after
Check for motor overheating.
a fixed time delay. The time delay varies with unit size.
Check if the motor is mechanically overloaded.
Troubleshooting
Check that the supply voltage matches the When using terminal 53 or 54, check that the
frequency converter voltage. thermistor is connected correctly between either
terminal 53 or 54 (analog voltage input) and
Perform input voltage test.
terminal 50 (+10 V supply). Also check that the
Perform soft charge circuit test. terminal switch for 53 or 54 is set for voltage.
Check 1-93 Thermistor Source selects terminal 53
WARNING/ALARM 9, Inverter overload
The frequency converter is about to cut out because of an or 54.
overload (too high current for too long). The counter for When using digital inputs 18 or 19, check that
electronic, thermal inverter protection issues a warning at the thermistor is connected correctly between
98% and trips at 100%, while giving an alarm. The either terminal 18 or 19 (digital input PNP only)
frequency converter cannot be reset until the counter is and terminal 50. Check 1-93 Thermistor Source
below 90%. selects terminal 18 or 19.
The fault is that the frequency converter has run with
more than 100% overload for too long. WARNING/ALARM 13, Over current
Troubleshooting The inverter peak current limit (approximately 200% of the
Compare the output current shown on the LCP rated current) is exceeded. The warning lasts about 1.5 s,
with the frequency converter rated current. then the frequency converter trips and issues an alarm.
Shock loading or fast acceleration with high inertia loads
Compare the output current shown on the LCP
can cause this fault.
with measured motor current.
Troubleshooting:
Display the Thermal Drive Load on the LCP and
Remove power and check if the motor shaft can
monitor the value. When running above the
be turned.
frequency converter continuous current rating,
the counter increases. When running below the Check that the motor size matches the frequency
frequency converter continuous current rating, converter.
the counter decreases. Check parameters 1-20 to 1-25 for correct motor
WARNING/ALARM 10, Motor overload temperature data.
According to the electronic thermal protection (ETR), the
motor is too hot. Select whether the frequency converter
issues a warning or an alarm when the counter reaches

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ALARM 14, Earth (ground) fault ALARM 32, Motor phase W missing
There is current from the output phases to earth, either in Motor phase W between the frequency converter and the
the cable between the frequency converter and the motor motor is missing.
or in the motor itself. Remove power from the frequency converter and check
Troubleshooting motor phase W.
Remove power to the frequency converter and
ALARM 38, Internal fault
repair the earth fault. When an internal fault occurs, a code number defined in
Check for earth faults in the motor by measuring Table 4.4 is displayed.
4 4 the resistance to ground of the motor leads and
the motor with a megohmmeter.
Troubleshooting
Cycle power
ALARM 16, Short circuit Check that the option is properly installed
There is short-circuiting in the motor or motor wiring.
Check for loose or missing wiring
Remove power to the frequency converter and repair the
short circuit. It may be necessary to contact your Danfoss supplier or
service department. Note the code number for further
WARNING/ALARM 17, Control word timeout troubleshooting directions.
There is no communication to the frequency converter.
The warning is only active when 8-04 Control Word Timeout No. Text
Function is NOT set to [0] Off. 0 Serial port cannot be initialised. Contact your
If 8-04 Control Word Timeout Function is set to [5] Stop and Danfoss supplier or Danfoss Service Department.
Trip, a warning appears and the frequency converter ramps 256-258 Power EEPROM data is defective or too old.
down until it trips, while giving an alarm. 8-03 Control Replace power card.
Timeout Time could possibly be increased. 512-519 Internal fault. Contact your Danfoss supplier or
Troubleshooting: Danfoss Service Department.
Check connections on the serial communication 783 Parameter value outside of min/max limits
cable. 1024-1284 Internal fault. Contact your Danfoss supplier or the
Increase 8-03 Control Word Timeout Time Danfoss Service Department.
1299 Option SW in slot A is too old
Check the operation of the communication
1300 Option SW in slot B is too old
equipment.
1302 Option SW in slot C1 is too old
Verify a proper installation based on EMC 1315 Option SW in slot A is not supported (not allowed)
requirements. 1316 Option SW in slot B is not supported (not allowed)
WARNING 24, External fan fault 1318 Option SW in slot C1 is not supported (not
The fan warning function is an extra protective function allowed)
that checks if the fan is running/mounted. The fan warning 1379-2819 Internal fault. Contact your Danfoss supplier or
can be disabled in 14-53 Fan Monitor ([0] Disabled). Danfoss Service Department.
1792 HW reset of DSP
Troubleshooting
Check for proper fan operation. 1793 Motor derived parameters not transferred correctly
to DSP
Cycle power to the frequency converter and
1794 Power data not transferred correctly at power up
check that the fan operates briefly at start-up.
to DSP
Check the sensors on the heatsink and control 1795 The DSP has received too many unknown SPI
card. telegrams
ALARM 30, Motor phase U missing 1796 RAM copy error
Motor phase U between the frequency converter and the 2561 Replace control card
motor is missing. 2820 LCP stack overflow
2821 Serial port overflow
Remove power from the frequency converter and check
2822 USB port overflow
motor phase U.
3072-5122 Parameter value is outside its limits
ALARM 31, Motor phase V missing 5123 Option in slot A: Hardware incompatible with
Motor phase V between the frequency converter and the control board hardware
motor is missing.
5124 Option in slot B: Hardware incompatible with
Remove power from the frequency converter and check control board hardware
motor phase V.

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No. Text WARNING 59, Current limit

5125 Option in slot C0: Hardware incompatible with The current is higher than the value in 4-18 Current Limit.
control board hardware Ensure that Motor data in parameters 1-20 to 1-25 are set
5126 Option in slot C1: Hardware incompatible with correctly. Possibly increase the current limit. Be sure that
control board hardware the system can operate safely at a higher limit.
5376-6231 Internal fault. Contact your Danfoss supplier or WARNING 60, External interlock
Danfoss Service Department. A digital input signal is indicating a fault condition external
to the frequency converter. An external interlock has
Table 4.4 Internal Fault Codes

ALARM 44, Ground fault 2

commanded the frequency converter to trip. Clear the
external fault condition. To resume normal operation, 4 4
apply 24 V DC to the terminal programmed for external
There is a discharge from the output phases to earth,
interlock. Reset the frequency converter.
either in the cable between the frequency converter and
the motor or in the motor itself. WARNING 66, Heatsink temperature low
This warning is based on the temperature sensor in the
Troubleshooting
IGBT module.
Turn off the frequency converter and remove the
earth fault. Troubleshooting

Measure the resistance to ground of the motor The heatsink temperature measured as 0 °C could indicate
leads and the motor with a megohmmeter to that the temperature sensor is defective, thus causing the
check for earth fault in the motor. fan speed to increase to the maximum. If the sensor wire
between the IGBT and the gate drive card is disconnected,
WARNING 47, Control voltage fault
this warning is produced. Also, check the IGBT thermal
The 24 V DC is measured on the control card. The external
sensor.
24 V DC backup power supply may be overloaded,
otherwise contact your Danfoss supplier. ALARM 79, Illegal power section configuration
The scaling card has an incorrect part number or is not
WARNING 48, 1.8 V supply low
installed. The MK102 connector on the power card could
The 1.8 V DC supply used on the control card is outside of
not be installed.
allowable limits. The power supply is measured on the
control card. Check for a defective control card. If an ALARM 80, Drive initialised to default value
option card is present, check for an overvoltage condition. Parameter settings are initialised to default settings after a
manual reset. To clear the alarm, reset the unit.

ALARM 51, AMA check Unom and Inom ALARM 84, LCP error
The settings for motor voltage, motor current and motor ALARM 84 is generated by the LCP and indicates an error
power are wrong. Check the settings in parameters 1-20 to with the LCP.
1-25. ALARM 95, Broken belt
ALARM 52, AMA low Inom Torque is below the torque level set for no load, indicating
The motor current is too low. Check the setting in a broken belt. 22-60 Broken Belt Function is set for alarm.
4-18 Current Limit. Troubleshoot the system and reset the frequency converter
after the fault has been cleared.
ALARM 53, AMA motor too big
The motor is too big for the AMA to operate. WARNING 200, Fire mode
This warning indicates the frequency converter is operating
ALARM 54, AMA motor too small
in fire mode. The warning clears when fire mode is
The motor is too small for the AMA to operate.
removed. See the fire mode data in the alarm log.
ALARM 55, AMA parameter out of range
WARNING 202, Fire mode limits exceeded
The parameter values of the motor are outside of the
While operating in fire mode one or more alarm conditions
acceptable range. AMA does not run.
have been ignored which would normally trip the unit.
ALARM 56, AMA interrupted by user Operating in this condition voids unit warranty. Cycle
The user has interrupted the AMA. power to the unit to remove the warning. See the fire
ALARM 57, AMA internal fault mode data in the alarm log.
Try to restart AMA again. Repeated restarts can over heat WARNING 250, New spare part
the motor. The power card or switch mode power supply has been
ALARM 58, AMA Internal fault exchanged. The frequency converter type code must be
Contact your Danfoss supplier. restored in the EEPROM. Select the correct type code in
14-23 Typecode Setting according to the label on the unit.
Remember to select ‘Save to EEPROM’ to complete.

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WARNING 251, New typecode

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. Following the

4 4
procedure ensures that all circuitry in the frequency
converter is functioning properly before putting the unit
into operation.

1. Perform visual inspection procedures as described

in Table 4.1.
2. Perform static test procedures to ensure that
frequency converter is safe to start.
3. Disconnect motor cables from output terminals
(U, V, W) of frequency converter.
4. Apply AC power to frequency converter.
5. Give the frequency converter a run command
and slowly increase reference (speed command)
to approximately 40 Hz.
6. Use 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 V. If unbalanced voltage is measured, refer to
6.4.2 Input Voltage Test.
7. Stop the frequency converter and remove input
power. Allow 20 minutes for DC capacitors to
fully discharge.
8. Reconnect motor cables to frequency converter
output terminals (U, V, W).
9. Reapply power and restart frequency converter.
Adjust motor speed to a nominal level.
10. Use a clamp-on style ammeter, measure output
current on each output phase. All currents must
be balanced.

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5 Frequency Converter and Motor Applications

NOTICE
5.1 Torque Limit, Current Limit, and Never adjust these parameters to random values even
Unstable Motor Operation though it seems to improve operation. Such adjustments
can result in unpredictable operation under changing
Excessive loading of the frequency converter can result in conditions.
warning or tripping on torque limit, over current, or
inverter time. Avoid this situation by sizing the frequency 5.1.1 Overvoltage Trips
converter properly for the application. Also ensure that
intermittent load conditions cause anticipated operation in Overvoltage trip occurs when the DC bus voltage reaches 5 5
torque limit or an occasional trip. However, specific its DC bus alarm voltage high (see 1.9.1 Short Circuit and
parameters that are improperly set, can cause nuisance or Over-current Trips). Before tripping, the frequency converter
unexplained occurrences. The following parameters are displays a high voltage warning. Mostly, fast deceleration
important in matching the frequency converter to the ramps with respect to load inertia causes an over voltage
motor for optimum operation. condition. During deceleration of the load, inertia of the
system acts to sustain the running speed. Once the motor
Parameters 1-20 to 1-25 configure the frequency converter frequency drops below the running speed, the load begins
for the connected motor. These parameters set overhauling the motor. The motor then becomes a
generator and starts returning energy to the frequency
• motor power converter. This is called regenerative energy. Regeneration
occurs when the speed of the load is greater than the
• voltage
commanded speed. The diodes in the IGBT modules rectify
• frequency this return and raises the DC bus. If the amount of
• current returned voltage is too high, the frequency converter trips.

• rated motor speed

It is important to set these parameters accurately. Enter There are a few ways to overcome this situation. One
the motor data required as listed on the motor nameplate. method is to reduce the deceleration rate so it takes
For effective and efficient load control, the frequency longer for the frequency converter to decelerate. A rule of
converter relies on this information for calculating the thumb is that the frequency converter can only decelerate
output waveform in response to the changing demands of the load slightly faster than it would take for the load to
the application. naturally coast to a stop. A second method is to allow the
over voltage control function (2-17 Over-voltage Control) to
1-29 Automatic Motor Adaption (AMA) activates the take care of the deceleration ramp. When enabled, the
Automatic Motor Adaptation (AMA) function. When AMA is overvoltage control function regulates deceleration at a
performed, the frequency converter measures the electrical rate that maintains the DC bus voltage at an acceptable
characteristics of the motor and sets various frequency level. One caution with over voltage control is that it does
converter parameters based on the findings. 2 key not make corrections to unrealistic ramp rates.
parameter values set by this function are stator resistance
and main reactance, 1-30 Stator Resistance (Rs) and For example, the deceleration ramp has to be 100 s due to
1-35 Main Reactance (Xh). If unstable motor operation is the inertia, and the ramp rate is set at 3 s. Overvoltage
experienced, perform AMA if this operation has not already control initially engages, then disengages and allows the
been performed. AMA can only be performed on single frequency converter to trip. This is purposely done so the
motor applications within the programming range of the unit's operation is not misinterpreted.
frequency converter. Consult the Quick Guide for more
information on this function.
The frequency converter has an AC brake which increases
magnetisation current to increase loss in motor and reduce
As stated, the AMA function must be set 1-30 Stator DC-link voltage. If the DC-link voltage exceeds a certain
Resistance (Rs) and 1-35 Main Reactance (Xh). The values for voltage, the overvoltage control increases the frequency.
these parameters can either be supplied by the motor
manufacturer, or contain factory default values.

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5.1.2 Mains Phase Loss Trips • Digital inputs (18, 19, 27, 29)

• Analog outputs (42, 45)

The frequency converter actually monitors phase loss by
monitoring the amount of ripple voltage on the DC bus. • 10 V output
Ripple voltage on the DC bus is a product of a phase loss. • Analog inputs (53, 54)
The main concern is that ripple voltage causes overheating
in the DC bus capacitors and the DC coil. If the ripple
• Serial communication bus (68, 69)

voltage on the DC bus is left unchecked, the lifetime of The presence of a correct reading indicates that the
the capacitors and DC coil would be drastically reduced. microprocessor of the frequency converter has detected
the desired signal. See 2.3 Frequency Converter Inputs and
Outputs.
When the input voltage becomes unbalanced or a phase

5 5
disappears completely, the ripple voltage increases. This
situation causes the frequency converter to trip and issue This data can also be read in parameter group 16-6* Inputs
Alarm 4, Mains Phase Loss. In addition to missing phase and Outputs.
voltage, a line disturbance or imbalance can cause an
increased bus ripple. Line disturbances can be caused by If there is no correct indication, check if the signal is
line notching, defective transformers, or other loads that present at the input terminals of the frequency converter.
can affect the form factor of the AC waveform. Mains Use a voltmeter or oscilloscope in accordance with
imbalances which exceed 3% cause sufficient DC bus 6.4.7 Input Terminal Signal Tests.
ripple to initiate a trip.
If the signal is present at the terminal, the control card is
Output disturbances can have the same effect of increased defective and must be replaced. If the signal is not
ripple voltage on the DC bus. A missing or lower than present, the problem is external to the frequency
normal output voltage on one phase can cause increased converter. The circuitry providing the signal along with its
ripple on the DC bus. When a mains imbalance trip occurs, associated wiring must then be checked.
it is necessary to check both the input and output voltage
of the frequency converter. 5.1.4 Programming Problems
Severe imbalance of supply voltage or phase loss can Difficulty with operation of the frequency converter can be
easily be detected with a voltmeter. View line disturbances a result of improper programming of the frequency
through an oscilloscope. Conduct tests for converter parameters. 3 areas where programming errors
can affect frequency converter and motor operation are
• input imbalance of supply voltage

• input waveform • motor settings

• and output imbalance of supply voltage • references and limits

as described in 4 Troubleshooting. • and I/O configuration

See 2.3 Frequency Converter Inputs and Outputs.
5.1.3 Control Logic Problems
The frequency converter must be set up correctly for the
Problems with control logic can often be difficult to motor(s) connected to it. Parameters must have data from
diagnose, since there is usually no associated fault the motor nameplate entered into the frequency converter.
indication. The typical complaint is that the frequency These data enables the frequency converter processor to
converter does not respond to a given command. There match the frequency converter to power characteristics of
are 2 basic commands that must be given to any the motor. The most common result of the inaccurate
frequency converter to obtain an output. Commands motor data is that the motor drawing higher than normal
provided to the frequency converter to obtain an output: amounts of current must perform the task expected of it.
In such cases, setting the correct values to these
parameters and performing the Automatic Motor
• Start Command: to execute.
Adaptation (AMA) function usually solves the problem.
• Reference or Speed Command: to identify the
speed of execution.
Any references or limits set incorrectly result in less than
The frequency converters are designed to accept various acceptable frequency converter performance. For instance,
signals. First determine which of these signals the if maximum reference is set too low, the motor is unable
frequency converter is receiving to reach full speed. These parameters must be set

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according to the requirements of the particular installation.

References are set in parameter group 3-0* Reference Limits.
5.2 Internal Frequency Converter Problems
Incorrectly set I/O configuration usually results in the If an over temperature indication is displayed, determine
frequency converter not responding to the function as whether this condition actually exists within the frequency
commanded. Remember that for every control terminal converter or whether the thermal sensor is defective. If
input or output there are corresponding parameter not, the temperature sensor must be checked.
settings. These settings determine how the frequency
converter responds to an input signal or the type of signal 5.2.1 Current Sensor Faults
present at that output. Utilising an I/O function involves a
two-step process. The desired I/O terminal must be wired
When a current sensor fails, it is indicated sometimes by
properly, and the corresponding parameter must be set
accordingly. Control terminals are programmed in
an over-current alarm that cannot be reset, even with the
motor cables disconnected. However, the frequency
5 5
parameter groups 5-0* Digital I/O Mode and 6-0* Analog I/O
converter experiences frequent false ground fault trips.
Mode.
This is due to the DC offset failure mode of the sensors.

5.1.5 Motor/Load Problems The simplest method of determining whether a current

sensor is defective is to disconnect the motor from the
Problems with the motor, motor wiring, or mechanical load frequency converter. Then observe the current in the
on the motor can develop in a number of ways. The motor frequency converter display. With the motor disconnected,
or motor wiring can develop a phase-to-phase or phase-to- the current should be zero. A frequency converter with a
ground short resulting in an alarm indication. Checks must defective current sensor indicates some current flow. An
be made to determine whether the problem is in the indication of a fraction of 1 A is tolerable. However, that
motor wiring or the motor itself. value should be considerably less than 1 A. If the display
shows more than 1 A of current, there is a defective
A motor with unbalanced, or unsymmetrical, impedances current sensor. All 3 current sensors in FC 101 units are
on all 3 phases can result in uneven or rough operation, or mounted on one circuit board (either power card, SMPS
unbalanced output currents. For measurements, use a card, or current transducer card). The repair procedure is to
clamp-on style ammeter to determine whether the current replace all 3 current sensors at the same time.
is balanced on the 3 output phases. See 6.4.6 Output
Imbalance of Motor Supply Voltage Test. 5.2.2 Signal and Power Wiring
Considerations for Electromagnetic
Usually a current limit warning indicates an incorrect Compatibility
mechanical load. If possible, disconnect the motor from
the load to determine if the load is incorrect. This section provides an overview of general signal and
power wiring considerations when addressing the Electro-
Quite often, the indications of motor problems are similar magnetic Compatibility (EMC) concerns for typical
to the problems of a defect in the frequency converter commercial and industrial equipment. Only certain high-
itself. To determine whether the problem is internal or frequency phenomena (such as RF emissions, RF immunity)
external to the frequency converter, disconnect the motor are discussed. Low-frequency phenomena (such as
from the frequency converter output terminals. Perform harmonics, mains voltage imbalance, notching) are not
6.4.6 Output Imbalance of Motor Supply Voltage Test covered.
procedure on all 3 phases with an analog voltmeter. If the
3 voltage measurements are balanced, the frequency
converter is functioning correctly. Hence, the problem is
NOTICE
external to the frequency converter. Special installations or compliance to the European CE
EMC directives require strict adherence to relevant
standards and are not discussed here.
If the voltage measurements are not balanced, the
frequency converter is malfunctioning. Typically one or
more output IGBTs are not switching on and off correctly.
This problem can be a result of a defective IGBT or gate
signal.

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5.2.3 Effects of EMI

While electromagnetic interference (EMI) related distur- • Telephone interference

bances to frequency converter operation are uncommon,
the following detrimental EMI effects sometimes occur:
• Computer network data loss

• Digital control system faults

• Motor speed fluctuations

5.2.4 Sources of EMI
• Serial communication transmission errors

• Frequency converter CPU exception faults Modern frequency converters (see Illustration 5.1) utilize
• Unexplained frequency converter trips IGBTs to provide an efficient and cost effective means to
create the Pulse Width Modulated (PWM) output waveform
5 5 A disturbance resulting from other nearby equipment is
more common. Generally, other industrial control
necessary for accurate motor control. These devices rapidly
switch the fixed DC bus voltage creating a variable
equipment has a high level of EMI immunity. However,
frequency, and variable voltage PWM waveform. This high
non-industrial, commercial, and consumer equipment is
rate of voltage change [dU/dt] is the primary source of the
often susceptible to lower levels of EMI. Detrimental effects
frequency converter generated EMI.
to these systems include the following:

The high rate of voltage change caused by the IGBT

• Pressure/flow/temperature signal transmitter
switching creates high frequency EMI.
signal distortion or aberrant behaviour

• Radio and TV interference

130BX137.10
Rectifier DC Bus Inverter

Filter reactor

AC Line IGBT Motor

Filter capacitor

Sine wave
PWM waveform
Illustration 5.1 Frequency Converter Functionality Diagram

5.2.5 EMI Propagation 1 AC line

2 Frequency converter
Frequency converter generated EMI is both conducted to 3 Motor cable
the mains and radiated to nearby conductors. See 4 Motor
Illustration 5.2. 5 Stray capacitance
6 Signal wiring
7 Signal wiring
130BC344.10

2 4
1 3
8 Signal wiring
9 Ground

Table 5.1 Legend to Illustration 5.2

5 5

CAUTION
Stray capacitance between the motor conductors,
6
7 equipment ground, and other nearby conductors results
9
8 in induced high frequency currents.
Illustration 5.2 Ground Currents
High ground circuit impedance at high frequencies results
in an instantaneous voltage at points reputed to be at

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ground potential. This voltage can appear throughout a 2

130BC345.10
system as a common mode signal that can interfere with
4
control signals. 1 3

Theoretically, these currents return to the DC bus via the

ground circuit and a high frequency (HF) bypass network
within the frequency converter itself. However,
5
imperfections in the frequency converter grounding or the 6
equipment ground system can cause some of the currents
to travel out to the power network.
Illustration 5.4 Alternate Signal Conductor Currents

2
5 5
130BC154.10
4
1 3
1 AC line
2 Frequency converter
3 Motor cable
4 Motor
5
6 5 Stray capacitance
6 AC line

Table 5.3 Legend to Illustration 5.4

7 NOTICE
Illustration 5.3 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.
1 AC line
2 Frequency converter 5.2.6 Preventive Measures
3 Motor cable
4 Motor EMI-related problems are more effectively alleviated during
5 Stray capacitance the design and installation phases rather than after the
6 To BMS system is in service. Many of the listed steps can be
7 Signal wiring implemented at a relatively low cost compared to the cost
of identifying and fixing the problem later.
Table 5.2 Legend to Illustration 5.3
Grounding
NOTICE Ground the frequency converter and motor solidly to the
Unprotected or poorly routed signal conductors located equipment frame. A good high-frequency connection is
close to or in parallel to motor and mains conductors are necessary to allow the high-frequency currents to return to
susceptible to EMI. the frequency converter instead of travelling through the
power network. The ground connection is ineffective if it
Signal conductors are especially vulnerable when they are has high impedance to high-frequency currents. Therefore1
run in parallel to the power conductors for any distance. it must be as short and direct as practical. Flat-braided
EMI coupled into these conductors can affect either the cable has lower high-frequency impedance than round
frequency converter or the interconnected control device. cable. Mounting the frequency converter or motor onto a
See Illustration 5.4. painted surface creates an effective ground connection. In
addition, running a separate ground conductor directly
between the frequency converter and the running motor is
While these currents tend to travel back to the frequency
recommended.
converter, imperfections in the system cause some current
to flow in undesirable paths. This flow exposes other Cable routing
locations to the EMI. Avoid parallel routing of

• motor wiring

• mains wiring

• signal wiring

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If parallel routing is unavoidable, try to maintain a Serial communications cable selection

separation of 200 mm (6–8 inches) between the cables or There are various serial communication interfaces and
separate them with an grounded conductive partition. protocols in the market. Each of these interfaces
Avoid routing cables through free air. recommends one or more specific types of twisted-pair,
screened twisted-pair, or proprietary cables. Refer to the
Signal cable selection
manufacturer’s documentation when selecting these
Single conductor 600 V rated wires provide the least
cables. Similar recommendations apply to serial communi-
protection from EMI. Twisted-pair and screened twisted-
cation cables as to other signal cables. Using twisted-pair
pair cables are available which are designed to minimise
cables and routing them away from power conductors is
the effects of EMI. While unscreened twisted-pair cables
encouraged. While screened cable provides additional EMI
are often adequate, screened twisted-pair cables provide
protection, the screen capacitance may reduce the
another degree of protection. The signal cable screen must
maximum allowable cable length at high data rates.
5 5
be terminated in a manner that is appropriate for the
connected equipment. Avoid terminating the screen
through a pigtail connection as it increases the high
frequency impedance and spoils the effectiveness of the
screen.
A simple alternative is to twist the existing single
conductors to provide a balanced capacitive and inductive
coupling. This operation cancels 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
Motor conductors have the greatest influence on the EMI
characteristics of the system. These conductors must
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 to cause EMI problems, consider
alternate motor wiring methods.
Installing screened power cable is the most effective
means to alleviate EMI problems. The cable screen forces
the noise current to flow directly back to the frequency
converter. Thus, the noise current cannot get back into the
power network or take other undesirable high-frequency
paths. Unlike most signal wiring, the screening on the
motor cable must be terminated at both ends.
If a screened motor cable is not available, then 3-phase
conductors along with ground in a conduit provides some
degree of protection. This technique is not as effective as
screened cable due to the unavoidable contact of the
conduit with various points within the equipment.

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6 Test Procedures

130BC299.10
6.1 Non-repairable Units
H1-H5 and I2-I4 are non-repairable units and should not be
repaired. The information about Line/Motor/UDC+-
terminals is useful to verify what went wrong with these
frequency converters, for statistics and WIIS purposes, but
1
also to avoid replacing a frequency converter that is
actually not defective. 8

7
130BB634.10 2 6 6
3

MAINS
6

2
4 4
Motor

U V W
-DC+DC
2
Illustration 6.2 I2 Frame
IP54 380-480 V, 0.75-4.0 kW
3

1 RS-485
2 Line in
3 Ground
4 Wire clamps
Illustration 6.1 H1-H5 Frame 5 Motor
IP20 200-240 V, 0.25-11 kW and IP20 380-480 V, 0.37-22 kW 6 UDC
7 Relays
8 I/O
1 Line
Table 6.2 Legend to Illustration 6.2
2 Ground
3 Motor
4 Relays

Table 6.1 Legend to Illustration 6.1

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130BC201.10

130BD011.10
6 6

Illustration 6.4 I4 Frame

IP54 380-480 V, 0.75-4.0 kW
Illustration 6.3 I3 Frame
IP54 380-480 V, 5.5-7.5 kW

1 RS-485
2 Line in
1 RS-485
3 Ground
2 Line in
4 Wire clamps
3 Ground
5 Motor
4 Wire clamps
6 UDC
5 Motor
7 Relays
6 UDC
8 I/O
7 Relays
8 I/O Table 6.4 Legend to Illustration 6.4

Table 6.3 Legend to Illustration 6.3

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6.2 Introduction • Digital voltmeter/ohmmeter capable of reading

real RMS
WARNING • Analog voltmeter
DISCHARGE TIME! • Oscilloscope
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is
• Current meter

not powered. To avoid electrical hazards, disconnect AC

mains, any permanent magnet type motors, and any 6.3 Static Test Procedures
remote DC-link power supplies, including battery
backups, UPS and DC-link connections to other All tests should be made with a meter capable of testing
frequency converters. Wait for the capacitors to fully diodes. Use a digital volt/ohmmeter (VOM) set on the
discharge before performing any service or repair work. diode scale or an analog ohmmeter set on Rx100 scale.
The amount of wait time is listed in the Table 1.1. Failure Before making any checks, disconnect all connections for:
to wait the specified time after power has been removed
before doing service or repair could result in death or • input
6 6
serious injury.
• motor

This section contains detailed procedures for testing

• brake resistor

frequency converters. Previous sections of this manual Ensure the frequency converter is disconnected from
provide symptoms, alarms, and other conditions which power, before performing static tests.
require additional test procedures to diagnose the
frequency converter further. The results of these tests
indicate the appropriate repair actions. Again, because the
WARNING
frequency converter monitors input and output signals, Disconnection of the input cable whilst the frequency
motor conditions, AC, and DC power and other functions, converter is powered, could result in electrical shock,
the source of fault conditions may exist outside of the personal injury, and death.
frequency converter. Testing described here isolates many • Do not disconnect the input cable whilst the
of these conditions as well. Disassembly and Assembly frequency converter is powered.
Instructions describes detailed procedures for removing
and replacing frequency converter components.
The purpose of performing static testing is to check for
any short circuit of the power components.
Frequency converter testing is divided into Static Tests, and
Dynamic Tests. Static tests are conducted without power
applied to the frequency converter. Most frequency 6.3.1 Pre-test Precautions
converter problems can be diagnosed simply with these
tests. Static tests are performed with little or no Consider the following safety precautions before
disassembly. The purpose of static testing is to check for performing static tests.
shorted power components. Perform these tests on any
unit suspected of containing faulty power components • Prepare the work area according to the ESD
before applying power. regulations.

• Ground the ESD mat and wrist strap.

CAUTION • Ensure that the ground connection between
For dynamic test procedures, main input power is body, the ESD mat, and the frequency converter
required. All devices and power supplies connected to is always present while performing service.
mains are energized at rated voltage. Use extreme
• Handle disassembled electronic parts with care.
caution when conducting tests on a powered frequency
converter. Contact with powered components could • Perform the static test before powering up the
result in electrical shock and personal injury. fault unit.

• Perform static test after completing the repair

Dynamic tests are performed with power applied to the and assembly of the frequency converter.
frequency converter. Dynamic testing traces signal circuitry • Connect the frequency converter to the mains
to isolate faulty components. only after completion of static tests.

• Complete all necessary precautions for system

startup, before applying power to frequency
converter.

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6.3.2 Rectifier Circuit Test 6.3.3 Inverter Section Tests

Pay close attention to the polarity of the meter leads to The inverter section is primarily made up of the IGBTs used
ensure the identification of any faulty component, in case for switching the DC bus voltage to create the output to
an incorrect reading appears. the motor. The frequency converter also has clamping
capacitors between +UDC and -UDC on the IGBT.
Described next is the procedure to conduct the static test
on the rectifier.
CAUTION
Disconnect motor leads when testing inverter section.
NOTICE With leads connected, a short circuit in one phase reads
In H6 units the +/-UDC terminals are not readily in all phases, making isolation difficult.
accessible. Find terminals K601 (+) and K611 (-) between
the DC capacitors. Before starting tests, ensure that meter is set to diode
In H7-H8 units the +/-UDC terminals are directly scale.
6 6 accessible on MK900 on the power card.
In I7-I8 units the +/-UDC terminals are accessible on Inverter test part I
MK900 on the power card or on MK3 on the current 1. Connect the positive (+) meter lead to the
sensor board. positive (+) DC bus terminal.
For further details, see 6.3.5 Location of UDC Terminals
before measuring) 2. Connect the negative (-) meter lead to terminals
U, V, and W in sequence.
Before starting tests, ensure that meter is set to diode Each reading must show infinity.
scale.
Inverter test part II
Rectifier test part I 1. Reverse the meter leads by connecting the
1. Connect the positive (+) terminal of the negative (-) meter lead to the positive (+) DC bus
multimeter lead to the positive (+) DC Bus. terminal.
2. Connect the negative (-) terminal of the 2. Connect the positive (+) meter lead to U, V, and
multimeter lead to the input terminal L1, L2, L3 W in sequence. Each reading should show a
in turn. The multimeter indicates Infinity. diode drop.
Rectifier test part II Inverter test part III
3. Reverse the meter leads by connecting the 1. Connect the positive (+) meter lead to the
negative (-) terminal of the multimeter lead to negative (-) DC bus terminal.
the positive (+) DC Bus. 2. Connect the negative (-) meter lead to terminals
4. Connect the positive (+) terminal of the U, V, and W in sequence. Each reading should
multimeter lead to the input terminal L1, L2, L3 show a diode drop.
in turn. The multimeter indicates Diode drop. Inverter test part IV
Rectifier test part III 1. Reverse the meter leads by connecting the
5. Connect the positive (+) terminal of the negative (-) meter lead to the negative (-) DC bus
multimeter lead to the negative (-) DC Bus. terminal.
6. Connect the negative (-) terminal of the 2. Connect the positive (+) meter lead to U, V, and
multimeter lead to the input terminal L1, L2, L3 W in sequence.
in turn. The multimeter indicates a diode drop. Each reading should show infinity.
Rectifier test part IV
7. Reverse the meter leads by connecting the 6.3.4 Intermediate Section Tests
negative (-) terminal of the multimeter lead to
the negative (-) DC Bus.
NOTICE
8. Connect the positive (+) terminal of the
This test is applicable for H7, H8, I7, and I8 units only.
multimeter lead to the input terminal L1, L2, L3
in turn. The multimeter indicates Infinity.
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.

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1. Test for short circuits with the ohmmeter set on 6.3.5 Location of UDC Terminals
Rx100 scale or, for a digital meter, select diode.
2. Measure across the positive (+) DC terminal and H6
the negative (–) DC terminal. Observe the meter Remove the IP20 front cover, then remove the capacitor
polarity. vibration support. The terminals K601 (+UDC) and K611 (-
UDC) are located between the 4 capacitors on the circuit
3. The meter starts out with low ohms and then
board. Remove the metal cover to access these terminals.
move towards infinity as the meter charges the
capacitors.

130BC352.10
4. Reverse meter leads.
5. The meter pegs at zero while the meter
discharges the capacitors. The meter then begins
moving slowly toward 2 diode drops as the meter
charges the capacitors in the reverse direction.
Although the test does not ensure that the
capacitors are fully functional, it ensures that no 6 6
short circuits exist in the intermediate circuit.
Incorrect reading
A short circuit could be caused by a short in the inrush
circuit, 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. Illustration 6.5 UDC Terminals Location on H6 Frequency
Converter
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. If suspecting a failure within the

130BC353.10
capacitor bank, replace the entire bank. Replace the
capacitor bank in accordance with the disassembly
procedures.

Illustration 6.6 Metal Cover over Terminals

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130BC356.10
130BC354.10
Illustration 6.9 +/- UDC Terminals
6 6
H9
The UDC terminals are available on connectors at the
bottom of the frequency converter. Static measurements
can be done directly from here.
Illustration 6.7 The UDC Terminals on the Circuit Board

130BC351.10
H7 and H8
Remove the IP20 front cover to access the terminals
directly on the power card MK900.
130BC355.10

W V U

L3 L2 L1 DC+ DC-

Illustration 6.10 UDC Terminals Location on H9 Frequency

Converter

Illustration 6.8 Power Card

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Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

H10

130BC358.10
Remove the front terminal cover to access the connectors.
The UDC terminals are located inside the frequency
converter.

130BC351.10
W V U

Illustration 6.13 +/- UDC Terminals on Current Sensor Board

6 6
L3 L2 L1 DC+ DC-

130BC359.10
Illustration 6.11 UDC Terminals Location on H10 Frequency
Converter

I7 and I8
Remove the IP54 front cover to access the +/- UDC
terminals, either on the power card MK900 or on MK3 on
the current sensor board.
130BC356.10

Illustration 6.14 +/- UDC Terminals on Current Sensor Board -

Close-up View

6.4 Dynamic Test Procedures

NOTICE
Test procedures in this section are numbered for
reference only. Tests do not need to be performed in
Illustration 6.12 +/- UDC Terminals on Power Card this order. Perform tests only as necessary.

WARNING
Never disconnect the input cabling to the frequency
converter with power applied due to danger of severe
injury or death.

CAUTION
Take all the necessary safety precautions for system
start-up before applying power to the frequency
converter.

Dynamic tests are conducted with the power applied to

the medium power size frequency converter.

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 Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

Dynamic tests are performed without the motor being 6.4.2 Input Voltage Test
connected to UVW connector. Program the frequency
converter to approximately 50 Hz on start. 1. Apply power to frequency converter.
2. Use the DVM to measure the input mains voltage
Dynamic tests can indicate if one of the IGBT does not
between the frequency converter input terminals
switch, and the output voltage drops on the fault terminal,
in sequence:
UVW.
L1 to L2
L1 to L3
Dynamic tests are conducted to check the IGBT. Conduct L2 to L3
the test without the motor being connected to the
For 380 V frequency converters, all measurements must be
frequency converter. Program the multimeter to AC 1000
within the range of 342–550 V AC. Readings of less than
V.
342 V AC indicate problems with the input mains voltage.
For 525–600 V frequency converters, all measurements
Described next is the procedure to conduct the dynamic
must be within the range of 446–600 V AC. Readings of
6 6 test on the IGBT.
less than 446 V AC indicate problems with the input mains
voltage.
1. Connect the positive terminal of the multimeter
lead to the U connector, and connect the
In addition to the actual voltage reading, the balance of
negative terminal to the V terminal.
the voltage between the phases is also important. The
2. Connect the positive terminal of the multimeter frequency converter can operate within specifications as
lead to the U connector, and connect the long as the imbalance of supply voltage is not more than
negative terminal to the W terminal. 3%.
3. Connect the positive terminal of the multimeter
lead to the V connector, and connect the Danfoss calculates mains imbalance per an IEC specifi-
negative terminal to the W terminal. cation.

The meter reading is 450 V ±25 V when performing the

Imbalance=0.67 X (Vmax–Vmin)/Vavg
dynamic test at 400 V mains, and 50 Hz/1500 RPM output
depending on the instrument used. For example, if 3-phase readings were taken and the
results were 500 V AC, 478.5 V AC, and 478.5 V AC; then
The reading must be within ±1.5%. 500 V AC is Vmax, 478.5 V AC is Vmin, and 485.7 V AC is Vavg,
resulting in an imbalance of 3%.
6.4.1 No Display Test (Display is Optional)
Although the frequency converter can operate at higher
mains imbalances, the lifetime of components, such as DC
A frequency converter with no display in the LCP can be
bus capacitors, is shortened.
the result of several causes. First, verify that there is no
display. A single character in the display or a dot in the
upper corner of the display indicates a communication Incorrect reading
error. Check that all option cards are properly installed.
When this condition occurs, the green power-on LED is
CAUTION
Open (blown) input fuses or tripped circuit breakers
illuminated.
usually indicate a more serious problem. Before
replacing fuses or resetting breakers, perform static
If the LCD display is dark and the green power-on LED is tests.
not lit, proceed with the following tests.
An incorrect reading here requires further investigation of
First test for proper input voltage. the main supply. 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 this test was successful, check for voltage to the control
card.

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Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

6.4.3 Basic Control Card Voltage Test current while the third deviates by more than 5%.
If all 3 phases are different from one another,
1. Measure the control voltage at terminal 12 swap the phase with the highest current with the
regarding terminal 20. The meter must read 21-27 phase with the lowest current.
V DC. 4. Remove power to frequency converter.
An incorrect reading here could indicate that a fault in the 5. Swap the phase that appears to be incorrect with
customer connections loads down the supply. Disconnect one of other 2 phases.
control wiring and repeat the test. If this test is successful,
6. Reapply power to the frequency converter and
then continue. Remember to check the customer
place it in run.
connections. If still unsuccessful, change the control card.
7. Repeat the current measurements.
2. Measure the 10 V DC control voltage at terminal If the imbalance of supply voltage moves with swapping
50 regarding terminal 55. The meter must read the leads, the mains supply is suspect. Otherwise, it may
between 9.2 and 11.2 V DC. indicate a problem with the gating of the rectifiers.
An incorrect reading here could indicate that a fault in the
customer connections loads down the supply. Disconnect 6.4.5 Input Waveform Test
6 6
control wiring and repeat the test. If this test is successful,
then continue. Remember to check the customer Testing the current waveform on the input of the
connections. If still unsuccessful, change the control card. frequency converter can help troubleshooting mains phase
loss conditions or suspected problems with the SCR/diode
Replace the LCP with a known good one. If the problem modules. Phase loss caused by the mains supply can be
persists, replace the control card in accordance with the easily detected. In addition, the SCR/diode modules control
disassembly procedures. the rectifier section. If one of the SCR/diode modules
becomes defective or the gate signal to the SCR lost, the
6.4.4 Input Imbalance of Supply Voltage frequency converter responds the same as loss of one of
Test the phases.

Theoretically, the current drawn on all 3 input phases must The following measurements require an oscilloscope with
be equal. Some imbalance may be seen, however, due to voltage and current probes.
variations in the phase to phase input voltage, and single
phase loads within the frequency converter. Under normal operating conditions, the waveform of a
single phase of input AC voltage to the frequency
A current measurement of each phase reveals the converter appears as in Illustration 6.15.
balanced condition of the line. To obtain an accurate
reading, the frequency converter must run at its rated
Input A

130BX142.10

load, or at a load of not less than 40%.

1. Perform the input voltage test before checking
the current, in accordance with procedure.
Voltage imbalances automatically result in a
corresponding current imbalance.
2. Apply power to the frequency converter and
place it in run. 0.0 ms 5 ms/Div.

Illustration 6.15 Normal AC Input Voltage Waveform

3. Using a clamp-on ammeter (analog preferred),
read the current on each of 3 input lines at L1(R),
L2(S), and L3(T).
The waveform shown in Illustration 6.16 represents the
Typically, the current should not vary from phase
input current waveform for the same phase as shown in
to phase by more than 5%. Should a greater
Illustration 6.15 while the frequency converter is running at
current variation exist, it indicates a possible
40% load. The 2 positive and 2 negative jumps are typical
problem with the mains supply to the frequency
of any 6-diode bridge. It is the same for frequency
converter, or a problem within the frequency
converters with SCR/diode modules.
converter. One way to determine if the mains
supply is at fault is to swap 2 of the incoming
phases. This assumes that 2 phases read one

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 Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

Input B
It could be the result of a defective power card or an

130BX143.10
improper connection of the output circuitry.

NOTICE
Use an analog voltmeter for monitoring output voltage.
Digital voltmeters are sensitive to waveform and
switching frequencies and commonly return erroneous
0.0 ms 5 ms/Div. readings.
Illustration 6.16 AC Input Current Waveform with Diode Bridge
The initial test can be made with the motor connected and
running its load. If suspect readings are recorded,
With a phase loss, the current waveform of the remaining disconnect the motor cables to isolate the problem further.
phases would take on the appearance shown in
Illustration 6.17. 1. Using a voltmeter, measure AC output voltage at
6 6 Input B
130BX144.10
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 3 readings must be balanced within 8 V AC 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 60 Hz the voltage should be approximately equal to the
0.0 ms 5 ms/Div.
mains voltage applied. At 30 Hz, it is about half of that,
Illustration 6.17 Input Current Waveform with Phase Loss and so on, for any other speed selected. The exact voltage
reading is less important than balance between phases.

Always verify the condition of the input voltage waveform 2. Next, monitor 3 output phases at the motor
before forming a conclusion. The current waveform follows terminals 96 (U), 97 (V), and 98 (W) with the
the voltage waveform. If the voltage waveform is incorrect, clamp on the ammeter. An analog device is
proceed to investigate the reason for the AC supply preferred. To achieve an accurate reading, run the
problem. If the voltage waveform on all 3 phases is frequency converter above 40 Hz as this is
correct, but the current waveform is not, the input rectifier normally the frequency limitation of such meters.
circuit in the frequency converter is suspect. Perform the The output current must be balanced from phase to phase
static soft charge and rectifier tests and also the dynamic and no phase must be more than 2-3% different from
diode module test. another. If these tests are successful, the frequency
converter is operating normally.
6.4.6 Output Imbalance of Motor Supply
Voltage Test 3. If a greater imbalance exists than described
above, disconnect the motor cables and repeat
Check the balance of the output voltage and current to the voltage balance test.
measure the electrical functioning between the frequency Since the current follows the voltage, it is necessary to
converter and the motor. In testing the phase-to-phase differentiate between a load problem and a frequency
output, both voltage and current are monitored. Conduct converter problem. Should a voltage imbalance in the
static tests on the inverter section of the frequency output be detected with the motor disconnected, it is
converter before this procedure. necessary to test the gate drive circuits for proper firing. If
output voltage is unbalanced, measure from ±UDC to the
If the voltage is balanced but the current is not, it output phases U, V and W, to find out which IGBT is not
indicates that the motor is drawing an uneven load. This firing correctly. To determine if there is a gate firing
could be the result of a defective motor, a poor problem, replace the power card. This applies for
connection in the wiring between the frequency converter frequency converters with separate IGBT modules. For
and the motor, or a defective motor overload. frequency converters with IGBTs on the power card, the
solution may already be found.
If the output current is unbalanced as well as the voltage,
the frequency converter is not gating the output properly. If the voltage was balanced, but the current imbalanced
when the motor was connected, the load is suspect. There

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Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

could be a faulty connection between the frequency Verify that the reference voltage power supply is correct
converter and motor or a defect in the motor itself. Look as follows.
for bad connections at any junctions of the output wires 1. Use a voltmeter for measuring the voltage at
including connections made to contactors and overloads. control card terminal 50 with respect to terminal
Also, check for burned or open contacts in such devices. 55. The meter must read between 9.2 and 11.2 V
DC.
6.4.7 Input Terminal Signal Tests If the 10 V supply voltage is not present, conduct
6.4.3 Basic Control Card Voltage Test earlier in this section.
The presence of signals on either the digital or analog
input terminals of the frequency converter can be verified If 10 V is present, proceed with checking the individual
on the frequency converter display. Digital or analog input inputs as follows.
status can be selected or read in parameters 16-60 to 2. Connect the (-) negative meter lead to reference
16-64. terminal 55.
3. Connect the (+) positive meter lead to desired
Digital Inputs
With digital inputs displayed, control terminals 18, 19, 27,
terminal 53 or 54.
6 6
and 29 are shown left to right, with a 1 indicating the For analog input terminals 53 and 54, a DC voltage
presence of a signal. between 0 and +10 V DC must be read to match the
analog signal sent to the frequency converter. Or a reading
If the desired signal is not present in the display, the
of 0.9 to 4.8 V DC corresponds to a 4-20 mA signal.
problem is 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 NOTICE
control terminals. A (-) minus sign preceding any reading above indicates a
reversed polarity. In this case, reverse the wiring to the
Verify that the control voltage power supply is correct analog terminals.
as follows:
1. Use a voltmeter for measuring voltage at control
6.5 Initial Start Up Or After Repair Drive
card terminal 12 and 13 with respect to terminal
20. The meter should read 21-27 V DC. Tests
If the 24 V supply voltage is not present, test the control Following any repair to a frequency converter or testing of
card in 6.2.1 Introduction. a frequency converter suspected of being faulty, the
following procedure must be followed. Following this
If 24 V is present, proceed with checking the individual procedure ensures that all circuitry in the frequency
inputs as follows: converter is functioning properly before putting it into
2. Connect the (-) negative meter lead to reference operation.
terminal 20.
3. Connect the (+) positive meter lead to the 1. Perform visual inspection procedures as described
terminals in sequence. in Table 4.1.

The presence of a signal at the desired terminal must 2. Perform static test procedures to ensure that the
correspond to the digital input display readout. A reading frequency converter is safe to start.
of 24 V DC indicates the presence of a signal. A reading of 3. Disconnect motor cables from output terminals
0 V DC indicates no signal is present. (U, V, W) of the frequency converter.
4. Apply AC power to frequency converter.
Analog Inputs
5. Give the frequency converter a run command
The value of signals on analog input terminals 53 and 54
and slowly increase reference (speed command)
can also be displayed. The voltage or current in mA,
to approximately 40 Hz.
depending on the switch setting, is shown in line 2 of the
display. 6. Using an analog voltmeter or a DVM capable of
measuring true RMS, measure phase-to-phase
If the desired signal is not present in the display, the
output voltage on all 3 phases: U to V, U to W, V
problem is either in the external control wiring to the
to W. All voltages must be balanced within 8 V. If
frequency converter, or a faulty control card. To determine
measuring unbalanced voltage, refer to 6.4.2 Input
the fault location, use a voltmeter to test for a signal at
Voltage Test.
the control terminals.

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 Test Procedures VLT® HVAC Basic Drive FC 101 Service Manual

7. Stop the frequency converter and remove input

power. Allow 20 minutes for DC capacitors to
fully discharge.
8. Reconnect motor cables to frequency converter
output terminals (U, V, W).
9. Reapply power and restart frequency converter.
Adjust motor speed to a nominal level.
10. Using a clamp-on style ammeter, measure output
current on each output phase. All currents must
be balanced.

6 6

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7 H-Frame Size Disassembly and Assembly Instructions

7.1 Electrostatic Discharge (ESD) 7.3 H6 Frame Size Disassembly and

Assembly Instructions
CAUTION
Frequency converters contain dangerous voltages when 7.3.1 Control Card and Control Card
connected to the main voltage. Never perform any Mounting Plate
disassembly when power is applied. Remove power to
the frequency converter, and wait until the frequency 1. Remove the LCP and the protection foil
converter capacitors fully discharge. Only a competent underneath it.
technician must carry out the service. 2. Remove the 3 screws (T10) from the control card.
Many electronic components within the frequency
3. Remove the control card.
converter are sensitive to static electricity. Voltages so
low that they cannot be felt, seen, or heard can reduce 4. Remove the 4 bolts on the bottom of the frame
the life, affect performance, or completely destroy
sensitive electronic components. 5.
underneath the cable connector.
Remove the screws (T10) in the control card
7 7
mounting plate.
CAUTION 6. Press barbs on ribbon cable and remove it.
Use correct ESD procedures to prevent damage to 7. Remove screws (T20) in cover plate.
sensitive components when servicing the frequency
8. Remove the control card mounting plate.
converter.
Reinstall in the reverse order.
NOTICE
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
1.4.1 Frame Size Definitions to determine frame size.

7.2 General Disassembly Procedure

This procedure explains how to remove the outer parts of
the frequency converter that are common for H frame
sizes. When this procedure is completed, the inside
components are accessible.

1. Remove the plastic cover beneath the LCP with a

flat-edged screwdriver.
2. Loosen and remove 4 screws (T20) on the front
cover.
3. Remove the front cover.

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7.3.2 Heatsink Fan Assembly

130BC108.11
1

1. Unplug the fan cable

2 2. Remove 4 screws on fan cover plate.
3. Remove the fan.
3 Reinstall in the reverse order.

130BC113.11
4 1

7 7
3

Illustration 7.1 Control Card and Control Card Mounting Plate

Illustration 7.2 Heatsink Fan Assembly

1 LCP
2 Cradle 1 Fan cover plate

3 Control card 2 Screws

4 Control card mounting plate 3 Fan assembly

Table 7.1 Legend to Illustration 7.1 Table 7.2 Legend to Illustration 7.2

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7.3.3 DC Coil 7.3.4 DC Link Card

1. Remove the 4 screws on the DC coil cover to 1. Remove the 6 screws on coil mounting plate.
access the DC coils.
2. Remove the coil mounting plate.
2. Remove the 4 screws to loosen the cables from
3. Loosen the 4 screws from the DC Link card.
the DC Link card.
4. Press one of the barbs to loosen the link card.
3. Remove the 6 screws on the DC coils (3 screws
on each coil). 5. Unplug the 10-pin ribbon cable and the filter
cable.
4. Remove the coils.
6. Remove the DC Link card.
Reinstall in the reverse order.
Reinstall in the reverse order. Join the mounting snaps.

130BC109.11
1

130BC110.11
1

7 7
2
2

Illustration 7.3 DC Coil

Illustration 7.4 DC Link Card

1 DC coil cover
2 DC coils 1 Coil mounting plate
2 Capacitor bank metal cover
Table 7.3 Legend to Illustration 7.3 3 DC link card

Table 7.4 Legend to Illustration 7.4

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7.3.5 RFI Filter 7.3.6 Power Card

1. Remove the protection cover. 1. Remove the 3 screws on the U V W cable

2. Remove the 6 distance bushes. connector.

3. Remove the 2 screws on the frame side. 2. Remove the connector.

4. Remove the 3 screws from U V W cables. 3. Remove the 3 small screws (T10) from the power
card.
5. Press the barbs on the side of the filter.
NOTICE
6. Remove the RFI filter.
If it is difficult to get out the screws, use a magnet.
Reinstall in the reverse order.

4. Remove the 6 remaining screws (T20).

130BC111.11
1 5. Lift the power card and slide it out of the frame.
Reinstall in the reverse order.

NOTICE
7 7 If it is difficult to remove the power card, it is helpful to
2
press the frame sides outwards while pressing the barbs
on the side of the power card.

130BC112.11
1

Illustration 7.5 RFI Filter

Illustration 7.6 Power Card

1 RFI filter
1 Power card
2 EMC shield
2 Power card mounting plate
Table 7.5 Legend to Illustration 7.5
Table 7.6 Legend to Illustration 7.6

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130BC108.11
1
7.4 H7 Frame Size Disassembly and
Assembly Instructions
2
7.4.1 Control Card and Control Card
Mounting Plate

1. Remove the LCP by pressing the barbs on the 3

side.
2. Remove the foil.
3. Remove the 3 screws (T10).
4
4. Gently, lift off the control card.
5. Press the barb on the LCP ribbon cable and pull
it out of the control card mounting plate.
6. Remove the mounting plate.
Reinstall in the reverse order.
7 7

Illustration 7.7 Control Card and Control Card Mounting Plate

1 LCP
2 Cradle
3 Control card
4 Control card mounting plate

Table 7.7 Legend to Illustration 7.7

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7.4.2 Power Card 7.4.3 Inrush Card

1. Remove the LCP ribbon cable from the power 1. Remove the 2 screws (T20) from the filter shield.
card.
2. Remove the shield.
2. Unplug all other cables from the power card,
3. Remove the 4 screws (T20) from the power card
including the 3 gate cables at the bottom of the
mounting plate.
card.
4. Remove the power card mounting plate.
3. Remove the 3 screws (T20) from the mounting
plate. 5. Unplug all cables from the inrush card.

4. Remove the power card by pushing in the 6 6. Remove the 6 screws (T20) from the inrush card.
retaining clips. 7. Remove the inrush card.
NOTICE Reinstall in the reverse order.
Use a screwdriver if the retaining clips are hard to reach.
5. Slide the power card out and remove it.

130BC346.10
1

Reinstall in the reverse order.

7 7
130BC125.11

Illustration 7.9 Inrush Card

1 EMC shield
Illustration 7.8 Power Card
2 Power card mounting plate
3 Inrush card

1 Power card Table 7.9 Legend to Illustration 7.9

Table 7.8 Legend to Illustration 7.8

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7.4.4 RFI Filter 7.4.5 Relay Transducer Card

1. Remove the red/black cables from the filter cable. 1. Unplug cables on the relay transducer card.
2. Remove the protective foil. 2. Loosen the right cable connector using a hex 5
3. Remove the 3 filter cables screws using a hex 8 key.
key. 3. Open the plastic clamp to remove the cables
4. Remove the 2 screws (T20) from the EMC shield. from the connector.

5. Remove the EMC shield. 4. Remove the 2 screws (T20) from the holding
bracket.
6. Remove the 8 screws (T20) on the filter cable
cover. 5. Remove the holding bracket.

7. Loosen the left cable connector using a hex 5 key 6. Remove the 3 cable screws (T20).
7. Remove the 3 screws on relay card (T20).
8. Remove the entire filter assembly.
8. Remove the Relay card by pushing in the
Reinstall in the reverse order.
retaining clips on the standoffs. Use a screwdriver
if necessary.

7 7
130BC126.11

1
9. Remove the mounting plate.
2
Reinstall in the reverse order.

130BC127.11
1

Illustration 7.10 RFI Filter

1 RFI filter
2 Screws Illustration 7.11 Relay or Transducer Card
3 EMC shield

Table 7.10 Legend to Illustration 7.10

1 Relay transducer card
2 Relay card mounting plate

Table 7.11 Legend to Illustration 7.11

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7.4.6 Rectifier Modules 1

130BC131.11
1. Loosen and remove the 2 cables (T20).
2. Remove the 6 screws (T20) from the shield.
3. Remove metal shield and plastic cover.
4
4. Remove the 2 screws (T20) from each of the
rectifier modules. 3
5. Remove the 3 rectifier modules. 2

7.4.7 IGBT

1. Remove the 4 screws (T20) from the cable

connector plate.
2. Remove the cable connector plate.
3. Loosen the coil cables (T20).

7 7 4. Unplug the cables.

5. Remove the 2 screws from each of the 2
capacitors
6. Remove the capacitors.
7. Remove the 4 screws (T20) from the bus bar. Illustration 7.12 IGBT

8. Remove the cables from the IGBTs.

9. Remove the 2 screws (T20) from each IGBT.
1 Cable mounting plate
10. Remove the IGBTs. 2 IGBT

CAUTION
3 Bus bar
4 Capacitor
The IGBTs and the heatsink have thermal paste on them.
Be careful not to touch the paste directly as it is Table 7.12 Legend to Illustration 7.12
poisonous.
11. Remove the thermal paste from the IGBT.
12. Clean the heatsink.
Reinstall in the reverse order. Join the mounting snaps.

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7.4.8 Heatsink Fan Assembly 7.4.9 DC Coil

1. Remove the 4 screws (T20) from the fan cover 1. Remove the 4 screws (T20) from the DC coil
plate. cover plate.
2. Press the fan cover plate outwards using a 2. Remove the 4 screws (T20) from the heatsink.
screwdriver.
3. Remove the heatsink.
3. Remove the fans and the fan cover plate.
4. Remove 4 screws (T20) from each of the 2 DC
Reinstall in the reverse order. Coils.
5. Remove the coils.

130BC132.11
Reinstall in the reverse order.

130BC133.12
1 1
2

7 7

3
Illustration 7.13 Heatsink Fan Assembly

1 Fan cover
2 Fan assembly

Table 7.13 Legend to Illustration 7.13

Illustration 7.14 DC Coil

1 DC coil cover plate

2 Heatsink
3 DC coil

Table 7.14 Legend to Illustration 7.14

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7.4.10 Capacitor Bank

7.5 H8 Frame Size Disassembly and
1. Remove the foil.
Assembly Instructions
2. Remove the 6 screws on the bottom plate.
3. Remove the bottom plate. 7.5.1 Control Card and Control Card
Mounting Plate
4. Remove the 4 screws (T20) from the capacitor
mounting plate.
1. Remove the LCP by pressing the barbs on the
5. Remove the mounting plate. side.
6. Turn the capacitor bank upside-down. 2. Remove the foil.
7. Remove the hex nut with a hex 19 key. 3. Remove the 3 screws (T10).
8. Remove the capacitor. 4. Gently, lift off the control card.
Reinstall in the reverse order. 5. Press the barb on the LCP ribbon cable and pull
it out of the control card mounting plate.
1 6. Remove the mounting plate.
130BC348.10

7 7 Reinstall in the reverse order.

Illustration 7.15 Capacitor Bank

1 Foil
2 Bottom plate
3 Capacitor bank

Table 7.15 Legend to Illustration 7.15

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7.5.2 Power Card

130BC108.11
1
1. Remove 2 screws (T20) from the EMC shield.
2. Remove cables from EMC shield.
2
3. Remove the EMC shield.
4. Remove the LCP ribbon cable from the power
3 card.
5. Unplug all other cables from the power card.
6. Remove the 3 screws (T20) from the mounting
plate.
4 7. Remove the power card by pushing in the 6
retaining clips.

NOTICE
Use a screwdriver if the retaining clips are hard to reach.
8. Slide the power card out and remove it.
Reinstall in the reverse order. 7 7

130BC125.11
1

Illustration 7.16 Control Card and Control Card Mounting Plate

1 LCP
2 Cradle
3 Control card
4 Control card mounting plate

Table 7.16 Legend to Illustration 7.7

Illustration 7.17 Power Card

1 Power card

Table 7.17 Legend to Illustration 7.17

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7.5.3 Inrush Card 7.5.4 Rectifier Modules

1. Remove the 4 screws (T20) from the power card

mounting plate.
CAUTION
Wear protective gloves when cleaning up the
2. Remove the power card mounting plate. thermal paste as it is poisonous.
3. Unplug all cables from the inrush card.
4. Remove the 6 screws (T20) from the inrush card. 1. Remove cables and foil.

5. Remove the inrush card. 2. Remove coil cords (T20).

Reinstall in the reverse order. 3. Remove 6 screws (T25).

4. Remove screws in coil cables (T20).
5. Remove the 6 screws (T25) from the bar.

130BC346.10
1

6. Remove the bar.

7. Loosen and remove the 3 cables using a hex 10
key.

7 7 8.
9.
Remove the plastic cover.
Remove the 2 screws (T20) on each of the
rectifier modules
2 10. Remove the thermal paste paper.
11. Clean up any excessive thermal paste.
Reinstall in the reverse order. Join the mounting snaps.
3

Illustration 7.18 Inrush Card

1 EMC shield
2 Power card mounting plate
3 Inrush card

Table 7.18 Legend to Illustration 7.18

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7.5.5 RFI Filter

130BC128.11
1

1. Remove the 3 screws (T20) from the small EMC

2 shield.
2. Remove the EMC shield.
3. Loosen left cable connector using a hex 8 key.
3 4. Remove the 4 screws (T20) from the filter.

4
5. Remove the entire filter assembly.
Reinstall in the reverse order.

130BC126.11
1
2

3 7 7

Illustration 7.19 Rectifier Modules

1 Foil Illustration 7.20 RFI Filter

2 Bus bar
3 Plastic cover
4 Rectifier modules 1 RFI filter
2 Screws
Table 7.19 Legend to Illustration 7.19 3 EMC shield

Table 7.20 Legend to Illustration 7.20

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7.5.6 Relay Transducer Card 7.5.7 IGBT

1. Remove the 4 screws (T20) on the plate.

CAUTION
2. Carefully remove cables before removing the Wear protective gloves when cleaning up the
plate. thermal paste as it is poisonous.
3. Loosen the cables in the right cable connector
using a hex 8 key. 1. Remove the 2 screws from the cable retaining
4. Pull out the cables. guide.

5. Remove the 3 screws (T30) on the relay card. 2. Remove the cable retaining guide.

6. Remove the 2 10-pin ribbon cables. 3. Remove the 4 screws (T20) from the cable
connector plate.
7. Remove the 3 screws (T20) from the relay card.
4. Remove the cable connector plate.
8. Press the 3 retaining clips.
5. Remove the 2 cable screws (T20)
9. Remove the relay card.
6. Remove the 2 screws (T30) in each of the 2
10. Remove the relay card mounting plate. capacitors.
7 7 Reinstall in the reverse order. 7. Remove the capacitors.
8. Remove the 2 screws (T30) from the bus bar.
130BC127.11

1
9. Remove the 4 screws (T20) holding the
capacitors.
10. Remove the bus bar.
2
11. Remove the gate cables from the IGBTs.
12. Remove the 4 screws from each IGBT.
13. Remove the thermal paper.
14. Remove the thermal paste from the IGBTs and
the heatsink.
Reinstall in the reverse order. Join the mounting snaps.

Illustration 7.21 Relay Transducer Card

1 Relay transducer card

2 Relay card mounting plate

Table 7.21 Legend to Illustration 7.21

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1 7.5.8 Heatsink Fan Assembly

130BC131.11
1. Remove the 4 screws (T20) from the fan cover
plate.
2. Press the fan cover plate outwards using a
4 screwdriver.
3. Remove the fans and the fan cover plate.
3
Reinstall in the reverse order.
2

130BC132.11
2
1

7 7

Illustration 7.22 IGBT

Illustration 7.23 Heatsink Fan Assembly

1 Cable mounting plate

2 IGBT 1 Fan cover
3 Bus bar 2 Fan assembly
4 Capacitor
Table 7.23 Legend to Illustration 7.13
Table 7.22 Legend to Illustration 7.22

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7.5.9 DC Coil 7.5.10 Capacitor Bank

1. Remove the 4 screws (T20) from the DC coil 1. Remove the foil.
cover plate. 2. Remove the 4 screws from the bottom plate.
2. Remove the 4 screws (T20) from the heatsink. 3. Remove the bottom plate.
3. Remove the heatsink. 4. Remove the 4 screws from the capacitor bank
4. Remove 4 screws (T20) from each of the 2 DC assembly.
Coils. 5. Remove the assembly.
5. Remove the coils. 6. Turn the assembly upside-down.
Reinstall in the reverse order. 7. Remove the 2 hex nuts with a hex 19 key.
8. Remove the 2 capacitors.

130BC133.12
1 Reinstall in the reverse order.
2

130BC348.10
7 7
3

Illustration 7.24 DC Coil

1 DC coil cover plate

2 Heatsink
3 DC coil Illustration 7.25 Capacitor Bank

Table 7.24 Legend to Illustration 7.14

1 Foil
2 Bottom plate
3 Capacitor bank

Table 7.25 Legend to Illustration 7.25

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7.6.2 Power Card Cover

7.6 H10 Frame Size Disassembly and
1. Press and loosen the 3 barbs at the bottom, and
Assembly Instructions the 3 barbs at the top.
7.6.1 Control Card and Control Card 2. Remove the power card cover.
Mounting Plate Reinstall in the reverse order. Join the mounting snaps.

1. Remove the LCP cradle. LCP cradle can be

1

130BC103.11
removed by hand.
2. Remove 3 screws (T10) securing the control card
mounting plate to the control assembly support
bracket.
3. Carefully lift out the control card.
Reinstall in the reverse order. 130BC101.11

7 7
1

3
Illustration 7.27 Power Card Cover

1 Power card cover

Table 7.27 Legend to Illustration 7.27

Illustration 7.26 Control Card and Control Card Mounting Plate

1 LCP
2 Control card mounting plate
3 Control card

Table 7.26 Legend to Illustration 7.26

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7.6.3 Power Card 7.6.4 Heatsink and DC Coils

1. Remove the 4 screws (T10) for the DC coil cables. 1. Remove the 7 mounting screws from top surface.
2. Remove the 5 screws (T10) for the heatsink. 2. Press and loosen the 3 barbs at the bottom.
3. Remove the 4 IGBT screws (T25). 3. Unplug the DC coil cables.
4. Unplug fan cable connector. 4. Remove the heatsink.

CAUTION 5. Lift out the DC coils.

The power card and the heatsink have thermal paste on Reinstall in the reverse order.
them. Wear protective gloves as the paste is poisonous.
5. Lift out the power card.

130BC105.11
6. Remove the capacitor bank gasket.
Reinstall in the reverse order.
130BC104.11

7 7 1

Illustration 7.29 Heatsink

Illustration 7.28 Power Card

1 Heatsink

Table 7.29 Legend to Illustration 7.29

1 Power card

130BC106.11
Table 7.28 Legend to Illustration 7.28

Illustration 7.30 DC Coil

1 DC coil

Table 7.30 Legend to Illustration 7.30

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7.6.5 Heatsink Fan Assembly

1. Remove 2 screws (T10) on the DC coil mounting

plate
2. Remove the plate.
3. Press and loosen the 2 barbs on the fan.
4. Remove the fan.
Reinstall in the reverse order.

130BC107.11

7 7
1

Illustration 7.31 Heatsink Fan Assembly

1 Heatsink fan
2 Fan mounting plate

Table 7.31 Legend to Illustration 7.31

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8 I-Frame Size Disassembly and Assembly Procedures

130BC059.11
1

8.1 General Disassembly Procedure

This procedure explains how to remove the outer parts of 2

the frequency converter that are common for all I frame

sizes. When this procedure is completed, the inside
components are accessible. 3
4
1. Loosen and remove the 4 screws (T20) from the
5
front cover.
2. Remove the front cover.
3. Remove the screw and sheet metal next to the
EMC shield.
4. Loosen and remove the 4 screws (T20) from the
cable entry.

8 8 5. Remove the cable entry.

8.2 I6 Frame Size Disassembly and

Assembly Instructions
8.2.1 Control Card and Control Card
Mounting Plate

1. Remove LCP cradle. Illustration 8.1 Control Card and Control Card Mounting Plate

2. Remove 3 screws (T12) on the control board.

3. Remove the control board. 1 LCP and cradle
4. Remove 1 screw (T20) on the fan bracket. 2 Control card and mounting plate
3 Support bracket
5. Unplug the fan cable and remove the fan.
4 Terminal plates
6. Remove 4 screws (T20) on the control card
5 EMC shield
mounting plate.
7. Unplug ribbon cable. Table 8.1 Legend to Illustration 8.1

8. Remove control card mounting plate.

Reinstall in the reverse order.

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8.2.2 Cable Mounting Plate 8.2.3 Heatsink Fan Assembly

1. Remove the ribbon cable. 1. Unplug cable from power card.

2. Remove 1 screw (T20) from shield metal. 2. Remove 2 screws (T20) from the fan mounting
3. Use a flat screwdriver to release the retainers and plate.
connection terminals. 3. Push the cable downwards. Use a screwdriver to
4. Use a hex 4 key to loosen the screws in the cable press the gasket down through the entry.
connector. 4. Pull out fan assembly.
5. Pull out the cables. Reinstall in the reverse order.
6. Slide the connector to the side and remove it.

130BC064.11
7. Remove 2 screws (T20) from the mounting plate.
Reinstall in the reverse order.
130BC060.11 2

8 8
2
1

Illustration 8.3 Heatsink Fan Assembly

1 Fan cover
Illustration 8.2 Cable Mounting Plate 2 Fan assembly

Table 8.3 Legend to Illustration 8.3

1 EMC shield
2 Cable mounting plate

Table 8.2 Legend to Illustration 8.2

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8.2.4 SMPS Card 8.2.5 Bus Bar Unit

1. Remove the 3 black plastic covers. 1. Remove the 2 screws from the snubber capacitor
2. Unplug and remove the fan. on the bus bar unit.

3. Unplug all other cables. 2. Remove the snubber capacitor.

4. Remove the 2 screws (T20) at MK101. 3. Use a Hex 8 key to remove 2 screws from the bus
bar unit.
5. Remove the 3 screws (T20) at K103A, K104A, and
K105A. 4. Remove the 6 small screws (T10).

6. Remove the 4 screws (T20) and from the SMPS 5. Remove the remaining 9 screws (T20).
card. 6. Unplug cables.
7. Lift off the SMPS card. 7. Lift out the bus bar unit.
Reinstall in the reverse order. Reinstall in the reverse order.

1
130BC061.11

130BC062.11
1

8 8

Illustration 8.4 SMPS Card

1 SMPS card

Table 8.4 Legend to Illustration 8.4

Illustration 8.5 Bus Bar Unit

1 Fan
2 Bus bar unit

Table 8.5 Legend to Illustration 8.5

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8.2.6 Power Card 8.2.7 DC Coil

1. Remove 7 screws (T20) 1. Remove 4 screws (T20) from the coil.

2. Remove 5 screws (T10) on the Power Card. 2. Lift the coil.
3. Lift out the power card. Reinstall in the reverse order.
Reinstall in the reverse order.

130BC065.11
130BC063.11
1

Illustration 8.7 DC Coil 8 8

Illustration 8.6 Power Card

1 DC coil

1 Power card
Table 8.7 Legend to Illustration 8.7

Table 8.6 Legend to Illustration 8.6

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8.2.8 RFI Filter

8.3 I7 Frame Size Disassembly and
1. Remove 2 screws (T20) from the filter.
Assembly Instructions
2. Lift out the filter.
Reinstall in the reverse order. 8.3.1 Control Card and Control Card
Mounting Plate

130BC066.11
1. Remove 2 screws (T20) from the 2 cover plates.

1
2. Remove the LCP cradle.
3. Remove 3 screws (T10) from the control card.
4. Remove the control card.
5. Remove 2 screws (T20) from the bracket next to
the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8. Remove the control card mounting plate.

8 8 Illustration 8.8 RFI Filter

Reinstall in the reverse order.

1 RFI filter

Table 8.8 Legend to Illustration 8.8

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8.3.2 Power Card

130BC059.11
1

1. Unplug and remove the LCP ribbon cable.

2
2. Unplug all other cables from the power card.
3. Remove 3 screws (T20) on the power card.

3
4. Remove the power card.
4 Reinstall in the reverse order.
5

130BC070.11
1

8 8

Illustration 8.10 Power Card

Illustration 8.9 Control Card Mounting Plate

1 Power card
1 LCP and cradle
2 Control card and mounting plate Table 8.10 Legend to Illustration 8.10
3 EMC shield
4 Terminal plates
5 EMC shield

Table 8.9 Legend to Illustration 8.9

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8.3.3 Power Card Mounting Plate 8.3.4 Inrush Card

1. Remove 4 screws (T20) from the power card 1. Unplug all cables.
mounting plate.
2. Remove 6 screws (T20) from the inrush card.
2. Remove the power card mounting plate with the
3. Remove the inrush card.
fan attached.
Reinstall in the reverse order.
Reinstall in the reverse order.

130BC072.11
1

130BC071.11
1

8 8
Illustration 8.12 Inrush Card
Illustration 8.11 Power Card Mounting Plate

1 Inrush card
1 Power card mounting plate
Table 8.12 Legend to Illustration 8.12
Table 8.11 Legend to Illustration 8.11

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8.3.5 Bus Bar 8.3.6 RFI Filter

1. Unplug and remove the red/black cable. 1. Unplug the 3 filter cables from the thyristors
2. Remove the black plastic cover. using a hex 8 key.

3. Remove 8 screws (T20) from the support bracket. 2. Loosen the 3 cables from the cable connector
using a hex 5 key.
4. Remove the bus bar assembly.
3. Remove 3 screws (T20) from the support bracket.
Reinstall in the reverse order.
4. Remove support bracket.
5. Remove 4 screws (T20) from the RFI Filter.

130BC073.11
1
6. Remove the entire assembly.
Reinstall in the reverse order.

130BC076.11
1

8 8
Illustration 8.13 Bus Bar

1 Bus bar

Table 8.13 Legend to Illustration 8.13 Illustration 8.14 RFI Filter

1 RFI filter

Table 8.14 Legend to Illustration 8.14

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8.3.7 Relay Transducer Card 8.3.8 Fan

1. Remove the 3 clamps on each side of the 2 cable 1. Remove 2 screws (T20) on the fan bracket.
connectors. 2. Remove 2 screws (T20) from the fan.
2. Remove the cable connector with no cables 3. Remove the fan.
attached.
Reinstall in the reverse order.
3. Remove 3 screws (T20) from the support bracket.
4. Loosen the 3 cables from the relay transducer 1

130BC077.10
card.
5. Remove the cable connector with cables and
retaining guide attached.
6. Unplug all other cables from the relay transducer
card.
7. Remove the 3 screws (T20)
8. Remove the relay transducer card.
Reinstall in the reverse order.

8 8
130BC075.11

Illustration 8.16 Fan

1 Fan

Table 8.16 Legend to Illustration 8.16

Illustration 8.15 Relay Transducer Card

1 Relay transducer card

Table 8.15 Legend to Illustration 8.15

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8.3.9 Terminal Plate 8.3.10 DC Bus Bar Assembly

1. Remove the black plastic cover. 1. Remove 2 screws (T20) from the 2 snubbers.
2. Remove 4 screws (T20) on the cover plate. 2. Remove the snubbers.
3. Remove the terminal plate. 3. Loosen and remove cables from bus bar assembly
Reinstall in the reverse order. and DC coil.
4. Remove 6 screws (T20) from the bus bar
assembly.

130BC078.11
1 5. Remove the bus bar assembly.
Reinstall in the reverse order.

130BC080.11
1

8 8
Illustration 8.17 Terminal Plate

1 Terminal plate

Table 8.17 Legend to Illustration 8.17 Illustration 8.18 DC Bus Bar Assembly

1 DC bus bar assembly

Table 8.18 Legend to Illustration 8.18

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8.3.11 Heatsink Fan Assembly 8.3.12 Capacitor Bank

1. Remove gate cables from IGBTs. 1. Remove 4 screws (T20) from each of the
2. Remove 2 screws (T20) from the heatsink fan capacitors.
assembly. 2. Remove the capacitors.
3. Push the fan cable down through the gasket. Reinstall in the reverse order.
4. Carefully press the gasket down with a

130BC081.11
screwdriver.
1
5. Remove the fan assembly.
Reinstall in the reverse order.

130BC350.10

2
1

8 8 Illustration 8.20 Capacitors

1 Capacitors

Illustration 8.19 Heatsink Fan Assembly Table 8.20 Legend to Illustration 8.20

1 Fan cover plate

2 Fan assembly

Table 8.19 Legend to Illustration 8.19

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8.3.13 DC Coil 8.3.14 IGBT

1. Remove 5 screws (T20) on the potted coil. 1. Remove 2 screws (T20) from each of the 3 IGBTs.
2. Remove the DC coil.
CAUTION
Reinstall in the reverse order. The IGBTs and the heatsink have thermal paste on them.
Wear protective gloves as the paste is poisonous.
2. Remove all IGBTs.

130BC082.11
1
Reinstall in the reverse order.

130BC083.11
2
1

Illustration 8.21 DC Coil 8 8

1 Bus bar
Illustration 8.22 IGBT
2 DC coil

Table 8.21 Legend to Illustration 8.21

1 IGBT

Table 8.22 Legend to Illustration 8.22

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8.3.15 Thyristor
8.4 I8 Frame Size Disassembly and
1. Remove 2 screws (T20) from each of the 3
thyristors.
Assembly Procedure

CAUTION 8.4.1 Control Card and Control Card

Mounting Plate
The thyristors and the heatsink have thermal paste on
them. Wear protective gloves as the paste is poisonous.
1. Remove 2 screws (T20) from the 2 cover plates.
2. Remove the thyristors.
2. Remove the LCP cradle.
Reinstall in the reverse order.
3. Remove 3 screws (T10) from the control card.
4. Remove the control card.

130BC074.11
1

5. Remove 2 screws (T20) from the bracket next to

the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8. Remove the control card mounting plate.

8 8 Reinstall in the reverse order.

Illustration 8.23 Thyristor

1 Thyristor

Table 8.23 Legend to Illustration 8.23

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8.4.2 Power Card

130BC059.11
1

1. Unplug and remove the LCP ribbon cable.

2
2. Unplug all other cables from the power card.
3. Remove 3 screws (T20) on the power card.

3
4. Remove the power card.
4 Reinstall in the reverse order.
5

130BC070.11
1

8 8

Illustration 8.25 Power Card

Illustration 8.24 Control Card Mounting Plate

1 Power card
1 LCP and cradle
2 Control card and mounting plate Table 8.25 Legend to Illustration 8.10
3 EMC shield
4 Terminal plates
5 EMC shield

Table 8.24 Legend to Illustration 8.9

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8.4.3 Power Card Mounting Plate 8.4.4 Inrush Card

1. Remove 4 screws (T20) from the power card 1. Unplug all cables.
mounting plate.
2. Remove 6 screws (T20) from the inrush card.
2. Remove the power card mounting plate with the
3. Remove the inrush card.
fan attached.
Reinstall in the reverse order.
Reinstall in the reverse order.

130BC072.11
1

130BC071.11
1

8 8
Illustration 8.27 Inrush Card
Illustration 8.26 Power Card Mounting Plate

1 Inrush card
1 Power card mounting plate
Table 8.27 Legend to Illustration 8.12
Table 8.26 Legend to Illustration 8.11

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8.4.5 Bus Bar 8.4.6 RFI Filter

1. Unplug and remove the red/black cable. 1. Unplug the 3 filter cables from the thyristors
2. Remove the black plastic cover. using a hex 8 key.

3. Remove 6 screws (T20) and 2 screws (T30) from 2. Loosen the 3 cables from the cable connector
the support bracket. using a hex 5 key.

4. Remove the bus bar assembly. 3. Remove 3 screws (T20) from the support bracket.

Reinstall in the reverse order. 4. Remove support bracket.

5. Remove 4 screws (T20) from the RFI Filter.
6. Remove the entire assembly.

130BC073.11
1
Reinstall in the reverse order.

130BC076.11
1

8 8

Illustration 8.28 Bus Bar

1 Bus bar
Illustration 8.29 RFI Filter
Table 8.28 Legend to

1 RFI filter

Table 8.29 Legend to Illustration 8.14

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8.4.7 Relay Transducer Card 8.4.8 Terminal Plate

1. Remove 2 screws (T20) from each of the 2 cable 1. Remove 4 screws (T20) on the cover plate.
connectors.
2. Remove the complete terminal plate including
2. Remove the cable connector. cable connector.
3. Remove 3 screws (T20) from the support bracket. Reinstall in the reverse order.
4. Loosen the 3 cables (T30) from the relay
transducer card.

130BC078.11
1
5. Unplug all other cables from the relay transducer
card.
6. Remove the 3 screws (T20).
7. Remove the relay transducer card.
Reinstall in the reverse order. 130BC075.11

8 8 Illustration 8.31 Terminal Plate

1 Terminal plate

Table 8.31 Legend to Illustration 8.31

Illustration 8.30 Relay Transducer Card

1 Relay transducer card

Table 8.30 Legend to Illustration 8.30

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8.4.9 DC Bus Bar Assembly 8.4.10 Heatsink Fan Assembly

1. Remove 2 screws (T30) from each of the 2 1. Remove 4 screws (T20) from the heatsink fan
snubbers. assembly.
2. Remove the snubbers. 2. Push the cables down through the gaskets.
3. Loosen and remove the 2 cables from bus bar 3. Carefully press the gaskets down with a
assembly and DC coil. screwdriver.
4. Remove 2 screws (T30). 4. Remove the fan assembly.
5. Remove 8 screws (T20) on top of the bus bar Reinstall in the reverse order.
assembly.
6. Remove the bus bar assembly.

130BC094.11
Reinstall in the reverse order.
1

130BC080.11

2
8 8
Illustration 8.33 Heatsink Fan Assembly

1 Fan cover plate

2 Heatsink fan

Illustration 8.32 DC Bus Bar Assembly Table 8.33 Legend to Illustration 8.33

1 Bus bar assembly

Table 8.32 Legend to Illustration 8.32

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8.4.11 Capacitor Bank 8.4.12 DC Coil

1. Remove 4 screws (T20) from each of the 1. Remove 5 screws (T20) on the potted coil.
capacitors.
2. Remove the DC coil.
2. Remove the capacitors.
Reinstall in the reverse order.
Reinstall in the reverse order.

130BC082.11
1

130BC081.11
1

8 8 Illustration 8.34 Capacitors

Illustration 8.35 DC Coil

1 Bus bar
1 Capacitors 2 DC coil

Table 8.34 Legend to Illustration 8.20 Table 8.35 Legend to Illustration 8.21

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8.4.13 IGBT 8.4.14 Thyristor

1. Remove 4 screws (T20) from each of the 3 IGBTs. 1. Remove 2 screws (T20) from each of the 3
thyristors.
CAUTION
The UGBTs and the heatsink have thermal paste on CAUTION
them. Wear protective gloves as the paste is poisonous. The thyristors and the heatsink have thermal paste on
2. Remove all IGBTs. them. Wear protective gloves as the paste is poisonous.
2. Remove the thyristors.
Reinstall in the reverse order.
Reinstall in the reverse order.

130BC083.11
1

130BC074.11
1

8 8

Illustration 8.36 IGBT

Illustration 8.37 Thyristor

1 IGBT
1 Thyristor
Table 8.36 Legend to Illustration 8.36
Table 8.37 Legend to Illustration 8.23

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 Block Diagrams VLT® HVAC Basic Drive FC 101 Service Manual

9 Block Diagrams

9.1 Block Diagrams, Frame Sizes H and 9

9.1.1 H6 Frame Size

130BC339.10
Brake not connected to terminal on FC 101

AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS

Motor
L2 x3 RFI _ RL 2 x3 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1

Tmp_ VGDS
P_BRF
7 xGD
RL 2

EEP RL 2

9 9
SMPS RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
Control Card UINV_P SAFE _ FB
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
VGD +/- 15 /UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”

Illustration 9.1 H6 Frame Size

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Block Diagrams VLT® HVAC Basic Drive FC 101 Service Manual

9.1.2 I6 Frame Size

130BC137.10
Brake not connected to terminal on FC101

AC /DC BR DC /AC
RFI (variations)
Inrush A
L1 U
MAINS

Motor
x3
L2 x3 RFI _ RL 2 A V
L3 A
W
o
C

RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1

Tmp _ VGDS
P_ BRF
7 xGD
RL 2

SMPS EEP RL 2
RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
Control Card SAFE _ FB
UINV_ P VCX (GX ) 5V
Tmp _VGDS
D-I/O
A-I/O UINV_ N VCC
VCC (GND ) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND ) 24V
Ext. Imax2 comp.
FAN 2
FFB 2 fans Level
Shift
LCP ACP MCP

9 9
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”

Illustration 9.2 I6 Frame Size

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 Block Diagrams VLT® HVAC Basic Drive FC 101 Service Manual

9.1.3 H7, H8, I7, I8 Frame Size

130BC340.10
Thyristor x3 AC / DC Brake not connected to terminal on FC 101
BR DC /AC
RFI (variations)
A
U

Motor
L1 x3
V
MAINS

A
L2 W
A
L3 o
C

RFI _RL 1 BR BR INV Temp.

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1

uC+ RL 1

Tmp_VGDS
P _BRF
7 xGD
EEP RL 2
RL 2

RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

VDD (GND) 24V Imax 2 comp.

E _FAN Level
E _FFB Shift

LCP ACP MCP Ext.

Display CAN
fans

9 9
”Internal Communication”
control ”Internal supply bus”
panel

Illustration 9.3 H7, H8, I7, I8 Frame Size

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Block Diagrams VLT® HVAC Basic Drive FC 101 Service Manual

9.1.4 H9 Frame Size

130BC136.10
Brake not connected to terminal on FC101

AC/DC BR DC /AC
RFI (variations)
Inrush
A
L1 U
MAINS

Motor
x3
L2 x3 RFI _ RL 2 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp .
FB GD GD conv.

GD
Supply
RL 1

uC+ RL 1

Tmp_VGDS
P _BRF
7 xGD
RL 2

SMPS
EEP RL 2
RFI _ RL 1
RFI _RL 2
VGD+/- 15/UDC-/-5
Inrush
Control Card UINV _ P VCX (GX ) 5V
SAFE _ FB
Tmp_VGDS
D-I/O UINV _ N
VCC ( GND ) 5V VCC
A-I/O
FAN 1 Int.
Isol. RS 485
FFB 1 fans
VDD ( GND ) 24V
Imax 2 comp.
VGD +/- 15/UDC -/-5 Level
Shift
LCP ACP MCP

9 9
Display
CAN
”Internal Communication”
control ”Internal supply bus”
panel

Illustration 9.4 H9 Frame Size

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 Block Diagrams VLT® HVAC Basic Drive FC 101 Service Manual

9.1.5 H10 Frame Size

130BC138.10
Brake not connected to terminal on FC 101

AC /DC BR DC /AC
RFI (variations)
Inrush
A
L1 U

Motor
MAINS

x3
L2 x3 RFI _ RL 2 A V
L3 A W
o
C

RFI _ RL 1
BR BR INV Temp .
FB GD GD conv.

GD
Supply
RL 1

RL 1
uC+

Tmp_VGDS
P_ BRF
7 xGD
RL 2

RL 2
SMPS EEP
RFI _ RL 1
RFI _ RL 2 VGD +/- 15/UDC -/-5
Inrush
Control Card UINV _ P VCX ( GX) 5V
SAFE _ FB
Tmp _ VGDS
D-I/O UINV_ N
VCC (GND ) 5V VCC
A-I/O
FAN 1 Int.
Isol. RS 485
FFB 1 fans
VDD ( GND ) 24V
Imax 2 comp.
VGD +/- 15/UDC -/-5 Level
Shift
LCP ACP MCP

9 9
Display
CAN
”Internal Communication”
control
panel
”Internal supply bus”

Illustration 9.5 H10 Frame Size

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Index VLT® HVAC Basic Drive FC 101 Service Manual

Index
H
Heatsink....... 11, 12, 13, 28, 60, 66, 67, 72, 74, 76, 77, 79, 88, 95,
A 97
AMA........................................................................ 34, 36, 37, 39, 41, 42
Analog
input..................................................................................................... 36 I
output........................................................................................... 19, 42 IGBT..................................... 12, 13, 16, 24, 28, 34, 41, 43, 44, 50, 54
signal............................................................................... 19, 20, 36, 57 Impedance........................................................................ 22, 26, 43, 45
signals.................................................................................................. 18
Input
cabling................................................................................................. 53
C signal............................................................................... 18, 20, 39, 43
Cable cross section............................................................................. 22 terminal............................................................................................... 36

Capacitor Inverter time.......................................................................................... 41

Capacitor................ 12, 13, 15, 16, 22, 24, 25, 40, 42, 50, 59, 66
bank............................................................................................... 26, 51
L
Circuitry.................................... 18, 23, 24, 31, 34, 40, 42, 49, 56, 57 LCP......................... 15, 16, 18, 19, 23, 33, 34, 55, 59, 63, 68, 69, 78
Control LED................................................................................... 6, 33, 35, 36, 54
card................................................ 20, 23, 24, 25, 33, 36, 42, 54, 57
terminal....................................... 18, 19, 20, 21, 23, 33, 36, 43, 57
wiring....................................................................... 18, 19, 33, 34, 57 M
Current Main assemblies.............................................................................. 6, 23
rating.................................................................................................... 37 Motor
waveform.............................................................................. 26, 28, 55 current.................................................................................................. 39
data................................................................................................ 37, 39
power................................................................................................... 39
D
DC
bus capacitor..................................................................................... 54 O
bus inductor....................................................................................... 26 Output
capacitor.............................................................................................. 58 Output...... 17, 18, 19, 20, 23, 24, 28, 31, 32, 34, 35, 39, 40, 41,
coil...................................................................... 14, 15, 16, 24, 42, 50 42, 43, 44, 49, 50, 54, 56, 57
Deceleration rate................................................................................. 41 current.................................................................................................. 37
short circuit........................................................................................ 24
Digital
signal...................................................................................... 19, 24, 49
input....................................................................................... 18, 20, 37
voltage....................................................... 18, 34, 40, 42, 54, 56, 57
output.................................................................................... 19, 20, 24
Over
Diode.............................................................. 24, 41, 49, 50, 51, 55, 56
current........................................................................................... 17, 41
Display line............................................................................................. 19 temperature................................................................................ 35, 43
Over-current.......................................................................................... 35
E
Electrical Installation in General................................................... 10
P
EMC......................................................................... 32, 38, 43, 65, 69, 71 Peak voltage.......................................................................................... 25
Phase loss.......................................................................... 35, 37, 42, 55
F Power
Form card..... 12, 13, 14, 15, 16, 20, 23, 24, 25, 28, 51, 56, 62, 64, 69,
A............................................................................................................. 20 70, 81, 83, 84, 91, 92
C relay............................................................................................ 19, 20 component.................................................................................. 32, 49
Programming........................................................................................ 36
G Pulse reference..................................................................................... 19
Gate signal............................................................................... 28, 43, 55 PWM............................................................................................ 23, 28, 44
Gating circuit......................................................................................... 25
Ground cabling.................................................................................... 22 R
Reference signal.................................................................................. 34
Relay......................................................... 12, 13, 15, 16, 24, 26, 65, 72

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Index VLT® HVAC Basic Drive FC 101 Service Manual

Remote input................................................................................. 18, 19

Reset.................................................................................................. 37, 39
RFI relay................................................................................................... 26
RS-485........................................................................................ 18, 19, 20

S
SCR...................................................................................................... 25, 55
Serial bus..................................................................... 18, 19, 33, 34, 36
Short circuit............................................................... 17, 38, 49, 50, 51
Signal conductor................................................................................. 45
Status
line......................................................................................................... 18
messages...................................................................................... 18, 33
Switch................................................................................................ 24, 32
Switching function............................................................................. 24

T
Thermal sensor.............................................................................. 28, 43
Thyristor.................................................................................................. 24
Torque limit.................................................................................... 41, 43
Trip
condition............................................................................................. 34
lock................................................................................................. 35, 36

V
Voltage
imbalance............................................................................. 37, 43, 56
waveform..................................................................................... 28, 56

W
Waveform.............................................. 23, 26, 28, 41, 42, 44, 55, 56

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Index VLT® HVAC Basic Drive FC 101 Service Manual

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