SM00015B

VACON NX SERVICE MANUAL

Appendix FR10

[email protected] Tel +358 (0)201 212 575 Fax +358 (0)204 335 091

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1. SERVICE MANUAL REVISION HISTORY.................................................. 52. MAIN CIRCUIT DIAGRAMS..................................................................... 63. EXPLODED VIEW ................................................................................... 9

3.1. FR10 ......................................................................................... 93.2. FR10 stand alone ...................................................................... 17

4. MEASUREMENT INSTRUCTIONS........................................................... 184.1. Power unit safety notices ........................................................... 18

4.1.1. Visual checking's and measurements before powering up . 184.1.2. Checking the power unit............................................... 18

4.2. Measurements .......................................................................... 194.3. Main circuit measurements......................................................... 19

4.3.1. Rectifier measurements ............................................... 194.3.2. IGBT measurements .................................................... 19

4.4. Driver board measurements ....................................................... 204.4.1. IGBT gate resistance ................................................... 20

4.5. Programming............................................................................ 214.6. Asic board ................................................................................ 21

4.6.1. How to power up unit for the measurements................... 224.6.2. Checking of optical fiber and IGBT-control circuit ............. 24

4.7. How the optical fiber link starts................................................... 274.8. LED on control panel ................................................................. 274.9. If unit is switched to mains too often. (>1 time/Min.) .................... 274.10. Temperature signal measurement ............................................. 284.11. Current signal measurement..................................................... 304.12. DC-voltage measurement ......................................................... 324.13. Fan inverter............................................................................ 324.14. Fan........................................................................................ 344.15. Fan capacitors......................................................................... 344.16. Main circuit capacitors.............................................................. 344.17. Rectifying board ...................................................................... 354.18. Board variations...................................................................... 374.19. Testing after repair.................................................................. 39

5. REPLACEMENT INSTRUCTIONS............................................................ 405.1. How to remove FR10 unit from the cabinet................................... 405.2. Asic......................................................................................... 47

5.2.1. Asic assembly............................................................. 485.2.2. Asic modifications and connections ................................ 49

5.3. Driver and adapter board ........................................................... 505.4. Rectifier board .......................................................................... 525.5. How to remove block assembly ................................................... 535.6. Right block assembly ................................................................. 55

5.6.1. Main circuit busbars 500V............................................. 585.6.2. Rectifier module.......................................................... 615.6.3. Power module............................................................. 625.6.4. Rectifier module sub-assembly...................................... 63

5.7. Left block assembly ................................................................... 655.7.1. Main circuit busbars 500V............................................. 665.7.2. Power module............................................................. 69

5.8. Main circuit busbars left and right block 690V ............................... 705.9. Balancing resistor coupling 500V and 690V................................... 74

24h on-call service phone +358 (0)40 83 71 150

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5.9.1. 500V unit ................................................................... 745.9.2. 690V unit ................................................................... 74

5.10. Fan and fan inverter.................................................................755.11. Wiring ....................................................................................785.12. EMC-modifications ...................................................................845.13. FR10 stand alone IP21 .............................................................85

6. SPECIFICATIONS .................................................................................866.1. Drive revision history .................................................................866.2. NTC-values...............................................................................926.3. Torque specifications .................................................................93

Revision history


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1. SERVICE MANUAL REVISION HISTORY

TABLE 1. Updates in the service manual.

Service Manual revision

Updated/added material

SM00015A First version

SM00015B Revision history, measurement instructions and replacement instructions updated.

Revision history updated

Main circuit diagrams


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2. MAIN CIRCUIT DIAGRAMS

FIGURE 1. NX/FR10/FC/500V and 690V cooling



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FIGURE 2. NX/FR10/FC/500V and 690V Power modules



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FIGURE 3. NX/FR10/FC/500V and 690V control

Exploded view


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3. EXPLODED VIEW

3.1. FR10

FR10342

FR10340

FR10341

FR10151

FR10152FR10080

FR10925VB00497

PP01094

FR10313

FR10217

VB00330

PP00011

FR10846 ASSEMBLY

FAN ASSEMBLY

FR10081

FR10312

FR10846 ASSEMBLY

FR10219

FR10846 ASSEMBLY

FIGURE 4. FR10 main assembly

Exploded view


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FIGURE 5. Right block assembly

FR10164

PP10019

VB00459 500V

FR10851 500V

POWER

RECTIFIER

PP01005

PP00016

FR10001

FR10125

FR10006FR10008

FR10005

VB00460 690V

BUS BAR KIT(RIGHT SIDE)

MODULE

MODULE

Exploded view


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FIGURE 6. Left block assembly

POWERMODULE FR10004

FR10125

FR10852 500VBUS BAR KIT(LEFT SIDE)

FR10005

FR10016

FR10125

FR10002

FR10849ASICASSEMBLY

Exploded view


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FIGURE 7. Busbar kit 690V right block

FR10853 690VBUS BAR KIT(RIGHT SIDE)

Exploded view


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FIGURE 8. Busbar kit 690V left block

FR10854 690VBUS BAR KIT(LEFT SIDE)

Exploded view


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FIGURE 9. Inverter assembly

FR10846 Fan inverter assembly leftFR10847 Fan inverter assembly right

PP00011VB00299

FR10844 Isolation transformer assembly leftFR10845 Isolation transformer assembly right

Exploded view


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FIGURE 10. Asic assembly

FW60070

VB00451

FW60064

FW60062

FR00086

FR10349

Exploded view


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FIGURE 11. main fan assembly

PP01080

Exploded view


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3.2. FR10 stand alone

FIGURE 12. FR10 stand alone

Measurement instructions


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4. MEASUREMENT INSTRUCTIONS

4.1. Power unit safety notices

Always when you are starting analysis / checking measures, make sure that the unit or module at repair is not powered up, if it is not intended to be. Make sure there are no remaining dangerous voltages in circuitry and that there is no other voltage sources for life threatening dangerous potentials. Therefore ensure that main supply is switched off and main terminals and DC busbars are de-energized.

Make sure that the environment you are working at is safe and won't cause risk of personal injury, damage to the unit, or environment. If you are repairing on the field make sure that supply voltage can't be switched on during service and your service actions won't cause any unnecessary disturbance or interruption to the process. Also remember to follow local / national safety rules and regulation.

Busbars, internal components and circuit boards are at mains potential when the Vacon frequency converter is connected to the mains. This voltage is extremely dan-gerous and may cause death or severe injury if you come contact with it.

4.1.1. Visual checking's and measurements before powering up

Checking of cooling tunnel:

1.Remove the main fans.

2.Check the cooling tunnel and clean the heat sink and cooling tunnel if necessary.

4.1.2. Checking the power unit:

1.Remove plastic covers.

2.Check possible burn marks, broken components or foil on boards, power module and/or rectifier module. Replace the boards, power module and/or rectifier module without testing if they are badly burnt.

3.Test capacitors, measure ac-choke, power module and rectifier module. See specific instructions.



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4.2. Measurements

NOTE! BOTH POWER MODULE SUBASSEMBLIES (LEFT AND RIGHT) MUST BE REPLACED IF ONE IS BROKEN.

4.3. Main circuit measurements

1. Remove plastic covers see (replacement instructions chapter 5.

2. Measure diodes forward and reverse bias, see table 2 and figure 13.

4.3.1. Rectifier measurements

3. Measure forward bias on rectifier from input terminal L1/L2/L3 to DC+ and reversed bias DC+ to L1/L2/L3.

4. Measure forward bias on rectifier from DC- to input terminal L1/L2/L3 and reverse bias from L1/L2/L3 to DC-.

4.3.2. IGBT measurements

5. Measure forward bias off free wheeling diode from DC- to U/V/W output terminal and reverse bias from U/V/W to DC-.

6. Measure forward bias on IGBT from U/V/W output terminal to DC+ and reverse bias from DC+ to U/V/W

FIGURE 13.

TABLE 2.

DC- to input L1, L2, L3 0,35V

DC+ to input L1, L2, L3 1,2V

DC- to output U, V, W 0,3V

DC+ to output U, V, W 0,3V

~0,5V Infinite Reversed biassedForward biassedPN-junction PN-junction



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4.4. Driver board measurements

4.4.1. IGBT gate resistance

Measure gate resistance from driver board, connect multi-meter test leads to driver board between emitter and gate (+/- 15V pin). Start measurements from branch X3 and continue in order thought all branches. Gate resistance is ~500 ohm, if board is OK figures 14 and 15.

• If any of these measuring values doesn't match to given values, then the power module/modules could be a broken and you should replace them.

• See instructions for replacing of power module in replacement chapter. • Out side pins can be used.• If all measured values are OK then continue to the next chapter.

FIGURE 14. Driver board measurement points

X3

X4

X5

X6

X8

X9

X10

X11

+/- 15V +/- 15VE E

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

E E

E E

E E

E E

E E



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FIGURE 15.

4.5. Programming

When you change control board or power board, you have to program the changed boards with device properties program. Available in www.service.vacon.com

4.6. Asic board

If unit doesn’t wake up after it is switch to mains the problem mighty be in:• Asic or opto/starcoupler wont wake up • Vacon-bus don't send data>>Not ready!

TABLE 3. Programming

software hardware

frame 10 control driver

asic (power) asic

Emitter

+/- 15V+/- 15V

500 500

Measure both +/- 15V pins against emitter pin in each branch.



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4.6.1. How to power up unit for the measurements

NOTE! IF DC- IS OFF WHEN YOU POWER UP THE UNIT, IT WILL BREAK THE ASIC BOARD.

1. Take off DC supply wires from busbars see figure 16.

2. Connect DC+ and DC- from external power supply to these wires, DC+ to red- and DC- to black wire. Use nominal voltage and 2A current limit. If using smaller current limit than 2A connect the main fans off. Fan supply cable connector located bottom of the unit figure 17. Current value without main cooling fans is ~400mA.

3. Power up quickly! If you lift the voltage up too slow, unit will give you a fault code F_7. (Asic wakes up before driver board). This won't cause any harm for a unit and you can reset the fault as normally.

4. Turn external power supply on and Asic board, driver board and rectifier board wakes up.

5. Continue to the next chapter.

FIGURE 16. DC busbars

DC- DC+



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FIGURE 17. Fan supply cable



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4.6.2. Checking of optical fiber and IGBT-control circuit

1. Unplug all optical fibers from driver board.

2. Turn on the external power supply use nominal voltage.

3. Connect multimeter test leads between emitter and +/- 15V pin, mea-sure voltage, shine light to optical receiver and measure voltage again. Voltage changes from -15V to +15V when shining the light to optical receiver. Repeat measurement to other +/- 15V pin in X3 branch, see values in table 4.

4. Repeat measurements in step 3 to branches X4/VH, X5/UH, X6/WL, X6/VL and X6/UL.

5. Connect multi-meters black test lead to DC- busbar and red test lead to output ter-minal (U,V,W). Shine light to optical receivers WL, VL and UL. Multi-meter should show that IGBT threshold voltage if the whole circuit from optical receiver to output is work-ing.

6. Connect multi-meters red test lead to DC+ busbar and black test lead to output phase (U,V,W). Shine light to optical receivers WH, VH and UH. Multi-meter should show that IGBT threshold voltage if the whole circuit from optical fibre to output is working.

7. Whit this measurement you can’t be sure that both blocks are operating. Drive will trip I2t hardware protection if one of the blocks is not operating

NOTE! CONNECT ALL FIBERS BACK TO DRIVER BOARD AFTER THE MEASUREMENTS SEE FIG-URE 19.

TABLE 4.

Optical fiber receiver

Branch

number

Voltage

“light off”

Voltage

“light on”

WH X3 -15V +15V

VH X4 -15V +15V

UH X5 -15V +15V

WL X6 -15V +15V

VL X6 -15V +15V

UL X6 -15V +15V

Emitter

+/- 15V+/- 15V

1. 2.



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FIGURE 18. Branch numbers

FIGURE 19. Optical fibers in driver board

X3

X4

X5

X6

X7

X8

X9

X10

X11

X12

DC-DC-

+/- 15V +/- 15VE E

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

+/- 15V +/- 15V

E E

E E

E E

E E

E E

~16V ~16V

~17V ~17V

~3V Temp ~3V

~0V Current I u,v,w ~0V

Over current I2tSaturation

5 3 1 6 4 2Optical fibers numbering

WH VH UH WL VL ULOptical receivers



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FIGURE 20. Optical receivers and branch numbers

WH VH UH WL VL UL

WH X3

VH X4

UH X5

WL X6

UL X6VL X6

X3 WH

X4 VH

X5 UH

X6 WL

X6 ULX6 VL

Optical receivers



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4.7. How the optical fiber link starts

Turn the main switch "ON" and boards wake up Asic generates +24 V and wake up control board, if control is not supplied with external output (24V). Fiber "5" starts synchronize AD-communication between control and Asic board. Asic board will start to send data "7" and receive data "6". Asic board starts to do measurements (Udc + temp + current). After Udc has reached nominal level, charging relays disconnects the charging circuit and tyristors start running. When run command is given, Fiber "1" will give enable signal from control to Asic board. Fibers “2”, “3” and “4” operate.

4.8. LED on control panel.

Light is ON > everything is OK, If LED is flashing quickly it means that fault could be in >

• Switching power supply might be overloaded.• Rectifier board • Fan• Brake chopper• Opto adapter board vacon bus is not working

Flashing slowly

Bad connection on the cards. Check all connectors on cards.

• opto adapter• optical fibers• Asic-control

4.9. If unit is switched to mains too often. (>1 time/Min.)

• If drive is powered "ON" and “OFF” too many times, at in 15 sec. > Power OFF > Power ON >OFF > ON > drive will trip to fault F4 or F1 or F31. faults can be reset from panel.

• Faults are generated if driver board wakes up later than Asic or shuts down before asic. This don’t happen if drive is powered < 1 time / min.

Hardware is monitored and protected by following signals.

• Feedback• Output current• Temperature• Saturation trip• I2T- Hardware trip• “Over current trip

If you get all the trips you haven’t powered driver boards or you haven’t connected all the flat cables between Asic and driver boards.



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4.10. Temperature signal measurement

NOTE! PAY ATTENTION AT FOLLOWING MEASUREMENT BECAUSE YOU CAN DO IT SHORT CIR-CUIT BY ACCIDENT. CURRENT MEASUREMENT CIRCLE WILL GO BROKEN EASILY.

Pull out right side pin connector which contains TEMP signal (middle) and measure the left side value figure 21.

1. Measure temp pin against DC- Value should be ~3V, if you get a correct value left side is OK.

2. Repeat same measurement to right side.

3. If all measured values were OK, then continue to the next chapter

-see value table in chapter 6.

Temperature measurement, Highest value is displayed

• = U - Phase• = V - Phase > Highest is displayed!• = W - Phase• = Asic board > NOT DISPLAYED!

If temperature warning comes up and temperature in panel is showing normal values below 85°C, then the problem might be in Asic board:

• Fan to cool down asic board have failed.• Environment is too warm.

Temperature limits

• warning at 85°C• Trip at 90°C



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FIGURE 21. Temperature signal measure point

Temp Temp

DC- DC-



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4.11. Current signal measurement

NOTE! PAY ATTENTION AT FOLLOWING MEASUREMENT BECAUSE YOU CAN DO SHORT CIR-CUIT BY ACCIDENT. CURRENT MEASUREMENT CIRCLE WILL BROKEN EASILY.

• Measure DC voltage from connector X7 and X12 on driver board, connect test leads between current pin and DC-.

• OFF SET values should be DC 0V.• Check shunt resistors• If problem was in the shunt resistors you should change all shunt resistors.

Shunt resistor values in tables 5 and 6

FIGURE 22. Shunt resistors

.

TABLE 5. FR10 500V

Unit IN/A VB number R1 R2 R3 R4 Total R

358 VB00537A 100 100 560 2200 44,964

460 VB00497A 68 82 680 6800 35,065

520 VB00498A 68 68 390 470 29,322

TABLE 6. FR10 690V

Unit IN/A VB number R1 R2 R3 R4 Total R

261 VB00545A 150 120 560 3300 64,842

325 VB00510A 100 120 1200 5600 51,692

385 VB00511A 68 120 1200 4700 41,512



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FIGURE 23. Current signal measure point

Iu IuIv IvIw Iw

DC- DC-



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4.12. DC-voltage measurement

Check monitoring page at unit measuring voltages.

- If unit is not measuring anything, problem might be in:

• Asic board > Change and program Asic board.• Opto adapter board > Replace it.

Monitoring value is too small > Check asic boards programming. If problem was not in monitoring value, go back to Asic board programming.

4.13. Fan inverter

There are two fans and fan inverter for main cooling. Wire harness comes from the asic board plug X11 and connects to left side fan inverter plug X8. From left side inverter plug X3 goes wire harness to right side inverter plug X8. Right side fan inverter plug X3 need a jumper connector, because it´s last inverter on the chain whit out the jumper inverter doesn’t operate.

The inverter supply voltage comes from the DC busbar and goes to fuse base. From there it goes to inverters.

Make sure that power supply is “off “ when checking the fuses, wire harness, fan capacitor and cooling fan.

1. Measure fuses with multimeter. Check contact between fuse and fuse block's con-tact areas with multimeter and visually.

2. Check the fan inverter wire harness and all wire harness connectors for possible loose connections.

3. Measure the fan capacitor, compare measured value to capacitor value, if value doesn't match, you should replace the fan capacitor.

4. Measure the main fan resistance from fan supply cable values in chapter 4.6.1.

5. Connect external power supply to DC+/- busbars, check that you have connected back DC+/- wires to Asic and driver board. Asic board will broke if DC- is off when powering the unit.

Turn the external power supply “on”. use nominal voltage and 2A current limit,

6. Measure the operating voltage from the fan inverter fuse base connectors.

7. Check the wire harness that is coming from Asic board connector X11. Wire harness goes to left inverter connector X8. Unplug connector X8 and measure signals from connectors pin 2 and pin 3.



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7. Measure signals from inverter X8 connector, Pin 2 is fan control from asic (+15v=inactive, 0v=active), Pin 3 +15v.

8. Measure also other two inverters. Values should be same as the values step 7.

9. Define damaged inverter by changing the jump (connector X3) to first block inverter after Asic board, if fan start running, fault is in the second fan inverter. Run-ning a fan you need at least 2A power supply.

10. Check also insulating strength between coil and earth.

11. Running a fan without control. Connect pins (connector X8 pin3 and connector X2 pin 1) together

12. You can test fan when driver boards are power up. Put the fan supply wire back to inverter board and test fans one by one. Lift current up in 2A.

FIGURE 24. Dip switch default settings in FR9 and bigger units unit dip switch setting as FR9 in table 6

Check also the insulation strength between coil and base whit insulator tester. Insulation test voltage 1kV

TABLE 7. Dip switch settings

State S1 S2 S3 S4

running

frequency

S2=motor voltage

S3=motor voltage

Frame size

ON 60 Hz OFF OFF 220VAC FR8

OFF OFF 230VAC

OFF 50 Hz ON ON 240VAC FR9

ON ON 250VAC



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4.14. Fan

4.15. Fan capacitors

Measure fan capacitors capacitance value with multimeter, if capacitance value is smaller than 6.65 uF change capacitor to new one.

4.16. Main circuit capacitors

1. Test each capacitor separately with external DC-power supply. Measure the capaci-tors charging time.

2. Set power supply output voltage to capacitor nominal voltage see correct voltage from capacitor label and set the current limit to 50mA. Connect DC wires to capaci-tors.

3. Turn power supply on and measure the charging time.

4. Calculate capacitors capacitance (C=capacitance), use formula in table 9.

5. Compare calculated value to value in capacitor label.

6. Leakage current should be less than 3mA when voltage has stabilized.

7. Abort test if current leakage is sufficiently higher when voltage has stabilized.

8. Discharge each capacitor after testing. Use a proper resistor that can handle the discharging current.

9. If you have to replace broken capacitor to new ones you have to replace all capaci-tors witch are in same block than the damaged capacitor. Check also busbars and insulators and replace them if they are damaged

TABLE 8. Measure resistance between fan supply wires

Wires Resistance

brown-black ~60

blue-black ~26

blue-brown ~34

TABLE 9.

1. Q=I*t I=charging current

t=measured charging time

2. C=Q/U U=voltage



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4.17. Rectifying board

Power up only the rectifier board

Rectifier board VB00459 500V two diodes in parallel connection and VB00460 690V unit didoes connected to series.

1.Disconnect connectors X13, X12, X11 and X10 from rectifier board.

2.Test relays by attaching DC-power supply +24V to rectifying boards connector DC+ X13-PIN5 and DC- to connector X13-PIN3 and X13-PIN1 figure 13.

Do first measurements with out the DC supply

3.Measure diode biased forward from J3, J7 and J11 to X9 figure 13.

Switch DC-power supply ON.

6.Measure diodes biassed forward from J3 -> X10/1, J7 -> X11/1 and J11 -> X12/1.

7.Compare measurement results to values in table 4.

8.If measurement results are not compatible to values in table. Replace rectifying board (see replacement instructions

NOTE! USE ONLY AT LAST BLOCK OTHERWISE FEEDBACK COMES TOO EARLY FROM BLOCK. X13 AND JUMPER X50 "ON".

NOTE! JUMPER X50 ON RECTIFIER BOARDS MUST BE "OFF" EXEPT FOR THE LAST ONE.

- If everything is OK, F8-7 will not appear (System fault charging switch) and unit should be ready state.

TABLE 10. Measurements on rectifier board

Voltage OFF Resistance Voltage ON Resistance

J3 to X9 0 ohm J3 to X10/1 0 ohm





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FIGURE 25. Rectifier board VB00459

D C - / p i n 3

D C + / p i n 5

X 1 0 / 1

X 1 1 / 1

X 1 2 / 1

X 9

X 1 3

X 1 0

X 1 1

X 1 2

J 3

J 7

J 1 1

D C - / p i n 1



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4.18. Board variations

• Remember ESD-protection (Wrist trap)• Remove resistors what is mentioned in precept. Cut the resistor legs by side cutting

pliers. • Check Removed component environment! (Possibility of circuit board damage) • Checking of modification • Check components correctness after the modification.

Modification marking

Mark voltage value in the card after modification by strike out the wrong voltage value.

FIGURE 26. Driver

1. 500V / 400V unit: remove resistors R56, R110, R114, and R128

2. 690V unit: remove resistors R39, R109, R123, R137 and jumper X2

R128 R114

R110

R56

X2

R137

R109

R39

R123



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FIGURE 27. Asic

1. 500V / 400V unit: remove jumpers X12 and X17.

2. 690V unit: remove jumpers X14, X141, X142 and X17

X17

X14

X12

X141

X142



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4. 19. Testing after repair

Disbalance measurement will be made as last measurement on-site with motor or in motor test bench in your service department.

Purpose of measurement is to check IGBT function.

Measurement should be made when FR10 is running a motor at nominal voltage. Dis-balance measurement are made phase by phase at nominal current. For measurement you need an oscilloscope.

Replacement instructions


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5. REPLACEMENT INSTRUCTIONS

5.1. How to remove FR10 unit from the cabinet

NOTE! BEFORE MAINTENANCE MAKE SURE THAT MAIN SUPPLY IS SWITCHED OFF AND MAIN TERMINALS AND DC BUS BARS ARE DE-ENERGIZED.

FIGURE 28.

• 1. Unscrew four fastening screw and remove metal plate figure 29/A.

• 2. remove cable trough cover cut cable ties and unplug serial cable from panel figure 28.

• 3. Unscrew two fastening screw from control box mounting plate, turn plate to left side of the cabinet figure 29/B. Remove cable tie holder from cabinet figure 28/1.

• 4. Remove front and connec-tion covers figure 30.

• 5. Unscrew three nylon nut and remove input cables plastic insulator figure 31.

• 6. Remove insulators which are located between terminals fig-ure 32/A. Unscrew input motor and optional DC / brake fasten-ing bolts and remove cables, fasten removed cables to cabi-net upper edge whit cable ties so they are not in the way when unit is pulled out of the cabinet figure 32/B.

• 7. install vacon service table to cabinet (figure.

• 8. Remove unit fastening screw figure 33, pull unit out of the cabinet and secured to service table figure 34.

• 9. Remove unit side panels fig-ure 30.



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FIGURE 29.

Metal plate fastening screws

Control box mounting plate fasten-ing screws



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FIGURE 30. Covers

FIGURE 31. Input cables insulator

1. Main termi-nal covers (FR10342).

2. Screw M5*16 (black), 3Nm.

3. Front cover (FR10340).

4. Side plates (FR10341).

Remove three nylon nuts and remove insulator.



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FIGURE 32.

Insulators between ter-minals

Input cables attached to cabinet upper edge.



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FIGURE 33. Unit fastening screws

1. Unit upper side of the unit, unscrew two fastening screws.

2. Earth wire, open fastening nut and remove cable

3. Bottom side of the unit unscrew two Fastening screws.



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FIGURE 34. Service table

Assembly service table and adjust table to correct high figure 34/3, fasten table to the cabinet whit two screws figure 34/1. Check that table is in correct high after the installation, do fine adjustment see figure 34/4 turn clockwise to lift the table and counterclockwise to lower it.

Vacon service table:

• 1. Fastening screws.• 2. Unit locking screws.• 3. Table high adjustment.• 4. Table high fine adjustment.



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FIGURE 35.

NOTE! WHEN REMOVING UNIT OUT OF THE CABINET DO NOT PULL FROM UNIT TERMINALS!



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5.2. Asic

FIGURE 36. Asic

NOTE! ASIC METAL PLATE ATTACHED TO DC-. DO NOT TOUCH THE PLATE, IF UNIT IS POWERED UP!

1. Remove the plastic covers figure 30.

2. Remove the asic cover. Unplug all wires and optical fibers from asic board.

3. Remove screws from the asic board brackets and pull brackets out.

4. Asic assembly see figure 37.

5. Attach in reverse order



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5.2.1. Asic assembly

FIGURE 37. Asic assembly

1. Remove asic cover, unplug asic cooling fan wire from asic board.

2. Remove the M4*8 (1Nm) combo screw from the asic board and slide the asic board out of the asic board brackets.

3. Remove four (4.) M4*8 (1Nm) combo screws from the plastic frame.

4. Remove the asic insulator from the asic frame.

5. Attach in reverse order

FIGURE 38. Asic board



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5.2.2. Asic modifications and

Asic wiring:

1. Optical fibers to driver board and control box

2. X3, X4 and X5

3. DC supply

4. Asic fan X11

connections

FIGURE 39. Asic board

Asic modifications:

• 400 / 500V unit remove jumper X12.• 690V unit remove jumpers X14, X141 and X142.

NOTE! AIR COOLED UNITS REMOVE JUMPER X17!

Asic connections:

• From Asic to control box optical fibers 1 -7 and X10 control box power supply. • From Asic to driver board optical fibers WL - Uh and ribbon cables X13, X14 and

X15.• From Asic connector X11 to left side inverter X8.• from Asic connector X2 to rectifier board X13 • X1 connector asic cooling fan



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5

5.3. Driver and adapter board

FIGURE 40. Assembly.

1. Remove all wires and optical fibers from driver board. Remove wires from the fuse base and lift fuses off. Open screws from the fuse base (M4*8taptite, 2Nm) and lift fuse base off.

2. Remove six screws from the board (M4*8taptite, 2Nm) supports and lift the board assembly off.



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5

3. Remove the pin connectors gently from the driver board (both sides) and remove drive adapter board.

FIGURE 41. Driver board connections

1. Optical fibers

2. X13, X14 and X15

3. Earthing

4. Rectifier wiring

5. X11

6. DC supply



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5

5.4. Rectifier board

FIGURE 42. Rectifier board

1. Unplug all wires from rectifier board (X13, X10, X11, X12).

2. Remove all fastening screws (arrows)M4*8combo, 2Nm

3. Remove the rectifier board.

4. Attach in reversed order



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5

5.5. How to remove block assembly

FIGURE 43. Right block

1. Remove Y-bus bars see figure 45.

2. Remove driver board, adapter board and board supports.

3. Remove IGBT cables from output terminals (U,V,W) and remove the terminal asse-bly.

4. Remove input cables from rectifier module (L1, L2,L3) and remove the input termi-nal assembly.

5. Open block fastening screws (M10*12 hexagonal M10 spring washer, 20Nm), two screws at upper edge and two screws at lower edge.

6. Remove block by pulling it out off the frame.



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5

FIGURE 44.

8. Remove left side block like the right side, except you have to remove the asic.



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5

5.6. Right block assembly

FIGURE 45. Y-bus bars

1. Remove the optical fibers and X13, X14, X15 and DC- from driver board.

2. Remove Y-bus bars.



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5

FIGURE 46. Balancing resistors and main supply cables

3. Remove balancing resistors wires from DC busbars.(M4*8 combo, 2Nm)

4. Unplug all wires from rectifier board see figure 42.

5. Remove main supply cables from rectifier module terminals.(M10 hexagonal M10 spring washer M10 washer, 12Nm)

6. Remove the rectifier board.



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5

FIGURE 47. Snubber capacitor

7. Remove the snubber capacitors screws (between the power and rectifier module) and lift the capacitors off.(M6*20 torx, 5Nm)



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5

5.6.1. Main circuit busbars 500V

FIGURE 48. Right block 500V

Parts and fastening torques:

1. Screw M6*16 torx, 4Nm


3. Screw hexagonal M10*20, M10 Spring washer, M10 Washer, 12Nm



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5

FIGURE 49. DC busbars right block

8. Remove all screws from DC busbars.

9. lift DC bus bars off.



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5

FIGURE 50. Right block assembly 500V



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5

5.6.2. Rectifier module

FIGURE 51. Rectifier module

9. Remove rectifier module fastening screws, four screws on both sides (4*8 taptite, 3Nm).

10. Lift the rectifier module off



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5

5.6.3. Power module

FIGURE 52. Power module right side

1. Remove Y-bus bars figure 45.

2. Remove balancing resistors wires from the DC busbars chapter 5.9.

3. Remove rectifier board.

4. Remove snubber capacitor figure 47.

5. Remove DC busbars

6. Remove cables from IGBT terminals (U,V,W).

7. Remove power module fastening screws four in both sides (4*8taptite, 3Nm).

8. Pull power module out off the frame.

9. attach in reversed order.



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5

5.6.4.

1. Clean heat sink carefully with spiritu-ous cleaning agent. (don’t use oily clean-ing agent)

2. Spread paste smoothly to bottom of the rectifier.

1 4

32

1 4

32

3. Install rectifiers and pre-tighten they to 1Nm torque see cor-rect tightening order in figure on the right, wait 180 min. and tighten rectifiers to final torque. See spec-ified torques in chap-ter 6

Rectifier module sub-assembly

FIGURE 53.



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5

4. Connect gate wires to rectifiers. Connect gate wires to rectifiers connec-tors. Black wire to PIN4 and colored wire to PIN5 (red, white and grey).

Grey

White

Red

Black=PIN4Red=PIN5



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5.7. Left block assembly

FIGURE 54.

1. Remove the Y-bus bars see figure 45.

2. Remove balancing resistors wires from busbars.(4*8 combo, 2Nm)

3. Remove snubber capacitors.(M6*20 torx, 5Nm)

4. Remove cables from IGBT terminals (U,V,W).



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5

5.7.1. Main circuit busbars 500V

FIGURE 55. Main circuit busbars fastening screws



3. Screw M10 hexagonal M10 Spring washer M10 washer, 12Nm

4. Screw pt4*30, 1.5Nm



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5

FIGURE 56. DC busbars left side

5. Remove bus bars.



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5

FIGURE 57. Left block assembly 500V



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5

5.7.2. Power module

FIGURE 58. Power module left

6. Remove power module fastening screws four in both side.(4*8taptite, 3Nm)

7. Pull power module out off the frame.8. attach in reversed order.



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5.8. Main circuit busbars left and right block 690V

FIGURE 59. main circuit busbars 690V left block



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5

FIGURE 60. Main circuit busbars fastening screws 690V

1. M6*16 torx, 4Nm

2. M6*20 torx, 4Nm

3. M6*25 torx, 4Nm

4. M6*20 torx, 5Nm



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5

FIGURE 61. Main circuit assembly 690V right block



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5

FIGURE 62. Main circuit busbars fastening screws 690V right block

1. M6*16 torx, 4Nm

2. M6*20 torx, 4Nm

3. M6*25 torx, 4Nm

4. M6*20 torx, 5Nm

5. M10 hexagonal M10 spring washer M10 washer, 12Nm



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5

5.9. Balancing resistor coupling 500V and 690V

5.9.1. 500V unit

Left module Right module

12

132

1 3 2 2 3 1

1

2

1

23

3 3

FIGURE 63. Balancing resistors 500V

5.9.2. 690V unit

Left module Right module

3 4 1 1 4 2

2

3

3

4

1

41 2 1

11

1 3 1

4

2

3

241

FIGURE 64. Balancing resistors 690V



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5

5.10. Fan and fan inverter

FIGURE 65. Fan inverter

1. Unplug all cables from inverter (X2, X8, X3 and fan supply cable).

2. Remove six fastening screws, two at front and four at bottom.(M5*10taptite, 4Nm)

3. Pull fan inverter out off the frame.

4. Attach in reversed order.

Inverter wiring:

• Left inverter X2, X8 and X3/11.• Right inverter X2, X8 and jumper connector to X3.



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5

FIGURE 66. Fan inverter

FIGURE 67. Main fan

1. Unplug fan supply cable from inverter.

2. Remove two fastening screws.(M6*20 torx, 3Nm)

3. Pull fan out off the frame.



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5

FIGURE 68. fan assembly

!!Install cool-ing fan in correct posi-tion to fan frame

NOTE! ATTACH COOLING FAN SUPPLY CABLE

TO MOUNTING FRAME, WITH

THREE RUB-BER GROMET AND ONE CABLE TIE

Cable tie fastening place



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5

5.11. Wiring

FIGURE 69. Wire harness

Wire harness connections

• 1. Asic board• 2. Control box• 3. DC -/+• 4. DC fuse base/6A fuses• 5. Driver board• 6. Measure board• 7. Fan inverter left block• 8. Fan inverter right block



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5

FIGURE 70. Optical fibers

Asic board

Driver board

Opto adapterboard

1 2 3 4 5 6 7

7654321

UU VV WWHL HL HL

WVU WVUHHH LLL



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5

FIGURE 71. Flat cables

Asic board

Driver board

NOTE! CONNECT FLAT CABLES SHIELD TO DC- (BLACK WIRE) AND FASTEN THEM WITH PLASTIC FAS-TENER TO METAL FRAME!

X3 X4 X5

X13X14X15



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5

FIGURE 72. Power supply

Driver board

Asic board

Rectifierboard

Optoadapterboard

DC-

DC+

X6

X2 X2



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5

FIGURE 73. Asic and rectifier control wires

Asic board

Driver board

Optoadapterboard

Rectifier

Faninverter

Faninverter

X8 X8

X3 X3

X11

X2

board



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5

FIGURE 74. Fan inverter, isolation transformer

Fan inverter

Isolation transformer

Earth capacitors

Fan capacitor

Main cooling fan

Blue Black

board

Brown Blue



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5

5.12. EMC-modifications

1. 2.

FIGURE 75. 1.=L and H level 2.=T level

FIGURE 76. EMC-bus bars 690V and capacitors

• Busbar (FR10016), Capacitor (PP10053)

TABLE 11.

EMC-level Capacitors Bus bars metal plate

400/500V

L/N 0 0 Closed

T 0 Open

690

L/N 3 3 Closed

T 0 0 Open



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5

5.13. FR10 stand alone IP21

FIGURE 77. Vacon service table

When servicing the stand alone unit you can remove the cabinet side panels or install the vacon service table direct to the cabinet. Attach service table to cabinet and adjust correct height. Make sure that you have fastened table to cabinet and secure it before pulling the FR10 unit out off the frame see chapter 5.1. for instructions.

Fuses

• PP20109 1000A 500V• PP20110 700A 690V

Breaker

• PP10025

Specifications


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6

6. SPECIFICATIONS

6.1. Drive revision history

TABLE 12.

Name of the product New P/N S.Nbr/date Changed to previous

Base under sheet FR10201J 4397874 /4.6.2004

Added four fastening lug

Asic cover, Asic insula-tor, Asic frame, Asic plastic frame, Asic

support, plastic screw

FW60070B, FW60064C, FW60062C, FR00086A, FR100349A, MC00533, MC00031

4397879 /1.6.2004

Asic assembly changed to same as in CH-units

Driver board support FR10023A 10119919/ 4.1.2005

Wire harness PP10008 10.9.2003 Fan_PWM wire removed from wire harness

5600uF 420V / 9.11.2004 Capacitors and connection changed. Before two

capacitor in series new connection three capacitor

in series

Frame right, frame left

FR10001F, FR10002F

4085058 / 2.6.2003

Affect interchangeability, new frames don’t fit to old mounting base unless the back plate FR102002F and

up plate FR10204D is changed.

Frame right FR10001K 1.2.2004 FR10 frame new holes and fastening places for FR11

parts. One new hole added for balancing resistors rocwels card support moved down 15mm

Cover plate FR10004D 12.1.2005 One fastening lug removed

Snubber capacitor support

FR10019A 10067341 / 20.9.2004

New part

Driver board support FR10020A 10063600 / 30.8.2004

New part

Down plate for mounting base

FR10201G 20.10.2003 Cover guide fastening changed. Don’t fit to units

manufactured before 20.10.2003

Specifications


87

6


Protection against contact

FR10202G Fastening places moved

Base back plate FR10202H 20.10.2003 Six lugs added to increase the side plate fastening

strength. Don’t fit to units manufactured before

20.10.2003

Base back plate FR10201K 4397874 / 4.6.2004

Four screws added to back plate earth cable fastening place moved to back plate

Main fan housing assembly

FR10203C 4397874 / 4.6.2004

Fan supply wire bushing insulator changed

Asic bracket fastening FR10202B 20.10.2003 Asic bracket fastening changed. Don’t fit to units

manufactured before 20.10.2003

Cover guide down left FR10215B 20.10.2003 Don’t fit to units manufac-tured before 20.10.2003

Cover guide down left FR10216B 20.10.2003 Don’t fit to units manufac-tured before 20.10.2003

Cover guide left up FR10216B 20.10.2003 New part

Cover guide right up FR10218A 20.10.2003 New part

Earthing capacitor PP10053 10033915 / 1.6.2004

Three 3n3 capacitor con-nected between earth and

input terminal

Cover guide down left as. cover guide down, isolation transformer

support

FR100163B, FR100216D, FR10161C

1.6.2004

Cover guides down left and right, plastic rivet, spring washer, screw M5*80, base

plate M5

FR10163C, FR10162D, MC00638A, MC00187, MC00641, MC00182

10.1.2005 Isolation transformer fas-tening changed

Bus bar PM FR10052E 1.6.2004

Inverter VB00299F 25.11.2003 New parts added to inverter assembly isolation transformer TE-260, earth-

ing capacitor 2.2uF/300VAC/*2

TABLE 12.

Specifications


88

6


Balancing resistor PP00056 10062240 / 17.9.2004

2*8K ohm balancing resis-tor changed to3*16K ohm. Two resistor in 500V units and three in 690V units

Fixing clips FR00030B 20.8.2004

Main fan touch cover FR10160 3.2.2004 Main fan touch cover added to mechanics

DC terminals tighten-ing torque increased

to 7 Nm and AC termi-nals tightening torque

to 14 Nm

6.10.2003

Bus bar, bus bar insu-lator

FR10080A, FR10081A

10134883 / 9.2.2005

DC insulator right FR10027A 12.1.2005

DC insulator PM2 FR10028A 10033919 / 18.5.2004

DC insulator left FR10026A 12.1.2005

Measurement board right

VB00525L 10.3.2005 Only in 500V units, all cur-rent ranges, IP-classes,

brand label and OEM devices

Measurement board left

VB00526L 10.3.2005 Only in 500V units, all cur-rent ranges, IP-classes,

brand label and OEM devices

Connector plate, earthing capacitor

FR10016, PP10036

6.5.2005 3n3 capacitors connected between input phase and

ground. Used only in EMC-lave T units. 6-pule units three capacitor, 12 pulse

units six capacitor.

Isolation transformer for the main cooling

fan

PP10057 30.5.2005 Current TE260_R577 trans-former replaced by TM330_R776 transformer.New TM330_R776 version. Compatibility: needs mechanical changes

TABLE 12.

Specifications


89

6


Change of cover guide assemblies (lower

right and left)

FR10161F, FR10162E, FR10163D, FR10215E, FR10216F, FR10221B

6.6.2005 Both (left and right) trans-former fastening plate changed 1-sided mounting for TM330.

Cover guide left lower,

Cover guide right lower.

FR10215F, FR10216G

8.6.2005 V2 (using roman number) added front side of lower cover guides. See (figure 93).

Fan enclosure assem-bly, front plate, back plate and fan enclo-

sure frame

FR10203D, FR10027G, FR10206D, FR10208D

1.7.2005 Spot welding replace whit rivets, part is fully compati-ble whit old one.

Fan inverter board VB00299FB, VB00399ED, VB005999CA, VB00699AA, VB00799BA

12.7.2005 Jumper wire soldered man-ually from DC- to crystal body.

Brake driver board VB00440D 13.7.2005 New IGBT-modules: SKM300GAL174D -> SKM400GAL176DSKM400GAL124D -> SKM600GAL126D

Fan capacitor PP00060 13.7.2005 Fan capacitor changed: Facon 7uF -> Arcotronics 7uF (MKP C.27/4).

Wire set FR10 PP10008j 15.7.2005 optical fibers length is increased 100mm. Old parts can be used in prod-ucts manufactured whit out the brake chopper.

TABLE 12.

Specifications


90

6


Asic cover FI10077, MC00699

24.8.2005 Asic-assemblies will be added asic-cover with the

dangerous labels. This part is manufactured by poly carbonate sheet. It pre-

vents and warns uninten-tional touching. Other

sticeris fitting on the asic cover and second one the metal cover for the asic

assembly.

FRAME 10 RIGHTFRAME 10 LEFT

FR10022BFR10002M

30.9.2005 Bending dimensions changed

Rectifier module mechanics changes Fr10 12-pulse 690V (Diotyr mod SKKH

250/18E G2)

PP01155 4.10.2005 Module mechanics and the terminal position is not

changed but the shape of the terminal is different. No

other changes needed.

Inverter board VB00299H 7.10.2005 New type of insulation, compatible with all older

versions.

Busbar FR10080B 20.10.2005 Burr on the wrong side of the busbar may damage the plastic insulation part

between two busbars.

ASIC Board VB00451K 31.10.2005 Missing resistor in the Asic board power up circuit. The

start up voltage varies from board to board.

Main covers FR10340

FR10345

FR11340

FR11345

10.11.2005 Rockwell Automation requires M5 Rubber nuts of

main covers would be replaced by M5 steel

threaded inserts

Additional information (See related documentation)

FR10 block connection - M10 spring wash

change

MC00101 21.11.2005 Wish to use the same type star washer in FR10 as in

FR11 instead of spring washer to mount the cool-ing ducts to the drive frame

(top+bottom plates).

TABLE 12.

Specifications


91

6

FIGURE 78.

4*8 combo screw MC00032 02.11.2005 The washers on the old screw breaks due to hydro-

gen brittleness (Finnish: Vetyhauraus) caused by the difficulties to control

the manufacturing process, at the supplier, for the used

coating type.

There is also a need for the transition from Phillips to Torx type screw heads for

better ergonomics and quality in Vacons factories.

FR10006 FR10006C 30.11.2005 Hole distance in counter-parts in FR10 is 17,5 mm

and in FR 11 16,5mm-->In FR11 the bridge card will

be bended when this part(hole dist. 17,5mm) is

installed.

FR10143 insulator for capacitors: external dimensions changed

FR10143C 07.12.2005 Another end of the insula-tor is longer than the other.

Longer end collides with the fan inverter's trans-

former coil.

TABLE 12.

Specifications


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6

6.2. NTC-values

TABLE 13. NTC values

Temperature on monitor page

Resistance Voltage at temp signal

-40 577 1,86

-35 604,5 1,94

-30 632 2,01

-25 661,5 2,1

-20 691 2,18

-15 722,5 2,26

-10 754 2,35

-5 787 2,43

0 820 2,52

5 854,5 2,61

10 889 2,69

15 925,5 2,79

20 962 2,87

25 1000 2,97

30 1039 3,06

35 1078,5 3,15

40 1118 3,24

45 1160 3,33

50 1202 3,43

55 1245 3,52

60 1288 3,61

65 1333,5 3,71

70 1379 3,8

75 1425,5 3,89

80 1472 3,99

85 1520,5 4,08

90 1569 4,17

95 1619,5 4,27

100 1670 4,36

105 1722 4,45

110 1774 4,55

115 1828 4,64

120 1882 4,73

Specifications


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6

6.3. Torque specifications

TABLE 14. Torque specifications

Part Screw Torque final / Nm NOTE!

Rectifier mounting M6*20 kombi 5 Nm 3h pre-assembly

Main fan M4*8 kombi 1.7 Nm

Touch cover main fan

M5*16 3 Nm

Asic fan M4*16 kombi 0,4 Nm

Control box assembly

M4*8 taptite 0,8 Nm

Capacitor M4*8 taptite 1 Nm

Capacitor bus bar M6*16 kombi 4 Nm

DC-/+ terminals M6*20 kombi 5 Nm

IGBT terminals (U, V, W)

M8*20 hexagonal screw

14 Nm

Rectifier terminals (L1, L2, L3)

M10*20 hexagonal screw

12 Nm

Rectifier board mounting

m4*8 kombi 1 Nm

Block mounting M10*12 hexagonal screw

20 Nm

Y-bus bar M10 nut 40 Nm

Input cable M10 nut 40 Nm

output cable M8*20 hexagonal screw

20 Nm

Main fan mounting M6*20 kombi 3 Nm

Vacon PlcRunsorintie 765380 Vaasa

Finland

Subject to changes without prior notice© 2005 Vacon Plc

SM00015B / 07.12.2005

SM00015B

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