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Appendix FI10
2
1
Main circuit diagrams 5
2
6 Main circuit diagrams
2
Main circuit diagrams 7
2
8 Exploded view
3. EXPLODED VIEW
NOTE! CHECK THE CORRECT SPARE PARTS FROM THE SPARE PART LIST AND DRIVE VERSION
HISTORY!
60FI13324
3
Exploded view 9
NOTE! CHECK THE CORRECT SPARE PARTS FROM THE SPARE PART LIST AND DRIVE VERSION
HISTORY!
60FI10013
60FI13329
60PP10049
60PP13034
70CPE00720
Power module
60FI13301
60FI13300
60FI10072 60FI10071
60FI10015
60VB00483
60FI10019
60FI10061
60PP20300
60PP20202
60FI13305 (Asic assembly) (8A fuses)
3
10 Exploded view
NOTE! CHECK THE CORRECT SPARE PARTS FROM THE SPARE PART LIST AND DRIVE VERSION
HISTORY!
Power module
60FI13330
70CPE00721
NOTE! OTHER PARTS IN 690V UNITS ARE THE SAME AS IN 500V UNITS.
3
Measurement instructions 11
4. MEASUREMENT INSTRUCTIONS
Before analyzing/checking measurements, make sure that the unit or module being
repaired is disconnected from the power supply, unless it is required to be powered
up. Make sure any dangerously high voltage remaining in the circuit is discharged and
that there is no voltage source with life threatening potential. It is imperative to
ensure that the main supply is switched off and the main terminals and DC busbars
are de-energized.
Also, make sure that the working environment is safe and will not cause personal
injury, damage to the unit or to the environment. If repairs are being carried out in
the field, make sure that the supply voltage cannot be switched on during service, and
the action of the service personnel will not cause unnecessary disturbance or interrup-
tion to the process.
NOTE! REMEMBER TO FILL ALL RESULTS OF THE ANALYSES TO THE FAULT REPORT WITH
DETAILED INFORMATION OF UNIT / MODULE TYPE. THE NX_ FAULT REPORT IS AVAILABLE
BY REQUEST FROM VACON PLC OR IT CAN BE DOWNLOADED FROM VACON SERVICE WWW-
PAGES.
4
12 Measurement instructions
MAKE SURE THAT THE UNIT OR BOARDS ARE NOT POWERED UP.
• Measure the forward bias of the free wheeling diode from DC- to U/V/W output ter-
minal and reverse bias from U/V/W to DC-.
• Measure forward bias from the IGBT, from U/V/W output terminal to DC+ and
reverse bias from DC+ to U/V/W.
DC+ DC-
U
V
W
4
Measurement instructions 13
Infinite ~0,5V
Reversed Forward
biased biased
PN-junction PN-juction
• Use nominal voltage and a 1A current limit. Power up quickly. If you lift the power
up too slowly, the unit will give the fault code F_7 (Asic wakes up before driver
board). This won’t cause any harm to the unit and you can reset the fault.
Connect the DC+/- supply wires from an external power supply to the Asic board
(Figure 10):
• Remove the 8A fuses from the fuse base (Figure 12).
• Connect the DC+/- from the external power supply to the fuse base. Be sure to
connect the DC wires to correct polarity and to correct side of the fuse base
(Figure 12). Use nominal voltage and a 1A current limit.
NOTE! AFTER THE MEASUREMENTS, MAKE SURE THAT ALL THE WIRES ARE RE-CONNECTED
CORRECTLY.
4
14 Measurement instructions
4
Measurement instructions 15
DC-
4
16 Measurement instructions
8A fuses
4
Measurement instructions 17
MAKE SURE THAT THE UNIT OR BOARDS ARE NOT POWERED UP.
• Measure the gate resistances from the driver board. Start the measurements from
connector X11/U_L and continue in order through all connectors. Connect the mul-
timeter test leads between emitter and gate (measure both gate pins). The gate
resistance is ~ 500Ω, if the board is OK (Figure 13).
• Measure the resistance between emitter and output phase. Connect the multimeter
test leads between emitter at connector X11/U_L and output terminal phase U.
Measure also phases V and W from connector X11/V_L -> V-terminal and X11/W_L
-> W-terminal. The resistance is ~ 0,5Ω, if the IGBT’s are OK.
• Measure the resistance between driver board X10/H_emitter and the DC- busbar.
Do the same measurement at connectors X9/H and X8/H. The resistance is ~ 0,5Ω,
if the IGBT’s are OK.
• You don‘t have to do measurements to branches X6, X5, X4 and X3 because they
are connected parallel with the X11/L, X10/H, X9/H and X8/H branches. If all mea-
surements were OK, proceed to the next step.
4
18 Measurement instructions
500Ω
emitter emitter
U/L gate gate U/L
gate gate
emitter emitter
V/L gate gate V/L
gate gate
emitter emitter
gate gate
W/L gate gate
W/L
emitter emitter
U/H gate
gate
gate U/H
gate
emitter emitter
V/H gate gate V/H
gate gate
emitter emitter
W/H gate gate W/H
gate gate
4
Measurement instructions 19
4
20 Measurement instructions
emitter emitter
U/L gate gate U/L
gate gate
emitter emitter
V/L gate gate V/L
gate gate
emitter emitter
gate gate
W/L gate gate
W/L
emitter L L L H H H emitter
U/H gate U U gate U/H
gate
V W V W
gate
emitter emitter
V/H gate gate V/H
gate gate
emitter emitter
W/H gate gate W/H
gate gate
Flashlight
FIGURE 14. Driver board optical fibre and IGBT control circuit measurements
4
Measurement instructions 21
NOTE! PAY ATTENTION TO THE FOLLOWING MEASUREMENT. IF YOU MAKE A SHORT CIRCUIT
BY ACCIDENT, IT CAN BRAKE THE CURRENT MEASUREMENT CIRCUIT!
Iw Iw
Iv Iv
Iu Iu
X12
X7
Example of
the current 0V
signal mea-
surement.
DC- DC-
4
22 Measurement instructions
4
Measurement instructions 23
Itr Itr
X12
Example of X7
the over 14,4V
current trip
signal mea-
surement.
DC- DC-
4
24 Measurement instructions
Temp Temp
X7
Example of
the temp 3V
signal mea-
surement.
DC- DC-
4
Measurement instructions 25
Temperature limits:
• Warning at 85°C
• Trip at 90°C
4
26 Measurement instructions
Fan capacitor
• Measure the fan capacitor capacitance value with a multimeter. Compare the mea-
sured value to the value on the capacitor. If the measured value is smaller than
6.65μF, change the capacitor.
4
Measurement instructions 27
• The dip switch is shown in Figure 21 and the dip switch settings in Table 4.
• The default dip switch settings in FR9 and bigger units, see Figure 22. The settings
are shown for frames FR9 and larger (ON = up, OFF=down).
TABLE 4. Dip switch settings on the fan power supply 60VB00299 and 60VB00399
State S1 S2 S3 S4
Running fre- S2=Motor S3=Motor Frame size
quency voltage voltage
ON 60 Hz OFF OFF 220VAC FR8
OFF ON 230VAC
OFF 50 Hz ON OFF 240VAC FR9-FR13
ON ON 250VAC
4
28 Measurement instructions
FIGURE 22. Dip switch settings for FR9 and larger frames
Measure the isolation transformers winding. See Table 5 and Figure 23.
4
Measurement instructions 29
4
30 Measurement instructions
MAKE SURE THAT THE DC WIRES ARE CONNECTED TO CORRECT POLARITY ON THE CAPACI-
TORS BEFORE TURNING ON THE POWER SUPPLY.
TABLE 7.
1. Q=Ixt I=charging current
t=measured
charging time
2. C=Q/U U=voltage
• Compare the calculated value to the value on the capacitor label.
• The leakage current should be less than 3mA when the voltage has stabilized.
• Abort the test if the leakage current is sufficiently higher when the voltage has sta-
bilized.
• Discharge each capacitor after testing. Use a proper resistor, which can
handle the discharging current.
• If you have to replace broken capacitors with new ones, you have to replace all the
capacitors in the same block with the damaged capacitors. Check also the busbars
and insulators and replace them if they are damaged.
4
Replacement instructions 31
5. REPLACEMENT INSTRUCTIONS
1.
2.
3.
4.
5.
Output cable fastening
screws (M10x30, M10
spring washer and M10
washer).
5
32 Replacement instructions
5.2. Covers
2.
4.
1.
3.
5.
Side panel:
• Open the fastening screw and pull the cover out of the frame. When installing the
side panel, make sure the panel can easily slide to its correct place.
5
Replacement instructions 33
1.
2.
• Disconnect the cooling fan supply cable from the connector, remove the fastening
screws and pull the cooling fan out of the frame.
5
34 Replacement instructions
6. 1.
5.
3.
4.
5
Replacement instructions 35
2.
1.
5
36 Replacement instructions
3. 2. 1.
4. Earthing capacitor: Dis-
connect the capacitor wires,
unscrew the
assembly fasten- 5.
3. Inverter ing screw and
board: Discon- remove the
capacitors. 6.
nect the wires
from connector
7.
X8, X2, X3, X4
and X5, remove
the two fasten-
ing screws and
lift the inverter
board out of the
frame.
9.
8. 8. 4.
5
Replacement instructions 37
5
38 Replacement instructions
New parts:
• External fan supply assembly, PP13050
• End fan inverter connector, PP00033
• Bushing rubber, 60MC00016
2.
3.
1.
5.
4. 6.
5
Replacement instructions 39
X1 1
FIGURE 32. Installing jumper PP00033 in connector X11 on the Asic board and fuse
holder wiring.
5
40 Replacement instructions
2.
5.
3.
4.
1.
Asic cooling fan
supply wire. Con-
nector X1 on the
asic board.
• Unscrew the four (4) fastening screws from the asic cover, disconnect the asic cool-
ing fan supply wire from asic board connector X1 and remove the cover.
• Disconnect the optical fibers, flat cables, power supply and control box power sup-
ply from the asic board.
• Unscrew the asic mounting box fastening screw and remove the assembly, see
Figure 33 for instructions to replace the asic board.
• Asic connections, see main circuit diagrams (Chapter 2).
5
Replacement instructions 41
1.
2.
3.
4.
6. 5.
5
42 Replacement instructions
4. 3.
5. 1.
2.
6.
5
Replacement instructions 43
2.
1.
• Unscrew the three fastening screws and remove the air block plate.
5
44 Replacement instructions
5.9. DC-busbars
1.
2.
3.
7.
4. 5. 6.
5
Replacement instructions 45
8.
9. 10.
NOTE! WHEN INSTALLING THE BUSBARS BACK TO THE UNIT, MAKE SURE THAT THE INSULA-
TOR (FI10053) IS INSTALLED BETWEEN THE BUSBARS.
5
46 Replacement instructions
1.
2.
• Disconnect the flat cables, DC supply wires, measurement wires and optical fibers
from the driver board.
• Remove the driver board support plate.
• Remove the driver board fastening screws and lift off the board.
• Driver board connections, see main circuit diagrams (Chapter 2).
NOTE! IF YOU ARE INSTALLING A NEW DRIVER BOARD TO THE UNIT, MAKE SURE THAT
DRIVER BOARD MODIFICATION IS DONE PROPERLY, SEE CHAPTER 5.20.2 FOR INTRUC-
TIONS.
5
Replacement instructions 47
4.
2. 1.
3.
5
48 Replacement instructions
1.
2.
4.
3.
DC-feed busbars:
• Remove the earth capacitor wires from the busbars.
• Unscrew the busbar fastening screws and remove them.
5
Replacement instructions 49
2.
1.
3.
4.
5.
2. 1.
EMC-shield:
• Unscrew the motor cable fastening screws from the IGBT-terminals.
• Cut the cable ties from the EMC-shield and remove the motor cables.
• Unscrew the EMC-shield fastening screws and remove the shield.
5
50 Replacement instructions
2.
1.
3.
Snubber capacitors:
• Unscrew the fastening screws from the IGBT-terminals and lift off the snubber
capacitor assemblies.
5
Replacement instructions 51
1.
2.
3.
• The FI10 unit has two balancing resistor assemblies. The assemblies are connected
to each other with a wire harness, which is connected to the main circuit busbars.
• Unplug the wire harness from the balancing resistor assembly connectors and
remove the fastening screws.
NOTE! WHEN REPLACING THE BALANCING RESISTOR ASSEMBLIES, MAKE SURE THAT THE
RESISTOR WIRES ARE CONNECTED CORRECTLY.
5
52 Replacement instructions
1 2. 3. 4. 5. 6.
7. 8.
7. 8.
FIGURE 46. 500V main circuit busbar screws: M6x20 (red) and M6x16 (yellow)
5
Replacement instructions 53
1. 2. 3. 4. 5. 6.
7. 8.
7. 8.
FIGURE 48. 690V main circuit busbar screws: M6x20 (red) and M6x16 (yellow)
5
54 Replacement instructions
1.
2.
5
Replacement instructions 55
2.
1.
5
56 Replacement instructions
5.17. Wiring
Black
White
Red
5
Replacement instructions 57
Green Black
White
Red
5
58 Replacement instructions
X28
X22
X1
X4
X2
X3
X6
X3
X5
X1
X4
X6
X5
X2
X15
X15
X23 X29
X14
X14
X24 X30
X7
X7
X31
X25
X1
Driver
driver supply cable
DC+/-
X10
X11
Asic
X6 fibers
X2 CTRL
5
Replacement instructions 59
Driver
UL VL WL UH VH WH
X5
X4
X3
Driver
X5 X4 X3
Asic
FIGURE 56. Measurement cables
5
Replacement instructions 60
B+ B-
FI 9/10
NXP
CONTROL
PE
U V W CHARGING CHARGING
FEEDBACK RELAY
24VDC
OEVA
X9 X15
25 26 21 22 23
5
Replacement instructions 61
DC+ DC-
EXTERNAL
SUPPLY
B+ B-
FI 9/10
NXP
CONTROL
CHARGING CHARGING
FEEDBACK RELAY
FAN
24VDC
OEVA
X9 X15
PE 25 26 21 22 23
U V W
M
FIGURE 58. Charging circuit wiring with external supply
5
Replacement instructions 62
2. 690V units:
• Remove jumpers X14, X141, X142 and X17.
5
Replacement instructions 63
R56
R114
R128
R109
R123
R137
R110
R39
X2
2. 690V units:
• Remove resistors R39, R109, R123, R137 and jumper X2 (red in Figure 60).
5
64 Specifications
6. SPECIFICATIONS
6
Specifications 65
6
66 Specifications
6
Specifications 67
6
68 Specifications
6
Specifications 69
6
VACON Plc.
Runsorintie 7
65380 Vaasa
Finland
SM00029 C
29.12.2010
J.Kukkonen