Mg90k502 Service Guide Frame F

ENGINEERING TOMORROW
Service Guide
VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
VLT® HVAC Drive FC 102 • VLT® AQUA Drive FC 202
VLT® AutomationDrive FC 302
vlt-drives.danfoss.com
Contents Service Guide
Contents
1 Introduction 7
1.1 Purpose 7
1.2 Additional Resources 7
1.3 Abbreviations 8
1.4 Conventions 8
1.5 Tools Required 8
1.6 General Torque Tightening Values 9
2 Safety 10
2.1 Introduction 10
2.2 Safety Symbols 10
2.3 Qualified Personnel 10
2.4 Safety Precautions 10
2.5 Electrostatic Discharge 12
3 Product Overview 13
3.1 Product Overview 13
3.2 Service Report 13
3.3 Enclosure Size Identification 13
3.3.1 T4 (380–480 V AC) Voltage Rating 14
3.4 Exploded Views, F1–F4 Enclosures 16
3.4.1 Options Cabinet 18
3.4.2 Rectifier Cabinet 19
3.4.3 Inverter Cabinet 20
3.5.2 Rectifier/Inverter Cabinet 24
3.6.2 Rectifier Cabinet 28
3.6.3 Inverter Cabinet 29
3.7 Location of Optional Components 30
4 Operator Interface and Drive Control 31

4.1 Introduction 31
4.2 User Interface 31
4.2.1 Layout 31
4.2.2 Menus 33
MG90K502 Danfoss A/S © 07/2019 All rights reserved. 1

Contents VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
4.2.3 Parameter Settings 34

4.2.4 Uploading and Downloading Parameter Settings 34
4.2.5 Restoring Factory Default Settings 34
4.3 Status Messages 35
4.4 Status Message Definitions 36
4.5 Service Functions 39
4.6 Frequency Converter Inputs and Outputs 39
4.6.1 Input Signals 40
4.6.2 Output Signals 40
4.6.3 Control Supply 40
4.7 Control Terminals 40
4.8 Control Terminal Functions 41
4.9 Grounded Shielded Cables 42
5 Internal Frequency Converter Operation 43

5.1 Introduction 43
5.2 Description of Operation 43
5.2.1 Logic Section 44
5.2.2 Logic-to-Power Interface 45
5.2.3 Power Section 45
5.3 Sequence of Operation 46
5.3.1 Rectifier and Option Cabinet 46
5.3.2 Intermediate Section 48
5.3.3 Inverter Section 49
5.3.4 Brake Option 50
5.3.5 Cooling Fans 51
5.3.6 Fan Control 51
5.3.7 Module Layout 52
5.3.8 Soft Charge Layout 52
5.3.9 Load Sharing and Regeneration 53
5.3.10 Specific Card Connections 53
6 Troubleshooting 54
6.1 Troubleshooting Tips 54
6.2 Exterior Fault Troubleshooting 54
6.3 Fault Symptom Troubleshooting 54
6.4 Visual Inspection 55
6.5 Fault Symptoms 56
6.5.1 No Display 56
6.5.2 Intermittent Display 56
6.5.3 Motor Does Not Run 56
2 Danfoss A/S © 07/2019 All rights reserved. MG90K502

6.5.4 Incorrect Motor Operation 56

6.6 Alarms and Warnings 57
6.7 Alarm and Warning Definitions 61
7 Frequency Converter and Motor Applications 71

7.1 Torque Limit, Current Limit, and Unstable Motor Operation 71
7.1.1 Overvoltage Trips 72
7.1.2 Mains Phase Loss Trips 72
7.1.3 Control Logic Problems 73
7.1.4 Programming Problems 73
7.1.5 Motor Load Problems 74
7.2 Internal Frequency Converter Problems 74
7.2.1 Overtemperature Faults 74
7.2.2 Current Sensor Faults 74
7.3 Electromagnetic Interference 75
7.3.1 Effect of EMI 75
7.3.2 Sources of EMI 75
7.3.3 EMI Propagation 76
7.3.4 Preventive Measures 78
7.3.5 Proper EMC Installation 79
8 Test Procedures 80
8.1 Introduction 80
8.2 Tools Required for Testing 80
8.2.1 Signal Test Board 81
8.2.2 Metering Tools 81
8.3 Pre-test Precautions 81
8.4 Static Tests for Rectifier Module 81
8.4.1 Access to Rectifier Module Test Points 81
8.4.2 Soft Charge Fuse Test 85
8.4.3 Soft Charge and Rectifier Circuit Tests 85
8.5 Static Tests for Inverter Module 86
8.5.1 Access to Inverter Module Test Points 86
8.5.2 Inverter Circuit Tests 88
8.5.3 Brake IGBT Tests 89
8.6 Fan Continuity Tests 89
8.6.1 Fan Continuity Test 1 89
8.6.4 Fan Continuity Test 4 (F1–F4 only) 91


8.7 Dynamic Test Procedures 92
8.7.1 Split Bus Mode 92
8.7.2 Warnings 92
8.7.3 No Display Text 93
8.7.4 Input Voltage Test 93
8.7.5 Basic Control Card Voltage Test 93
8.7.6 DC Undervoltage Test 94
8.7.7 Input Imbalance of Supply Voltage Test 94
8.7.8 Input Waveform Test 94
8.7.9 Gate Signal Test 95
8.7.10 IGBT Switching Test 95
8.7.11 Current Sensor Test 96
8.7.12 Testing Current Feedback with the Signal Test Board 96
8.7.13 Input Terminal Signal Tests 96
8.7.14 Output Imbalance of Motor Supply Voltage Test 98
8.8 Module Static Test Procedures 98
8.8.1 Inverter Module 98
8.8.2 Rectifier Module 99
8.9 System Test 100
9 Special Test Equipment 101

9.1 Test Equipment 101
9.1.1 Split Bus Supply 101
9.1.2 Signal Test Board 101
9.1.3 Signal Test Board Pin Outs: Description and Voltage Levels 102
10 Top-level Component Disassembly/Reassembly 105

10.1 Before Proceeding 105
10.1.1 For Your Safety 105
10.1.2 Tools Required 106
10.1.3 Module Service Shelf 106
10.2 Disassembly/Reassembly 107
10.2.1 AC Line Input Fuse Replacement 107
10.2.2 DC Link Fuse Replacement 109
10.2.3 Door Fan Replacement 110
10.2.4 Heat Sink Fan Replacement 111
10.2.5 Rectifier Module Replacement 112
10.2.6 Inverter Module Replacement 116
10.2.7 MDCIC Mounting Panel Disassembly/Reassembly 118

10.2.8 DC Link Inductor Replacement (F1–F4 Units with a 335 or Earlier Build Date) 120
10.2.9 DC Link Inductor Replacement (F1–F4 Units with a 345 or Later Build Date) 122
10.2.10 MDCIC Replacement 128
10.2.11 Fan Transformer Replacement 132
11 Module Disassembly/Reassembly 133

11.1 Inverter Module 133
11.1.1 Power Card Replacement 134
11.1.2 Upper Capacitor Bank Assembly Replacement (without removing power card) 136
11.1.3 Lower Capacitor Bank Assembly Replacement 138
11.1.4 High-frequency Board Replacement 140
11.1.5 Current Sensor Replacement 141
11.1.6 Current Sensor Retrofit 143
11.1.7 Brake IGBT Module Replacement 149
11.1.8 IGBT Module Replacement 151
11.1.9 Gatedrive Card Replacement 153
11.2 Rectifier Module 154
11.2.1 Power Card Replacement 157
11.2.2 12-pulse MPIC Replacement 159
11.2.3 Power Card Mounting Plate Disassembly/Reassembly 161
11.2.4 Soft Charge Card Replacement 163
11.2.5 Soft Charge Card Mounting Plate Disassembly/Reassembly 165
11.2.6 Soft Charge Resistor Replacement 167
11.2.7 SCR Module Replacement 169
11.2.8 Diode Module Replacement 171
11.2.9 Heat Sink Thermal Sensor Replacement 173
12 Power-dependent Specifications 174

12.1 F1-F4 Enclosures 174
12.1.1 FC 102, 380–480 V 174
12.1.2 FC 102, 525–690 V 175
12.1.3 FC 202, 380–480 V 176
12.1.4 FC 202, 525–690 V 177
12.1.5 FC 302, 380–500 V 179
12.1.6 FC 302, 525–690 V 180
12.2 F8-F9 and F10-F13 Enclosures 182
12.2.1 FC 102, 380–480 V 182
12.2.2 FC 102, 525–690 V 183
12.2.3 FC 202, 380–480 V 184
12.2.4 FC 202, 525–690 V 186
12.2.5 FC 302, 380–500 V 189

12.2.6 FC 302, 525–690 V 191

12.3 Ratings Tables 194
12.3.1 Warning and Alarm Trip Points 194
12.3.2 DC Voltage Levels 195
13 Block Diagrams 196

13.1 Block Diagrams for F1–F4 Enclosures 196
13.2 Block Diagrams for F8–F9 Enclosures 207
13.3 Block Diagrams for F10-F13 Enclosures 215

Introduction Service Guide
1 Introduction 1 1
1.1 Purpose • The VLT® AQUA Drive FC 202, 110–1400 kW

Operating Instructions provide information
This guide is intended to be used by a qualified technician required to install and commission the 6-pulse
to identify faults and perform repairs on 6-pulse and 12- frequency converter for water and waste water
pulse frequency converters in F-sized enclosures. applications.
The guide provides the following information:

• The VLT® AutomationDrive FC 302, 90–1200 kW
• Data for the different enclosure types required to install and commission the 6-pulse
• Description of user interfaces and internal frequency converter for automation applications.
processing
• The VLT® HVAC Drive FC 100 12-Pulse Operating
• Troubleshooting and test instructions Instructions provides information required to
• Assembly and disassembly instructions install and commission the 12-pulse frequency
converter for heating/air conditioning
VLT® is a registered trademark. applications.
1.2 Additional Resources • The VLT® AQUA Drive FC 202 12-Pulse Operating
Instructions provides information required to
Additional resources are available to understand advanced
install and commission the 12-pulse frequency
drive functions and programming.
converter for water and waste water applications.
• The VLT® HVAC Drive FC 102 Programming Guide • The VLT® AutomationDrive FC 302 12-Pulse
provides greater detail on working with Operating Instructions provides information
parameters and heating/air conditioning required to install and commission the 12-pulse
application examples. frequency converter for automation applications.
• The VLT® AQUA Drive FC 202 Programming Guide • Literature for various options available with the F-
sized enclosures are found at
provides greater detail on working with
www.danfoss.com/en/search/?filter=type
parameters and water and waste water
%3Adocumentation%2Clanguage%3Aen_en
application examples.
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• The VLT® AutomationDrive FC 301/FC 302
Programming Guide provides greater detail on
working with parameters and automation
application examples.
• The VLT® HVAC Drive FC 102, 110–1400 kW Design
Guide provides detailed capabilities and
functionality to design motor control systems for
heating/air conditioning applications.
• The VLT® AQUA Drive FC 202, 110–1400 kW Design
Guide provides detailed capabilities and
water and waste water applications.
• The VLT® AutomationDrive FC 302, 90–1200 kW
Design Guide provides detailed capabilities and
automation applications.
• The VLT® HVAC Drive FC 102, 315–1400 kW
required to install and commission the 6-pulse
frequency converter for heating/air conditioning
applications.

Introduction VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
1 1 1.3 Abbreviations 1.4 Conventions

°C Degrees Celsius • Numbered lists indicate procedures.
°F Degrees Fahrenheit
• Bulleted lists indicate other information.
AC Alternating current
AEO Automatic energy optimization
• Italicized text indicates the following:
ACP Application control processor - Cross-reference.

AWG American wire gauge - Link.
AMA Automatic motor adaptation
- Parameter name.
DC Direct current
Electrically erasable programmable - Parameter option.
EEPROM
read-only memory - Parameter group name.
EMC Electromagnetic compatibility
EMI Electromagnetic interference
• All dimensions in drawings are in mm (inch).
ESD Electrostatic discharge • An asterisk (*) indicates default setting of a

parameter.
ETR Electronic thermal relay
fM,N Nominal motor frequency 1.5 Tools Required
FC Frequency converter
IGBT Insulated-gate bipolar transistor Item Description
IP Ingress protection ESD protection kit Wrist strap and mat
ILIM Current limit Metric socket set 7–19 mm
IINV Rated inverter output current Socket extensions 100–150 mm (4 inch and 6 inch)
IM,N Nominal motor current Magnetic sockets –
IVLT,MAX Maximum output current Ratchet wrench –
Rated output current supplied by the Torque wrench Torque range 0.5–19 Nm
IVLT,N (6–170 in-lb)
frequency converter
Ld Motor d-axis inductance Torx driver set T10–T50
Lq Motor q-axis inductance Needle nose pliers –
LCP Local control panel Screwdrivers Standard and Phillips
LED Light-emitting diode
Table 1.2 Tools Required to Service Frequency Converter
MCP Motor control processor
N.A. Not applicable Item Description
National Electrical Manufacturers
NEMA Digital Volt-Ohm Meter • Rated for true RMS
Association (PWM-compatible)
PM,N Nominal motor power
• Rated for the mains voltage of
the frequency converter
PCB Printed circuit board
PE Protective earth • Supports the diode mode
PELV Protective extra low voltage Analog voltmeter –
PWM Pulse width modulation Oscilloscope –
Rs Stator resistance Clamp-on ammeter Rated for true RMS
Regen Regenerative terminals Split bus supply p/n 130B3146
RPM Revolutions per minute Signal test board p/n 176F8437
RFI Radio frequency interference Signal test board extension p/n 130B3147
SCR Silicon controlled rectifier Test cable p/n 176F8766
SMPS Switch mode power supply
TLIM Torque limit Table 1.3 Instruments Recommended to Test Frequency Converter
UM,N Nominal motor voltage

Xh Motor main reactance
Table 1.1 Abbreviations

Introduction Service Guide
1.6 General Torque Tightening Values 1 1

Use a torque wrench to ensure that correct torque is
applied. Incorrect torque can cause electrical connection
problems. For fastening hardware described in this guide,
use the values listed in Table 1.4 to Table 1.6.
NOTICE
TORQUE VALUES
The torque values in the following tables are not
intended for SCR, diode, or IGBT fasteners. Refer to the
instructions included with those replacement parts for
correct values.
Shaft Torx/hex Class A Class B

size drives size Nm (in-lb) Nm (in-lb)
M4 T20/7 mm 1.2 (10) 0.8 (7)
M5 T25/8 mm 2.3 (20) 1.2 (10)
M6 T30/10 mm 3.9 (35) 2.3 (20)
M8 T40/13 mm 9.6 (85) 3.9 (35)
M10 T50/17 mm 19.1 (169) 9.6 (85)
M12 –/18 mm or 37.9 (335) –
19 mm
Table 1.4 Torque Values Standard Thread
Shaft Torx drives Class A Class B

size size Nm (in-lb) Nm (in-lb)
M4.8 T25 5.7 (50) 3.1 (27)
M5 T25 1.7 (15) 1.7 (15)
Table 1.5 Torque Values for Thread-cutting into Metal
Shaft Torx drives Class A Class B

size size Nm (in-lb) Nm (in-lb)
M4 T20 2.8 (24) 2.8 (24)
M5 T25 5.1 (45) 4.0 (35)
Table 1.6 Torque Values for Thread-forming into Plastic

Class A: Clamping metal
Class B: Clamping PCA or plastic

Safety VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
2 Safety
2 2
2.1 Introduction 2.4 Safety Precautions
This section describes requirements to personnel and safe
practices to observe when performing service and
WARNING
maintenance procedures. HIGH VOLTAGE
Drives contain high voltage when connected to AC mains
2.2 Safety Symbols input, DC supply, or load sharing. Failure to perform
installation, start-up, and maintenance by qualified
The following symbols are used in this guide:
personnel can result in death or serious injury.
• Only qualified personnel must perform instal-
WARNING lation, start-up, and maintenance.
Indicates a potentially hazardous situation that could
result in death or serious injury.
• Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that there is no remaining voltage on
CAUTION the drive.
Indicates a potentially hazardous situation that could
result in minor or moderate injury. It can also be used to
alert against unsafe practices. WARNING
UNINTENDED START
NOTICE When the frequency converter is connected to AC mains,
DC power supply, or load sharing, the motor may start at
Indicates important information, including situations that
any time. Unintended start during programming, service,
can result in damage to equipment or property.
or repair work can result in death, serious injury, or
property damage. The motor can start by means of an
2.3 Qualified Personnel external switch, a serial bus command, an input
reference signal from the LCP or LOP, via remote
Correct and reliable transport, storage, installation,
operation using MCT 10 Set-up Software, or after a
operation, and maintenance are required for the trouble-
cleared fault condition.
free and safe operation of the frequency converter. Only
To prevent unintended motor start:
qualified personnel are allowed to install or operate this
equipment. • Disconnect the frequency converter from the
mains.
Qualified personnel are defined as trained staff, who are • Press [Off/Reset] on the LCP before
authorized to install, commission, and maintain equipment, programming parameters.
systems, and circuits in accordance with pertinent laws and
regulations. Also, the qualified personnel must be familiar
• The frequency converter, motor, and any driven
equipment must be fully wired and assembled
with the instructions and safety measures described in this when the frequency converter is connected to
guide. AC mains, DC power supply, or load sharing.
Authorized personnel
Authorized personnel are qualified personnel, trained by
Danfoss to service Danfoss products.

Safety Service Guide
WARNING WARNING
DISCHARGE TIME UNINTENDED MOTOR ROTATION
The frequency converter contains DC-link capacitors, WINDMILLING 2 2
which can remain charged even when the frequency Unintended rotation of permanent magnet motors
converter is not powered. High voltage can be present creates voltage and can charge the unit, resulting in
even when the warning LED indicator lights are off. death, serious injury, or equipment damage.
Failure to wait the specified time after power has been
removed before performing service or repair work can • Ensure that permanent magnet motors are
blocked to prevent unintended rotation.
result in death or serious injury.
1. Stop the motor.
2. Disconnect AC mains and remote DC-link power WARNING
supplies, including battery back-ups, UPS, and SHOCK HAZARD AND RISK OF INJURY
DC-link connections to other frequency For dynamic test procedures, mains input power is
converters. required, and all devices and supplies connected to
3. Disconnect or lock PM motor. mains are energized at rated voltage. Contact with
powered components can result in death or serious
4. Wait for the capacitors to discharge fully. The
injury.
minimum duration of waiting time is specified
in Table 2.1. • Do not touch energized parts of the frequency
converter when connected to mains.
5. Before performing any service or repair work,
use an appropriate voltage measuring device to
make sure that the capacitors are fully
discharged. CAUTION
INTERNAL FAILURE HAZARD
An internal failure in the frequency converter can result
Minimum waiting
Voltage Power range in serious injury when the frequency converter is not
time
[V] [kW (hp)] properly closed.
(minutes)
380–480 315–1000 (450–1350) 40 • Ensure that all safety covers are in place and
380–500 250–800 (350–1200) 40
securely fastened before applying power.
525–690 355–1400 (400–1400) 40
Table 2.1 Discharge Time WARNING

SHOCK HAZARD
WARNING The drive can cause a DC current in the PE conductor
and thus result in death or serious injury.
LEAKAGE CURRENT HAZARD
Leakage currents exceed 3.5 mA. Failure to ground the • When a residual current-operated protective
frequency converter properly can result in death or device (RCD) is used for protection against
serious injury. electrical shock, only an RCD of Type B is
allowed on the supply side.
• Ensure the correct grounding of the equipment
by a certified electrical installer. Failure to follow the recommendation means that the
RCD cannot provide the intended protection.
WARNING
EQUIPMENT HAZARD
Contact with rotating shafts and electrical equipment
can result in death or serious injury.
• Ensure that only trained and qualified personnel
perform installation, start-up, and maintenance.
• Ensure that electrical work conforms to national
and local electrical codes.
• Follow the procedures in this guide.

Safety VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
CAUTION
RISK OF INJURY OR PROPERTY DAMAGE
2 2 Do not assume that a motor is wired properly after
completed service of the frequency converter.
Check for:
• Loose connections.
• Improper programming.
• Added equipment.
Failure to perform these checks can result in personal
injury, property damage, or less than optimal
performance.
NOTICE
LIFTING - EQUIPMENT DAMAGE RISK
Incorrect lifting can result in equipment damage.
• Use lifting lugs where provided.
• Prevent uncontrolled rotation.
WARNING
SHOCK HAZARD AND INJURY RISK
Even with the circuit breaker or disconnect in the OFF
position, mains voltage is still present in the following
options:
• Door interlock
• Space heater
• Cabinet light and outlet
• RCD monitor
• IRM monitor
• Emergency stop
• 24 V DC customer supply
2.5 Electrostatic Discharge

NOTICE
When performing service, use proper ESD procedures to
prevent damage to sensitive components.
NOTICE
Do not touch components on the circuit boards. Hold
circuit boards by the corners and edges only.
Many electronic components within the frequency

converter are sensitive to static electricity. Voltages so low
that they cannot be felt, seen, or heard can reduce the life,
affect performance, or completely destroy sensitive
electronic components.

Product Overview Service Guide
3 Product Overview
3.1 Product Overview For example, T4 for FC 102 and FC 202
3 3
3. Within the table, find the power rating (for
VLT® HVAC Drive series frequency converters are designed
example, P500), and look up the type of
for the HVAC markets. They operate in variable torque
frequency converter (for example, H for a 6-pulse
mode or constant torque down to 15 Hz and include
unit).
special features and options designed for fan and pump
applications. 4. Each power rating lists 2 enclosure sizes. The
enclosures are identical except for an options
cabinet added to the second enclosure.
VLT® AQUA Drive series frequency converters are designed
for water and waste water markets. They can operate in
130BE400.10
either constant torque or variable torque with limited
overload capabilities. Included are specific features and VLT R AutomationDrive
www.danfoss.com
T/C: FC-302P710T7E21B2XLC2XXSXXXXAXBXCXXXXDX
options for use on various water pumping and processing P/N: 134N7572 S/N: 000201H345
applications. 710 kW/750 HP, High Overload
IN: 6x525-690V 50/60Hz 721/619A
OUT: MOTOR 3x0-Vin 0-500Hz 875/750A
VLT® AutomationDrive series frequency converters are 1 2 3 4 5

fully programmable for either constant torque or variable 800 kW/950 HP, Normal Overload
IN: 6x525-690V 50/60Hz 813/697A
torque industrial applications. They operate various OUT: MOTOR 3x0-Vin 0-500Hz 989/860A
applications and incorporate a wide range of control and

communication options.
These models are available in IP21 (NEMA 1), and IP54 ASSEMBLED IN USA
(NEMA 12) enclosures.
3.2 Service Report CAUTION:

See manual for special condition/ mains fuse
Voir manuel de conditions speciales/fusibles
`
Report the serial number (S/N) of the frequency converter

WARNING:
when requesting support or preparing the service report. Stored charge, wait 30 min.
Charge residuelle,
` attendez 30
The serial number is listed on the nameplate. Refer to
Illustration 3.1 for details.
1 Product group and frequency converter series
3.3 Enclosure Size Identification 2 Power rating
Enclosure size is used throughout this guide whenever 3 Voltage rating (phases and mains)
procedures or components differ between frequency 4 FC type:
converters based on physical size. H = 6-pulse frequency converter
B = 12-pulse frequency converter
Find the enclosure size using the following steps: 5 Build date (wwy, where ww = the week and y = last digit of
1. Obtain the following information from the type the year).
code on the nameplate. Refer to Illustration 3.1. For example, 345 = week 34 of 2015.
1a Product group and frequency converter

Illustration 3.1 Using the Nameplate to Find the Enclosure Size
series (characters 1–6)
1b Power rating (characters 7–10)
1c Voltage rating (phases and mains)
(characters 11–12)
1d Type of frequency converter (16th
character)
2. Find the appropriate voltage rating table for the
product group and frequency converter series.
Refer to Table 3.1–Table 3.4.

Product Overview VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
3.3.1 T4 (380–480 V AC) Voltage Rating
Power FC Enclosure Enclosure size with

rating type size options cabinet
P315 B F8 F9
3 3 P355
P400
B
B
F8
F8
F9
F9
P450 B F8 F9
P500 H F1 F3
P500 B F10 F11
P560 H F1 F3
P560 B F10 F11
P630 H F1 F3
P630 B F10 F11
P710 H F1 F3
P710 B F10 F11
P800 H F2 F4
P800 B F12 F13
P1M0 H F2 F4
P1M0 B F12 F13
Table 3.1 T4 (380–480 V AC) Voltage Rating for VLT® HVAC Drive FC 102 and VLT® AQUA Drive FC 202

P250 B F8 F9
P315 B F8 F9
P355 B F8 F9
P400 B F8 F9
P450 H F1 F3
P450 B F10 F11
P500 H F1 F3
P500 B F10 F11
P560 H F1 F3
P560 B F10 F11
P630 H F1 F3
P630 B F10 F11
P710 H F2 F4
P710 B F12 F13
P800 H F2 F4
P800 B F12 F13
Table 3.2 T5 (380–500 V AC) Voltage Rating for VLT® AutomationDrive FC 302


P450 B F8 F9
P500
P560
B
B
F8
F8
F9
F9
3 3
P630 B F8 F9
P710 H F1 F3
P710 B F10 F11
P800 H F1 F3
P800 B F10 F11
P900 H F1 F3
P900 B F10 F11
P1M0 H F2 F4
P1M0 B F12 F13
P1M2 H F2 F4
P1M2 B F12 F13
P1M4 H F2 F4
P1M4 B F12 F13
Table 3.3 T7 (525–690 V AC) Voltage Rating for VLT® HVAC Drive FC 102 and VLT® AQUA Drive FC 202

P355 B F8 F9
P400 B F8 F9
P500 B F8 F9
P560 B F8 F9
P630 H F1 F3
P630 B F10 F11
P710 H F1 F3
P710 B F10 F11
P800 H F1 F3
P800 B F10 F11
P900 H F2 F4
P900 B F12 F13
P1M0 H F2 F4
P1M0 B F12 F13
P1M2 H F2 F4
P1M2 B F12 F13
Table 3.4 T7 (525–690 V AC) Voltage Rating for VLT® AutomationDrive FC 302

3.4 Exploded Views, F1–F4 Enclosures
130BE338.10
3 3
1
1 F1 enclosure (rectifier and inverter cabinets) 2 F3 enclosure (options, rectifier, and inverter cabinets)
Illustration 3.2 Exterior View, F1/F3 Enclosure

130BE337.10
1
3 3
1 F2 enclosure (rectifier and 2-door inverter cabinet) 2 F4 enclosure (options, rectifier, and 2-door inverter cabinet)
Illustration 3.3 Exterior View, F2/F4 Enclosure

3.4.1 Options Cabinet
130BD971.10
2
3 3 1
1 RCD/IRM 5 Mains circuit breaker or disconnect

2 Pilz relay 6 Mains fuses
3 RFI filter 7 Contactor
4 Mains input terminals
Illustration 3.4 Options Cabinet, F3 or F4 Enclosure

3.4.2 Rectifier Cabinet
130BD970.10
2
1
3 3
3
13
12
4
11
10
9 6
1 Optional equipment power disconnect – option 8 Mains input terminals, if unit does not contain an options cabinet
2 Optional equipment control power transformer – option 9 Module heat sink fan
3 DC bus bar 10 Fan door cover
4 AC mains fuse (T phase) – option 11 Rectifier module
5 AC mains fuse (S phase) – option 12 Signal wiring connectors
6 AC mains fuse (R phase) – option 13 Power card supply fuse
7 Manual motor starter – option
Illustration 3.5 Rectifier Cabinet, F1–F4 Enclosure

3.4.3 Inverter Cabinet
130BD969.11
1
3 3
14
10
9 15
8
3
7
13
12
11
10
6
5
1 DC link inductor 9 Signal wiring connectors

2 (-) DC bus bar 10 SMPS fuse and fan fuse
3 (+) DC bus bar 11 DC fuse
4 Motor output bus bar 12 MDCIC board
5 Brake output bus bar – option 13 Control card
6 Fan door cover 14 Control mounting plate
7 Module heat sink fan 15 Fan transformer
8 Inverter module
Illustration 3.6 Inverter Cabinet, F1 or F3 Enclosure

130BA862.13
2 3
3 3
6 5
1 Control card and control card options 5 Motor terminals

2 MDCIC 6 Brake terminals – option
3 DC inductors 7 Safety covers
4 Brake terminals – option
Illustration 3.7 Inverter Cabinet, F2 or F4 Enclosure

130BE334.10
3 3
1
1 F8 enclosure (rectifier/inverter cabinet) 2 F9 enclosure (options and rectifier/inverter cabinets)
Illustration 3.8 Exterior View, F8–F9 Enclosure

e30bh583.10
1
3
3 3
9
5
1 Safety relay coil fuse with Pilz relay – option 6 Mains input L12, L22, L32
2 Pilz relay terminal – option 7 Input plates
3 RCD or IRM terminal – option 8 Mains input L11, L21, L31
4 RFI filter – option 9 2x3-phase mains disconnect – option
5 Mains fuses – option
Illustration 3.9 Options Cabinet, F9 Enclosure

3.5.2 Rectifier/Inverter Cabinet
1 2
130BB532.12
3 3
11 5
7
10
9 8
1 Auxiliary fan terminals (104, 106) 6 Motor terminals 96 (U), 97 (V), 98 (W)
2 Relay 1 (01, 02, 03), relay 2 (04, 05, 06) 7 Mains input L11, L21, L31
3 Signal wiring connectors 8 Mains input L12, L22, L32
4 Inverter module 9 Ground PE terminals
5 Brake terminals 81 (-R), 82 (+R) – option 10 12-pulse rectifier module
Illustration 3.10 Rectifier/Inverter Cabinet, F8 or F9 Enclosure

130BE335.10
3 3
1
1 F10 enclosure (rectifier and inverter cabinets) 2 F11 enclosure (options, rectifier, and inverter cabinets)

130BE336.10
3 3 1
1 F12 enclosure (rectifier and 2-door inverter cabinet) 2 F13 enclosure (options, rectifier, and 2-door inverter cabinet)

130BB700.11
2
3 3
1
5 4
1 Safety relay coil fuse with Pilz relay – option 5 Mains input L11, L21, L31
2 Pilz relay terminal – option 6 2x3-phase manual disconnect
3 Mains fuses – option 7 Mains fuses – option
4 Mains input L12, L22, L32 8 RCD or IRM terminal – option
Illustration 3.13 Options Cabinet, F11 or F13 Enclosure

3.6.2 Rectifier Cabinet
130BB755.13
1
3 3
4
3
1 DC link inductors 4 Mains input L11, L21, L31

2 Mains fuses – option 5 Rectifier module
3 Mains input L12, L22, L32
Illustration 3.14 Rectifier Cabinet, F10–F13 Enclosure

3.6.3 Inverter Cabinet
130BE333.10
2
3 3
5 4
1 Control card and control card options 4 Motor terminals

2 MDCIC 5 Brake terminals – option
3 Brake terminals – option 6 Safety covers
Illustration 3.15 Inverter Cabinet, F12–F13 Enclosure (F10–F11 Enclosures Are Similar, But Contain Only 2 Inverter Modules)

3.7 Location of Optional Components

Units are manufactured in different configurations due to the optional components available. Depending on the unit config-
uration, optional equipment can be mounted in the inverter, rectifier, or options cabinet.
Mains and motor options

3 3
Options Cabinet location
AC fuse Rectifier or options
Disconnect Options
Circuit breaker Options
Contactor Options
A1 RFI filter Options
Load share Rectifier
Regen connection Inverter
Common motor terminals Inverter
Table 3.5 Location of Mains and Motor Options
Enclosure options

Cabinet lights and power outlet Mounted between rectifier and inverter cabinets
Space heater and thermostat Mounted between rectifier and inverter cabinets
Table 3.6 Location of Enclosure Options
Control options

NAMUR terminals Inverter
Manual motor starter Rectifier
30 A fuse-protected terminals Rectifier
24 V DC supply Rectifier
Table 3.7 Location of Control Options
Monitoring options

Residual current monitor Options
Insulation resistance monitor Options
External temperature monitoring Inverter
Pilz safety relay Inverter
Table 3.8 Location of Monitoring Options

Operator Interface and Driv... Service Guide
4 Operator Interface and Drive Control
4.1 Introduction 4.2.1 Layout

Frequency converters are designed with self-diagnostic The LCP is activated when the frequency converter receives
circuitry to isolate fault conditions and show messages that power from 1 of the following:
simplify troubleshooting and service. The operating status • Mains voltage
of the frequency converter is shown in real time. Virtually
every command given to the frequency converter results in • DC bus terminal 4 4
some indication on the local control panel (LCP) display. • 24 V DC external supply
Fault logs are maintained within the frequency converter
The LCP is divided into the following functional groups.
for fault history.
130BD809.11
The frequency converter monitors supply and output A1.2
Status 1(1)
voltages along with the operational condition of the motor A1.1 0.0 % 0.00 A 0.00 kW A1.3
and load. When the frequency converter issues a warning
0.0Hz A2
or alarm, the fault is not always within the frequency
converter itself. In fact, for most service calls, the fault 2605 kWh A3
condition exists outside of the frequency converter. Most

Off Remote Stop
of the warnings and alarms that the frequency converter
shows are in response to faults outside of the frequency
converter. This service guide provides techniques and test B1 Quick Main Alarm B4
Status
procedures to help isolate a fault condition whether in the Menu Menu Log
frequency converter or elsewhere. B2 B3
C2
Familiarity with the information provided on the LCP
Ca
ck
nc
Ba
C1
el
display is important. More diagnostic data can be accessed
easily through the LCP.
C3
4.2 User Interface
Info
On OK
D1
Warn.
The local control panel (LCP) is the combined display and D2 C4
keypad on the front of the unit. See Illustration 4.1. D3
Alarm C5
The LCP has several user functions: Hand

Off
Auto Reset
On On
• Starts, stops, and controls speed when in local
control.
E1 E2 E3 E4
• Shows operational data, status, warnings, and Illustration 4.1 Local Control Panel (LCP)
alarms.
• Programs frequency converter functions.
• Manually resets the frequency converter after a
fault when auto reset is inactive.

Operator Interface and Driv... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
A. Display area D. Indicator lights

Each display readout has a parameter associated with it. Indicator lights are used to identify the frequency
Refer to Illustration 4.1. The information shown on the LCP converter status and to provide a visual notification of
can be customized for user application by selecting warning or fault conditions.
options in the Quick Menus Q1 My Personal Menu.
Callout Indicator Indicator Function
Callout Parameter number Default setting light
A1.1 0-20 Refer to Table 4.6 – D1 On Green Activates when the frequency
A1.2 0-21 Table 4.8 converter receives power from
4 4 A1.3 0-22 the mains voltage or a 24 V
external supply.
A2 0-23
A3 0-24 D2 Warn. Yellow Activates when warning
conditions are active. Text
Table 4.1 LCP Display Area appears in the display area
identifying the problem.
B. Menu keys D3 Alarm Red Activates during a fault
Menu keys are used to access the menu for setting up condition. Text appears in the
parameters, toggling through status display modes during display area identifying the
normal operation, and viewing fault log data. problem.
Callout Key Function Table 4.4 LCP Indicator Lights

B1 Status Shows operational information.
B2 Quick Menu Allows access to parameters for initial E. Operation keys and reset
set-up instructions. Also provides The operation keys are found toward the bottom of the
detailed application steps. Refer local control panel.
to chapter 4.2.2.1 Quick Menus.
B3 Main Menu Allows access to all parameters. Refer to Callout Key Function
chapter 4.2.2.6 Main Menu Mode. E1 [Hand On] Starts the frequency converter in local
B4 Alarm Log Shows a list of current warnings and the control. An external stop signal by control
last 10 alarms. input or serial communication overrides
the local hand on.
Table 4.2 LCP Menu Keys E2 Off Stops the motor but does not remove
power to the frequency converter.
C. Navigation keys E3 Auto On Puts the system in remote operational
Navigation keys are used for programming functions and mode so it can respond to an external
moving the display cursor. The navigation keys also start command by control terminals or
provide speed control in local (hand) operation. Adjust serial communication.
display brightness by pressing [Status] and [▲]/[▼] keys. E4 Reset Resets the frequency converter manually
after a fault has been cleared.
Callout Key Function
C1 Back Reverts to the previous step or list in the Table 4.5 LCP Operation Keys and Reset
menu structure.
C2 Cancel Cancels the last change or command as
long as the display mode has not changed.
C3 Info Shows a definition of the function being
shown.
C4 OK Accesses parameter groups or enables an
option.
C5 ▲▼◄► Moves between items in the menu.
Table 4.3 LCP Navigation Keys

4.2.2 Menus Parameter Default setting

Parameter 0-01 Language English
4.2.2.1 Quick Menus Parameter 0-20 Display Line 1.1 Small Speed [RPM]
Parameter 0-21 Display Line 1.2 Small Motor current
The Quick Menus mode provides a list of menus used to Parameter 0-22 Display Line 1.3 Small Power [kW]
configure and operate the drive. Select Quick Menus by Parameter 0-23 Display Line 2 Large Frequency
pressing the [Quick Menu] key. The resulting readout Parameter 0-24 Display Line 3 Large Reference %
appears on the LCP display. Parameter 15-51 Frequency Converter Serial
Number
4 4
e30bf243.11
0 RPM 0.00 A 1(1) Table 4.8 Q1 My Personal Menu Settings for
Quick Menus VLT® AutomationDrive FC 302
Q1 My Personal Menu 4.2.2.3 Q2 Quick Set-up

Q2 Quick Setup
The parameters in Q2 Quick Set-up are the basic
Q4 Smart Setup parameters that are always necessary for set-up. This menu
Q5 Changes Made provides the most efficient set-up for most applications.
Illustration 4.2 Quick Menu View
Perform the unit set-up in the order listed. Refer to the
programming guide for the set-up steps.
4.2.2.2 Q1 My Personal Menu 4.2.2.4 Q5 Changes Made
The Personal Menu is used to define the LCP display (refer Select Q5 Changes Made for information about:
to chapter 4.2.1 Overview) and store pre-selected • The 10 most recent changes.
parameters. Store important set-up values by using up to • Changes made from default setting.
20 pre-programmed parameters. These parameters are
selected in parameter 0-25 My Personal Menu. 4.2.2.5 Q6 Loggings
Parameter Default setting
Use Q6 Loggings for fault finding. To get information about
the display line readout, select Loggings. The information is
Parameter 0-20 Display Line 1.1 Small Reference %
shown as graphs. Only show parameters selected in
parameter 0-20 Display Line 1.1 Small to
Parameter 0-22 Display Line 1.3 Small Power [kW]
parameter 0-24 Display Line 3 Large can be viewed. It is
Parameter 0-23 Display Line 2 Large Frequency
possible to store up to 120 samples in the memory for
Parameter 0-24 Display Line 3 Large kWh counter later reference.
Parameter 15-51 Frequency Converter Serial
Number Q6 Loggings
Parameter 0-20 Display Line 1.1 Small Speed [RPM]
Table 4.6 Q1 My Personal Menu Settings for
Parameter 0-21 Display Line 1.2 Small Motor Current
VLT® HVAC Basic Drive FC 102
Parameter 0-22 Display Line 1.3 Small Power [kW]
Parameter Default setting
Parameter 0-24 Display Line 3 Large Reference %
Parameter 0-20 Display Line 1.1 Small Reference [Unit] Table 4.9 Loggings Parameter Examples
Parameter 0-21 Display Line 1.2 Small Analog input 53
Parameter 0-24 Display Line 3 Large Feedback [Unit]
Parameter 15-51 Frequency Converter Serial
Number
Table 4.7 Q1 My Personal Menu Settings for

VLT® AQUA Drive FC 202

4.2.2.6 Main Menu Mode 4.2.4 Uploading and Downloading

Parameter Settings
The LCP provides access to the Main Menu mode. Select
the Main Menu mode by pressing the [Main Menu] key. The frequency converter operates using parameters stored
The resulting readout appears on the LCP display. on the control card, which is located within the frequency
converter. The upload and download functions move the
e30bp066.14
1107 RPM 3.84 A 1(1) parameters between the control card and the LCP.
Main Menu
4 4 0-** Operation/Display
1-** Load/Motor
1.
2.
Press [Off].
Go to parameter 0-50 LCP Copy and press [OK].
2-** Brakes
3-** References/Ramps 3. Select 1 of the following:
3a To upload data from the control card to
Illustration 4.3 Main Menu View the LCP, select [1] All to LCP.
3b To download data from the LCP to the
control card, select [2] All from LCP.
Lines 2 through 5 on the display show a list of parameter
4. Press [OK]. A progress bar shows the uploading or
groups that can be selected via the [▲] and [▼] keys. downloading process.
All parameters can be changed in the main menu. Option 5. Press [Hand On] or [Auto On].
cards added to the unit enable extra parameters associated
with the option device.
4.2.5 Restoring Factory Default Settings
4.2.3 Parameter Settings
NOTICE
Establishing the correct programming for applications LOSS OF DATA
requires setting several parameter functions. Details for Loss of programming, motor data, localization, and
parameters are provided in the programming guide. monitoring records occurs when restoring default
settings. To create a back-up, upload data to the LCP
before initialization. Refer to chapter 4.2.4 Uploading and
Parameter settings are stored internally in the frequency
Downloading Parameter Settings.
converter, allowing the following advantages:
• Parameter settings can be uploaded into the LCP
memory and stored as a back-up. Restore the default parameter settings by initializing the
unit. Initialization is carried out through
• Multiple units can be programmed quickly by
parameter 14-22 Operation Mode or manually.
connecting the LCP to the unit and downloading
the stored parameter settings.
Parameter 14-22 Operation Mode does not reset settings
• Settings that are stored in the LCP are not such as the following:
changed when restoring factory default settings. • Running hours
• Serial communication options
• Personal menu settings
• Fault log, alarm log, and other monitoring
functions

Recommended initialization 4.3 Status Messages

1. Press [Main Menu] twice to access parameters.
When the frequency converter is in status mode, status
2. Go to parameter 14-22 Operation Mode and press messages automatically appear in the bottom line of the
[OK]. LCP display (refer to Illustration 4.4.) Status messages are
3. Scroll to Initialization and press [OK]. defined in Table 4.10 – Table 4.12.
4. Remove power to the unit and wait for the
130BB037.11
display to turn off. Status 1(1)
5. Apply power to the unit. Default parameter
settings are restored during start-up. Start-up
799RPM 7.83A
0.000
36.4kW
4 4
takes slightly longer than normal. 53.2%
6. After alarm 80, Drive initialized to default value

appears, press [Reset].
Manual initialization Auto Remote Ramping
Hand Local Stop
Manual initialization resets all factory settings except for 1 Off Running
Jogging
the following: .
.
• Parameter 15-00 Operating hours 2 .
3 Stand-by
• Parameter 15-03 Power Up's
• Parameter 15-04 Over Temp's 1 The first part of the status line indicates where the stop/
• Parameter 15-05 Over Volt's start command originates. Refer to Table 4.10.
2 The second part of the status line indicates where the
To perform manual initialization:
speed control originates. Refer to Table 4.11.
1. Remove power to the unit and wait for the
3 The last part of the status line gives the present frequency
display to turn off.
converter status. The status shows the operational mode
2. Press and hold [Status], [Main Menu], and [OK] that the frequency converter is in. Refer to Table 4.12.
simultaneously while applying power to the unit
(approximately 5 s or until an audible click Illustration 4.4 Status Display
sounds and the fan starts). Start-up takes slightly
longer than normal.
NOTICE
In auto/remote mode, the frequency converter requires
external commands to execute functions.

4.4 Status Message Definitions Catch up The value set in parameter 3-12 Catch up/slow
Down Value corrects the output frequency.
Table 4.10 – Table 4.12 define the listed status messages. 1. Catch up is selected as a function for a
digital input (parameter group 5-1* Digital
Off The frequency converter does not react to any Inputs). The corresponding terminal is
control signal until [Auto On] or [Hand On] is active.
pressed. 2. Catch up was activated via serial communi-
Auto The start/stop commands are sent via the cation.
4 4
control terminals and/or the serial communi-
cation.
Coast • Coast inverse was selected as a function
for a digital input (parameter group 5-1*
Hand The navigation keys on the LCP can be used
Digital Inputs). The corresponding terminal
to control the frequency converter. Stop
is not connected.
commands, reset, reversing, DC brake, and
other signals applied to the control terminals • Coast activated by serial communication.
can override local control. Control ready PROFIdrive profile was selected in
parameter 8-10 Control Profile. The frequency
Table 4.10 Operating Mode
converter needs the first part (for example,
0x047E) of the 2-part start command via serial
Remote The speed reference is given from
communication to allow starting. Using a
• External signals. terminal is not possible.
• Serial communication. Ctrl. ramp-down [1] Ctrl. ramp-down was selected in
• Internal preset references. parameter 14-10 Mains Failure.
Local The frequency converter uses reference values

• The mains voltage is below the value set
in parameter 14-11 Mains Fault Voltage Level
from the LCP.
at mains fault.
Table 4.11 Reference Site • The frequency converter ramps down the
motor using a controlled ramp down.
AC braking AC braking was selected in
Current high The frequency converter output current is
parameter 2-10 Brake Function. The AC braking
above the limit set in parameter 4-51 Warning
overmagnetizes the motor to achieve a
Current High.
controlled slow down.
Current low The frequency converter output current is
AMA finish OK Automatic motor adaptation (AMA) was
below the limit set in parameter 4-50 Warning
carried out successfully.
Current Low.
AMA ready AMA is ready to start. Press [Hand On].
DC hold [1] DC hold is selected in
AMA running AMA process is in progress.
parameter 1-80 Function at Stop and a stop
Braking The brake chopper is in operation. The brake
command is active. The motor is held by a DC
resistor absorbs the generative energy.
current set in parameter 2-00 DC Hold/Preheat
Braking max. The brake chopper is in operation. The power
Current.
limit for the brake resistor defined in
DC stop The motor is held with a DC current
parameter 2-12 Brake Power Limit (kW) has
(parameter 2-01 DC Brake Current) for a
been reached.
specified time (parameter 2-02 DC Braking
Bus jog 1 PROFIdrive profile was selected in
Time).
parameter 8-10 Control Profile. The Jog 1
• DC brake is activated in parameter 2-03 DC
function is activated via serial communication.
Brake Cut In Speed [RPM] and a stop
The motor is running with parameter 8-90 Bus
command is active.
Jog 1 Speed.
Bus jog 2 PROFIdrive profile was selected in • DC brake (inverse) is selected as a function
for a digital input (parameter group 5-1*
parameter 8-10 Control Profile. The Jog 2
Digital Inputs). The corresponding terminal
function is activated via serial communication.
is not active.
The motor is running with parameter 8-91 Bus
Jog 2 Speed. • The DC brake is activated via serial
communication.

DC voltage U0 In parameter 1-01 Motor Control Principle and Kinetic back-up In parameter 14-10 Mains Failure, a function
in parameter 1-80 Function at Stop, [4] DC was set as [4] kinetic back-up. The mains
Voltage U0 is selected. When a stop command voltage is below the value set in
(for example, Stop (inverse)) is activated, the parameter 14-11 Mains Fault Voltage Level. The
voltage selected according to the frequency converter is running the motor
parameter 1-55 V/f Characteristic - V is applied momentarily with kinetic energy from the
to the motor. inertia of the load.
Feedback high The sum of all active feedbacks is above the Motor check In parameter 1-80 Function at Stop, [2] Motor
feedback limit set in parameter 4-57 Warning Check was selected. A stop command is active.
Feedback High. To ensure that a motor is connected to the 4 4
Feedback low The sum of all active feedbacks is below the frequency converter, a permanent test current
feedback limit set in parameter 4-56 Warning is applied to the motor. Only available in VLT®
Feedback Low. HVAC Drive FC 102 and VLT® AQUA Drive FC
Flying start The frequency converter is testing if the 202.
connected motor is running with a speed that Off1 [1] PROFIdrive profile was selected in
is in the adjusted speed range. The process parameter 8-10 Control Profile. The Off1
was started by connecting a digital input function is activated via serial communication.
(parameter group 5-1* Digital Inputs) The motor is stopped via the ramp.
programmed as coast inverse or by Off2 [1] PROFIdrive profile was selected in
connecting to the mains. parameter 8-10 Control Profile. The Off2
Freeze output The remote reference is active, which holds function is activated via serial communication.
the present speed. The output of the frequency converter is
• Freeze output was selected as a function disabled immediately and the motor coasts.
for a digital input (parameter group 5-1* Off3 [1] PROFIdrive profile was selected in
Digital Inputs). The corresponding terminal parameter 8-10 Control Profile. The Off3
is active. Speed control is possible only via function is activated via serial communication.
the terminal functions speed up and speed The motor is stopped via the ramp.
down. OVC control [2] Enabled was activated in
• Hold ramp is activated via serial communi- parameter 2-17 Over-voltage Control. The
cation. connected motor supplies the frequency
converter with generative energy. The
Freeze output A freeze output command has been given, but
overvoltage control adjusts the V/Hz ratio to
request the motor remains stopped until a run
run the motor in controlled mode, and to
permissive signal is received.
prevent the frequency converter from tripping.
Freeze ref. Freeze reference was selected as a function for
Power unit off (For frequency converters with a 24 V external
a digital input (parameter group 5-1* Digital
supply installed only.) Mains supply to the
Inputs). The corresponding terminal is active.
frequency converter is removed, but the
The frequency converter saves the actual
control card is supplied by the external 24 V.
reference. Changing the reference is now only
Pre-magnetize Premagnetization is selected in
possible via terminal functions speed up and
parameter 1-80 Function at Stop. A stop
speed down.
command (for example, stop inverse) is
Jog request A jog command has been given, but the
activated. A suitable constant magnetizing
motor is stopped until a run permissive signal
current is applied to the motor.
is received via a digital input.
Protection md Protection mode is active. The unit has
Jogging The motor runs as programmed in
detected a critical status (an overcurrent or
parameter 3-19 Jog Speed [RPM].
overvoltage).
• Jog was selected as function for a digital • To avoid tripping, switching frequency is
input (parameter group 5-1* Digital Inputs).
reduced to 1500 kHz if
The corresponding terminal (for example,
parameter 14-55 Output Filter is set to [2]
Terminal 29) is active.
Sine-Wave Filter Fixed. Otherwise, the
• The jog function is activated via the serial switching frequency is reduced to 1000 Hz.
communication.
• If possible, protection mode ends after
• The jog function was selected as a reaction approximately 10 s.
for a monitoring function (for example, No
signal). The monitoring function is active.
• Protection mode can be restricted in
parameter 14-26 Trip Delay at Inverter Fault.

QStop The motor decelerates using Standby In auto-on mode, the frequency converter
parameter 3-81 Quick Stop Ramp Time. starts the motor with a start signal from a
• [4] Quick stop inverse was selected as a digital input or serial communication.
function for a digital input (parameter Start delay In parameter 1-71 Start Delay, a delay starting
group 5-1* Digital Inputs). The time was set. A start command is activated
corresponding terminal is not active. and the motor starts after the start delay time
expires.
• The quick stop function was activated via
serial communication. Start fwd/rev [8] Start and 11 [Start reversing] were selected
4 4
as functions for 2 different digital inputs
Ramping The motor accelerates/decelerates using the
(parameter group 5-1* Digital Inputs). The
active ramp up/down. The reference, a limit
motor starts in forward or reverse depending
value, or a standstill is not yet reached.
on which corresponding terminal is activated.
Ref. high The sum of all active references is above the
Start inhibit PROFIdrive profile was selected in
reference limit set in parameter 4-55 Warning
parameter 8-10 Control Profile. The start
Reference High.
inhibition is active. The frequency converter
Ref. low The sum of all active references is below the needs the first part (for example, 0x047E) of
reference limit set in parameter 4-54 Warning the 2-part start command via serial communi-
Reference Low. cation to allow starting. Refer to the Control
Run on ref. The frequency converter is running in the ready function in this table.
reference range. The feedback value matches Stop The frequency converter receives a stop
the setpoint value. command from 1 on the following:
Run request A start command has been given, but the
• LCP
motor is stopped until a run permissive signal
is received via digital input. Only available in • Digital input
VLT® HVAC Drive FC 102 and VLT® AQUA Drive • Serial communication
FC 202. Trip An alarm occurs and the motor stops. Once
Running The frequency converter drives the motor, the the cause of the alarm is cleared, reset the
ramping phase is done, and the motor frequency converter manually by
revolutions are outside the on-reference range. • Pressing [Reset].
Occurs when 1 of the motor speed limits
(parameters 4-11 to 4-14) is set, but the
• Remotely by control terminals.
maximum reference is outside this range. • Via serial communication.

Sleep boost The boost function in parameter 22-45 Setpoint Trip lock An alarm occurs and the motor stops. Once
Boost is enabled. This function is only possible the cause of the alarm is cleared, cycle power
in closed-loop operation. Only available in to the frequency converter. Reset the
VLT® HVAC DriveFC 102 and VLT® AQUA frequency converter manually by
DriveFC 202. • Pressing [Reset].
Sleep mode The energy saving function is enabled, which
• Remotely by control terminals.
means the motor has now stopped, but
restarts automatically when required. Only • Via serial communication.
available inVLT®
HVAC Drive FC 102 and VLT® Unit/drive not [1] PROFIdrive profile was selected in
AQUA Drive FC 202. ready parameter 8-10 Control Profile. A control word
Speed down The value set in parameter 3-12 Catch up/slow is sent to the frequency converter via serial
Down Value is used to correct the output communication with Off 1, Off 2, and Off 3
frequency. active. Start inhibit is active. To enable start,
• Speed down was selected as a function for refer to Start inhibit function in this table.
a digital input (parameter group 5-1* Digital
Inputs). The corresponding terminal is Table 4.12 Operation Status
active.
• Speed down was activated via serial

NOTICE
communication. In auto/remote mode, the frequency converter requires
external commands to execute functions.
Speed high Motor speed is above the value set in
parameter 4-53 Warning Speed High.
Speed low Motor speed is below the value set in
parameter 4-52 Warning Speed Low.

4.5 Service Functions operating or the frequency converter not responding to a

remote input.
Service information for the frequency converter is on
display lines 3 and 4. Service information includes
130BA012.12
• Operating hours.
• Power ups.
• Trips.
• Fault logs of status values during the 20 most
recent events that stopped the frequency 4 4
converter.
• Frequency converter nameplate data. 55
3
54
53
50
130BC283.10
1(1) 42
4.2% 0.81A 39
Operating Data 15-0
*
15-04 Over Temp’s 69 20
68
61 33
0 32
29
27 4
19
2 18
13
12
Illustration 4.5 Example of Service Information

1
See the programming guide for information on accessing 1 Digital I/O terminals
and viewing parameters, and for service information 2 RS485 (EIA-485) terminal
available in parameter group 15-** Drive Information. 3 Analog I/O terminals
4.6 Frequency Converter Inputs and 4 USB connector
Outputs
Illustration 4.6 Control Terminals
The frequency converter operates by receiving control
input signals. The frequency converter can also output
status data or control auxiliary devices. Control input is
connected to the frequency converter in 3 possible ways.
One way to control the frequency converter is through the
LCP on the front of the frequency converter when
operating in hand mode. These inputs include start, stop,
reset, and speed reference.
Another control source is through serial communication

from a fieldbus. A serial communication protocol supplies
commands and references to the frequency converter, can
program the frequency converter, and reads status data
from the frequency converter. The fieldbus connects to the
frequency converter through the RS485 serial port or
through a communication option card.
The third way is through signal wiring connected to the

frequency converter control terminals. Refer to
Illustration 4.6. The frequency converter control terminals
are located below the frequency converter LCP. Improperly
connected control wiring can be the cause of a motor not

4.6.1 Input Signals command to auxiliary equipment. Some options include

more terminals for output signals.
The frequency converter can receive 2 types of remote
input signals: digital or analog. Digital inputs are wired to More terminals are Form C relay outputs on terminals 01,
terminals 18, 19, 20 (common), 27, 29, 32, and 33. Analog 02, and 03, and terminals 04, 05, and 06.
inputs are wired to terminals 53 or 54 and 55 (common).
Underneath the LCP is a switch used for setting the analog 4.6.3 Control Supply
terminal functions. Some options include more terminals
4 4
for input signals. Terminals 12 and 13 provide 24 V DC low voltage power to
the digital input terminals (18–33). Those terminals must
Analog signals can be either voltage (0–10 V DC) or be supplied with power from either terminal 12 or 13, or
current (0–20 mA or 4–20 mA). Analog signals can be from a customer-supplied external 24 V DC power source.
varied like dialing a rheostat up and down. The frequency Improperly connected control wiring is a common service
converter can be programmed to increase or decrease issue for a motor not operating or a frequency converter
output in relation to the amount of current or voltage. For not responding to a remote input.
example, a sensor or external controller can supply a
variable current or voltage. The frequency converter 4.7 Control Terminals
output, in turn, regulates the speed of the motor
Control terminals must be programmed. Each terminal has
connected to the frequency converter in response to the
specific functions it performs and a numbered parameter
analog signal.
associated with it. Refer to Table 4.13. The setting selected
in the parameter enables the function of the terminal. It is
Digital signals are a simple binary 0 or 1 that act as a important to confirm that the control terminal is
switch. A 0–24 V DC signal controls the digital signals. A programmed for the correct function.
voltage signal lower than 5 V DC is a logic 0 (open). A
voltage higher than 10 V DC is a logic 1 (closed). Digital
In addition, the input terminal must be receiving a signal.
inputs to the frequency converter are switched commands
Confirm that the control and power sources are wired to
such as start, stop, reverse, coast, reset.
the terminal. Then check the signal.
NOTICE Signals can be checked in 2 ways. To select digital input

SERIAL COMMUNICATION FORMAT for display, press the [Status] key as discussed previously,
Do not confuse these digital inputs with serial communi- or use a voltmeter to check for voltage at the control
cation formats where digital bytes are grouped into terminal. Refer to chapter 8.7.13 Input Terminal Signal Tests.
communication words and protocols.
For proper operation of the frequency converter, the
The RS485 serial communication connector is wired to frequency converter input control terminals must be:
terminals (+) 68 and (-) 69. Terminal 61 is common and is • Wired properly.
sometimes used for terminating shields when the control
cable is run between multiple frequency converters, not
• Powered.
other devices. Refer to chapter 4.9 Grounded Shielded Cables • Programmed correctly for the intended function.
for correct methods for terminating a shielded control • Receiving a signal.
cable.
4.6.2 Output Signals
The frequency converter also produces output signals that

are carried through either the RS485 fieldbus or terminal
42. Output terminal 42 operates in the same manner as
the inputs. The terminal can be programmed for either a
variable analog signal in mA or a digital signal (0 or 1) in
24 V DC. In addition, a pulse reference can be provided on
terminals 27 and 29. Output analog signals generally
indicate the frequency converter frequency, current,
torque, and so on, to an external controller or system.
Digital outputs can be control signals used to open or
close a damper, for example, or to send a start or stop

4.8 Control Terminal Functions

Table 4.13 describes the functions of the control terminals. Many of these terminals have multiple functions determined by
parameter settings. Some options provide more terminals.
Terminal Function
01, 02, 03 and 04, 05, 06 Two Form C output relays. Maximum 240 V AC, 2 A. Minimum 24 V DC, 10 mA, or 24 V AC, 100 mA. Can
be used for indicating status and warnings. Found on the power card.
4 4
12, 13 24 V DC supply to digital inputs and external transducers. The maximum output current is 200 mA.
18, 19, 27, 29, 32, 33 Digital inputs for controlling the frequency converter. R = 2 kΩ. Less than 5 V = logic 0 (open). Greater
than 10 V = logic 1 (closed). Terminals 27 and 29 are programmable as digital/pulse outputs.
20 Common for digital inputs.
37 0–24 V DC input for Safe Torque Off (some units).
39 Common for analog and digital outputs.
42 Analog and digital outputs for indicating values such as frequency, reference, current, and torque. The
analog signal is 0/4 to 20 mA at a maximum of 500 Ω. The digital signal is 24 V DC at a minimum of 500
Ω.
50 10 V DC, 15 mA maximum analog supply voltage for potentiometer or thermistor.
53, 54 Selectable for 0–10 V DC voltage input, R = 10 kΩ, or analog signals 0/4 to 20 mA at a maximum of
200 Ω. Used for reference or feedback signals. A thermistor can be connected here.
55 Common for terminals 53 and 54.
61 RS485 common.
68, 69 RS485 interface and serial communication.
Table 4.13 Control Terminals and Functions
Terminal 18 19 27 29 32 33 37 53 54 42 1–3 4–6

Parameter 5-10 5-11 5-12 5-13 5-14 5-15 5-19 6-1* 6-2* 6-5* 5-4* 5-4*
Table 4.14 Control Terminals and Associated Parameters

4.9 Grounded Shielded Cables

Connect the shielded control cables with cable clamps at both ends to the metal cabinet of the drive. Table 4.15 shows
ground cabling for optimal results.
Correct grounding
4 4
Fit control cables and cables for serial communication with cable clamps at both ends to
ensure the best possible electrical connection.
Incorrect grounding
Do not use twisted cable ends (pigtails) since it increases shield impedance at high
frequencies.
Ground potential protection

When the ground potential between the drive and the PLC or other interface device is
different, electrical noise occurs that can disturb the entire system. Fitting an equalizing
cable next to the control cable resolves this issue. Minimum cable cross-section is 8.36
mm2 (8 AWG).
50/60 Hz ground loops

When using long control cables, 50/60 Hz ground loops can occur, disturbing the entire
system. Connecting 1 end of the shield with a 100 nF capacitor and keeping the lead short
resolves this issue.
Serial communication control cables

Low-frequency noise currents between drives can be eliminated by connecting 1 end of
the shielded cable to drive terminal 61. This terminal connects to ground through an
internal RC link. Reduce the differential mode interference between conductors by using
twisted-pair cables.
Table 4.15 Shielded Cable Grounding

Internal Frequency Converte... Service Guide
5 Internal Frequency Converter Operation
5.1 Introduction
130BD880.10
1 2 3
This section is intended to provide an operational overview
of the main assemblies and circuitry of a frequency
converter, also called an AC drive. With this information, a L1 T1
L2 T2
repair technician can better understand the operation of
L3 T3
the frequency converter and the troubleshooting process.
5.2 Description of Operation

A frequency converter is an electronic controller that
5 5
4
supplies a regulated amount of AC power to a 3-phase
asynchronous motor. By supplying variable frequency and 7
voltage to the motor, the frequency converter varies the
5
motor speed or maintains a constant speed as the load on
the motor changes. Also, the frequency converter can stop
6
and start a motor without the mechanical stress associated
with a line start.
1 Rectifier (SCR/diodes) 5 Logic-to-power interface
In its basic form, the frequency converter can be divided 2 DC link (DC bus) 6 Control logic
into the following 4 main areas: 3 Inverter (IGBTs) 7 Soft charge circuitry
• Rectifier 4 Power section
• DC link (DC bus)

Illustration 5.1 6-pulse Internal Processing
• Inverter
• Control
Within those areas, components are grouped into the
130BD881.11
1 3 4
following sections: 2
• Control logic
L11
• Logic-to-power interface L21
L31 5
T1
T2
• Power
T3
L12
L22
L32
1 Rectifier (SCR/diodes) 4 Inverter (IGBTs)

2 DC inductor (rectifier 5 DC link capacitor
1)
3 DC link (DC bus) 6 DC inductor (rectifier 2)
Illustration 5.2 12-pulse Internal Processing
These areas and components are covered in greater detail

in chapter 5.3 Sequence of Operation.

Internal Frequency Converte... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
5.2.1 Logic Section • 24 V DC is used for switching functions such as

start, stop, forward, and reverse. The 24 V DC
Microprocessor supply can provide 200 mA of power, part of
The control card contains most of the logic section. Refer which can be used to power external encoders or
to Illustration 5.3. The primary logic element of the control other devices.
card is a microprocessor, which supervises and controls the • 10 V DC supply on terminal 50 is rated at 17 mA
operation of the frequency converter. In addition, separate and is available for use with speed reference
PROMs contain the parameters to provide the user with circuitry.
programmable options. These parameters are programmed
External interfaces
to enable the frequency converter to meet specific
Two relays for monitoring frequency converter status are
application requirements. This data is then stored in an
on the power card. These relays are programmable
EEPROM. The EEPROM provides security during power-
5 5 down and also allows changes to the operational
through parameter group 5-4* Relays. The relays are Form
C, meaning it has 1 normally open contact and 1 normally
characteristics of the frequency converter.
closed contact on a single throw. The contacts of the relay
PWM waveforms are rated for a maximum load of 240 V AC at 2 A
A custom-integrated circuit generates a pulse width resistance.
modulation (PWM) waveform that is then sent to the
The control card logic circuitry allows for the addition of
interface circuitry on the power card. The PWM waveform
custom operating software and option modules for
is created using an improved control scheme called VVC+.
synchronizing the following:
VVC+ provides a variable frequency and voltage to the
motor that matches the requirements of the motor.
• Control
Continuous pulsing SFAVM PWM waveform is available • Serial communication
through parameter group 14-** Special Functions. The • More relays
SFAVM PWM waveform dynamically responds to system
changes to meet the variable requirements of the load. • Cascade pump controller
Local control panel (LCP)
130BC365.12
3 4 5 USB
Another part of the logic section is the local control panel
(LCP). The LCP is a removable keypad/display mounted on
the front of the frequency converter. The LCP provides the
interface between the operator and the internal logic of
6
the frequency converter. All the programmable parameter
settings of the frequency converter can be uploaded into
the EEPROM of the LCP. This upload function is useful for
maintaining a back-up frequency converter profile and 7
1 2
parameter set. When downloaded, it is used to program
other frequency converters or to restore a program to a
repaired unit. The LCP is removable during operation to
8
prevent program changes. With the addition of a remote
mounting kit, the LCP can be mounted in a remote
location up to 3 metres away.
Control terminals 9 Ethernet PROFIBUS PROFINET 10
Control terminals, with programmable functions, are I/P
provided for input commands such as run, stop, forward,

reverse, and speed reference. More output terminals are
provided to supply signals that run peripheral devices or 1 Power card 6 Relay 1 and relay 2
monitor and report status. The analog and digital output 2 Micro controller system 7 Analog in, analog out
signals are powered through an internal frequency 3 LCP 8 Digital in, digital out
converter supply. 4 B-option slot 9 24 V back-up supply
5 Standard bus 10 Optional at control card
The control card logic can communicate via serial link or
USB with outside devices such as personal computers or
programmable logic controllers (PLC). The control card also Illustration 5.3 Control Card External Interfaces
provides 2 voltage supplies for use from the control
terminals.

5.2.2 Logic-to-Power Interface Soft charge circuit

With the SCR/diode modules, the soft charge circuit limits
The logic-to-power interface isolates the high-voltage the inrush current when power is first applied and the DC
components of the power section from the low-voltage bus capacitors are charging. The soft charge circuit
signals of the logic section. The interface consists of the switches off the SCRs so the charging current bypasses the
power card and the gatedrive card. modules and passes through the soft charge resistors. This
bypass results in a slower charge to the capacitors. Once
The control card handles much of the fault processing for the capacitors are charged, the SCRs are switched on and
output short circuit and ground fault conditions. The the charging current flows directly to the modules. The DC
power card provides conditioning of these signals. The bus circuitry smooths the pulsating DC voltage created
control card then handles the scaling of current feedback while converting the AC supply.
and voltage feedback. DC coils
DC coils reduce mains harmonics. The DC coil has 2 coils 5 5
Power card wound on a common core. One coil resides in the positive
The power card contains a switch mode power supply side of the DC bus and the other coil in the negative side.
(SMPS) that provides the unit with 24 V DC, +18 V DC, 12-pulse frequency converters use 2 DC coils. 6-pulse
-18 V DC, and 5 V DC operating voltages. The SMPS is frequency converters use 1 DC coil per inverter module.
supplied by DC bus voltage and powers the logic and DC bus capacitors
interface circuitry. The DC bus capacitors are arranged into a capacitor bank
A customer-supplied 24 V DC supply powers an optional along with bleeder and balancing circuitry. Each inverter
secondary SMPS (MCB 107). The MCB 107 supplies the module contains 2 DC capacitor banks.
logic circuitry when the main input is disconnected. This Inverter
option keeps units with communication options live on a The inverter section is made up of 6 IGBTs, commonly
network when the frequency converter is not powered referred to as switches. Two IGBTs are necessary for each
from the mains. phase of the 3-phase supply, for a total of 6 IGBTs. These 6
Circuitry for controlling the speed of the cooling fans is IGBTs are housed in an IGBT module. Due to the high
also provided on the power card. current handling requirements, each inverter module
contains 3 IGBT modules, which are run in parallel. Each
Gatedrive card
inverter module can be paralleled with 1 or 2 extra
The gate drive signals from the control card to the output
inverter modules to provide the required current for the
transistors (IGBTs) are isolated and buffered on the
power size.
gatedrive card. In units that have the dynamic brake
option, the driver circuits for the brake transistors are on Current level measurement
this card. A Hall-effect current sensor is on each output phase of the
inverter module to measure motor current. This type of
For some 12-pulse frequency converters, an MPIC card is
device is used instead of more common current
connected to the power card to control extra SCRs in the
transformer (CT) devices to reduce the frequency and
12-pulse units. All other functions are identical.
phase distortion that CTs introduce into the signal. The
Hall-effect sensors monitor the average, peak, and ground
5.2.3 Power Section leakage currents. The current sensors from each inverter
module are summed with the same phase of the other
The power section consists of the following components: inverter modules by the MDCIC to provide 1 current level
• AC input and output terminals to the control card.
• AC and DC bus bars
• Fusing
• Harnessing
• Circuitry
- Soft charge and SCR/diode modules in
the rectifier
- DC bus filter circuitry containing the DC
coils (intermediate or DC bus circuit)
- Output IGBT modules that make up the
inverter section
• Optional components

5.3 Sequence of Operation Frequent cycling

Positive temperature coefficient (PTC) resistors on the soft
5.3.1 Rectifier and Option Cabinet charge card are in series with the soft charge resistor.
Frequent cycling of the input power or the DC bus
Input power charging over an extended time can cause the PTC
When input power is first applied to the frequency resistors to heat up due to the current flow. Resistance of
converter, it enters through the input terminals. the PTC device increases with temperature, eventually
adding enough resistance to the circuit to prevent
• 6-pulse (L1, L2, and L3)
significant current flow. These PTC resistors protect the soft
• 12-pulse (L11, L21, L31 and L12, L22, and L32) charge resistor and other components from damage
Depending on the configuration, the unit contains several during continuous attempts to charge the DC bus.
optional components through which the power flows
5 5 before reaching the SCRs. For example, fuses are an option
DC bus voltage
The low-voltage supplies are activated when the DC bus
that limits damage caused by a short circuit in the power reaches approximately 50 V DC less than the alarm voltage
section. For a diagram of the 6-pulse configuration, refer to low for the DC bus. After a short delay, an inrush enable
Illustration 5.4. For 12-pulse configuration, refer to signal is sent from the control card to the SCR gating
Illustration 5.5. circuit on the power card. The SCRs are gated automat-
If optional components are provided, power flows through ically when forward biased, acting similar to an
them in the following sequence: uncontrolled rectifier.
• Disconnect When the DC bus capacitors are fully charged, the voltage
• Fuses on the DC bus is equal to the peak voltage of the input
mains. Theoretically, this value can be calculated by
- FU1, FU2, and FU3 (6-pulse)
multiplying the mains value by 1.414 (V AC x 1.414).
- FU1, FU2, FU3, FU4, FU5, and FU6 (12- However, since AC ripple voltage is present on the DC bus,
pulse) the actual DC value is closer to V AC x 1.38 under
unloaded conditions and can drop to V AC x 1.32 while
• Contactor
running under load.
• RFI
For example, a frequency converter connected to a
The SCRs are not gated, allowing current to travel to the nominal 460 V line, while sitting idle, the DC bus voltage is
rectifier on the soft charge card. The SCR and diode approximately 635 V DC (460 x 1.38).
modules are separate. Extra fuses on the soft charge card
provide protection in the event of a short in the soft As long as power is applied to the frequency converter,
charge or fan circuits. Three-phase power is branched off this voltage is present in the DC link and the inverter
and sent to the power card. The soft charge card provides circuit. It is also fed to the switch mode power supply
the power card with a reference of the main supply (SMPS) on the power card and is used for generating all
voltage and provides a supply voltage for the cooling fans. other low-voltage supplies.
Charging process
During the charging process, the top diodes of the soft
charge rectifier conduct and rectify during the positive half
cycle. The diodes in the main rectifier conduct during the
negative half cycle. The DC voltage is applied to the bus
capacitors through the soft charge resistor. Charging the
DC bus through this resistor limits the high inrush current
that would otherwise be present.

3
5 5
Rectifier Inverter 1 Inverter 2 Inverter 3
44
130BX187.13
Illustration 5.4 6-pulse Rectifier Circuit
130BX423.12
3
Rectifier 1 Rectifier 2 Inverter 1 Inverter 2 Inverter 3
Illustration 5.5 12-pulse Rectifier Circuit

5.3.2 Intermediate Section
Following the rectifier section, voltage passes to the intermediate section. (Refer to Illustration 5.6). An LC filter circuit
consisting of the DC bus inductor and the DC bus capacitor banks in each inverter module smooths the rectified voltage.
The DC bus inductor provides series impedance to changing current, which aids the filtering process while reducing
harmonic distortion to the input AC current waveform.
Each inverter module contains 1 or 2 DC capacitor bank assemblies consisting of up to 8 capacitors arranged in a series/
parallel configuration. Also contained within the assembly is the bleeder/balance circuitry. This circuitry maintains equal
voltage drops across each capacitor and provides a current path for discharging the capacitors once power has been
5 5 removed from the frequency converter.
44
130BX186.12
Illustration 5.6 Inverter Sections
High-frequency filter card

Also located in the intermediate section is the high-frequency (HF) filter card for each inverter module. Each card contains a
high-frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interference with other
sensitive equipment in the area. The circuit, as with other RFI filter circuitry, is sensitive to unbalanced phase-to-ground
voltages in the 3-phase AC input line. Occasionally, this sensitivity results in nuisance overvoltage alarms. For this reason, the
high-frequency filter card contains a set of relay contacts in the ground connection of the filter capacitors. The relay is tied
into the RFI/HF switch, which can be switched on or off in parameter 14-50 RFI Filter. The RFI/HF switch disconnects the
ground references to all filters to eliminate nuisance overvoltage conditions created by unbalanced phase-to-ground
voltages.

5.3.3 Inverter Section
In the inverter section, gate signals are received from the Monitoring the waveform
control card through the MDCIC. Then the gate signals are Hall-effect current sensors monitor the output current of
sent to each inverter module power card and the gatedrive each inverter module and deliver proportional signals via
card to the IGBT gates. Refer to Illustration 5.6. The output the power cards to the MDCIC. The signals are summed,
of each IGBT, connected in series, then passes through the buffered, and delivered to the control card. The control
current sensors. card logic uses these current signals to determine proper
waveform compensations based on load conditions. They
Output waveform further serve to detect overcurrent conditions, including
Once a run command and speed reference are provided, ground faults and phase-to-phase shorts on the output.
the IGBTs begin switching to create the output waveform,
as shown in Illustration 5.7. Looking at the phase-to-phase 5 5
voltage waveform with an oscilloscope, the pulse width
modulation (PWM) principle creates a series of pulses that
vary in width. The pulses are narrower as 0 crossing is
approached and wider the farther from 0 crossing. The
width is controlled by the pulse duration of applied DC
voltage. Although the voltage waveform is a consistent
amplitude, the inductances within the motor windings
serve to average the voltage delivered. As the pulse width 130BX136.10
of the waveform varies, the average voltage seen by the Illustration 5.7 Output Voltage and Current Waveforms
motor varies as well. The PWM principle results in a current
waveform that takes on the sine-wave shape expected in
an AC system. The pulse rate determines the frequency of System monitoring
the waveform. By employing a sophisticated control During normal operation, the power card and control card
scheme, the frequency converter delivers a current monitor various functions within the frequency converter:
waveform that nearly replicates a true AC sine-wave. • Current feedback
• DC bus voltage and mains voltage
• Voltage delivered to the motor
• Heat sink temperature for each rectifier

5.3.4 Brake Option
For frequency converters equipped with the dynamic brake option, 2 brake IGBTs along with terminals 81(R-) and 82(R+) are
included in each inverter module for connecting an external brake resistor.
The function of the brake IGBT is to limit the voltage in the DC link whenever the maximum voltage limit is exceeded. (Refer
to Illustration 5.8). By switching the externally mounted resistor across the DC bus to remove excess DC voltage present on
the bus capacitors, the DC-link voltage is limited. Typically, excess DC bus voltage results from an overhauling load causing
regenerative energy to be returned to the DC bus. For example, when the load drives the motor, it causes the voltage to
return to the DC bus circuit.
5 5 Placing the brake resistor externally has the following advantages:

• Selecting the resistor based on application need
• Dissipating the energy outside of the control panel
• Protecting the frequency converter from overheating if the brake resistor is overloaded
The brake IGBT gate signal originates on the control card and is delivered to the brake IGBTs via the MDCIC to each inverter
module power card and gatedrive card. Also, the power and control cards monitor the brake IGBT and brake resistor
connection for short circuits and overloads.
44
130BX190.12
Illustration 5.8 Brake Option

5.3.5 Cooling Fans 5.3.6 Fan Control
All F-size enclosures are equipped with cooling fans to 5.3.6.1 Fan Speed
provide airflow along the heat sinks and within the
enclosures. Mains voltage is used to power all fans. The cooling fans are controlled with sensor feedback that
Circuitry on the power card regulates the voltage to 200 V regulates fan operation and speed control as described in
AC or 230 V AC, before the autotransformers steps the Table 5.1 – Table 5.3.
voltage down for the fans. On/off and high/low speed
IGBT thermal sensor measured temperature
control of the fans is provided to reduce overall acoustical
noise and extend the life of the fans. IGBT thermal sensor Temperature
Fan turn ON low speed 55 °C (131 °F)
The following conditions activate the fans:
• 60% of nominal current exceeded.
Fan low speed to high speed
Fan high speed to low speed
65 °C (149 °F)
65 °C (149 °F)
5 5
• Specific heat sink temperature exceeded (power Fan turn OFF from low speed 50 °C (122 °F)
size dependent).
Table 5.1 IGBT Thermal Sensor
• Specific power card ambient temperature
exceeded. Power card ambient temperature sensor measured
• Specific control card ambient temperature temperature
exceeded.
Power card ambient Temperature
• DC hold active.
Fan turn ON to low speed 50 °C (122 °F)
• DC brake active. Fan low speed to high speed 65 °C (149 °F)
• Premagnetization of the motor. Fan high speed to low speed 65 °C (149 °F)
Fan turns off <50 °C (<122 °F)
• Automatic motor adaptation in progress.
• Regardless of the heat sink temperature, the fans Table 5.2 Power Card Ambient Temperature Sensor
are started shortly after mains input power is
applied to the frequency converter. Control card thermal sensor measured temperature
Control card ambient Temperature

Once fans are started, they run for a minimum of 10
Fan turn ON to low speed 55 °C (131 °F)
minutes.
Fan turn OFF from low speed 50 °C (122 °F)
Fan turns low speed to high speed >62 °C (>144 °F)
Fan turns high speed to low speed <62 °C (<144 °F)
Table 5.3 Control Card Thermal Sensor
Output current value

If the output current is greater than 60% of rated current
or if the power card ambient temperature is >50 °C
(>122 °F), the fan turns on low speed. After operating for
10 minutes, the fans turn off automatically.

5.3.6.2 Fan Location
Fan location Control source

F1–F4 F8–F9 F10–F13
Door fan 1, options cabinet Inverter module 1 Rectifier module 1 Rectifier module 1
Door fan 2, options cabinet – – Rectifier module 2
Door fan 1, rectifier cabinet Inverter module 2 Rectifier module 1 Rectifier module 1
Door fan 2, rectifier cabinet – – Rectifier module 2
Door fan 1, inverter cabinet Inverter module 2 Inverter module 1 Inverter module 1
Door fan 2, inverter cabinet Inverter module 2 – Inverter module 2
Heat sink fan, rectifier module 1 Inverter module 1 Rectifier module 1 Rectifier module 1
5 5 Heat sink fan, rectifier module 2

Heat sink fan, inverter module 1
–
Inverter module 1
–
Inverter module 1
Rectifier module 2
Inverter module 1
Heat sink fan, inverter module 2 Inverter module 2 – Inverter module 2
Heat sink fan, inverter module 3 Inverter module 3 – Inverter module 3
Table 5.4 Fan Location and Control Source
5.3.7 Module Layout
Module F1 F2 F3 F4 F8 F9 F10–F11 F12–F13

Rectifier 1 Only 1 Only 1 Only 1 Only 1 Only 1 Only 1
Left module Left module
module module module module module module
Rectifier 2 – – – – – – Right module Right module
Inverter 1 Center Only 1
Left module Left module Left module Left module Left module Left module
module module
Inverter 2 Right Center Right Center
– – Right module Center module
module module module module
Inverter 3 Right Right
– – – – – Right module
module module
Table 5.5 Location and Module Numbering
5.3.8 Soft Charge Layout
F1 F2 F3 F4 F8 F9 F10 F11 F12

Rectifier module 1 2 3 2 3 2 2 1 1 1
Rectifier module 2 – – – – – – 1 1 2
Table 5.6 Location of and Number of Soft Charge Cards

5.3.9 Load Sharing and Regeneration 5.3.10 Specific Card Connections
Units with the built-in load sharing option contain FK102 connector
terminals 89 (+) DC and 88 (-) DC. Within the frequency FK102 connector (terminals 104, 105, and 106) is on the
converter, these terminals connect to the DC bus on the power cards and provides a connection for an external
input side of the DC link reactor. The use of the load temperature switch. The input could be used, for example,
sharing terminals has 2 configurations. to monitor the temperature of an external brake resistor. A
normally closed switch can be connected between
In the first configuration, the terminals are used to tie the terminals 104 and 106. Terminals 104 and 106 are on TB3
DC bus circuits of multiple frequency converters together, inside the rectifier cabinet towards the top. If the input
allowing 1 frequency converter in a regenerative mode to changes states, the frequency converter trips on alarm 27,
Brake Chopper Fault. Also, the input SCRs would be
share its excess bus voltage with another frequency
converter in motoring mode. This configuration reduces disabled to prevent further energy from being supplied to 5 5
the need for external dynamic brake resistors while also the DC bus. If no such input is used, or the normally open
saving energy. Any number of frequency converters can be configuration is selected, install a jumper between
connected in this way, as long as they are of the same terminals 104 and 106.
voltage rating. Also, it may be necessary to install DC FK103 connector
reactors and DC fuses and mains AC reactors on the mains. FK103 (terminals 100, 101, 102, and 103) is on the power
Attempting such a configuration requires detailed consid- cards and provides a connection for an external supply to
erations. Do not attempt without first consulting Danfoss power AC cooling fans using the mains voltage. The
Application Engineering. terminals on the power card are wired to plugs on the top
of the modules. For 6-pulse units, the connection is only
In the second configuration, the frequency converter is on the inverter module. For the 12-pulse units, the
powered exclusively from a DC source. An external DC connection is on both the inverter and the rectifier
source is required. Do not attempt without first consulting modules. This connection is required when the frequency
Danfoss Application Engineering converter is used in a load sharing application where no
AC power is provided to the mains input terminals. To use
Units with a built-in regeneration option contain terminals this connection, remove the jumpers from terminals 100
82 (+) DC and 83 (-) DC. Within the frequency converter, and 102, and 101 and 103. Then connect the auxiliary
the regeneration terminals connect to the DC bus on the mains voltage supply to terminals 100 and 101.
output side of the DC-link reactor. MK112 power card
The power card MK112 (terminals 1–3 and 4–6 provide
Use regeneration terminals to connect 1 frequency access to 2 auxiliary relays. The relays are wired to a
converter to 1 external regeneration module. Do not use terminal mounted in the inverter cabinet above the
the regeneration terminals to connect together the DC bus MDCIC. These relays are Form C sets of contacts, meaning
circuits of multiple frequency converters. 1 normally open and 1 normally closed contact on a single
throw. The contacts are rated for a maximum of
240 V AC, 2 A and a minimum of 24 V AC, 10 mA or
24 V AC, 100 mA. The relay can be programmed via
parameter 5-40 Function Relay to indicate frequency
converter status.

Troubleshooting VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
6 Troubleshooting
6.1 Troubleshooting Tips 6.2 Exterior Fault Troubleshooting

• Some points in the frequency converter are Servicing a frequency converter that has been operational
referenced to the negative DC bus. These points for an extended period is slightly different from a new
are at bus potential even though diagrams can installation. When using proper troubleshooting procedures
show them as a neutral reference. on a long-term installation, do not assume that a motor is
wired properly. Look for issues such as loose connections,
• If any of the DC bus fuses are blown, always
improper programming, or added equipment. It is best to
ensure that no DC bus voltage is present on
develop a detailed approach, beginning with a physical
either side of the DC fuses. When any DC bus
inspection of the system. Refer to Table 6.1.
fuse is blown, capacitor banks in the other
modules are no longer electrically connected. As 6.3 Fault Symptom Troubleshooting
6 6 a result, a module can have stored voltage even
when the rest of the system has none. This troubleshooting section is organized based on the
symptom being experienced. Refer to chapter 6.5 Fault
• Do not assume that the frequency converter
Symptoms.
contains no voltage when the LCP indicator lights
are off.
Typical symptoms include:
• Never apply power to a unit that is suspected of
• Unrecognizable display on the LCP.
being faulty. Many faulty components within the
frequency converter can damage other • Problems with motor operation.
components when power is applied. Always • Warning or alarm shown by the frequency
complete the steps described in converter.
chapter 8.9 System Test.
The frequency converter processor monitors inputs and
• With an external supply and cable assembly, the outputs along with internal frequency converter functions.
logic section of the frequency converter can be Thus, an alarm or warning does not necessarily indicate a
powered without applying power to the rest of problem within the frequency converter itself. For a list of
the unit. This method of power isolation is warnings and alarms, refer to Table 6.2.
recommended for troubleshooting logic
problems. Chapter 6.7 Alarm and Warning Definitions describes how to
• Never attempt to defeat any fault protection troubleshoot that particular symptom. When necessary,
circuitry within the frequency converter. Doing so detailed discussions of frequency converters and system
results in unnecessary component damage and troubleshooting are provided in this chapter for the
can cause personal injury. qualified repair technician to analyze the problem
effectively.
• Always use factory approved replacement parts.
The frequency converter has been designed to
operate within certain specifications. Incorrect Always perform a system test when the following
parts can affect tolerances and damage the unit. conditions apply:
• Starting a frequency converter for the first time.
• Read the instruction and service guides. A
thorough understanding of the unit is the best • Approaching a frequency converter that is
approach. If in doubt, consult the factory or suspected of being faulty.
authorized repair center for assistance. • After a repair to the frequency converter.
Refer to chapter 8.9.1 System Test.

Troubleshooting Service Guide
6.4 Visual Inspection

Table 6.1 lists conditions that require visual inspection as part of any initial troubleshooting procedure.
Inspect for Description

Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that reside on either
the input power side of frequency converter or the output side to the motor. Examine the operation and
condition of these items for possible causes of operational faults. Check the function and installation of
pressure sensors or encoders or other devices that provide feedback to the frequency converter.
Cable routing Avoid routing the following in parallel:
• Motor wiring
• Mains wiring
• Signal wiring
If parallel routing is unavoidable, try to maintain a separation of 150–200 mm (6–8 in) between the
cables, or separate them with a grounded conductive partition. Avoid routing cables through free air. 6 6
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 screened cable or a twisted
pair is recommended. Ensure that the screen is terminated correctly. Refer to chapter 4.9 Grounded
Shielded Cables.
Cooling Check the operational status of all cooling fans. Check the door filters on NEMA 1 (IP21)/NEMA 12 (IP54)
units. Check for blockage or constrained air passages. Make sure that the bottom gland plate is installed.
Display The local control panel display shows the following:
• Warnings
• Alarms
• Status
• Fault history
Interior The frequency converter interior must be free of dirt, metal chips, moisture, and corrosion. Check for
burnt or damaged power components or carbon deposits resulting from 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 regarding electromagnetic capability. Refer to the frequency converter
operating instructions and chapter 7 Frequency Converter and Motor Applications for further details.
Environmental conditions Under specific conditions, these units can be operated within a maximum ambient temperature of 50 °C
(122 °F). Humidity levels must be less than 95% noncondensing. Check for harmful airborne contam-
inates such as sulphur-based compounds.
Grounding The frequency converter requires a dedicated ground wire from its frame to the building ground. It is
also recommended that the motor be grounded to the frequency converter frame. The use of a conduit
or mounting the frequency converter onto 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, proper fusing, and blown fuses.
Motor Check the nameplate ratings of the motor. Ensure that the motor ratings correspond with the frequency
converters. Make sure that the motor parameters (parameter 1-20 Motor Power [kW] to
parameter 1-25 Motor Nominal Speed) are set according to the motor ratings.
Output to motor wiring Check for loose connections. Check for switching components in the output circuit. Check for faulty
contacts in the switch gear.
Programming Make sure that the frequency converter parameter settings are correct according to motor, application,
and I/O configuration.
Proper clearance Frequency converters require adequate top and bottom clearance to ensure proper airflow for cooling in
accordance with the frequency converter size. Frequency converters with exposed heat sinks out the
back must be mounted on a flat solid surface.
Vibration Look for any unusual amount of vibration around the frequency converter. Mount the unit solidly or use
shock mounts.
Table 6.1 Visual Inspection

6.5 Fault Symptoms Run OK, 0 Hz

This message indicates that a run command has been
6.5.1 No Display given to the frequency converter, but the reference (speed
command) is 0 or missing.
• Check that power is supplied. To ensure that the proper reference signal is present at the
• Cycle power to the unit. frequency converter input terminals, check the control
wiring. Also check that the unit is programmed properly to
• Reinitialize the frequency converter (refer to
accept the signal. Refer to chapter 8.7.13 Input Terminal
chapter 4.2.5 Restoring Factory Default Settings).
Signal Tests.
6.5.2 Intermittent Display Off 1 (2 or 3)

This message indicates that bit #1 (or #2, or #3) in the
control word is logic 0. This situation only occurs when the
Cutting out or flashing of the entire display and power LED
frequency converter is being controlled via the fieldbus.
indicates that the supply (SMPS) is shutting down due to
an overload. Check for: A correct control word must be transmitted to the
6 6 • Improper control wiring. frequency converter over the communication bus to
correct this error.
• Overload of the 24 V output.
STOP
• Fault within the frequency converter.
One of the digital input terminals 18, 19, 27, 29, 32, or 33
Check for a problem in the control wiring by disconnecting (parameter group 5-1* Digital Inputs) is programmed for [6]
all control wiring from the control terminal blocks on the Stop Inverse. The corresponding terminal is low (logic 0).
installation card.
Ensure that the parameters are programmed correctly and
that any digital input programmed for [6] Stop Inverse is
If the display stays lit, then the problem is in the control high (logic 1).
wiring (external to the frequency converter). Check all
control wiring for shorts or incorrect connections. DC undervolt
If the unit is equipped with an external 24 V DC option,
check that mains power is supplied to the frequency
If the display continues to cut out, refer to chapter 6.5.1 No
converter.
Display.
6.5.3 Motor Does Not Run 6.5.4 Incorrect Motor Operation
Occasionally, a fault can occur where the motor continues

If this symptom is detected, first verify that the unit is
to run, but not in the correct manner. The symptoms and
properly powered up (display is lit) and that no warning or
causes can vary considerably. Many of the possible
alarm messages are shown. The most common cause is
problems are listed by symptom.
either incorrect control logic or an incorrectly programmed
frequency converter. Such occurrences result in one or
more of the following status messages being shown. Wrong speed/unit does not respond to command
Possible incorrect reference (speed command).
Cause: LCP Stop Ensure that the unit is programmed correctly according to
Action: The [Off] key has been pressed. the reference signal being used, and that all reference
limits are set correctly.
Press the [Auto On] or [Hand On] key.
Motor speed unstable
Cause: Standby
Possible incorrect parameter settings, faulty current
This condition indicates that there is no start signal at
feedback circuit, or loss of motor (output) phase.
terminal 18.
Check the settings of all motor parameters, including all
Action: Ensure that a start command is present at terminal
motor compensation settings such as slip compensation
18. Refer to chapter 8.7.13 Input Terminal Signal Tests.
and load compensation. For closed loop-operation, check
Cause: Unit ready PID settings.
Terminal 27 is low (no signal).
Action: Ensure that terminal 27 is logic 1. Refer to
chapter 8.7.13 Input Terminal Signal Tests.

Motor runs rough Alarms that are trip locked offer extra protection, since the
mains supply must be switched off before the alarm can
• Possible overmagnetization
be reset. After being switched back on, the frequency
• IGBT misfiring converter is no longer blocked and can be reset once the
• Motor under heavy load problem is fixed.
• Alarm 13 trips intermittently

Alarms that are not trip locked can also be reset using the
Check settings of all motor parameters. automatic reset function in parameter 14-20 Reset Mode.
Motor draws high current, but cannot start
Possible open winding in motor or open phase in
connection to motor. WARNING
Run an AMA to check the motor for open windings and
AUTOMATIC RESET
unbalanced resistance. Inspect all motor wiring Automatic reset should not be used in industrial
connections. applications where it can unexpectedly cause the
frequency converter and motor to restart. Always use the
Motor does not brake
Possible fault in the brake circuit. Possible incorrect setting
manual restart setting in parameter 14-20 Reset Mode. 6 6
Failure to use manual reset in industrial applications can
in the brake parameters. The ramp down time is too short. cause death or serious injury.
The LCP may show an alarm or warning message.
Check all brake parameters and ramp-down time If a warning and alarm is marked against a code in
(parameter groups 2-0* DC-Brake and 3-4* Ramp 1). Table 6.2, it means that either a warning occurs before an
alarm, or it can be specified whether it is a warning or an
6.6 Alarms and Warnings
alarm that is shown for a given fault.
The frequency converter indicates a warning or an alarm
by the relevant indicator light on the LCP and a code on This situation is possible, for instance, in
the display. parameter 1-90 Motor Thermal Protection. After an alarm or
trip, the motor coasts, and the alarm and warning flash on
A warning remains active until its cause is no longer the frequency converter. Once the problem has been
present. Under certain circumstances, operation of the rectified, only the alarm continues flashing.
motor can still be continued. Warning messages can be
critical, but are not necessarily so.
An alarm indicates that the frequency converter tripped.

The alarm must be reset to restart operation once its
problem is fixed. Resetting can be done one of 4 ways:
• By using the [Reset] control key on the LCP
• Via a digital input with the Reset function
• Via serial communication/optional fieldbus
• By resetting automatically using the [Auto Reset]
function
NOTICE
After a manual reset using the [RESET] key on the LCP,
the [Auto on] key must be pressed to restart the motor.
If an alarm cannot be reset, it is possible that the problem

is not fixed or that the alarm is trip locked. Refer to
Table 6.2.

No. Description Warning Alarm/trip Alarm/trip lock Parameter reference

1 10 V low X – – –
2 Live zero error (X) (X) – 6-01
3 No motor (X) – – 1-80
4 Mains phase loss (X) (X) (X) 14-12
5 DC-link voltage high X – – –
6 DC-link voltage low X – – –
7 DC overvoltage X X – –
8 DC undervoltage X X – –
9 Inverter overloaded X X – –
10 Motor ETR overtemperature (X) (X) – 1-90
11 Motor thermistor overtemperature (X) (X) – 1-90
12 Torque limit X X – –
13 Overcurrent X X X –
6 6 14
15
Ground fault
Hardware mismatch
X
–
X
X
X
X
–
–
16 Short circuit – X X –
17 Control word timeout (X) (X) – 8-04
18 Start failed – X – –
19 Discharge temperature high X X – –
22 Hoist mechanical braking – X – –
23 Internal fans – – – –
24 External fans – – – –
25 Brake resistor short-circuited X – – –
26 Brake resistor power limit (X) (X) – 2-13
27 Brake chopper short-circuited X X – –
28 Brake check (X) (X) – 2-15
29 Heat sink temp X X X –
30 Motor phase U missing (X) (X) (X) 4-58
31 Motor phase V missing (X) (X) (X) 4-58
32 Motor phase W missing (X) (X) (X) 4-58
33 Inrush fault – X X –
34 Fieldbus communication fault X X – –
36 Mains failure – – – –
37 Imbalance of supply voltage – X – –
38 Internal fault – X X –
39 Heat sink sensor – X X –
40 Overload of digital output terminal 27 (X) – – –
41 Overload of digital output terminal 29 (X) – – –
42 Overload of digital output on X30/6 or overload (X) – – –
of digital output on X30/7
45 Ground fault 2 X X X –
46 Power card supply – X X –
47 24 V supply low X X X –
48 1.8 V supply low – X X –
49 Speed limit X X – –
50 AMA calibration failed – X – –
51 AMA check Unom and Inom – X – –
52 AMA low Inom – X – –
53 AMA motor too large – X – –
54 AMA motor too small – X – –
55 AMA parameter out of range – X – –
56 AMA interrupted by user – X – –
57 AMA timeout – X – –

No. Description Warning Alarm/trip Alarm/trip lock Parameter reference

58 AMA internal fault X X – –
59 Current limit X – – –
60 External interlock – – – –
61 Encoder loss (X) (X) – –
62 Output frequency at maximum limit X – – –
63 Mechanical braking low – (X) – –
64 Voltage limit X – – –
65 Control board overtemperature X X X –
66 Heat sink temperature low X – – –
67 Option configuration has changed – X – –
68 Safe torque off activated – X – –
69 Power card temperature – X X –
70 Illegal FC configuration – – – –
71
72
PTC 1 safe torque off
Dangerous failure
X
X
X
X
X
X
–
–
6 6
73 Safe torque off auto restart X X – –
76 Power unit setup X – – –
77 Reduced power mode X – – –
78 Tracking error X X – –
79 Illegal PS config – X X –
80 Frequency converter initialized to default value – X – –
81 CSIV corrupt – X – –
82 CSIV parameter error – X – –
90 Encoder loss (X) (X) – –
91 Analog input 54 wrong settings – – X –
92 No-flow X X – 22-2*
93 Dry pump X X – 22-2*
94 End of curve X X – 22-5*
95 Broken belt X X – 22-6*
96 Start delayed X – – 22-7*
97 Stop delayed X – – 22-7*
98 Clock fault X – – 0-7*
100–199 Refer to operating instructions for MCO 305 – – – –
200 Fire mode (X) – – –
201 Fire mode was active (X) – – –
202 Fire mode limits exceeded (X) – – –
243 Brake IGBT X X – –
244 Heat sink temperature X X X –
245 Heat sink sensor – X X –
246 Power card supply – X X –
247 Power card temperature – X X –
248 Illegal PS config – X X –
250 New spare part – – X –
251 New type code – X X –
Table 6.2 Alarm/Warning Code List

(X) Dependent on parameter
LED indication
Warning Yellow
Alarm Red (flashing)
Trip lock Yellow and red
Table 6.3 Description of LED Indicator Lights

Alarm Word and Extended Status Word

Bit Hex Dec Alarm word Warning word Extended status word
0 00000001 1 Brake check Brake check Ramping
1 00000002 2 Pwr. card temp Pwr. card temp AMA running
2 00000004 4 Ground fault Ground fault Start CW/CCW
3 00000008 8 Ctrl. card temp Ctrl. card temp Slow down
4 00000010 16 Ctrl. word TO Ctrl. word TO Catch up
5 00000020 32 Overcurrent Overcurrent Feedback high
6 00000040 64 Torque limit Torque limit Feedback low
7 00000080 128 Motor Th over Motor Th over Output current high
8 00000100 256 Motor ETR over Motor ETR over Output current low
9 00000200 512 Inverter overld. Inverter overld. Output freq high
10 00000400 1024 DC under volt DC under volt Output freq low
11 00000800 2048 DC over volt DC over volt Brake check ok
6 6 12
13
00001000
00002000
4096
8192
Short circuit
Inrush fault
DC voltage low
DC voltage high
Braking max
Braking
14 00004000 16384 Mains ph. loss Mains ph. loss Out of speed range
15 00008000 32768 AMA not OK No motor OVC active
16 00010000 65536 Live zero error Live zero error –
17 00020000 131072 Internal fault 10 V low –
18 00040000 262144 Brake overload Brake overload –
19 00080000 524288 U phase loss Brake resistor –
20 00100000 1048576 V phase loss Brake IGBT –
21 00200000 2097152 W phase loss Speed limit –
22 00400000 4194304 Fieldbus fault Fieldbus fault –
23 00800000 8388608 24 V supply low 24 V supply low –
24 01000000 16777216 Mains failure Mains failure –
25 02000000 33554432 1.8 V Supply low Current limit –
26 04000000 67108864 Brake resistor Low temp –
27 08000000 134217728 Brake IGBT Voltage limit –
28 10000000 268435456 Option change Unused –
29 20000000 536870912 Frequency converter Unused –
initialized
30 40000000 1073741824 Safe torque off Unused –
Table 6.4 Description of Alarm Word, Warning Word, and Extended Status Word
The alarm words, warning words and extended status words can be read out via fieldbus or optional fieldbus for diagnosis.
Also, refer to parameter 16-90 Alarm Word, parameter 16-92 Warning Word, and parameter 16-94 Ext. Status Word.
Bit Hex Dec Alarm Word 2 Warning Word 2

0 00000001 1 – Start Delayed
1 00000002 2 – Stop Delayed
9 00000200 512 Discharge Temperature High Discharge Temperature High
10 00000400 1024 Start Limit –
11 00000800 2048 Speed Limit –
Table 6.5 Description of Alarm Word 2 and Warning Word 2

6.7 Alarm and Warning Definitions WARNING 6, DC link voltage low

The DC-link voltage (DC) is lower than the low-voltage
WARNING 1, 10 Volts low warning limit. The limit depends on the drive voltage
The control card voltage is less than 10 V from terminal 50. rating. The unit is still active.
Remove some of the load from terminal 50, as the 10 V
WARNING/ALARM 7, DC overvoltage
supply is overloaded. Maximum 15 mA or minimum 590 Ω.
If the DC-link voltage exceeds the limit, the drive trips after
A short circuit in a connected potentiometer or incorrect a certain time.
wiring of the potentiometer can cause this condition.
Troubleshooting
Troubleshooting • Connect a brake resistor.
• Remove the wiring from terminal 50. If the • Extend the ramp time.
warning clears, the problem is with the wiring. If
the warning does not clear, replace the control • Change the ramp type.
card. • Activate the functions in parameter 2-10 Brake
WARNING/ALARM 2, Live zero error Function.
This warning or alarm only appears if programmed in • Increase parameter 14-26 Trip Delay at Inverter 6 6
parameter 6-01 Live Zero Timeout Function. The signal on 1 Fault.
of the analog inputs is less than 50% of the minimum
value programmed for that input. Broken wiring or a faulty • If the alarm/warning occurs during a power sag,
use kinetic back-up (parameter 14-10 Mains
device sending the signal can cause this condition.
Failure).
Troubleshooting
WARNING/ALARM 8, DC under voltage
• Check connections on all analog mains terminals. If the DC-link voltage drops below the undervoltage limit,
- Control card terminals 53 and 54 for the drive checks for 24 V DC back-up supply. If no 24 V DC
signals, terminal 55 common. back-up supply is connected, the drive trips after a fixed
- VLT® General Purpose I/O MCB 101 time delay. The time delay varies with unit size.
terminals 11 and 12 for signals, terminal Troubleshooting
10 common. • Check that the supply voltage matches the drive
- VLT® Analog I/O Option MCB 109 voltage.
terminals 1, 3, and 5 for signals, • Perform an input voltage test.
terminals 2, 4, and 6 common.
• Perform a soft-charge circuit test.
• Check that the drive programming and switch
WARNING/ALARM 9, Inverter overload
settings match the analog signal type.
The frequency converter has run with more than 100%
• Perform an input terminal signal test. overload for too long and is about to cut out. The counter
WARNING/ALARM 3, No motor for electronic thermal inverter protection issues a warning
No motor has been connected to the output of the at 98% and trips at 100% with an alarm. The frequency
frequency converter. This warning or alarm appears only if converter cannot be reset until the counter is below 90%.
programmed in parameter 1-80 Function at Stop. Troubleshooting
Troubleshooting • Compare the output current shown on the LCP
Check the connection between the frequency converter with the frequency converter rated current.
and the motor. • Compare the output current shown on the LCP
WARNING/ALARM 4, Mains phase loss with the measured motor current.
A phase is missing on the supply side, or the mains • Show the thermal frequency converter load on
voltage imbalance is too high. This message also appears the LCP and monitor the value. When running
for a fault in the input rectifier. Options are programmed in above the frequency converter continuous
parameter 14-12 Function at Mains Imbalance. current rating, the counter increases. When
Troubleshooting running below the frequency converter
continuous current rating, the counter decreases.
• Check the supply voltage and supply currents to
the frequency converter.
WARNING 5, DC link voltage high
The DC-link voltage (DC) is higher than the high-voltage
warning limit. The limit depends on the drive voltage
rating. The unit is still active.

WARNING/ALARM 10, Motor ETR overtemperature WARNING/ALARM 12, Torque limit

According to the electronic thermal protection (ETR), the The torque has exceeded the value in
motor is too hot. The frequency converter can be parameter 4-16 Torque Limit Motor Mode or the value in
configured to give an alarm when the counter reaches parameter 4-17 Torque Limit Generator Mode.
100% in parameter 1-90 Motor Thermal Protection. If the Parameter 14-25 Trip Delay at Torque Limit can change this
motor is overloaded by more than 100% for too long, this warning from a warning-only condition to a warning
fault is shown. Check that parameter 1-24 Motor Current is followed by an alarm.
set correctly. Troubleshooting
Troubleshooting • If the motor torque limit is exceeded during
• Check whether motor is overheated. ramp-up, extend the ramp-up time.
• Verify that the motor is not mechanically • If the generator torque limit is exceeded during
overloaded. ramp-down, extend the ramp-down time.
• Verify that the parameter 1-24 Motor Current is set • If torque limit occurs while running, increase the
correctly. torque limit. Make sure that the system can
6 6 • Check that motor data in parameter 1-20 Motor operate safely at a higher torque.
Power [kW] through parameter 1-25 Motor • Check the application for excessive current draw
Nominal Speed is set correctly. on the motor.
• Check parameter 1-91 Motor External Fansetting. WARNING/ALARM 13, Over current
The inverter peak current limit (approximately 200% of the
• Run AMA in parameter 1-29 Automatic Motor
rated current) is exceeded. The warning lasts approximately
Adaptation (AMA).
1.5 s, then the frequency converter trips and issues an
WARNING/ALARM 11, Motor thermistor overtemp alarm. Shock loading or quick acceleration with high-inertia
Check whether the thermistor is disconnected. Select loads can cause this fault. If the acceleration during ramp-
whether the frequency converter issues a warning or an up is quick, the fault can also appear after kinetic back-up.
alarm in parameter 1-90 Motor Thermal Protection. If extended mechanical brake control is selected, a trip can
Troubleshooting be reset externally.
• Check for motor overheating. Troubleshooting
• Check if the motor is mechanically overloaded. • Remove the power and check if the motor shaft
can be turned.
• When using terminal 53 or 54, check that the
thermistor is connected correctly between either • Check that the motor size matches the frequency
terminal 53 or 54 (analog voltage input) and converter.
terminal 50 (+10 V supply). Also check that the • Check that the motor data is correct in
terminal switch for 53 or 54 is set for voltage. parameters 1-20 to 1-25.
Check that parameter 1-93 Thermistor Source
ALARM 14, Ground fault
selects terminal 53 or 54.
There is a discharge from the output phases to ground,
• When using terminal 18, 19, 31, 32, or 33 (digital either in the motor or in the cable between the frequency
inputs), check that the thermistor is connected converter and the motor.
correctly between the digital input terminal used
Troubleshooting
(digital input PNP only) and terminal 50. Select
the terminal to use in parameter 1-93 Thermistor • Turn off the frequency converter and remove the
ground fault.
Source.
• Measure the resistance to ground of the motor
cables and the motor with a megohmmeter to
check for ground faults in the motor.

ALARM 15, Hardware mismatch WARNING/ALARM 19, Discharge temperature high

A fitted option is not operational with the present control The warning indicates that the discharge temperature
board hardware or software. exceeds the level programmed in parameter 28-24 Warning
Level. If so programmed in parameter 28-25 Warning Action,
Record the value of the following parameters and contact
the drive lowers the speed of the compressor in an
the local Danfoss supplier:
attempt to lower the discharge temperature.
• Parameter 15-40 FC Type.
The alarm indicates that the discharge temperature
• Parameter 15-41 Power Section.
exceeds the level programmed in
• Parameter 15-42 Voltage. parameter 28-26 Emergency Level.
• Parameter 15-43 Software Version. WARNING 22, Hoist mechanical brake
• Parameter 15-45 Actual Typecode String. 0 = The torque reference was not reached before timeout.
1 = There was no brake feedback before the timeout.
• Parameter 15-49 SW ID Control Card.
WARNING 23, Internal fan fault
• Parameter 15-50 SW ID Power Card.
The fan warning function is a protective function that
• Parameter 15-60 Option Mounted. checks if the fan is running/mounted. The fan warning can 6 6
• Parameter 15-61 Option SW Version (for each be disabled in parameter 14-53 Fan Monitor ([0] Disabled).
option slot). For drives with DC fans, a feedback sensor is mounted in
ALARM 16, Short circuit the fan. If the fan is commanded to run and there is no
There is short-circuiting in the motor or motor wiring. feedback from the sensor, this alarm appears. For drives
with AC fans, the voltage to the fan is monitored.
Troubleshooting
• Remove the power to the frequency converter Troubleshooting
and repair the short circuit. • Check for proper fan operation.
• Cycle power to the drive and check that the fan
WARNING operates briefly at start-up.
HIGH VOLTAGE • Check the sensors on the control card.
Frequency converters contain high voltage when
WARNING 24, External fan fault
connected to AC mains input, DC supply, or load sharing.
The fan warning function is a protective function that
Failure to use qualified personnel to install, start up, and
checks if the fan is running/mounted. The fan warning can
maintain the frequency converter can result in death or
be disabled in parameter 14-53 Fan Monitor ([0] Disabled).
serious injury.
For drives with DC fans, a feedback sensor is mounted in
• Disconnect power before proceeding.
the fan. If the fan is commanded to run and there is no
feedback from the sensor, this alarm appears. For drives
WARNING/ALARM 17, Control word timeout with AC fans, the voltage to the fan is monitored.
There is no communication to the frequency converter.
The warning is only active when parameter 8-04 Control Troubleshooting
Timeout Function is NOT set to [0] Off. • Check for proper fan operation.
If parameter 8-04 Control Timeout Function is set to [5] Stop
and trip, a warning appears, and the frequency converter • Cycle power to the drive and check that the fan
operates briefly at start-up.
ramps down to a stop and shows an alarm.
Troubleshooting • Check the sensors on the heat sink.
• Check the connections on the serial communi- WARNING 25, Brake resistor short circuit
cation cable. The brake resistor is monitored during operation. If a short
circuit occurs, the brake function is disabled and the
• Increase parameter 8-03 Control Timeout Time.
warning appears. The frequency converter is still
• Check the operation of the communication operational, but without the brake function.
equipment.
Troubleshooting
• Verify that proper EMC installation was • Remove the power to the frequency converter
performed. and replace the brake resistor (refer to
ALARM 18, Start failed parameter 2-15 Brake Check).
The speed has not been able to exceed
parameter 1-77 Compressor Start Max Speed [RPM] during
start within the allowed time that was set in
parameter 1-79 Compressor Start Max Time to Trip. A
blocked motor can cause this alarm.

WARNING/ALARM 26, Brake resistor power limit the thermal sensor in the rectifier module can also trigger
The power transmitted to the brake resistor is calculated as this alarm.
an average value over the last 120 s of run-time. The
calculation is based on the DC-link voltage and the brake Troubleshooting
resistor value set in parameter 2-16 AC brake Max. Current. • Check fan resistance.
The warning is active when the dissipated braking power
is higher than 90% of the brake resistor power. If option [2] • Check soft charge fuses.
Trip is selected in parameter 2-13 Brake Power Monitoring, • Check IGBT thermal.
the frequency converter trips when the dissipated braking ALARM 30, Motor phase U missing
power reaches 100%. Motor phase U between the frequency converter and the
WARNING/ALARM 27, Brake chopper fault motor is missing.
The brake transistor is monitored during operation, and if a
short circuit occurs, the brake function is disabled, and a WARNING
warning is issued. The frequency converter is still HIGH VOLTAGE
6 6 operational but, since the brake transistor has short-
circuited, substantial power is transmitted to the brake
connected to AC mains input, DC supply, or load sharing.
resistor, even if it is inactive. Failure to use qualified personnel to install, start up, and
Troubleshooting maintain the frequency converter can result in death or
• Remove power to the frequency converter and serious injury.
remove the brake resistor. • Disconnect power before proceeding.
• Troubleshoot the short circuit.
WARNING Troubleshooting
• Remove the power from the frequency converter
OVERHEATING RISK and check motor phase U.
The surge in power can cause the brake resistor to
ALARM 31, Motor phase V missing
overheat and possibly catch fire. Failure to remove power
Motor phase V between the frequency converter and the
to the frequency converter and remove the brake resistor
motor is missing.
can cause equipment damage.
WARNING/ALARM 28, Brake check failed

WARNING
HIGH VOLTAGE
The brake resistor is not connected or not working.
Troubleshooting connected to AC mains input, DC supply, or load sharing.
• Check parameter 2-15 Brake Check. Failure to use qualified personnel to install, start up, and
ALARM 29, Heat sink temp maintain the frequency converter can result in death or
The maximum temperature of the heat sink has been serious injury.
exceeded. The temperature fault does not reset until the • Disconnect power before proceeding.
temperature drops below a defined heat sink temperature.
The trip and reset points are different based on the
frequency converter power size. Troubleshooting
Troubleshooting
and check motor phase V.
Check for the following conditions:
• Ambient temperature too high
• Motor cable too long
• Incorrect airflow clearance above and below the
frequency converter
• Blocked airflow around the frequency converter
• Damaged heat sink fan
• Dirty heat sink
For the D, E, and F-size enclosures, this alarm is based on
the temperature measured by the heat sink sensor
mounted inside the IGBT modules. For F-size enclosures,

ALARM 32, Motor phase W missing Number Text

Motor phase W between the frequency converter and the 0 The serial port cannot be initialized. Contact the
motor is missing. Danfoss supplier or Danfoss service department.
256–258 The power EEPROM data is defective or too old.
WARNING Replace the power card.
HIGH VOLTAGE 512–519 Internal fault. Contact the Danfoss supplier or
Frequency converters contain high voltage when Danfoss service department.
connected to AC mains input, DC supply, or load sharing. 783 Parameter value outside of minimum/maximum
Failure to use qualified personnel to install, start up, and limits.
maintain the frequency converter can result in death or 1024–1284 Internal fault. Contact the Danfoss supplier or
serious injury. Danfoss service department.
• Disconnect power before proceeding. 1299 The option software in slot A is too old.
1300 The option software in slot B is too old.
1302 The option software in slot C1 is too old.
Troubleshooting
1315 The option software in slot A is not supported/
allowed. 6 6
and check motor phase W.
1316 The option software in slot B is not supported/
ALARM 33, Inrush fault allowed.
Too many power-ups have occurred within a short time 1318 The option software in slot C1 is not supported/
period. allowed.
Troubleshooting 1379–2819 Internal fault. Contact the Danfoss supplier or
• Let the unit cool to operating temperature. Danfoss service department.

1792 Hardware reset of digital signal processor.
WARNING/ALARM 34, Fieldbus communication fault
1793 Motor-derived parameters not transferred correctly
The fieldbus on the communication option card is not
to the digital signal processor.
working.
1794 Power data not transferred correctly at power-up
WARNING 35, Out of frequency range to the digital signal processor.
This warning is active if the output frequency has reached 1795 The digital signal processor has received too many
parameter 4-52 Warning Speed Low or unknown SPI telegrams. The AC drive also uses
parameter 4-53 Warning Speed High. If the frequency this fault code if the MCO does not power up
converter is set to [3] Closed Loop in parameter 1-00 Config- correctly. This situation can occur due to poor EMC
uration Mode, the warning is active in the display. If the protection or improper grounding.
frequency converter is not in this mode, bit 008000 Out of 1796 RAM copy error.
frequency range in the extended status word is active but 1798 Software version 48.3X or newer is used with MK1
there is no warning in the display. control card. Replace with MKII issue 8 control
WARNING/ALARM 36, Mains failure card.
This warning/alarm is only active if the supply voltage to 2561 Replace the control card.
the drive is lost and parameter 14-10 Mains Failure is not 2820 LCP stack overflow.
set to [0] No function. 2821 Serial port overflow.
Troubleshooting 2822 USB port overflow.
• Check the fuses to the drive and mains supply to 3072–5122 Parameter value is outside its limits.
the unit. 5123 Option in slot A: Hardware incompatible with the
control board hardware.
ALARM 37, Phase imbalance
5124 Option in slot B: Hardware incompatible with the
There is a current imbalance between the power units.
control board hardware.
ALARM 38, Internal fault 5125 Option in slot C0: Hardware incompatible with the
When an internal fault occurs, a code number defined in control board hardware.
Table 6.6 is shown.
5126 Option in slot C1: Hardware incompatible with the
Troubleshooting control board hardware.
• Cycle power. 5376–6231 Internal fault. Contact the Danfoss supplier or
• Check that the option is properly installed. Danfoss service department.
• Check for loose or missing wiring. Table 6.6 Internal Fault Codes
It may be necessary to contact the Danfoss supplier or
service department. Note the code number for further
troubleshooting directions.

ALARM 39, Heat sink sensor Troubleshooting

No feedback from the heat sink temperature sensor. • Check for a defective power card.
The signal from the IGBT thermal sensor is not available on WARNING 48, 1.8 V supply low
the power card. The problem could be on the power card, The 1.8 V DC supply used on the control card is outside of
on the gatedrive card, or the ribbon cable between the the allowable limits. The supply is measured on the control
power card and gatedrive card. card.
WARNING 40, Overload of digital output terminal 27 Troubleshooting
Check the load connected to terminal 27 or remove the • Check for a defective control card.
short-circuit connection. Check parameter 5-00 Digital I/O
Mode and parameter 5-01 Terminal 27 Mode.
• If an option card is present, check for
overvoltage.
WARNING 41, Overload of digital output terminal 29 WARNING 49, Speed limit
Check the load connected to terminal 29 or remove the The warning is shown when the speed is outside of the
short-circuit connection. Also check parameter 5-00 Digital specified range in parameter 4-11 Motor Speed Low Limit
I/O Mode and parameter 5-02 Terminal 29 Mode.
6 6 WARNING 42, Overload of digital output on X30/6 or
[RPM] and parameter 4-13 Motor Speed High Limit [RPM].
When the speed is below the specified limit in
overload of digital output on X30/7 parameter 1-86 Trip Speed Low [RPM] (except when starting
For terminal X30/6, check the load connected to terminal or stopping), the frequency converter trips.
X30/6 or remove the short-circuit connection. Also check ALARM 50, AMA calibration failed
parameter 5-32 Term X30/6 Digi Out (MCB 101) (VLT® Contact the Danfoss supplier or Danfoss Service
General Purpose I/O MCB 101). Department.
For terminal X30/7, check the load connected to terminal ALARM 51, AMA check Unom and Inom
X30/7 or remove the short-circuit connection. Check The settings for motor voltage, motor current, and motor
parameter 5-33 Term X30/7 Digi Out (MCB 101) (VLT® power are wrong.
General Purpose I/O MCB 101).
Troubleshooting
ALARM 46, Power card supply • Check the settings in parameters 1-20 to 1-25.
The supply on the power card is out of range. Another
ALARM 52, AMA low Inom
reason can be a defective heat sink fan.
The motor current is too low.
There are 3 supplies generated by the switch mode supply
Troubleshooting
(SMPS) on the power card:
• 24 V. • Check the settings in parameter 1-24 Motor
Current.
• 5 V.
ALARM 53, AMA motor too big
• ±18 V. The motor is too large for the AMA to operate.
When powered with VLT® 24 V DC Supply MCB 107, only ALARM 54, AMA motor too small
the 24 V and 5 V supplies are monitored. When powered The motor is too small for the AMA to operate.
with 3-phase mains voltage, all 3 supplies are monitored.
ALARM 55, AMA parameter out of range
Troubleshooting The AMA cannot run because the parameter values of the
• Check for a defective power card. motor are outside of the acceptable range.
• Check for a defective control card. ALARM 56, AMA interrupted by user
• Check for a defective option card. The AMA is manually interrupted.
• If a 24 V DC supply is used, verify proper supply ALARM 57, AMA internal fault
power. Try to restart the AMA. Repeated restarts can overheat the
motor.
• Check for a defective heat sink fan.
ALARM 58, AMA Internal fault
WARNING 47, 24 V supply low Contact the Danfoss supplier.
The supply on the power card is out of range.
WARNING 59, Current limit
There are 3 supplies generated by the switch mode supply The current is higher than the value in
(SMPS) on the power card: parameter 4-18 Current Limit. Ensure that the motor data in
• 24 V. parameters 1-20 to 1-25 is set correctly. Increase the current
• 5 V. limit if necessary. Ensure that the system can operate safely
at a higher limit.
• ±18 V.

WARNING 60, External interlock ALARM 67, Option module configuration has changed
A digital input signal indicates a fault condition external to One or more options have either been added or removed
the frequency converter. An external interlock has since the last power-down. Check that the configuration
commanded the frequency converter to trip. Clear the change is intentional and reset the unit.
external fault condition. To resume normal operation, apply ALARM 68, Safe Stop activated
24 V DC to the terminal programmed for external interlock, Safe Torque Off (STO) has been activated. To resume
and reset the frequency converter. normal operation, apply 24 V DC to terminal 37, then send
WARNING 61, Tracking Error a reset signal via bus, digital I/O, or by pressing [Reset].
An error has been detected between the calculated motor If an alarm occurs during start-up, ensure that the 4-pole
speed and the speed measurement from the feedback fused disconnect is in the closed (horizontal) position.
device. The function for Warning/Alarm/Disable is set in Mains power will need to be present to remove the alarm.
parameter 4-30 Motor Feedback Loss Function. Error setting
is found in parameter 4-31 Motor Feedback Speed Error. ALARM 69, Power card temperature
Allowed error time is found in parameter 4-32 Motor The temperature sensor on the power card is either too
hot or too cold.
Feedback Loss Timeout. During the commissioning process,
this function can be useful. Troubleshooting 6 6
WARNING 62, Output frequency at maximum limit • Check that the ambient operating temperature is
If the output frequency reaches the value set in within limits.
parameter 4-19 Max Output Frequency, the drive issues a • Check for clogged filters.
warning. The warning ceases when the output drops
below the maximum limit. If the drive is unable to limit
• Check fan operation.
the frequency, it trips and issues an alarm. The latter may • Check the power card.
happen in the flux mode if the drive loses control of the ALARM 70, Illegal FC configuration
motor. The control card and power card are incompatible. To
Troubleshooting check compatibility, contact the Danfoss supplier with the
• Check the application for possible causes. type code from the unit nameplate and the part numbers
of the cards.
• Increase the output frequency limit. Ensure that
the system can operate safely at a higher output WARNING/ALARM 71, PTC 1 Safe Stop
frequency. Safe Torque Off (STO) has been activated from the VLT®
PTC Thermistor Card MCB 112 because the motor is too
ALARM 63, Mechanical brake low
warm. Once the motor cools and the digital input from the
The actual motor current has not exceeded the release
MCB 112 is deactivated, normal operation can resume
brake current within the start delay time window.
when the MCB 112 applies 24 V DC to terminal 37 again.
WARNING 64, Voltage limit When the motor is ready for normal operation, a reset
The combination of load and speed requires a motor signal is sent (via serial communication, digital I/O, or by
voltage higher than the actual DC-link voltage. pressing [Reset] on the LCP). If automatic restart is
WARNING/ALARM 65, Control card over temperature enabled, the motor can start when the fault is cleared.
The cutout temperature of the control card is 85 °C ALARM 72, Dangerous failure
(185 °F). Safe Torque Off (STO) with trip lock. Unexpected signal
Troubleshooting levels on Safe Torque Off and digital input from the VLT®
• Check that the ambient operating temperature is PTC Thermistor Card MCB 112.
within the limits. WARNING 73, Safe Stop auto restart
• Check for clogged filters. STO activated. With automatic restart enabled, the motor
can start when the fault is cleared.
• Check the fan operation.
WARNING 76, Power unit setup
• Check the control card.
The required number of power units do not match the
WARNING 66, Heat sink temperature low detected number of active power units.
The frequency converter is too cold to operate. This
This warning occurs when replacing a module for an F-size
warning is based on the temperature sensor in the IGBT
enclosure if the power-specific data in the module power
module. Increase the ambient temperature of the unit.
card does not match the rest of the frequency converter.
Also, a trickle amount of current can be supplied to the
frequency converter whenever the motor is stopped by Troubleshooting
setting parameter 2-00 DC Hold/Preheat Current to 5% and • Confirm that the spare part and its power card
parameter 1-80 Function at Stop. are the correct part number.

WARNING 77, Reduced power mode ALARM 94, End of curve

The frequency converter is operating in reduced power The feedback is lower than the setpoint. This condition can
mode (less than the allowed number of inverter sections). indicate leakage in the system. Parameter 22-50 End of
This warning is generated on power cycle when the Curve Function is set for alarm.
frequency converter is set to run with fewer inverters and Troubleshooting
remains on.
• Troubleshoot the system and reset the frequency
ALARM 78, Tracking error converter after clearing the fault.
The difference between setpoint value and actual value ALARM 95, Broken belt
exceeds the value in parameter 4-35 Tracking Error. Torque is below the torque level set for no load, indicating
Troubleshooting a broken belt. Parameter 22-60 Broken Belt Function is set
• Disable the function or select an alarm/warning for alarm.
in parameter 4-34 Tracking Error Function. Troubleshooting
• Investigate the mechanics around the load and • Troubleshoot the system and reset the frequency
motor. Check feedback connections from motor converter after clearing the fault.
6 6 encoder to drive. ALARM 96, Start delayed
• Select motor feedback function in Motor start has been delayed due to short-cycle
parameter 4-30 Motor Feedback Loss Function. protection. Parameter 22-76 Interval between Starts is
enabled.
• Adjust the tracking error band in
parameter 4-35 Tracking Error and Troubleshooting
parameter 4-37 Tracking Error Ramping. • Troubleshoot the system and reset the frequency
converter after clearing the fault.
ALARM 79, Illegal power section configuration
The scaling card has an incorrect part number or is not WARNING 97, Stop delayed
installed. The MK102 connector on the power card could Stopping the motor has been delayed because the motor
not be installed. has been running for less than the minimum time specified
in parameter 22-77 Minimum Run Time.
ALARM 80, Initialization to default value
Parameter settings are initialized to default setting after a WARNING 98, Clock fault
manual (3-finger) reset. Time is not set, or the RTC clock has failed. Reset the clock
in parameter 0-70 Date and Time.
ALARM 81, CSIV corrupt
CSIV file has syntax errors. WARNING 200, Fire mode
The frequency converter is operating in fire mode. The
ALARM 82, CSIV parameter error
warning clears when fire mode is removed. Refer to the
CSIV has failed to record a parameter.
fire mode data in the alarm log.
ALARM 91, Analog input 54 wrong settings
WARNING 201, Fire mode was active
Set switch S202 in position OFF (voltage input) when a
The frequency converter has entered fire mode. Cycle
KTY sensor is connected to analog input terminal 54.
power to the unit to remove the warning. Refer to the fire
ALARM 92, No flow mode data in the alarm log.
A no-flow condition is detected in the system.
WARNING 202, Fire mode limits exceeded
Parameter 22-23 No-Flow Function is set for alarm.
While operating in fire mode, 1 or more alarm conditions
Troubleshooting that would normally trip the unit have been ignored.
• Troubleshoot the system and reset the frequency Operating in this condition voids unit warranty. Cycle
converter after clearing the fault. power to the unit to remove the warning. Refer to the fire
ALARM 93, Dry pump mode data in the alarm log.
A no-flow condition in the system with the frequency WARNING 219, Compressor interlock
converter operating at high speed can indicate a dry At least 1 compressor is inversely interlocked via a digital
pump. Parameter 22-26 Dry Pump Function is set for alarm. input. The interlocked compressors can be viewed in
Troubleshooting parameter 25-87 Inverse Interlock.
• Troubleshoot the system and reset the frequency
converter after clearing the fault.

ALARM 243, Brake IGBT ALARM 245, Heat sink sensor

This alarm is only for F-size enclosures and is equivalent to This alarm is only for F-size enclosures and is equivalent to
alarm 27, Brake Chopper Fault. alarm 39, Heat Sink Sensor.
The report value in the alarm log indicates which power The report value in the alarm log indicates which power
module generated the alarm: module generated the alarm:
1 = Left most inverter module. 1 = Left most inverter module.
2 = Either the middle inverter module in a unit 2 = Either the middle inverter module in a unit
with 3 inverter modules or the right inverter with 3 inverter modules or the right inverter
module in a unit with 2 inverter modules. module in a unit with 2 inverter modules.
3 = Right inverter module in a unit with 3 3 = Right inverter module in a unit with 3
inverter modules. inverter modules.
5 = Either the rectifier module in a 6-pulse unit or 5 = Either the rectifier module in a 6-pulse unit or
the left rectifier module in a 12-pulse unit. The the left rectifier module in a 12-pulse unit. The
single jumper on the 44-pin jumper P1 on the
top of the module identifies it as 12-pulse.
top of the module identifies it as 12-pulse. 6 6
6 = Right rectifier module in a 12-pulse unit. Two 6 = Right rectifier module in a 12-pulse unit. Two
jumpers on the 44-pin jumper P1 on the top of jumpers on the 44-pin jumper P1 on the top of
the module identifies it as 12-pulse. the module identifies it as 12-pulse.
ALARM 244, Heat sink temperature ALARM 246, Power card supply
This alarm is only for F-size enclosures and is equivalent to This alarm is only for F-size enclosures and is equivalent to
alarm 29, Heat Sink Temp. alarm 46, Power Card Supply.
The report value in the alarm log indicates which power The report value in the alarm log indicates which power
module generated the alarm: module generated the alarm:
1 = Left most inverter module. 1 = Left most inverter module.
2 = Either the middle inverter module in a unit 2 = Either the middle inverter module in a unit
with 3 inverter modules or the right inverter with 3 inverter modules or the right inverter
module in a unit with 2 inverter modules. module in a unit with 2 inverter modules.
3 = Right inverter module in a unit with 3 3 = Right inverter module in a unit with 3
inverter modules. inverter modules.
5 = Either the rectifier module in a 6-pulse unit or 5 = Either the rectifier module in a 6-pulse unit or
the left rectifier module in a 12-pulse unit. The the left rectifier module in a 12-pulse unit. The
single jumper on the 44-pin jumper P1 on the single jumper on the 44-pin jumper P1 on the
top of the module identifies it as 12-pulse. top of the module identifies it as 12-pulse.
6 = Right rectifier module in a 12-pulse unit. Two 6 = Right rectifier module in a 12-pulse unit. Two
jumpers on the 44-pin jumper P1 on the top of jumpers on the 44-pin jumper P1 on the top of
the module identifies it as 12-pulse. the module identifies it as 12-pulse.

ALARM 247, Power card temperature

This alarm is only for F-size enclosures and is equivalent to
alarm 29, Power Card Temperature.
The report value in the alarm log indicates which power
module generated the alarm:
1 = Left most inverter module.
2 = Either the middle inverter module in a unit
with 3 inverter modules or the right inverter
module in a unit with 2 inverter modules.
3 = Right inverter module in a unit with 3
inverter modules.
5 = Either the rectifier module in a 6-pulse unit or
the left rectifier module in a 12-pulse unit. The
6 6 single jumper on the 44-pin jumper P1 on the

6 = Right rectifier module in a 12-pulse unit. Two
jumpers on the 44-pin jumper P1 on the top of
the module identifies it as 12-pulse.
ALARM 248, Illegal power section configuration
This alarm is only for F-size enclosures and is equivalent to
alarm 79, Illegal Power Section Configuration.
The report value in the alarm log indicates which power
module generated the alarm:
1 = Left most inverter module.
2 = Either the middle inverter module in a unit
with 3 inverter modules or the right inverter
module in a unit with 2 inverter modules.
3 = Right inverter module in a unit with 3
inverter modules.
5 = Either the rectifier module in a 6-pulse unit or
the left rectifier module in a 12-pulse unit. The
6 = Right rectifier module in a 12-pulse unit. Two
jumpers on the 44-pin jumper P1 on the top of
the module identifies it as 12-pulse.
WARNING 250, New spare part
The power or switch mode supply has been exchanged.
Restore the drive type code in the EEPROM. Select the
correct type code in parameter 14-23 Typecode Setting
according to the label on the drive. Remember to select
Save to EEPROM at the end.
WARNING 251, New typecode
The power card or other components are replaced, and the
type code has changed.

Frequency Converter and Mot... Service Guide
7 Frequency Converter and Motor Applications
7.1 Torque Limit, Current Limit, and For proper load control, the frequency converter relies on
Unstable Motor Operation this information for calculating the output waveform in
response to the application demands.
Excessive loading of the frequency converter can result in Parameter 1-29 Automatic Motor Adaptation (AMA)
warning or tripping on torque limit, overcurrent, or inverter This parameter activates the automatic motor adaptation
time. This situation is not a concern if the frequency (AMA) function. When AMA is performed, the frequency
converter is properly sized for the application and converter measures the electrical resistance of the motor
intermittent load conditions cause an occasional trip. stator windings (R1). Parameter 1-31 Rotor Resistance (Rr) –
However, nuisance or unexplained occurrences can be the parameter 1-35 Main Reactance (Xh) must be requested
result of improperly set parameters. The following from the motor manufacturer the optimal performance of
parameters are important in matching the frequency the frequency converter data. To set parameter 1-31 Rotor
converter to the motor for optimum operation. Resistance (Rr) – parameter 1-35 Main Reactance (Xh), use
the values supplied by the motor manufacturer or leave at
• Parameter 1-00 Configuration Mode sets the the factory default values.
frequency converter for open or closed-loop
operation, or torque mode operation.
Never adjust these parameters to random values even 7 7
though it seems to improve operation. Such adjustments
• Parameter 1-03 Torque Characteristics sets the can result in unpredictable operation under changing
mode in which the frequency converter operates. conditions.
• Parameters 1-20 to 1-29 match the frequency Parameter 4-17 Torque Limit Generator Mode and
converter to the motor and adapt to the motor parameter 4-16 Torque Limit Motor Mode
characteristics. These parameters set the limit for the frequency converter
• Parameter 4-16 Torque Limit Motor Mode, torque. The factory setting is 160% for VLT®
parameter 4-17 Torque Limit Generator Mode, and AutomationDrive FC 302 and 110% for VLT® HVAC Drive FC
parameter 14-25 Trip Delay at Torque Limit set the 102/VLT® AQUA Drive FC 202 and varies with motor power
torque control features of the frequency setting. For example, a frequency converter programmed
converter for the application. to operate a smaller motor yields a higher torque limit
value than when programmed for a larger motor. It is
Parameter 1-00 Configuration Mode
important that this value is not set too low for the
This parameter sets the frequency converter for open loop,
requirements of the application. Sometimes, it can be
closed-loop, or torque mode operation. In a closed loop
desirable to have a torque limit set at a lower value. This
configuration, a feedback signal controls the frequency
offers protection for the application as the frequency
converter speed. The settings for the PID controller play a
converter limits the torque. It can, however, require higher
key role for stable operation in closed loop, as described in
torque at initial start-up, which can cause nuisance
the operating instructions. In open loop, the frequency
tripping.
converter calculates the torque requirement based on
current measurements of the motor. Parameter 14-25 Trip Delay at Torque Limit
This parameter works with torque limit. This parameter
Parameter 1-03 Torque Characteristics
selects the period in which the frequency converter
This parameter sets the frequency converter for constant or
operates in torque limit before a trip. The factory default
variable torque operation. It is imperative that the correct
value is Off. This setting means that the frequency
torque characteristic is selected. For example, if the load
converter does not trip on torque limit, although the unit
type is constant torque, such as a conveyor, and [1]
can still trip from an overload condition. Built into the
Variable torque is selected, the frequency converter can
frequency converter is an internal inverter thermal
have difficulty starting the load. Consult Danfoss if
protection circuit. This circuit monitors the output load on
uncertain about the torque characteristics of an
the inverter. If the load exceeds 100% of the continuous
application.
rating of the frequency converter, a timer is activated. If
Parameter 1-20 Motor Power [kW] and the load remains excessive long enough, the frequency
parameter 1-25 Motor Nominal Speed converter trips on inverter time. Adjustments cannot be
These parameters configure the frequency converter for made to alter this circuit. Improper parameter settings
the connected motor. These parameters are motor power, effecting load current can result in premature trips of this
voltage, frequency, current, and nominal motor speed. type. The timer can be shown on the LCP.
Accurate setting of these parameters is important. Enter
the required motor data as listed on the motor nameplate.

Frequency Converter and Mot... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
7.1.1 Overvoltage Trips The frequency converter adds about 10% to the base
speed before a trip occurs. Otherwise, the speed could
This trip occurs when the DC bus voltage reaches its DC continue to rise to potentially unsafe levels.
bus alarm voltage high. Before tripping, the frequency
converter shows a high-voltage warning. Usually, the cause 7.1.2 Mains Phase Loss Trips
of an overvoltage condition is fast deceleration ramps
relative to the inertia of the load. During deceleration of The frequency converter monitors phase loss by
the load, inertia of the system acts to sustain the running monitoring the amount of ripple voltage on the DC bus.
speed. Once the motor frequency drops below the running Ripple voltage on the DC bus is a product of a phase loss,
speed, the load begins overtaking the motor. The motor and can cause overheating in the DC bus capacitors and
becomes a generator and starts returning energy to the the DC coil. If the ripple voltage on the DC bus is
frequency converter. This process is called regenerative unchecked, the lifetime of the capacitors is reduced
energy. Regeneration occurs when the speed of the load is drastically.
greater than the commanded speed. The diodes in the
IGBT modules rectify this return voltage, which raises the When the input voltage becomes unbalanced or a phase
DC bus. If the amount of returned voltage is too high, the disappears completely, the ripple voltage increases. This
frequency converter trips. increase causes the frequency converter to trip and issue
7 7 Ways to avoid overvoltage trips

Alarm 4, Mains Phase Loss. In addition to missing phase
voltage, a line disturbance or imbalance can cause an
• Reduce the deceleration rate. The frequency increased bus ripple.
converter can only decelerate the load slightly
faster than it would take for the load to naturally Possible sources of disturbance
coast to a stop.
• Line notching.
• Allow the overvoltage control circuit to take care
• Defective transformers.
of the deceleration ramp. When enabled, the
overvoltage control circuit regulates deceleration • Other loads that affect the form factor of the AC
at a rate that maintains the DC bus voltage at a waveform.
level that keeps the unit from tripping. Mains imbalances that exceed 3% cause sufficient DC bus
Overvoltage control corrects minor, but not major ripple to initiate a trip. Other causes of increased ripple
discrepancies between ramp rates. For example, if voltage on the DC bus include:
a deceleration ramp of 100 s is required, and the • Output disturbance.
ramp rate is set at 70 s, the overvoltage control
corrects it. However, with the same inertia, if the
• Missing or lower than normal output voltage on
1 phase.
ramp is set at a larger difference, such as 3 s,
overvoltage control engages initially, and then Checks
disengages, allowing the frequency converter to When a mains imbalance trip occurs, check both the input
trip. This trip is done deliberately to avoid and output voltage of the frequency converter.
confusion about the operation of the frequency Severe imbalance of supply voltage or phase loss is
converter. detectable with a voltmeter. View line disturbances
through an oscilloscope.
• Control regenerated energy with a dynamic
brake. If the DC bus level becomes too high, the Conduct tests for:
frequency converter switches the resistor across • Input imbalance of supply voltage.
the DC bus. The unwanted energy is dissipated • Input waveform.
into the external resistor bank mounted outside
of the frequency converter. This process increases • Output imbalance of supply voltage.
deceleration rate. Refer to chapter 8.7.7 Input Imbalance of Supply Voltage Test.
Less often, the load causes an overvoltage condition while
running at speed. When this condition occurs, the dynamic
brake option or the overvoltage control circuit can be
used. For example, if the speed of the load is greater than
the commanded speed, the overvoltage circuit increases
the frequency to match. The same restriction on the
amount of influence applies.

7.1.3 Control Logic Problems 7.1.4 Programming Problems
Problems with control logic can often be difficult to Difficulty with operation of the frequency converter can be
diagnose since there is usually no associated fault a result of improper programming of the frequency
indication. Typically, the frequency converter does not converter parameters.
respond to a given command.
The 3 areas where programming errors can affect
To obtain an output, provide these basic commands to the frequency converter and motor operation are:
frequency converter: • Motor settings.
• Start command: To execute. • References and limits.
• Reference or speed command: To identify the
• I/O configuration.
speed of execution.
Refer to chapter 4.6 Frequency Converter Inputs and Outputs.
The frequency converters are designed to accept various
signals. First determine which of these signals the
Set up the frequency converter correctly for the motor or
frequency converter is receiving:
motors connected to it. Parameter 1-20 Motor Power [kW] –
• Digital inputs (18, 19, 27, 29, 32, 33) parameter 1-25 Motor Nominal Speed must have data from
•
•
Analog outputs (42)
10 V output
the motor nameplate entered into the frequency converter.
This data enables the frequency converter processor to
7 7
match the frequency converter to the power characteristics
• Analog inputs (53, 54)
of the motor. The most common result of inaccurate motor
• Serial communication bus (68, 69) data is that the motor draws higher than normal amounts
The presence of a correct reading indicates that the of current to perform the task. In such cases, setting the
microprocessor of the frequency converter has detected correct values to these parameters and performing the
the signal. Refer to chapter 4.6 Frequency Converter Inputs AMA function usually solves the problem.
and Outputs and chapter 8.7.13 Input Terminal Signal Tests.
Any references or limits set incorrectly result in poor
This data can also be read in parameter group 16-6* Inputs frequency converter performance. For instance, if
& Outputs. maximum reference is set too low, the motor is unable to
reach full speed. Set these parameters according to the
requirements of the particular installation. References are
If there is no correct indication, check that the signal is
set in parameter group 3-0* Reference/Ramps.
present at the input terminals of the frequency converter.
Refer to chapter 8.7.13 Input Terminal Signal Tests.
Incorrectly set I/O configuration usually results in the
frequency converter not responding to the function as
If the signal is present at the terminal, the control card is
commanded. Remember that for every control terminal
defective and must be replaced. If the signal is not present,
input or output, there are corresponding parameter
the problem is external to the frequency converter. Check
settings. These settings determine how the frequency
the circuitry providing the signal along with its associated
converter responds to an input signal or the type of signal
wiring.
present at that output. Utilizing an I/O function involves a
2-step process. First, wire the I/O terminal properly, and
then set the corresponding parameter. Control terminals
are programmed in parameter groups 5-0* Digital I/O Mode
and 6-0* Analog I/O Mode.

7.1.5 Motor Load Problems 7.2.2 Current Sensor Faults
The motor or motor wiring can develop a phase-to-phase An overcurrent alarm that cannot be reset, even with the
or phase-to-ground short circuit resulting in an alarm motor cables disconnected, sometimes indicates current
indication. Check whether the problem is in the motor sensor failure. The frequency converter experiences
wiring or the motor itself. frequent false ground fault trips due to the DC offset
failure mode of the sensors.
A motor with unbalanced or asymmetrical impedances on
all 3 phases can result in rough operation or unbalanced An explanation of the internal composition of a Hall-effect
output currents. For measurements, use a clamp-on style type current sensor helps to explain these faults. Included
ammeter to determine whether the current is balanced on inside the device is an op-amp to amplify the signal to
the 3 output phases. Refer to chapter 8.7.14 Output usable levels in the receiving circuitry. The output at 0
Imbalance of Motor Supply Voltage Test. input level (0 A flow being measured) is 0 V, exactly
halfway between the plus and minus supply voltages. A
Usually, a current limit warning indicates an incorrect tolerance of ±15 mV is acceptable. In a 3-phase system
mechanical load. If possible, disconnect the motor from the that operates correctly, the sum of the 3 output currents is
load to determine if the load is incorrect. always 0.
7 7 Often, the indications of motor problems are similar to the When the sensor becomes defective, the output voltage
problems of a defective frequency converter. To determine level varies by more than the 15 mV. The defective current
whether the problem is with the frequency converter, sensor in that phase indicates current flow when there is
disconnect the motor from the frequency converter motor none. This condition results in the sum of the 3 output
terminals. Perform the test in chapter 8.7.14 Output currents being a value other than 0. If the deviation from 0
Imbalance of Motor Supply Voltage Test. If the 3 voltage (current amplitude) approaches a specific level, the
measurements are balanced, the frequency converter frequency converter assumes a ground fault and issues an
functions correctly. alarm.
If the voltage measurements are not balanced, the To determine whether a current sensor is defective,
frequency converter malfunctions. Typically, 1 or more disconnect the motor from the frequency converter and
output IGBTs do not function correctly. This problem can observe the current in the frequency converter display.
be a result of a defective IGBT or gate signal. With the motor disconnected, the current must be 0. A
frequency converter with a defective current sensor
7.2 Internal Frequency Converter Problems indicates some current flow. Because the current sensors
for the higher horse power frequency converters have less
To identify most problems related to failed power
resolution, an indication of a fraction of 1 A is tolerable.
components, perform a visual inspection and the static
However, that value must be considerably lower than 1 A.
tests as described in chapter 8 Test Procedures. However,
If the display shows more than 1 A of current, the current
the following problems must be diagnosed in a different
sensor is defective.
manner.
To determine which current sensor is defective, measure

7.2.1 Overtemperature Faults the voltage offset at zero current for each current sensor.
Refer to chapter 8.7.11 Current Sensor Test.
When an overtemperature indication occurs, determine
whether this condition exists within the frequency
converter or whether the thermal sensor is defective. If an
overtemperature condition is present in the frequency
converter, the outside of the unit is warm. If the exterior is
not warm, check the temperature sensor with an
ohmmeter.

7.3 Electromagnetic Interference

The following is an overview of general signal and power
wiring considerations when addressing the electromagnetic
compatibility (EMC) concerns for typical commercial and
industrial equipment. High-frequency RF emissions and
immunity are discussed. Compliance to national and
European CE EMC directives are required.
7.3.1 Effect of EMI
While electromagnetic interference (EMI) disturbances to

the operation of the unit are uncommon, the following
detrimental EMI effects can be seen:
• Motor speed fluctuations
• Serial communication transmission errors
• Frequency converter CPU exception faults
• Unexplained frequency converter trips 7 7
A disturbance resulting from other nearby equipment is
more common. Generally, other industrial control
equipment has a high level of EMI immunity. However,
non-industrial, commercial, and consumer equipment is
often susceptible to lower levels of EMI.
Detrimental effects to these systems can include the

following:
• Pressure/flow/temperature signal transmitter
signal distortion or aberrant behavior
• Radio and TV interference
• Telephone interference
• Computer network data loss
• Digital control system faults
7.3.2 Sources of EMI
Modern frequency converters (Illustration 7.1 and

Illustration 7.2) utilize IGBTs to provide an efficient and cost
effective means to create the pulse width modulated
(PWM) output waveform necessary for accurate motor
control. These IGBTs rapidly switch the fixed DC bus
voltage creating a variable frequency and a variable
voltage PWM waveform. This high rate of voltage change
[dU/dt] is the primary source of the frequency converters
generated EMI.
The high rate of voltage change caused by the IGBT

switching creates high frequency EMI.

130BD881.11
130BD880.10
1 3 4
1 2 3 2
L11
L21 T1
L1 T1 L31 5 T2
L2 T2 T3
L3 T3
6
L12
L22
4 L32
7
7
5
8
6
1 Rectifier (SCR/diodes)
7 7
1 Rectifier (SCR/diodes)
2 DC link (DC bus)
2 DC inductor - rectifier #1
3 Inverter (IGBTs)
3 DC link (DC bus)
4 Power section
4 Inverter (IGBTs)
5 Logic-to-power interface
5 DC link capacitor
6 Control logic
6 DC inductor - rectifier #2
7 Soft charge circuitry
Illustration 7.2 12-pulse Functionality Diagram

Illustration 7.1 6-pulse Functionality Diagram
7.3.3 EMI Propagation
Frequency converter-generated EMI is both conducted to the mains and radiated to nearby conductors. Refer to
Illustration 7.3. Stray capacitance between the motor conductors, equipment ground, and other nearby conductors results in
induced high-frequency currents.
High ground circuit impedance at high frequencies results in an instant voltage at points reputed to be at ground potential.
This voltage appears throughout a system as a common mode signal that interferes with control signals. 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, imperfections in the frequency converter grounding or the equipment ground system can cause
some of the currents to travel out to the power network.
Unprotected or poorly routed signal conductors located close to or in parallel to motor and mains conductors are
susceptible to EMI. Signal conductors are especially vulnerable when they are run parallel to the power conductors for any
distance. EMI coupled into these conductors can affect either the frequency converter or the interconnected control device.
Refer to Illustration 7.5.
These currents tend to travel back to the frequency converter. However, imperfections in the system cause some current to
flow in undesirable paths and expose other locations to EMI. When the mains conductors are close to the motor cables,
high-frequency currents can be coupled into the mains supply.

Drive
130BX138.11
Motor
AC line Motor cable
Stray capacitance Stray capacitance
Ground Potential 1 Potential 2 Potential 3
Illustration 7.3 Ground Currents
Drive 7 7
130BX139.12
Motor
AC line Motor cable
Stray capacitance
Signal wiring to BMS
Illustration 7.4 Signal Conductor Currents

130BX140.12
Drive
Motor
AC line Motor cable
Stray capacitance
AC line
Illustration 7.5 Alternate Signal Conductor Currents

7.3.4 Preventive Measures A simple alternative is to twist the existing single

conductors to provide a balanced capacitive and inductive
EMI-related problems are more effectively alleviated during coupling. This method cancels differential mode
the design and installation phases rather than during interference. While not as effective as true twisted-pair
service. cable, it can be implemented in the field using the
available materials.
Grounding Motor cable selection
The frequency converter and motor must be solidly The management of the motor conductors has the
grounded to the equipment frame. A good high-frequency greatest influence on the EMI characteristics of the system.
connection is necessary to allow the high-frequency These conductors must receive the highest attention
currents to return back to the frequency converter rather whenever EMI is a problem. Single conductor wires provide
than to travel through the power network. The ground the least protection from EMI emissions. Often, if these
connection is ineffective if it has high impedance to high- conductors are routed separately from the signal and
frequency currents. Therefore it must be as short and mains wiring, then no further consideration is needed. If
direct as practical. Flat-braided cable has lower high- the conductors are routed close to other susceptible
frequency impedance than round cable. Simply mounting conductors, or if the system is suspected to cause EMI
the frequency converter or motor onto a painted surface problems, consider alternate motor wiring methods.
does not create an effective ground connection. In
7 7 addition, running a separate ground conductor directly
Installing shielded power cable is the most effective
methods to alleviate EMI problems. The shield forces the
between the frequency converter and the running motor is
noise current to flow directly back to the frequency
recommended.
converter. This prevents it from flowing back into the
Cable routing power network or other undesirable high-frequency paths.
Avoid routing the following in parallel: Unlike most signal wiring, the shielding on the motor cable
must be terminated at both ends.
• Motor wiring
If a shielded motor cable is not available, then 3-phase
• Mains wiring
conductors plus ground in a conduit provides some
• Signal wiring protection. This technique is not as effective as shielded
If parallel routing is unavoidable, try to maintain a cable due to the unavoidable contact of the conduit with
separation of 200 mm (6–8 in) between the cables, or various points within the equipment.
separate them with a grounded conductive partition. Avoid Serial communications cable selection
routing cables through free air. There are various serial communication interfaces and
Signal cable selection protocols in the market. Each interface/protocol
Single conductor 600 V rated wires provide the least recommends 1 or more specific types of cables. Refer to
protection from EMI. Twisted-pair cables and shielded the manufacturer documentation when selecting these
twisted-pair cables are available that are designed to cables. Similar recommendations apply to serial communi-
minimize the effects of EMI. While unshielded twisted-pair cation cables as to other signal cables. Using twisted-pair
cables are often adequate, shielded twisted-pair cables cables and routing them away from power conductors is
provide another degree of protection. Terminate the signal encouraged. While shielded cable provides extra EMI
cable shield in a manner that is appropriate for the protection, the shield capacitance can reduce the
connected equipment. Avoid terminating the shield maximum allowable cable length at high data rates.
through a pigtail connection as this method increases the
high-frequency impedance and reduces the effectiveness
of the shield. Refer to chapter 4.9 Grounded Shielded Cables.

7.3.5 Proper EMC Installation
Illustration 7.6 shows a correct installation with EMC considerations in mind. Although most installations do not follow all the
recommended practices, the closer an installation resembles this example, the better immunity the network has against EMI.
If EMI problems occur in an installation, refer to this example. Attempt to replicate this installation recommendation as
closely as possible to alleviate such problems.
130BD628.11
7 7
1
10
2
9
4
8
6 U
V
W
PE
1 Stripped cable insulation 6 Motor cable, 3-phase cables, and ground

2 Clamped screen-to-ground point inside 7 To prevent ground loops due to variations in ground potential, fit an equalizing
cabinet cable next to the control cable. Minimum cable cross-section is 16 mm2 (4 AWG)
3 Control cables 8 Mains cable, 3-phase cables, and reinforced ground
4 Minimum 200 mm (7.9 in) between control 9 EMC cable gland
cables, motor cable, and mains cable
5 Screened cable 10 Gland plate
Illustration 7.6 Proper EMC Installation

Test Procedures VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
8 Test Procedures
8.1 Introduction 8.2 Tools Required for Testing
WARNING Item
ESD protection kit
Description
Wrist strap and mat
PERSONAL INJURY RISK Metric socket set 7–19 mm
Touching electrical parts of the frequency converter may Socket extensions 100–150 mm (4 inch and 6 inch)
be fatal even after equipment has been disconnected Magnetic sockets –
from AC power.
Ratchet wrench –
• Before touching any potentially live parts of the Torque wrench Torque range 0.5–19 Nm
frequency converter, refer to chapter 2 Safety. (6–170 in-lb)
• Wait for the frequency converter components to Torx driver set T10–T50
discharge fully. Refer to Table 2.1 or the label on Needle nose pliers –
the frequency converter for specific discharge Screwdrivers Standard and Phillips
time.
This section contains detailed procedures for testing Item Description
8 8 frequency converters. Previous sections of this guide

provide symptoms, alarms, and other conditions which
Digital Volt-Ohm Meter
(PWM-compatible)
• Rated for true RMS
require more test procedures to diagnose the frequency

converter further. The results of these tests indicate the
appropriate repair actions. • Supports the diode mode
Analog voltmeter –
Frequency converter testing is divided into static tests and Oscilloscope –
dynamic tests. Clamp-on ammeter Rated for true RMS
Split bus supply p/n 130B3146
Static tests Signal test board p/n 176F8437
Static tests are performed on the rectifier and inverter Signal test board extension p/n 130B3147
modules. These tests are conducted without power applied Test cable p/n 176F8766
to the frequency converter. Most frequency converter
problems can be diagnosed simply with these tests. Static Table 8.2 Instruments Recommended to Test Frequency Converter
tests are performed with little or no disassembly. The
purpose of static testing is to check for shorted power
components. Perform these tests on any unit suspected of
containing faulty power components before applying
power.
Dynamic tests
Dynamic tests are performed with power applied to the
frequency converter. Dynamic testing traces signal circuitry
to isolate faulty components.

Test Procedures Service Guide
8.2.1 Signal Test Board 8.3 Pre-test Precautions
The signal test board plugs into the top of the modules NOTICE
and tests the circuitry within the frequency converter. Its For best results, perform the static test procedures in this
use is described in the procedures where called out. Refer section in the order they appear.
to chapter 9.1.3 Signal Test Board Pin Outs: Description and
Voltage Levels for detailed pin descriptions. Observe the following safety precautions before
performing the static tests.
• Prepare the work area according to the ESD
130BX66.10
regulations.
• Ground the ESD mat and wrist strap.
• Ensure that the ground connection between
body, the ESD mat, and the frequency converter
is always present while performing service.
• Handle disassembled electronic parts with care.
• Perform the static test before powering up the
faulty unit.
• Perform static test after completing the repair
and assembly of the frequency converter.
• Connect the frequency converter to the mains 8 8
only after completion of static tests.
• Complete all necessary precautions for system
start up, before applying power to thefrequency
converter.
Illustration 8.1 Signal Test Board 8.4 Static Tests for Rectifier Module
8.4.1 Access to Rectifier Module Test Points
8.2.2 Metering Tools
WARNING
For best troubleshooting results, perform the static test SHOCK AND INJURY HAZARD
procedures described in this section in the order Touching electrical parts of the frequency converter can
presented. be fatal even after the equipment has been disconnected
from AC power.
Perform all tests with a meter capable of testing diodes.
Perform the following steps before touching any internal
Use a digital Volt-Ohm Meter (VOM) set on the diode scale
components:
or an analog ohmmeter set on Rx100 scale. Before making
1. Disconnect the mains power.
any checks, disconnect all input, motor, and brake resistor
connections. 2. Disconnect the motor.
3. If there is a brake option, disconnect the brake.
Diode drop
4. If there is a load share/regeneration option,
A diode drop reading varies depending on the model of
disconnect it.
ohmmeter. Whatever the ohmmeter shows as a typical
forward bias diode is defined as a diode drop in these 5. Wait for the capacitors to discharge fully. Refer
procedures. With a typical DVM, the voltage drop across to the label on the front of the frequency
most components is around 0.300 to 0.500. The opposite converter door for the exact discharge time.
reading is referred to as infinity, and most show the value 6. Ensure that the DC-bus capacitors have
OL for overload. discharged fully by measuring the DC bus using
a voltage meter.
Many of the following test procedures require access to

the DC bus. Refer to Illustration 8.2 – Illustration 8.4 for
rectifier module test points.

130BE346.10
1
8 8
1 Power card fuse 3 DC bus bars

2 Signal plug connectors 4 Mains input
Illustration 8.2 Rectifier Module Test Points, F1–4 Enclosure Size

130BE340.10
1
3
8 8
1 DC bus bar (rectifier 2) 5 Mains input

2 DC bus bar 6 Mains input
3 Signal plug connectors 7 DC bus bar (rectifier 1)
4 Motor output
Illustration 8.3 Rectifier and Inverter Module Test Points, F8–F9 Enclosure Size

130BE348.10
6
1
5
8 8
1 DC bus bar (module 2) 4 Mains input (module 1)

2 Signal plug connectors (module 2) 5 Signal plug connectors (module 1)
3 Mains input (module 2) 6 DC bus bar (module 1)
Illustration 8.4 Rectifier Module Test Points, F10–F13 Enclosure Size

8.4.2 Soft Charge Fuse Test Both the rectifier and soft charge circuits are tested
simultaneously. The soft charge circuit includes a soft
This test determines if any of the soft charge fuses are charge rectifier, fuses, and a soft charge resistor. The
open. rectifier circuit includes the SCR/diode modules. The soft
charge resistor limits the inrush current when power is
Use the 12-pin connector on the top of the rectifier applied to the frequency converter. The soft charge circuit
module for testing. card also provides snubbing for the SCRs.
1. L1 to pins 6, 11, and 12 (red wires).
2. L2 to pins 4, 9, and 10 (white wires). NOTICE
It is important to pay close attention to the polarity of
3. L3 to pins 2, 7, and 8 (black wires).
the meter leads to ensure identification of a faulty
A measurement of 0 Ω indicates good continuity. To component if an incorrect reading appears.
replace the fuses on the soft charge card, remove the
rectifier module. 8.4.3.1 Soft Charge/Rectifier Circuit Test 1
1. Set the meter to measure for a diode drop.

130BX332.12
1
2. Verify that power is disconnected from the
frequency converter and ensure that the
capacitors are fully discharged.
3.
4.
Remove the safety covers to access the unit.
Connect the positive (+) meter lead to the
8 8
2 positive (+) DC bus.
5. Connect the negative (-) meter lead to terminals
L1, L2, and L3 in turn.
6. Check the reading for each connection. Each
reading must show infinity. The meter can start
out at a low value and climb toward infinity as
capacitance is charged within the unit.
Incorrect reading
With the part 1 test connection, the SCRs in the SCR/diode
modules are reverse biased so they are blocking current
flow. If a short circuit exists, it is possible that either the
SCRs or the diodes in the soft charge rectifier are shorted.
To isolate between SCRs or the soft charge rectifier,
perform internal module testing.
1 Rectifier module
2 12-pin connector
8.4.3.2 Soft Charge/Rectifier Circuit Test 2
Illustration 8.5 Rectifier Detail
1. Set the meter to measure for a diode drop.
2. Reverse meter leads by connecting the negative
8.4.3 Soft Charge and Rectifier Circuit Tests (-) meter lead to the positive (+) DC bus.
3. Connect the positive (+) meter lead to L1, L2, and
Different enclosures contain multiple circuits, and it is L3 in turn.
important to perform these tests on each soft charge and
rectifier circuit.
reading must show a diode drop.
• F1–F4 enclosures contain 1 rectifier module, with
2 or 3 soft charge circuits and 1 rectifier circuit.
• F8–F9 enclosures contain 1 rectifier module, with
1 soft charge circuit and 2 rectifier circuits.
• F10–F13 enclosures contain 2 rectifier modules,
with 1 or 2 soft charge circuits and 1 rectifier
circuit per module.

Incorrect reading out at a low value and climb toward infinity as

With the part 2 test connection, even though the SCRs in capacitance is charged within the unit.
the SCR/diode modules are forward biased by the meter,
Incorrect reading
current does not flow through the SCRs without providing With the part 4 test connection, the diodes in the SCR/
a signal to their gates. The upper diodes in the soft charge diode modules and the lower diodes in the soft charge
rectifier are forward biased so the meter reads the voltage rectifier are reverse biased. If a short circuit exists, it is
drop across those diodes. possible that either the diodes in the SCR/diode modules
• If an open circuit reading (infinity sign) is present, or the lower diodes in the soft charge rectifier are shorted.
it indicates that the upper diodes in the soft To isolate between SCRs or the soft charge rectifier,
charge rectifier are open. It also can indicate that perform internal module testing.
1 or more of the soft charge fuses are open.
Furthermore, it can indicate that the soft charge
8.5 Static Tests for Inverter Module
resistor is open. To isolate between the 3 8.5.1 Access to Inverter Module Test Points
possibilities, perform internal module testing.
• A short circuit reading indicates either 1 or more
of the upper soft charge rectifier diodes are WARNING
shorted, or the SCRs are shorted in the SCR/diode SHOCK AND INJURY HAZARD
module. To isolate between SCRs or the soft Touching electrical parts of the frequency converter can
charge rectifier, perform internal module testing. be fatal even after the equipment has been disconnected
from AC power.
8 8 8.4.3.3 Soft Charge/Rectifier Circuit Test 3 Perform the following steps before touching any internal
components:
1. Set the meter to measure for a diode drop. 1. Disconnect the mains power.
2. Connect the positive (+) meter lead to the 2. Disconnect the motor.
negative (-) DC bus. 3. If there is a brake option, disconnect the brake.
3. Connect the negative (-) meter lead to terminals 4. If there is a load share/regeneration option,
L1, L2, and L3 in turn. disconnect it.
4. Check the reading for each connection. Each 5. Wait for the capacitors to discharge fully. Refer
reading must show a diode drop. to the label on the front of the frequency
Incorrect reading converter door for the exact discharge time.
With the part 3 test connection, the diodes in the SCR/ 6. Ensure that the DC-bus capacitors have
diode modules and the lower diodes in the soft charge discharged fully by measuring the DC bus using
rectifier are forward biased. The meter reads the diode a voltage meter.
drops. If a short circuit exists, it is possible that either the
diodes in the SCR/diode modules or the lower diodes in
the soft charge rectifier are shorted. To isolate between To access the inverter module test points, perform the
SCRs or the soft charge rectifier, perform internal module following steps:
testing. 1. If a brake option is present, remove 2 brake
option jumper bus bars from each module by
Although an open reading is possible, it is unlikely since it
removing the attaching nut at each end of the
indicates that both the diodes in the SCR/diode modules
bus bar.
and the lower diodes in the soft charge rectifier are open.
If that occurs, replace both diodes. 2. Remove 3 motor jumper bus bars from each
module by removing the attaching nut at each
8.4.3.4 Soft Charge/Rectifier Circuit Test 4 end of the bus bar.
3. Remove the positive DC jumper bus bar from the
1. Set the meter to measure for a diode drop. fuse by removing attaching hardware at each end
of the bus bar.
2. Reverse meter leads by connecting the negative
(-) meter lead to the negative (-) DC bus. 4. Remove the negative DC jumper bus bar from
the fuse by removing the attaching hardware at
3. Connect the positive (+) meter lead to L1, L2, and
each end of the bus bar.
L3 in turn. Each reading must show infinity.

130BX325.13
2
8 8
1 Positive (+) DC link fuse 3 Brake option jumper bus bar

2 Negative (-) DC link fuse 4 Motor jumper bus bar
Illustration 8.6 Inverter Module Test Points, F-size Enclosure

8.5.2 Inverter Circuit Tests 8.5.2.2 Inverter Circuit Test 2
The inverter module is primarily made up of the IGBTs 1. Reverse the meter leads by connecting the
used for switching the DC bus voltage to create the output negative (-) meter lead to the positive (+) DC bus
to the motor. The IGBTs are grouped into 3 per module. bar.
The frequency converter also has snubber capacitors on
2. Connect the positive (+) meter lead to U, V, and
each IGBT module.
W in sequence.
8.5.2.1 Inverter Circuit Test 1
Before starting tests, ensure that meter is set to diode Incorrect reading
scale. An incorrect reading indicates a failed IGBT in that inverter
1. Verify that power is disconnected from the module. Replace the IGBT module according to
frequency converter and ensure that the chapter 11.1.8 IGBT Module Replacement.
2. Remove the safety covers to access the unit. 8.5.2.3 Inverter Circuit Test 3
3. Connect the positive (+) meter lead to the (+)
1. Connect the positive (+) meter lead to the
positive DC bus bar.
negative (-) DC bus bar.
8 8 5.
U, V, and W in sequence.
Check the reading for each connection. Each
U, V, and W in sequence.
capacitance is charged within the unit. Incorrect reading
An incorrect reading indicates a failed IGBT in that inverter
Incorrect reading
module. Replace the IGBT module according to
chapter 11.1.8 IGBT Module Replacement.
8.5.2.4 Inverter Circuit Test 4
130BX319.13
1 2
1. Reverse the meter leads by connecting the

negative (-) meter lead to the negative (-) DC bus
bar.
5
2. Connect the positive (+) meter lead to U, V, and
W in sequence.
4 3. Check the reading for each connection. Each
capacitance is charged within the unit.
3
Incorrect reading
1 Top (-) DC link fuse bus bar

2 (-) DC link fuse (none in 12-pulse models F8/F9)
3 Bottom (+) DC link fuse bus bar
4 (+) DC link fuse (none in 12-pulse models F8/F9)
5 Top (+) DC link fuse bus bar
Illustration 8.7 Exploded View of Inverter Test Points

8.5.3.3 Brake IGBT Test 3

8.5.3 Brake IGBT Tests
1. Connect the positive (+) meter lead to the brake
This test can only be carried out on units equipped with a resistor terminal R- (81).
dynamic brake option. 2. Connect the negative (-) meter lead to the
negative (-) DC bus.
1. Verify that power is disconnected from the
frequency converter and ensure that the
2. Remove the safety covers to access the unit. capacitance is charged within the unit.
3. Note the position of the brake jumper bus bars Incorrect reading
before removal. An incorrect reading indicates that the brake IGBT is
4. Remove the brake jumper bus bars. Refer to defective. Replace the brake IGBT according to
chapter 8.5.1 Access to Inverter Module Test Points. chapter 11.1.7 Brake IGBT Module Replacement.
8.5.3.1 Brake IGBT Test 1 8.6 Fan Continuity Tests

Make all continuity checks using an ohmmeter set to Rx1
1. Verify that power is disconnected from the scale. A digital or analog ohmmeter can be used also.
frequency converter and ensure that the Some instability can result when measuring resistance of a
transformer with a multimeter. Reduce this instability by
turning off the auto-ranging function and setting the 8 8
resistor terminal R+ (82). measurement manually. For a list of fan locations and
source control, refer to chapter 5.3.6.2 Fan Location.
3. Connect the negative (-) meter lead to the brake
resistor terminal R- (81).
8.6.1 Fan Continuity Test 1
Incorrect reading
An incorrect reading indicates that the brake IGBT is
This test checks the fan fuses.
defective. Replace the brake IGBT according to
chapter 11.1.7 Brake IGBT Module Replacement.
Check the 15 A fan fuse on the top of each inverter
module.
8.5.3.2 Brake IGBT Test 2
An open fuse could indicate more faults. Replace the fuse
and continue the fan checks.
resistor terminal R- (81).
2. Connect the negative (-) meter lead to the brake
resistor terminal R+ (82).
Incorrect reading
An incorrect reading indicates that the brake IGBT is
defective. Replace the brake IGBT according to
chapter 11.1.7 Brake IGBT Module Replacement.

8.6.2 Fan Continuity Test 2 Incorrect reading

An incorrect reading makes it necessary to perform the
This test checks the continuity from the AC input terminals following steps:
to each inverter module. 1. Perform the rectifier module soft charge fuse test.
Refer to chapter 8.4.2 Soft Charge Fuse Test. If any
F1–F4 enclosure sizes soft charge fuses are open, replace the fuse and
1. Unplug the 10-pin connector from the top of retest the fan continuity.
each inverter module. 2. Check the wire harness between the rectifier
2. Verify that the 8-pin connector is plugged into module (12-pin connector) and each inverter
the top of the inverter module and that the 12- module (8-pin connector). If the wire harness is
pin connector is plugged into the top of the the problem, replace and retest the fan
rectifier module. continuity.
3. Read the terminals on the inverter module side 3. If the prior checks do not identify the problem,
(female connector). remove the faulty inverter module and check the
connections between the connectors on the top
4. For each inverter module, measure from L3 (T) to of the module and the power card. If these
terminal 1. The reading must be <1 Ω. connections are the problem, replace the faulty
5. For each inverter, measure from L2 (S) to terminal connectors and retest the fan continuity.
2. The reading must be <1 Ω.
NOTICE
8 8 F8–F9 enclosure sizes
1. Unplug the 10-pin connector from the top of
After this check, reconnect all connectors on top of the
rectifier module and the inverter modules.
each inverter module.
2. Verify that the 8-pin connector is plugged into 8.6.3 Fan Continuity Test 3
the top of the inverter module and that the 12-
pin connector is plugged into the top of the This test checks the fan transformer. There is 1 fan
rectifier module. transformer for each inverter module.
3. Read the terminals on the inverter module side

For F8–F13 enclosure sizes, there is also a fan transformer
(female connector).
inside the rectifier module. This transformer cannot be
4. For each inverter module, measure from L32 (T2) tested without removing the module from the frequency
to terminal 1. The reading must be <1 Ω. converter. The fan transformer inside the rectifier module
5. For each inverter module, measure from L22 (S2) has similar resistance readings.
to terminal 2. The reading must be <1 Ω.
F10–F13 enclosure sizes T4/T5 frequency converters
Some inverter modules are connected to S1 and T1, while 1. Unplug the 10-pin connector on the top of each
other inverter modules are connected to S2 and T2. inverter module.
1. Unplug the 10-pin connector from the top of 2. Read the terminals on the connector end of the
each inverter module. wire harness (male connector).
2. Verify that the 8-pin connector is plugged into 3. For each fan transformer, measure between pins 1
the top of the inverter module and that the 12- and 2. The reading must be approximately 4 Ω.
pin connector is plugged into the top of the
4. For each fan transformer, measure between pins 1
rectifier module.
and 7. The reading must be approximately 3 Ω.
5. For each fan transformer, measure between pins 2
(female connector).
and 7. The reading must be approximately 1 Ω.
4. For each inverter module, measure from T1/T2 to
terminal 1. The reading must be <1 Ω.
5. For each inverter module, measure from S1/S2 to
terminal 2. The reading must be <1 Ω.

T7 frequency converters To check for a failed fan (all F-size enclosures)

1. Disconnect the wiring from the fan terminals.
1. Unplug the 10-pin connector on the top of each
inverter module. 2. Read across the fan terminals on each fan. The
2. Read the terminals on the connector end of the reading must be approximately 78 Ω.
wire harness (male connector). 3. Replace any defective fans and repeat the test.
3. For each fan transformer, measure between pins 1 NOTICE
and 2. The reading must be approximately 7.4 Ω. After this check, reconnect the 10-pin connector on top
4. For each fan transformer, measure between pins 1 of inverter module number 2.
and 7. The reading must be approximately 3.6 Ω.
5. For each fan transformer, measure between pins 2 8.6.5 Fan Continuity Test 5 (F1–F4 only)
and 7. The reading must be approximately 3.2 Ω.
This test checks the rectifier heat sink fan and the door fan
Incorrect reading
in the options cabinet.
An incorrect reading indicates a defective fan transformer.
Replace the fan transformer.
NOTICE inverter module number 1.
After this check, reconnect the 10-pin connector to the
2. Read the terminals on the connector end of the
top of each inverter module.
wire harness (male connector).
8.6.4 Fan Continuity Test 4 (F1–F4 only) 3. Measure between pins 5 and 10.
8 8
• The reading for an F1 or F2 enclosure
This test checks the wiring between the inverter module size (no option cabinet) must be approx-
and the rectifier cabinet door fans (F1–F4 only). All 3 door imately 21 Ω.
fans are controlled from inverter module number 2. For • The reading for an F3 or F4 enclosure
inverter module location, refer to chapter 5.3.7 Module size (with option cabinet) must be
Layout. approximately 15 Ω.
Incorrect reading
inverter module number 2. An incorrect reading can indicate a failed fan or a bad wire
harness. The following steps are necessary to further
2. Read the terminals on the connector end of the
identify the problem:
1. Perform the heat sink fan ohm test on the
3. Measure between pins 5 and 10. The reading rectifier module.
must be approximately 25 Ω. 2. If the frequency converter is an F3 or F4
Incorrect reading enclosure size (with option cabinet), perform the
An incorrect reading can indicate a failed fan or a bad wire option cabinet door fan test.
harness. 3. If the previous checks do not identify the
problem, remove the faulty rectifier module and
check the connections between the connectors
on the top of the module and the power card. If
these connections are the problem, replace the
faulty connectors and retest the fan continuity.
4. If none of the checks identify the problem,
replace the wire harness between inverter
module number 1 and the rectifier module.
NOTICE
After this check, reconnect the 10-pin connector on top
of inverter module number 1.

8.6.6 Fan Continuity Test 6 8.6.7 Fan Continuity Test 7 (F3–F4 only)
This test checks the resistance of the heat sink fan on each This is an additional test for F3–F4 enclosure sizes. This test
module. checks the wiring between the rectifier module and the
option cabinet door fan.
Rectifier module (F1–F4 only)
1. Unplug the 8-pin connector from the top of the 1. Unplug the 8-pin connector from the top of the
rectifier module. rectifier module.
2. Read the terminals on the inverter module side 2. Read the terminals on the connector end of the
(female connector).
3. Measure between pins 5 and 8. The reading must
3. For each rectifier module, measure between pins
1 and 4. The reading must be approximately 21 be approximately 78 Ω.
Ω. Incorrect reading
Incorrect reading can indicate a failed fan or a bad wire
Inverter module (all F-size enclosures)
harness. Measure the fan resistance at the option cabinet
1. Unplug the 10-pin connector from the top of door fan. If bad, replace the door fan. If good, replace the
each inverter module. wire harness.
(female connector).
NOTICE
After this check, reconnect the 8-pin connector on top of
8 8 3. For each inverter module, measure between pins
5 and 10. The reading must be approximately 21
the rectifier module.
Ω.
8.7 Dynamic Test Procedures
Incorrect reading
An incorrect reading indicates either a defective heat sink The test procedures in this section are numbered for
fan or defective wiring to the fan. reference only and do not need to be performed order.
Perform tests only as necessary.
1. Remove the heat sink fan. Refer to
chapter 10.2.4 Heat Sink Fan Replacement.
8.7.1 Split Bus Mode
2. Make the following measurements on the
connector leading to the fan.
In the split bus mode, the DC bus in each module is split
3. Measure between pins 1 and 2. The reading must into 2 parts. One part connects to the DC bus and power
be approximately 21 Ω. card to provide low-voltage power for the SMPS. The other
4. Measure between pins 1 and 3. The reading must part provides low-voltage power to the DC capacitors and
be approximately 45 Ω. the output IGBTs for test purposes. For more information,
refer to chapter 9.1.1 Split Bus Supply.
5. Measure between pins 2 and 3. The reading must
be approximately 68 Ω.
8.7.2 Warnings
6. Measure between pins 1 and 4. Must read open.
WARNING
SHOCK HAZARD AND RISK OF INJURY
An incorrect reading here indicates a failed fan. Replace Never disconnect the input cabling to the frequency
the fan. Refer to chapter 10.2.4 Heat Sink Fan Replacement. converter with power applied. Contact with powered
components can result in death or serious injury.
If the readings are OK, the problem is the wire harness
inside the module. Remove the faulty module and replace
the fan wire harness.
NOTICE
After this check, reconnect all connectors on top of the
rectifier module and the inverter modules.

WARNING Readings of less than 446 V AC indicate problems with the

input AC mains voltage.
HIGH VOLTAGE
Drives contain high voltage when connected to AC mains In addition to the actual voltage reading, the balance of
input, DC supply, or load sharing. Failure to perform the voltage between the phases is also important. The
installation, start-up, and maintenance by qualified frequency converter can operate within specifications as
personnel can result in death or serious injury. long as the imbalance of supply voltage is not more
• Only qualified personnel must perform instal- than 3%.
lation, start-up, and maintenance.
• Before performing any service or repair work, Danfoss calculates line imbalance per an IEC specification.
use an appropriate voltage measuring device to Imbalance = 0.67 x (Vmax – Vmin) / Vavg
make sure that there is no remaining voltage on
the drive. 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
500 V AC is Vmax, 478.5 V AC is Vmin, and 485.7 V AC is Vavg,
WARNING resulting in an imbalance of 3%.
SHOCK HAZARD AND RISK OF INJURY
For dynamic test procedures, mains input power is Although the frequency converter can operate at higher
required, and all devices and supplies connected to line imbalances, the lifetime of components, such as DC
mains are energized at rated voltage. Contact with bus capacitors, is shortened.
powered components can result in death or serious
injury.
8 8
Incorrect reading
• Do not touch energized parts of the frequency An incorrect reading requires that the main supply is
converter when connected to mains. further tested for:
• Open (blown) input fuses or tripped circuit
breakers
8.7.3 No Display Text
NOTICE
A frequency converter with no display can result from Open (blown) input fuses or tripped circuit breakers
several causes. If the display is dark and the green power- usually indicate a more serious problem. Before replacing
on indicator light is not lit, proceed with the following fuses or resetting breakers, perform static tests.
tests. • Open disconnects or line side contactors
• Problems with the power distribution system
8.7.4 Input Voltage Test
8.7.5 Basic Control Card Voltage Test
1. Apply power to frequency converter.
2. Use a digital volt-meter to measure input mains 1. Measure the control voltage at terminal 12 in
voltage between the frequency converter input relation to terminal 20. A correct reading is 24 V
terminals in turn: DC (21–27 V DC).
2a For F1–F4 enclosure sizes Incorrect reading
L1 to L2 An incorrect reading can indicate that a fault in the
L1 to L3 customer connections is loading down the supply. Unplug
L2 to L3 the terminal strip and repeat the test. Remember to check
2b For F8–F13 enclosure sizes the customer connections.
L11 to L12 2. Measure the 10 V DC control voltage at
L21 to L22 terminal 50 in relation to terminal 55. A correct
L31 to L32 reading is 10 V DC (9.2–11.2 V DC).
Incorrect reading
For 380–480 V frequency converters, all measurements An incorrect reading can indicate that a fault in the
must be within the range of 342–528 V AC. Readings of customer connections is loading down the supply. Unplug
less than 342 V AC indicate problems with the input AC the terminal strip and repeat the test. Remember to check
mains voltage. For 525–690 V frequency converters, all the customer connections.
measurements must be within the range of 446–759 V AC.

Correct reading 6. Reapply power to the frequency converter and

A correct reading of both control card voltages indicates place it in run.
that the LCP or the control card is defective. Replace the
7. Repeat the current measurements.
LCP with a known good one. If the problem persists,
replace the control card. If the imbalance of supply current moves when swapping
the leads, then the mains supply is suspect. Otherwise, it
can indicate a problem with the gating of the SCR. This
8.7.6 DC Undervoltage Test
problem can be due to a defective SCR. It can also be
caused by problems in the gate signals from the power
The soft charge circuit initially charges the DC bus. If the
card to the module, including the power card wire harness
DC bus voltage is below normal, it indicates that either the
to the SCR gates. Further tests on the proper gating of the
mains voltage is out of tolerance or the soft charge circuit
SCRs require an oscilloscope equipped with current probes.
is restricting the DC-bus from charging. Ensure that the
mains voltage is correct by conducting the input voltage
test. 8.7.8 Input Waveform Test
Testing the current waveform on the input of the

If excessive input power cycling has occurred, the PTC
frequency converter helps in troubleshooting mains phase
resistors on the soft charge card can be restricting the bus
loss conditions or suspected problems with the SCR/diode
from charging. If so, expect to read a DC-bus voltage in
modules. This test easily detects phase loss caused by the
the area of 50 V DC. Refer to chapter 8.7.4 Input Voltage
mains supply.
Test.
8 8 8.7.7 Input Imbalance of Supply The SCR/diode modules control the rectifier section. If 1 of
the SCR/diode modules becomes defective or the gate
Voltage Test
signal to the SCR is lost, the frequency converter responds
the same as losing 1 of the phases.
Theoretically, the current drawn on all 3 input phases must
be equal. Some imbalance can be seen, however, due to
The following measurements require an oscilloscope with
variations in the phase-to-phase input voltage and single-
voltage and current probes.
phase loads within the unit.
Under normal operating conditions, the waveform of a

A current measurement of each phase reveals the balanced
single phase of input AC voltage to the frequency
condition of the line. To obtain an accurate reading, run
converter appears as in Illustration 8.8.
the frequency converter at its rated load or at a load of
not less than 40%.
Input A
130BX142.10
1. Perform the input voltage test. Refer to
chapter 8.7.4 Input Voltage Test. Voltage
imbalances result in a corresponding current
imbalance.
2. Apply power to the frequency converter and
place it in run.
5 ms/Div.
3. Using a clamp-on amp meter, read the current on
0.0 ms
Illustration 8.8 Normal AC Input Voltage Waveform

each of 3 input lines.
Typically, the current does not vary from phase-
to-phase by more than 5%. Greater current
variation indicates a problem with the mains The waveform shown in Illustration 8.9 shows the input
supply or a problem within the frequency current waveform for the same phase as in Illustration 8.8
converter. while the frequency converter is running at 40% load. The
2 positive and 2 negative humps are typical of any 6 diode
4. Remove power to frequency converter and let the bridge. It is the same for frequency converters with SCR/
capacitors discharge fully. diode modules.
5. Swap the phase that appears to be incorrect with
1 of the other 2 phases. If all 3 phases are The same waveform is seen when measuring a 12-pulse
different from one another, swap the phase with frequency converter between the rectifier and the
the highest current with the phase with the transformer.
lowest current.

Input B
Input A
130BX143.10
130BX153.10
8.00
6.00
4.00
2.00
0.00 V
-2.00
-4.00
0.0 ms 5 ms/Div.
-6.00
Illustration 8.9 AC Input Current Waveform with Diode Bridge -8.00

-4.0ms 50Us/Div
Illustration 8.11 Gate Signal Waveform
With a phase loss, the current waveform of the remaining

phases resembles Illustration 8.10. Incorrect reading
If 1 or more of the IGBT gate signals are missing, it
Input B
130BX144.10 indicates a faulty connection in the ribbon cable from the
control card to the MDCIC, or from the MDCIC to the
inverter module. Check the cables and replace if necessary.
If all 6 signals are missing, replace the control card.
Conduct the IGBT switching test with the frequency
converter powered as in this procedure.
8 8
0.0 ms 5 ms/Div. 8.7.10 IGBT Switching Test
Illustration 8.10 Input Current Waveform with Phase Loss
1. Power the unit in the split bus mode as described
in the gate signal test procedure.
Always verify the condition of the input voltage waveform 2. Observe the phase-to-phase output waveforms
before forming a conclusion. The current waveform follows on all 3 phases with the oscilloscope.
the voltage waveform. If the voltage waveform is incorrect,
investigate the reason for the AC supply problem. If the 3. All waveform readings must appear similar to
voltage waveform on all 3 phases is correct, but the Illustration 8.12.
current waveform is not, then check the input rectifier 4. Repeat this procedure for all inverter modules.
circuit in the frequency converter. Perform the soft charge
130BX337.10
and rectifier tests. Refer to chapter 8.4 Static Tests for
Rectifier Module.
8.7.9 Gate Signal Test
1. Remove the output bus bars from all inverter

modules.
2. Power the frequency converter in split bus mode.
Refer to chapter 8.7.1 Split Bus Mode.
3. Connect a 24 V DC supply to the (+) and (-) DC
bus bars.
4. Connect the signal test board to the 30-pin
connector at the top of the inverter module.
Illustration 8.12 Output Waveform
5. Apply a run command and a speed command
above 0 RPM. (Local start mode is sufficient).
6. Connect the common lead of an oscilloscope to Incorrect reading
terminal 4 of the signal test board. Observe the An incorrect reading indicates that an IGBT or gate driver
waveform on terminals 25–30 in turn. Each card is defective. Check all IGBT modules for signs of
reading must appear similar to Illustration 8.11. damage. If no damage is found, replace gate driver card.
7. Repeat this procedure for each inverter module.

8.7.11 Current Sensor Test • Motor check

• Premagnetizing
1. Apply power to the unit.
• DC hold
2. Ensure that the following parameter set-ups that
create a holding torque while at 0 speed are • DC brake
disabled: If the parameters are not disabled, the current
shown exceeds 1–2 A.
• Motor check
7. Run the frequency converter with a 0 speed
• Premagnetizing
reference.
• DC hold
8. In turn, measure AC voltage at terminals 1, 2, and
• DC brake 3 of the signal test board. These terminals
If the parameters are not disabled, the current correspond with current sensor outputs U, V, and
shown exceeds 1–2 A. W, respectively. Expect a reading near 0 V but no
greater than 15 mV.
3. Run frequency converter with a 0 speed
reference. 9. Repeat the procedure for each inverter module in
the frequency converter.
4. Read the output current in the display. It must
indicate approximately 1–2 A. Incorrect reading
A current sensor feedback signal here must read approxi-
Incorrect reading
mately 400 mV at 100% frequency converter load. Replace
8 8 If the current is greater than 1–2 A and a current
producing parameter is not active, perform the following
the corresponding current sensor if the reading is greater
than 15 mV. Refer to chapter 11.1.5 Current Sensor
steps: Replacement.
1. Remove power from frequency converter.
2. Ensure that the DC bus is fully discharged. 8.7.13 Input Terminal Signal Tests
3. Remove output motor bus bars from each
inverter module. The presence of signals on either the digital or analog
input terminals of the frequency converter can be verified
4. Apply power to frequency converter. on the frequency converter display. Parameter 16-60 Digital
5. Run frequency converter with a 0 speed Input – parameter 16-64 Analog Input 54 show the status for
reference. the standard inputs. Other parameters show the status of
option inputs.
6. Read the output current in the display. The
display must indicate less than 1 A.
Digital inputs
An incorrect reading indicates that further tests of the View the digital inputs by using parameter 16-60 Digital
current feedback signals are required. Refer to Input. The status of control terminals 18, 19, 27, 29, 32, and
chapter 8.7.12 Testing Current Feedback with the Signal Test 33 are shown (left to right) with terminal 33 on the right
Board. of the display. A 1 indicates the presence of a signal, which
means the logic is true and the input is on.
8.7.12 Testing Current Feedback with the
Signal Test Board
1. Remove power to the frequency converter.

2. Ensure that the DC bus is fully discharged.
3. Install the signal test board into the 30-pin test
connector socket in inverter 1.
4. Apply power to the frequency converter.
5. Using a DVM, connect the negative (-) meter lead
to terminal 4 (common) of the test board.
Illustration 8.13 Digital Inputs Display
6. Ensure that the following parameter set-ups that
create a holding torque while at 0 speed are
disabled:

Analog inputs
If the display does not show the correct signal, investigate
Terminals 53 and 54 are the standard analog input
the following:
terminals. Each terminal can be configured as a voltage
• External control wiring to the frequency converter input or a current input. Switch S201 on the control card
• Incorrect programming of parameter 5-00 Digital configures terminal 53. Switch S202 configures terminal 54.
I/O Mode
Use parameter 16-62 Analog Input 53 to show the value on
• Faulty control card terminal 53 and parameter 16-64 Analog Input 54 to show
Use parameter 5-00 Digital I/O Mode to program the digital the value on terminal 54.
inputs to either accept a sourcing output (PNP) or a
sinking output (NPN). When programmed for PNP (factory
default), the digital input turns on when 24 V DC is applied
to the digital input terminal. When programmed for NPN,
the digital input turns on when the terminal is connected
to signal common (terminal 20).
The power for the digital inputs can either come from the
(+)24 V DC built into the frequency converter, or from an
external supply. If an external supply is used, reference the
common of the supply to terminal 20.
Check for an internal power supply
1. Connect the (-) negative meter lead to Illustration 8.14 Analog Inputs Display
terminal 20. 8 8
2. Connect the (+) positive meter lead to
Incorrect signals indicate problems in the external control
terminal 12 or terminal 13 and measure the DC
wiring to the frequency converter, configuration of the
voltage.
switches, or a faulty control card.
A correct reading is 21–27 V DC. If the supply voltage is
The power for the analog inputs either comes from the
not present, perform the basic control card voltage test.
supply built into the frequency converter, or from an
See chapter 8.7.5 Basic Control Card Voltage Test.
external supply. If an external supply is used, reference the
common of the supply to terminal 55.
Check the individual inputs if parameter 5-00 Digital I/O
Mode is PNP Verify the control voltage supply
1. Connect the (-) negative meter lead to 1. Connect the (-) negative meter lead to
terminal 20. terminal 55.
2. Connect the (+) positive meter lead to each 2. Connect the (+) positive meter lead to
digital input in sequence and measure the DC terminal 50.
voltage. The correct reading is 9.2–11.2 V DC. If the supply voltage
The correct display for each digital input where the voltage is not present, perform the basic control card voltage test.
reading is greater than 10 V DC is 1. The correct display for Verify that the analog input is configured for the type of
each digital input where the voltage reading is less than 5 signal being sent to the frequency converter.
V DC is 0. If the display does not correspond with the Parameter 16-61 Terminal 53 Switch Setting shows the
measured inputs, the digital inputs on the control card configuration of terminal 53, and parameter 16-63 Terminal
have failed. Replace the control card. 54 Switch Setting shows the configuration of terminal 54. If
Check the individual inputs if parameter 5-00 Digital I/O the inputs are not configured correctly, power down the
Mode is NPN frequency converter and change switches S201 and S202.
1. Connect the (-) negative meter lead to
terminal 20. Check the individual inputs if configured for voltage
1. Connect the (-) negative meter lead to
2. Connect the (+) positive meter lead to each
terminal 55.
digital input in sequence and measure the DC
voltage. 2. Connect the (+) positive meter lead to terminal
53 or terminal 54 and measure the DC voltage.
The correct display for each digital input where the voltage
reading is less than 14 V DC is 1. The correct display for For each analog input, the measured DC voltage must
each digital input where the voltage reading is greater match the value shown in the display parameter. If the
than 19 V DC is 0. If the display does not correspond with display does not correspond with the measured input and
the measured inputs, the digital inputs on the control card the switch is configured for voltage, the analog input on
have failed. Replace the control card. the control card has failed. Replace the control card.

Check the individual inputs if configured for current 4. Use a voltmeter to measure AC output voltage at
1. Connect the (-) negative meter lead to the frequency converter motor terminals U, V, and
terminal 55. W. Measure phase-to-phase, checking U to V, then
U to W, and then V to W.
2. Connect the (+) positive meter lead to
All 3 readings must be within 8 V AC of each
terminal 53 or terminal 54 and measure the DC
other. The actual value of the voltage depends on
voltage.
the speed at which the frequency converter runs.
When configured for current, the current flows through a The V/Hz ratio is relatively linear (except in VT
200 Ω resistor to create a voltage drop. A 4 mA current mode). For example, if the rated motor frequency
flow creates approximately a 0.8 V DC voltage reading. A is 60 Hz, the voltage should be approximately
20 mA current flow creates approximately a 4.0 V DC equal to the applied mains voltage. At 30 Hz, it is
voltage reading. The display shows the mA value. If the about half of that. This also applies to any other
display does not correspond with the measured input, the speed selected. The exact voltage reading is less
analog input on the control card has failed. Replace the important than balance between phases.
control card.
5. Reconnect the motor to the frequency converter.
NOTICE 6. Use a clamp-on ammeter to monitor current on
A negative voltage reading indicates a reversed polarity. the 3 output phases at the motor terminals U, V,
Reverse the wiring to the analog input. and W. An analog ammeter is recommended. To
achieve an accurate reading, run the frequency
8.7.14 Output Imbalance of Motor Supply converter above 40 Hz.
8 8 Voltage Test 7. Check that the output current is balanced from

phase-to-phase, with no phase varying more than
Before checking output imbalance, make sure to test the 2–3%.
inverter module. Refer to chapter 8.5 Static Tests for Inverter
Module. When testing the phase-to-phase output, both 7a If each phase is within 2–3%, the
voltage and current are monitored. Perform the initial test frequency converter is balanced.
with the motor connected and running its load. 7b If any phase is above 3%, disconnect the
motor cables and repeat the voltage
NOTICE balance test.
If a voltage imbalance is detected with
FALSE OUTPUT READINGS the motor cables disconnected, then
Use an analog voltmeter for monitoring output voltage.
either the IGBT or gate driver card is
Digital voltmeters are sensitive to waveform and
defective. Refer to chapter 8.7.10 IGBT
switching frequencies and commonly return erroneous
Switching Test and chapter 8.7.9 Gate
readings.
Signal Test.
If the voltage is balanced, but the current is not, the motor 8.8 Module Static Test Procedures
is drawing an uneven load. This can be caused by the
following:
8.8.1 Inverter Module
• Defective motor
Heat sink temperature sensor test
• Poor connection in the wiring between the Remove the inverter module from the frequency converter.
frequency converter and the motor Refer to chapter 10.2.6 Inverter Module Replacement.
• Defective motor overload The temperature sensor is an NTC (negative temperature
If both the output current and voltage are unbalanced, the coefficient) device. As a result, high resistance means low
frequency converter does not work properly. This can be temperature. As temperature decreases, resistance
caused by the following: increases. Each IGBT module has an internally mounted
• Defective power card temperature sensor. The sensor is wired from the IGBT
module to the gatedrive card connector MK100. The center
• Improper connection of the output circuitry
IGBT module is used.
If suspect readings are recorded, perform the following
On the gatedrive card, the resistance signal is converted to
steps:
a frequency signal. The frequency signal is sent to the
1. Stop the motor and wait until the motor has
power card for processing. The temperature data is used to
stopped rotating.
regulate fan speed and to monitor for over/under
2. Set the frequency converter to coast. temperature conditions.
3. Disconnect the motor cables.

1. Set the ohmmeter to read Ω. NOTICE

2. Unplug connector MK100 on the gatedrive card SOFT CHARGE CARD LOCATIONS
and measure the resistance across the cable F1/F3 and F8/F9 enclosure sizes contain 2 cards per
leads. rectifier. F2/F4 contain 3 cards per rectifier. F10/F11
The relationship between temperature and resistance is contain 1 card per rectifier. F12/F13 contain 1 card in 1
non-linear. At 25 °C (77 °F), the resistance is approximately rectifier and 2 cards in the other one.
5 kΩ. At 0 °C (32 °F), the resistance is approximately 13.7
kΩ. At 60 °C (140 °F), the resistance is approximately 1.5 1. Remove the rectifier module from the frequency
kΩ. The higher the temperature, the lower the resistance. converter. Refer to chapter 10.2.5 Rectifier Module
Replacement.
Incorrect reading 2. Remove the power card mounting plate. Refer to
An incorrect reading indicates a faulty heat sink chapter 11.2.3 Power Card Mounting Plate
temperature sensor. Replace the sensor. Disassembly/Reassembly.
Refer to chapter 11.1.8 IGBT Module Replacement.
3. Disconnect the connector MK3 from each soft
charge card.
8.8.2 Rectifier Module
Since the rectifier test requires the soft charge resistor to
be in the circuit, verify that the resistor is good before
Heat sink temperature sensor test
proceeding.
Remove the rectifier module from the frequency converter.
Refer to chapter 10.2.5 Rectifier Module Replacement.
The temperature sensor is an NTC (negative temperature
1. Measure the resistance between pins A and B of
connector MK4 on the soft charge card. It must
8 8
coefficient) device. As a result, high resistance means low read 27 Ω (±10%) for 380–500 V frequency
temperature. As temperature decreases, resistance converters or 68 Ω (±10%) for 525–690 V
increases. The power card reads the resistance of the NTC frequency converters. If a reading falls outside
sensor to regulate fan speed and to monitor for overtem- this range, replace the soft charge resistor and
perature conditions. then continue tests. Refer to chapter 11.2.6 Soft
1. Set the ohmmeter to read Ω. Charge Resistor Replacement.
2. Based on the frequency converter model, perform If the resistor is defective and a replacement is not readily
the following step: available, the remainder of the tests can be carried out by
disconnecting the cable at connector MK4 on the soft
2a For F1–F4 and F10–F13 units, unplug
charge card and placing a temporary jumper across pins A
connector MK103 on power card and
and B. This method provides a path for continuity for the
measure across cable leads.
remaining tests. For the following tests, set the meter to
2b For F8–F9 units, there are 2 sensors diode check or Rx100 scale.
inside the module. Unplug connector
MK102 on the MPIC card and measure 2. Connect the negative (-) meter lead to the
across pins 1 and 5 for the first sensor positive (+) MK3 (A) (DC output to DC bus), and
and pins 2 and 6 for the second sensor. connect the positive (+) meter lead to MK1
The full range of the sensor is 787 Ω to 10 kΩ where 10 terminals R, S, and T in sequence. Each reading
kΩ equals 25 °C (77 °F) and 787 Ω equals 95 °C (203 °F). must show a diode drop.
The higher the temperature, the lower the resistance. 3. Reverse meter leads with the positive (+) meter
lead to the positive (+) MK3 (A). Connect the
Incorrect reading negative (-) lead to MK1 terminals R, S, and T in
An incorrect reading indicates a faulty heat sink sequence. Each reading must show open.
temperature sensor. Replace the sensor.
4. Connect the positive (+) meter lead to the
Refer to chapter 11.2.9 Heat Sink Thermal Sensor
negative (-) MK3 (C). Connect the negative (-)
Replacement.
meter lead to MK1 terminals R, S, and T in
Soft charge rectifier test sequence. Each reading must show a diode drop.
The frequency converter contains either 1 or 2 rectifier
5. Reverse the meter leads with the negative (-)
modules depending on the enclosure size. Repeat the
meter lead to the negative (-) MK3 (C). Connect
following test for each rectifier module and for each soft
the positive (+) meter lead to MK1 terminals R, S,
charge card inside the rectifier module.
and T in sequence. Each reading must show
open.

6. Remove any temporary jumpers. 6. Give the frequency converter a run command
7. Reconnect the MK3 on the soft charge card. (press [Hand on]) and slowly increase the
reference (speed command) to approximately
Incorrect reading 40 Hz.
An incorrect reading indicates that the soft charge rectifier
7. Using the signal test board (176F8437) and an
is faulty. Since the rectifier is not serviced as a component,
oscilloscope, check the waveform at pins 25–30
replace the entire soft charge card. Refer to
with the scope referenced to pin 4. This
chapter 11.2.4 Soft Charge Card Replacement.
procedure must be performed on each inverter
4 module. Each waveform must approximate the
130BX120.10
3 example in Illustration 8.16.
2 8. Connect a 24 V DC supply to the DC bus of the
1 frequency converter. This step can be done on
the DC bus output of the rectifier module or the
bus bars connecting to the top side of the DC
fuses on any of the inverter modules.
9. Observe the phase-to-phase waveform on the
output bus bars of each phase of each inverter
module. This waveform must appear the same as
the normal output waveform of a properly
operating frequency converter, except that the
8 8 amplitude is 24 V instead of the full output
voltage of a normal frequency converter.
1 MK1
10. Press [OFF] on the LCP.
2 MK3 11. Disconnect power from both supplies and
3 MK4 reinstall jumper connectors to the SMPS input
4 MK2 plugs on all modules.
Softcharge card description: 12. Reinstall the motor output bus bars on all
380–480/500 V: Blue MOV with 8 PTCs inverter modules.
525–690 V: Red MOV with 6 PTCs
13. Apply AC power to the frequency converter.
Illustration 8.15 Soft Charge Card Connectors 14. Apply a start command to the frequency
converter. Adjust the speed to a nominal level.
Observe that the motor is running properly.
8.9 System Test 15. Using a clamp-on style current meter, measure
the output current on each phase. All currents
After any repair to a frequency converter or testing of a must be balanced.
frequency converter suspected of being faulty, ensure that
Input A
130BX153.10
all frequency converter circuitry is functioning properly by 8.00

performing the following steps: 6.00
1. Perform visual inspection procedures as described 4.00
in chapter 6.4.1 Visual Inspection. 2.00
0.00 V
2. Perform static test on the frequency converter as
-2.00
described in chapter 8.4 Static Tests for Rectifier
-4.00
Module, chapter 8.5 Static Tests for Inverter Module,
-6.00
and chapter 8.8 Module Static Test Procedures.
-8.00
3. Remove the 3 output motor bus bars from each -4.0ms 50Us/Div
inverter module. Illustration 8.16 System Test Waveform: 2 V/div 100us/div Run
at 10 Hz
4. Connect a 610–800 V DC supply to the switch
mode supply (SMPS) input to each module using
the test cable (176F8766).
5. Apply power to the SMPS and check that the LCP
display lights up properly. (The fans do not
operate when powered in this manner.)

Special Test Equipment Service Guide
9 Special Test Equipment
9.1 Test Equipment 9.1.2 Signal Test Board

It is highly recommended that technicians have access to The signal test board provides access to various signals
the test equipment described in this chapter. Without the that can be helpful in troubleshooting the frequency
test equipment, some troubleshooting procedures cannot converter.
be carried out. The test equipment described here is
available from Danfoss.
The signal test board is plugged into the 30-pin panel
connector on the top of each inverter module. Points on
9.1.1 Split Bus Supply the signal test board can be monitored with or without the
DC bus disabled. Sometimes, the frequency converter
In split bus mode, the DC bus is split into 2 parts. One part needs the DC bus enabled and operating a load to verify
powers up the SMPS on the power card, allowing the certain test signals.
various logic circuits to be tested without the risk of
damaging the power components. The following is a description of the signals available on
the signal test board. Chapter 8 Test Procedures describes
The other part can be used to provide low-voltage power when these tests would be called for and what the signal
to the DC capacitors and output IGBTs for test purposes. A must be at that given test point.
low-voltage supply connected to the DC bus allows safe
testing of the output.
130BX66.10
Connecting the frequency converter in split bus mode: 9 9
1. Ensure that AC power has been removed and all
DC capacitors are fully discharged.
2. Remove the top and bottom safety covers from
each inverter module.
3. Remove the top safety cover from the rectifier
modules.
4. If a motor is connected to the frequency
converter, remove all output bars from each
inverter module.
5. If a brake resistor is connected, remove the brake
bus bars.
6. Remove the plugs from the 6-pin sockets on the
top of each inverter and rectifier module.
7. Connect the supply cable (p/n 176F8766) to the
6-pin sockets on each module. Illustration 9.1 Signal Test Board
8. Connect a DC supply to the input of the supply
cable. The supply must provide DC voltage
between 610–750 V and have a minimum current
rating of 250 mA. The Danfoss split bus supply
(p/n 130B3146) is designed for this application.
9. Apply the voltage to the unit. The LCP indicator
lights must illuminate as if the frequency
converter was powered normally.
WARNING
PERSONAL INJURY RISK
Do not apply AC mains voltage to the frequency
converter when it is wired in split bus mode.

Special Test Equipment VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
9.1.3 Signal Test Board Pin Outs: Description and Voltage Levels
Table 9.1 lists the pins on the signal test board. For each pin, its function, description, and voltage levels are provided. How
and when to perform the tests are described in chapter 8 Test Procedures.
Other than supply measurements, most of the signals being measured are made up of waveforms. Sometimes a digital
voltmeter can be used to verify the presence of such signals, however it cannot be relied on to verify that the waveform is
correct. An oscilloscope is the preferred test instrument. However, when similar signals are being measured at multiple
points, a digital voltmeter can be used. By comparing several signals to each other and obtaining similar readings, it can be
concluded that each of the waveforms matches one another and are therefore correct.
Pin Schematic Function Description Reading using a digital voltmeter

acronym
1 IU1 Current sensed in Input A 0.937 V ACpeak @ 165% of CT current
130BX148.10
2000.0
U phase, not 1500.0 rating. AC waveform @ output frequency

1000.0
conditioned 500.0 of the frequency converter.
0.0 mV
-500.0
-1000.0
-1500.0
-2000.0
-200 ms 1 ms/Div
~ 400 mv RMS @100% load

2 IV1 Current sensed in Input A 0.937 V ACpeak @ 165% of CT current
130BX148.10
2000.0
V phase, not 1500.0 rating. AC waveform @ output frequency

1000.0
conditioned of the frequency converter
9 9
500.0
0.0 mV
-500.0
-1000.0
-1500.0
-2000.0
-200 ms 1 ms/Div
~ 400 mv RMS @100% load

3 IW1 Current sensed in Input A 0.937 V ACpeak @ 165% of CT current
130BX148.10
2000.0
W phase, not 1500.0 rating. AC waveform @ output frequency

1000.0
conditioned 500.0 of the frequency converter.
0.0 mV
-500.0
-1000.0
-1500.0
-2000.0
-200 ms 1 ms/Div
~ 400 mv RMS @100% load

4 COMMON Logic common Used for all signals. –
5 AMBT Ambient temperature Used to control high and low fan speeds. 1 V DC approximately equal to 25 °C
(77 °F)
6 FANO Control card signal Signal from the control card to turn the fans on 0 V DC, ON command
and off. 5 V DC, OFF command
7 INRUSH Control card signal Signal from the control card to start gating the 3.3 V DC, SCRs disabled
SCR front end. 0 V DC, SCRs enabled
8 RL1 Control card signal Signal from control card to provide status of 0 V DC, relay active
Relay 01. 0.7 V DC, inactive
9 – Not used – –
11 VPOS +18 V DC regulated Red indicator light indicates that voltage is +18 V DC regulated supply +16.5 V DC to
supply present between VPOS and VNEG terminals. +19.5 V DC
+16.5 V DC to +19.5
V DC
12 VNEG -18 V DC regulated Red indicator light indicates that voltage is -18 V DC regulated supply
supply -16.5 V DC to present between VPOS and VNEG terminals. -16.5 V DC to -19.5 V DC
-19.5 V DC

Special Test Equipment Service Guide

acronym
13 DBGATE Brake IGBT gate Input A Voltage drops to 0 when brake is turned
130BX150.10
20.0
pulse train 15.0 off. Voltage increases to 4.04 V DC as
10.0
5.0 brake duty cycle reaches maximum.
0.0V
-5.0
-10.0
-15.0
-20.0
-400.0 us 20 us/Div.
Varies w/ brake duty cycle.

14 BRT_ON Brake IGBT 5 V logic Input A 5.10 V DC level with the brake turned off.
130BX151.10
20.0
level signal 15.0 Voltage decreases to 0 as brake duty cycle
10.0
5.0 reaches maximum.
0.0V
-5.0
-10.0
-15.0
-20.0
-400.0 us 20 us/Div.
Varies with brake duty cycle.

16 FAN_TST Control signal for Indicates that fan test switch is activated to +5 V DC, disabled
fans force the fans on high. 0 V DC, fans on high
17 FAN_ON Pulse train to gate Input A 5 V DC, fans off
130BX152.10
8.00
SCRs for fan voltage 6.00

4.00
control. In sync with 2.00
9 9
line frequency. 0.00 V
-2.00
-4.00
-6.00
-8.00
-4.0ms 2ms/Div
7 trigger pulses at 3 kHz.

18 HI_LOW Control signal from Signal to switch fan speeds between high and +5 V DC = fans on high,
power card low. Otherwise, 0 V DC
19 SCR_DIS Control signal for Indicates that SCR front end is enabled or 0.6 V DC to 0.8 V DC, SCRs enabled
SCR front end disabled. 0 V DC, SCR disabled
20 INV_DIS Control signal from Disables IGBT gate voltages. 5 V DC, inverter disabled
power card 0 V DC, inverter enabled
22 UINVEX Bus voltage scaled Signal proportional to UDC. OV switch must be off
down - 1 V DC = 450 V DC [T4/T5]
- 1 V DC = 610 V DC [T7]
23 VDD +24 V DC supply Yellow indicator light indicates that voltage is +24 V DC regulated supply
present. +23 to +25 V DC
24 VCC +5.0 V DC regulated Green indicator light indicates that voltage is +5.0 V DC regulated supply +4.75 V DC to
supply. +4.75 to present. +5.25 V DC
+5.25 V DC.
25 GUP_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, U phase, 6.00 Equal on all phases

4.00
positive. Signal 2.00 TP25–TP30
originates on control 0.00 V
-2.00
card. -4.00
-6.00
-8.00
-4.0ms 50Us/Div
2 V/div 100 us/div Run@10 Hz.

Special Test Equipment VLT® Drives FC Series, F1–F4/F8–F13 Enclosures

acronym
26 GUN_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, U phase, 6.00 Equal on all phases

4.00
negative. Signal 2.00 TP25–TP30
-2.00
card. -4.00
-6.00
-8.00
-4.0ms 50Us/Div

27 GVP_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, V phase, 6.00 Equal on all phases

4.00
-2.00
card. -4.00
-6.00
-8.00
-4.0ms 50Us/Div

28 GVN_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, V phase, 6.00 Equal on all phases

4.00
negative. Signal 2.00 TP25–TP30
-2.00
card. -4.00
-6.00
9 9
-8.00
-4.0ms 50Us/Div

29 GWP_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, W phase, 6.00 Equal on all phases

4.00
-2.00
card. -4.00
-6.00
-8.00
-4.0ms 50Us/Div

30 GWN_T IGBT gate signal, Input A 2.2–2.5 V DC
130BX153.10
8.00
buffered, W phase, 6.00 Equal on all phases TP25–TP30

4.00
negative. Signal 2.00

-2.00
card. -4.00
-6.00
-8.00
-4.0ms 50Us/Div
Table 9.1 Signal Test Board Pin Descriptions

Top-level Component Disasse... Service Guide
10 Top-level Component Disassembly/Reassembly
10.1 Before Proceeding NOTICE

ELECTROSTATIC DISCHARGE (ESD)
10.1.1 For Your Safety
Many electronic components within the frequency
converter are sensitive to static electricity. Voltages so
Review all safety warnings and cautions in chapter 2 Safety.
low that they cannot be felt, seen, or heard can be
harmful to electronic components. Use standard ESD
• DO NOT touch electrical parts of the frequency protective procedures whenever handling ESD sensitive
converter when connected to mains. Also make components. Failure to conform to standard ESD
sure that other voltage inputs have been discon- procedures can reduce component life, diminish
nected (linkage of DC intermediate circuit). There performance, or completely destroy sensitive electronic
may be high voltage on the DC-link even when components.
the indicator lights are turned off. Before
touching any potentially live parts of the
frequency converter, wait at least 40 minutes. WARNING
• Before conducting repair or inspection, SHOCK AND INJURY HAZARD
disconnect mains. The following options are powered before the optional
circuit breaker or disconnect. Even with the circuit
• [Off] on the LCP does not disconnect mains.
breaker or disconnect in the OFF position, mains voltage
• During operation and while programming is still present inside the frequency converter enclosure.
parameters, the motor may start without warning.
Failure to turn off the main service line/power to the
Press [Stop] when changing data.
frequency converter before working on the following
• When operating on a PM motor, disconnect options can result in death or serious injury:
motor cable. • Door interlock
10 10
WARNING • Space heater
SHOCK AND INJURY HAZARD • Cabinet light and outlet

Touching electrical parts of the frequency converter can • RCD monitor
be fatal even after the equipment has been disconnected
from AC power. Perform the following steps before
• IRM monitor
touching any internal components: • Emergency stop
1. Disconnect the mains power. • 24 V DC customer supply
2. Disconnect the motor.

3. Disconnect any brake option. NOTICE
If supplied with a circuit breaker or disconnect switch,
4. Disconnect any load share/regeneration option.
the cabinet doors are interlocked. To open the cabinet
5. Wait for the capacitors to discharge fully. Refer doors, set the circuit breaker and disconnect switch to
to the label on the front of the frequency the OFF position.
converter door for the exact discharge time.
6. Ensure that the DC-bus capacitors have
discharged fully by measuring the DC bus using
a voltage meter.

Top-level Component Disasse... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
NOTICE 10.1.3 Module Service Shelf

Inverter units contain 2 or 3 inverter modules. Drawings
in this section show units with 2 inverter modules. D-frame modules weigh up to 125 kg (275 lb) each and
Changes in instructions for units with 3 modules are require special handling. A service shelf (p/n 176F8835) is
noted. available from Danfoss to provide support of the modules
during removal from the frequency converter. This shelf, or
other suitable support equipment, is recommended.
10.1.2 Tools Required
Item Description
130BX333.12
ESD protection kit Wrist strap and mat
Metric socket set 7–19 mm
Socket extensions 100–150 mm (4 inch and 6 inch)
Magnetic sockets –
Ratchet wrench –
Torque wrench Torque range 0.5–19 Nm
(6–170 in-lb)
Torx driver set T10–T50
Needle nose pliers –
Screwdrivers Standard and Phillips
Item Description
Digital Volt-Ohm Meter • Rated for true RMS
(PWM-compatible)
10 10 • Supports the diode mode
Analog voltmeter –
Oscilloscope –
Clamp-on ammeter Rated for true RMS
Split bus supply p/n 130B3146
Signal test board p/n 176F8437
Signal test board extension p/n 130B3147
Test cable p/n 176F8766
Table 10.2 Instruments Recommended to Test Frequency Converter
Illustration 10.1 Module Service Shelf

10.2 Disassembly/Reassembly
10.2.1 AC Line Input Fuse Replacement
AC main fuses are optional. If AC fuses are the only power option added to the frequency converter, they are located in the
rectifier cabinet. If more power options are present, the AC fuses are located in the options cabinet.
Disassembly Reassembly
Follow fastener torque values as described in
AC fuses located in the rectifier cabinet
chapter 1.6 General Torque Tightening Values.
(F1 and F2 enclosures)
1. Remove bottom safety cover from the rectifier AC fuses located in the rectifier cabinet
cabinet. (F1 and F2 enclosures)
1. Install new fuses in the same order as they were
2. Remove hex bolts (8 mm) securing the fuses in
removed.
place. Refer to Illustration 10.2.
Remove fuses sequentially, front to back. If only 2. Reinstall hex bolts (8 mm) securing the fuses in
the fuse located in the back must be replaced, place. Refer to Illustration 10.2.
remove the front and middle fuses to gain access 3. Reinstall bottom safety cover onto the rectifier
to the back fuse. If more access is necessary, the cabinet.
left-most inverter module can be removed from
the inverter cabinet. Refer to AC fuses located in options cabinet
chapter 10.2.6 Inverter Module Replacement. 1. Install new fuses.
AC fuses located in options cabinet 2. Reinstall hex bolts (8 mm) securing the fuses in
1. Remove covers from the options cabinet to place. Refer to Illustration 10.3.
access the fuses. 3. Reinstall covers onto the options cabinet.
2. Remove hex bolts (8 mm) securing the fuses in
place. Refer to Illustration 10.3.
10 10

130BX334.11
130BX318.11
1
1 6
2 5
4
5
10 10
1 Monitoring options (RCD, IRM, Pilz relay)

2 Contactor
1 Rectifier module 3 RFI filter
2 AC mains input fuse 4 Mains AC power input terminals
3 Back AC fuse mounting plate (T) 5 Circuit breaker or disconnect
4 Middle AC fuse mounting plate (S) 6 AC mains/line fuses
5 Front AC fuse mounting plate (R)
Illustration 10.3 AC Fuses Located in the Options Cabinet
Illustration 10.2 AC Fuses Located in the Rectifier Cabinet (F3 and F4 shown)
(F1 and F2 only)

10.2.2 DC Link Fuse Replacement
Each inverter contains 2 DC link fuses, which are on the top of the inverter.
1. Remove covers from the inverter cabinet.
2. Remove the bus bars securing the top of fuses by
1. Install the fuses.
removing attaching hex bolts (18 mm).
2. Reinstall hex bolts (18 mm) securing the bottom
3. Remove hex bolts (18 mm) securing the bottom
of fuses. Refer to Illustration 10.4.
of the fuses. Refer to Illustration 10.4.
3. Reinstall the bus bars securing the top of fuses
with the attaching hex bolts (18 mm).
4. Reinstall covers onto the inverter cabinet.
130BX319.13
1 2
5
10 10
4
1 Top (-) DC link fuse bus bar 4 (+) DC link fuse (none in F8/F9 enclosures)
2 (-) DC link fuse (none in F8/F9 enclosures) 5 Top (+) DC link fuse bus bar
3 Bottom (+) DC link fuse bus bar
Illustration 10.4 DC Link Fuses on Top of Inverter

10.2.3 Door Fan Replacement
Door fans are in the top of the cabinet doors.
1. Unplug the electrical connector. 1. Center the widest part of the fastener opening on
Refer to Illustration 10.5. the plastic stud and twist the fan assembly
clockwise to lock it in place.
2. Remove the fan by twisting the fan assembly
counterclockwise so the widest part of the 2. Plug in the electrical connector.
fastener opening moves over the plastic stud. Pull
the fan off the door.
130BE349.10
10 10
2
3
1 Electrical connector 3 Fastener opening

2 Plastic stud
Illustration 10.5 Door Fan Assembly Detail

10.2.4 Heat Sink Fan Replacement
There is 1 heat sink fan inside the bottom of each rectifier and inverter module. Refer to Illustration 10.6.
1. Remove access panel by removing 6 nuts (8 mm). NOTICE
The fan plug fits only 1 way. However, if too much force
2. Unplug the fan electrical connector and remove 2
is used, the plug can be forced the wrong way.
nuts (10 mm) securing the fan in place.

1. Secure the fan in place using 2 nuts (10 mm).

2. Reconnect the electrical connector.
3. Secure the access panel using 6 nuts (8 mm).
130BE342.10
10 10
1
1 Module/heat sink 3 Connector

2 Fan 4 Access panel
Illustration 10.6 Removing Heat Sink Fan

10.2.5 Rectifier Module Replacement
CAUTION
HEAVY WEIGHT
The rectifier module weighs 136 kg (300 lb). For use in lifting the rectifier, 4 eye bolts and washers are stored at the left
bottom side of the rectifier cabinet. If required, attach bolts to holes provided at top of rectifier module. Failure to use
some method of support while removing or installing the module can result in injury.
1. Remove center mounted safety cover from
rectifier module by removing nuts (8 mm).
1. Using sufficient mechanical support to withstand
2. Remove top mounted safety cover from rectifier
the weight of the rectifier, place the rectifier into
module by removing nuts (8 mm).
the cabinet.
3. Remove DC bus bars.
2. Secure the module to the cabinet bracket using 2
3a For F1–F4 and F10–F14 enclosures, nuts (10 mm).
remove the 2 DC bus bars from the top
3. Reconnect the 4 white connectors to the rectifier
of the rectifier by removing the 4 nuts
module. Note that each connector is a different
(17 mm) that secure each bus bar (2 at
size for reassembly.
each end of bus bar).
4. Reinstall the 3 AC input power bus bars using 4
3b For F8–F9 enclosures, remove the 4 DC
nuts (17 mm) per bus bar. Refer to
bus bars from the top of the rectifier by
Illustration 10.7. The bus bars are stacked one
removing the 4 nuts (17 mm) that
behind the other.
secure each bus bar (2 at each end of
bus bar). 5. Reinstall the 2 DC bus bars to top of the rectifier
10 10 4. Remove the AC input power bus bars. using 4 nuts (17 mm) per bus bar.
6. Reinstall the top mounted safety cover to the
4a For F1–F4 and F10–F14 enclosures,
rectifier module using nuts (8 mm).
remove the 3 AC input power bus bars
in order to free the module for removal. 7. Reinstall the center mounted safety cover to the
Refer to Illustration 10.7. The bus bars rectifier module using nuts (8 mm).
are stacked one behind the other. Four
nuts (17 mm) secure each bus bar.
4b For F8–F9 enclosures, remove the 6 AC
input power bus bars to free the
module for removal. Refer to
Illustration 10.7. The bus bars are stacked
one behind the other. Four nuts
(17 mm) secure each bus bar.
5. Disconnect the 4 white connectors from the top
of the rectifier module. Note that each connector
is a different size for reassembly.
6. Remove the 2 nuts (10 mm) from the bracket at
the back of the rectifier. The bracket secures the
module to the cabinet.
7. Provide sufficient mechanical support to
withstand the weight of the rectifier. Withdraw
the rectifier from the cabinet.

130BX270.11
11
10
9
1
3 10 10
7
1 Connectors 7 Eye bolt

2 Back AC input power bus bar 8 Rectifier module
3 Middle AC input power bus bar 9 DC bus bar
4 Front AC input power bus bar 10 DC bus bar
5 Eye-bolt location 11 Mounting bracket
6 Eye-bolt washer
Illustration 10.7 F1–F4 Rectifier Cabinet Detail

130BE340.10
1
10 10
1 DC bus bar (rectifier 2) 5 Mains input

2 DC bus bar 6 Mains input
3 Signal plug connectors 7 DC bus bar (rectifier 1)
4 Motor output

130BE348.10
6
1
5
10 10
3
1 DC bus bar (module 2) 4 Mains input (module 1)

2 Signal plug connectors (module 2) 5 Signal plug connectors (module 1)
3 Mains input (module 2) 6 DC bus bar (module 1)

10.2.6 Inverter Module Replacement
NOTICE
F1–F4 BUILD DATES
For the F1-F4 enclosure sizes, the bus bar configuration that connects to the fuse differs according to the build date.
To identify the build date, refer to Illustration 3.1.
CAUTION
HEAVY WEIGHT
The inverter module weighs 136 kg (300 lb). For use in lifting the inverter, 4 eye bolts and washers are stored at the left
bottom side of the inverter cabinet. If required, attach bolts to holes provided at top of inverter module. Failure to use
some method of support while removing or installing the module can result in injury.
1. Remove the attaching screws and take off the
safety covers from the front of the inverter
module. 1. Using sufficient mechanical support, place the
inverter into the cabinet.
2. If the optional brake bus bars are present, remove
the 4 screws (T40) and take off the 2 brake bus 2. Secure the module to the cabinet bracket using 2
bars. nuts (10 mm).
3. Remove the 6 screws (T40) and take off the 3 3. For F1–F4 enclosures with a build date of 345 or
output AC bus bars. later:
4. Disconnect the 44-pin ribbon cable from the top 3a Connect the (+) fuse bus bar to the top
of the inverter module. of the front DC fuse using 1 hex bolt
10 10 5. Unplug the cable connectors (2 or 3, depending (18).
on unit) from the top of the inverter module. 3b Connect the (–) fuse bus bar to the top
Each connector is a different size for reassembly. of the back fuse using 1 hex bolt (18
mm). Then secure the (–) fuse bus bar
6. For F1–F4 enclosures with a build date of 345 or
to the DC bus using 1 nut (M10).
later:
4. For all F8–F13 enclosures and any F1–F4
6a Remove the nut (10 mm) that connects
enclosures with a build date before 345:
the (–) fuse bus bar to the DC bus, and
then remove the hex bolt (18 mm) at 4a Connect the DC bus bars to the top of
the top of the DC fuse. Take off the (–) both fuses using 1 hex bolt (18 mm) at
fuse bar. the top of each fuse.
6b Remove the hex bolt (18 mm) from the 5. Reconnect the cable connectors to the inverter
top of the other DC fuse and take off module. Each connector is sized differently.
the (+) fuse bus bar. 6. Reconnect the 44-pin ribbon cable to the top of
7. For all F8–F13 enclosures and any F1–F4 the module.
enclosures with a build date before 345: 7. Reinstall the 3 output AC bus bars using 6 screws
7a Remove the 2 hex bolts (18 mm) at the (T40), 2 screws per bus bar.
top of the fuses and take off the DC bus 8. If present, reinstall the 2 brake bus bars using 4
bars. screws (T40), 2 per bus bar.
8. Remove 2 nuts (10 mm) from the bracket at the 9. Reinstall the safety covers to the front of the
back of the inverter. The bracket secures the inverter module using the attaching screws.
module to the cabinet.
9. Support the inverter module with sufficient
mechanical support. Withdraw the inverter from
the cabinet.

7
8
1 10
2
3
11
4
12
5
6
13
10 10
130BE679.10
1 MDCIC mounting panel 8 Fuse bus bar (–)

2 Bracket 9 Fuse bus bar (+)
3 DC fuse 10 Hex bolt (18 mm)
(bus bar layout shown is from a 345 or later build date)
4 Inverter module 11 SMPS fuse and fan fuse
5 Brake bus bars - optional 12 Cable connectors
6 Motor output bus bar (W) 13 44-pin ribbon connector
7 Nut (M10)
Illustration 10.10 Inverter Cabinet Detail, F1–F4 Enclosure Sizes

10.2.7 MDCIC Mounting Panel Disassembly/Reassembly
This procedure applies only to F1–F4 and F10–F13 enclosure sizes.
1. Remove the attaching screws (8 mm) that secure
the top-mounted safety cover from the inverter
module, and then take off the safety cover. 1. Reinstall the MDCIC mounting panel using 4
screws (T25) to attach the panel to the inverter
2. Disconnect the ribbon cable between the control
cabinet.
card and the LCP.
2. Reinstall the customer interconnect wiring.
3. Before removing the MDCIC ribbon cable, note
which cable connects to each module for 3. Reinstall the relay connector to the MDCIC panel.
reassembly. Remove the MDCIC ribbon cable from 4. Reconnect the rectifier control cable to the
each inverter module. leftmost 6-pin connector on the MDCIC board.
4. Before removing the rectifier control cable, note 5. Reconnect the MDCIC ribbon cables to the
that the cable is the leftmost 6-pin connector on inverter modules.
the MDCIC board. Remove the rectifier control
cable from the MDCIC board. 6. Reattach the ribbon cable between the LCP and
the control card.
5. Remove the relay connector from the MDCIC
panel. 7. Reinstall the top mounted safety cover to the
inverter module using the attaching screws
6. Remove any customer interconnect wiring. (8 mm).
7. Remove the 4 screws (T25) that secure the MDCIC
panel, and take out the MDCIC mounting panel.
10 10

130BX268.11
1
8
3
10 10
7 5
1 MDCIC mounting panel 5 Rectifier control cable MK101

2 Relay connector (not shown) 6 MDCIC ribbon cable
3 MDCIC board cover plate 7 Control card to MDCIC ribbon cable
4 Attaching screw 8 Attaching screw
Illustration 10.11 Removing the MDCIC Mounting Panel

10.2.8 DC Link Inductor Replacement (F1–F4 Units with a 335 or Earlier Build Date)
To locate the build date, refer to Illustration 3.1.
CAUTION
HEAVY WEIGHT
The DC link inductor weighs 25 kg (55 lb). Failure to use some method of support while removing or installing the
inductor can result in injury.
1. Remove the inverter modules. Refer to
chapter 10.2.6 Inverter Module Replacement.
1. Install the DC link inductor into the cabinet.
2. Remove the MDCIC panel. The fan transformers
Secure the inductor to the cabinet using
do not need to be removed. Refer
nuts (10 mm).
to chapter 10.2.7 MDCIC Mounting Panel
Disassembly/Reassembly. 2. Reinstall the short bus bars to the angle bracket
bus bars using 2 screws (8 mm) per bus bar.
3. Remove the 8 screws (8 mm) that secure the 2
bus bars covering the DC link inductor. Then 3. Reinstall the 4 mounting plate bus bars using 1
remove the 2 bus bars. screw (8 mm) per mounting plate bus bar.
4. Remove the 4 screws (8 mm) that secure the 4 4. Reinstall the 2 bus bars that cover the inductor
mounting plate bus bars, and take out the 4 bus using 4 screws (8 mm) per bus bar.
bars. 5. Reinstall the MDCIC panel.
5. For each short bus bar that is attached to the 6. Reinstall the inverter modules. Refer to
angle bracket bus bar, remove the 2 screws (8
10 10 mm) per short bus bar. Remove the short bus
bars.
chapter 10.2.7 MDCIC Mounting Panel Disassembly/
Reassembly.
6. Remove the attaching nuts (10 mm) that secure

the DC link inductor to the cabinet, and take out
the inductor.

130BX253.11
1
1 DC link inductor 2 Bus bar
Illustration 10.12 Removing the DC Link Inductor
10 10
2
130BX254.11
3
2 2
1 DC link inductor 3 Short bus bars

2 Mounting plate bus bar 4 Angle bracket bus bar (not removed)
Illustration 10.13 DC Link Inductor Detail

10.2.9 DC Link Inductor Replacement (F1–F4 Units with a 345 or Later Build Date)
To locate the build date, refer to Illustration 3.1.
CAUTION
HEAVY WEIGHT
The DC link inductor weighs 25 kg (55 lb). Failure to use some method of support while removing or installing the
inductor can result in injury.
Disassembly
1. Remove the inverter modules. Refer to 11a Remove the M5 screws that secure the
chapter 10.2.6 Inverter Module Replacement. exterior exhaust grate to the top of the
cabinet.
2. Remove the MDCIC mounting panel. Refer
to chapter 10.2.7 MDCIC Mounting Panel 11b For each inductor, remove the 2 screws
Disassembly/Reassembly. (M6) from the upper support bracket.
3. Remove the 2 DC main bus bars. 12. Remove the upper duct plate.
See Illustration 10.14. See Illustration 10.16.
3a Remove the 8 (2-inverter units) or 12 (3- 12a Remove the 19 (2-inverter units) or 26
inverter units) M10 nuts. (3-inverter units) M5 nuts securing the
wire harness and the upper portion of
3b Remove the 4 (2-inverter units) or 8 (3-
the plate.
inverter units) M6 nuts from the
standoffs. 12b Detach the wire harness and move it to
the left side of the cabinet.
4. Remove 1 screw (M8) from each of the 2 jumper
bars. Remove the 2 jumper bus bars. 12c Remove 4 screws (M5) along the bottom
10 10 5. Remove the 2 (2-inverter units) or 3 (3-inverter edge of the plate.
units) M8 nuts that secure the (–) regen bus bar. 13. Remove the inductor module.
Remove the (–) regen bus bar. See Illustration 10.17.
6. Remove the 1 screw (M8) and 2 (M6) standoff 13a Remove the 2 screws (M6) from the
nuts that secure the (–) inductor-to-fuse bus bar. bottom support bracket on each
Remove the (–) inductor-to-fuse bus bar. inductor.
7. Remove the 2 (2-inverter units) or 3 (3-inverter 13b Remove the 4 nuts (M8) securing the
units) M8 nuts that secure the (+) regen bus bar. inductor to the cabinet.
Remove the (+) regen bus bar. 13c Using some method of support, pull out
8. Remove the 1 screw (M8) and 2 (M6) standoff the inductor.
nuts that secure the (+) inductor-to-fuse bus bar.
Remove the (+) inductor-to-fuse bus bar.
9. Remove the fan transformers from the upper duct
plate. See Illustration 10.15.
9a Disconnect the electrical connector from
the fan transformer.
9b Remove the 1 nut (13 mm) from the
center of the transformer.
10. Remove the inductor cover from the inductor.
10a Remove the 10 nuts (M6) and the hold-
down bracket.
10b Remove the standoff using a 19 mm
wrench.
11. Detach the inductor from the upper support
bracket.

Reassembly
Follow fastener torque values as described in 9. Reinstall the (–) regen bus bar using 2 (2-inverter
chapter 1.6 General Torque Tightening Values. units) or 3 (3-inverter units) M8 nuts.
1. Using some method of support, reinstall the 10. Reinstall the 2 jumper bus bars to each inductor
inductor module. See Illustration 10.17. using 1 screw (M8) per bus bar.
1a Secure the inductor to the cabinet with 11. Reinstall the 2 DC main bus bars.
4 nuts (M8). See Illustration 10.14.
1b Secure the inductor to the bottom 11a Reattach 4 (2-inverter units) or 8 (3-
support bracket using 2 screws (M6). inverter units) M6 nuts to the standoffs.
2. Reinstall the upper duct plate. 11b Secure the 2 DC main bus bars using 8
See Illustration 10.16. (2-inverter units) or 12 (3-inverter units)
M10 nuts.
2a Align the upper duct plate with the
screw holes and loosely fasten the 12. Reinstall the MDCIC mounting panel. Refer
bottom edge of the plate using 4 screws to chapter 10.2.7 MDCIC Mounting Panel
(M5). Disassembly/Reassembly.
2b Line up the wire harness along the 13. Reinstall the inverter modules. Refer to
middle and right side of the upper duct chapter 10.2.7 MDCIC Mounting Panel Disassembly/
plate. Reassembly.
2c Loosely fasten the upper portion of the
plate and the wire harness using 19 (2-
inverter units) or 26 (3-inverter units) M5
nuts.
2d Tighten all upper duct plate fasteners
according to proper torque rating.
3. Secure the inductor to the upper support bracket. 10 10
3a Inside the top exhaust grate, secure
each inductor to the upper support
bracket using 2 screws (M6).
3b Secure the top exhaust grate to the
frequency converter using M5 screws.
4. Fasten the inductor cover to the inductor. See
Illustration 10.15.
4a Secure with 10 nuts (M6) and the hold-
down bracket.
4b Reattach the standoff using a 19 mm
wrench. Tighten the standoff to 3.9 Nm
(35 in-lb).
5. Reinstall the fan transformers to the upper duct
plate.
5a Secure the fan transformer to the plate
using 1 nut (13 mm).
5b Reconnect the electrical connector to
the fan transformer.
6. Reinstall the (+) inductor-to-fuse bus bar using 1
screw (M8) and 2 nuts (M6) on the standoffs.
7. Reinstall the (+) regen bus bar using 2 (2-inverter
units) or 3 (3-inverter units) M8 nuts.
8. Reinstall the (–) inductor-to-fuse bus bar using 1
screw (M8) and 2 nuts (M6) on the standoffs.

130BE694.10
1 5
2
6
7
3
4
10 10
1 DC main bus bars 5 Inductor-to-fuse bus bar (–)

2 Inductor jumper bus bar (top jumper bus bars not shown) 6 Regen bus bar (+)
3 Fan transformer 7 Regen bus bar (–)
4 Upper duct plate 8 Inductor-to-fuse bus bar (+)
Illustration 10.14 Bus Bar Layout

130BE682.10
1
5
6
9
10
10 10
1 Nut (M6) 6 Nut (13 mm)

2 Plastic inductor cover 7 Fan transformer
3 Standoff 8 Electrical connector
4 Hold-down bracket 9 Wire clip/nut (M5)
5 Upper duct plate 10 Wire harness
Illustration 10.15 Removing the Inductor Cover and Fan Transformer from the Upper Duct Plate

10 10 130BE681.10
1 Upper support bracket screws (M6) 4 Wire clip/nut (M5)

2 Nut (M5) 5 Screw (M5)
3 Upper duct plate
Illustration 10.16 Removing Upper Duct Plate

1
2
3
4
130BE683.10
1 DC link inductor 3 Bottom support bracket

2 Nut (M8) 4 Screw (M6)
Illustration 10.17 Removing the DC Link Inductor

10 10

10.2.10 MDCIC Replacement
This procedure applies only to F1–F4 and F10–F13 enclosure sizes. To remove and replace the multi-drive control interface
card (MDCIC), use the following steps.
NOTICE
PARTS REUSE
Replacement scaling cards are not included with the replacement MDCIC board. Retain the scaling cards (1 per module)
so they can be reinstalled on the new MDCIC board.
NOTICE
BEFORE DISASSEMBLY
To make cable reinstallation easier, note the position of the following cables before disconnecting them:
• Inverter module ribbon cables.
• Rectifier control cables.
• STO cable (if any).
130BF590.10
10 10 3
1 Control card ribbon cable 3 Screw (8 mm)

2 Inverter module ribbon cables 4 MDCIC cover
Illustration 10.18 MDCIC Mounting Panel and Cables

Disassembly new card. See Illustration 10.20 and

Use the following steps to find the issue number of the Illustration 10.22.
MDCIC before removal. The issue number indicates
2b If character 13 is 0, disconnect the Safe
whether to install the jumper cable included with the
Torque Off (STO) cable from MK111 and
replacement MDCIC.
retain the cable.
3. Disconnect the control card ribbon cable from
130BF593.10
connector MK100 on the MDCIC by gently pulling
the cable to the left.
4. Disconnect the inverter module ribbon cables
from the MDCIC.
130B6840 010300G016 Ordr. No. 176F8773
5. Unplug the rectifier control cables from
connectors MK101 and MK102 on the MDCIC.
1 2 34 There is 1 cable for F1–F4 enclosures, or 2 cables
for F10–F13 enclosures.
1 MDCIC assembly number 3 MDCIC issue number
6. Remove the MDCIC by detaching 9 screws (T25)
2 MDCIC serial number 4 MDCIC revision number
securing the card to the panel standoffs.
7. Remove the scaling cards from the MDCIC. Retain
Illustration 10.19 MDCIC Barcode Label the scaling cards (1 per module) for reinstallation
on the new MDCIC.
1. Detach 2 screws (8 mm) from the MDCIC cover
130BF594.10
and remove the cover. See Illustration 10.18.
2. On the MDCIC bar code label, note the MDCIC
issue number (character 13). See Illustration 10.19.
2a If character 13 is 1–5, connect the
jumper cable (provided with the
10 10
replacement MDCIC) to MK111 on the
Illustration 10.20 Jumper Cable (178N0167)

1
4
130BF591.10
1 Cover screw 4 Scaling card
2 MDCIC cover 5 MDCIC screw
3 MDCIC 6 MDCIC mounting panel
Illustration 10.21 Exploded View of MDCIC Mounting Panel
10 10

Reassembly 5. Attach the control card ribbon cable to connector

MK100.
1. Reinstall the scaling cards on the new MDCIC.
6. Attach the STO cable to MK111. If no STO cable is
2. Attach the new MDCIC to the panel standoffs
present, check that the jumper cable is attached
using 9 screws (T25). Torque to 1.2 Nm (10 in-lb).
to MK111.
3. Connect the inverter module ribbon cables to the
7. Reinstall the MDCIC cover using 2 screws (8 mm).
original positions (Inverter 1–4) on the MDCIC.
Torque to 2.3 Nm (20 in-lb).
4. Attach the 6-pin rectifier control cables to
connectors MK101 and MK102. There is 1 cable
for F1–F4 enclosures, or 2 cables for F10–F13
enclosures.
130BF592.10
130B6840010300G16 Ordr. No. 176F8773
10 10
5
1 Barcode label 4 Safe Torque Off (STO) cable connector (MK111)

2 Control card cable connector (MK100) 5 Inverter module cable connectors (Inverter 1–4)
3 Scaling card 6 Rectifier cable connectors (MK101 and MK102)
Illustration 10.22 MDCIC Detail

10.2.11 Fan Transformer Replacement
1. Remove the MDCIC panel.
Refer to chapter 10.2.7 MDCIC Mounting Panel
Disassembly/Reassembly. 1. Reinstall the fan transformer to the panel. Secure
with the nut (13 mm).
2. Disconnect the electrical connector from the fan
transformer. 2. Reconnect the electrical connector to the fan
transformer.
3. Remove the nut (13 mm) from the center of the
fan transformer securing transformer to panel. 3. Reinstall the MDCIC panel.
130BX255.11
10 10
1
1 Fan transformer
2 Fan transformer connector
3 Nut (13 mm)
Illustration 10.23 Removing the Fan Transformer

Module Disassembly/Reassemb... Service Guide
11 Module Disassembly/Reassembly
11.1 Inverter Module
CAUTION
TRAINING REQUIRED
Only certified technicians who are trained by Danfoss are permitted to test and repair module components. Repair work
conducted by non-certified technicians can result in personal injury or equipment damage.
1. Remove the inverter module from the frequency converter. Refer to chapter 10.2.6 Inverter Module Replacement.
2. Remove the right side cover plate from the inverter module by removing 4 nuts (10 mm). For reassembly, note the
2 studs on the panel edge. This side mounts to the front of unit.
130BX309.12
1
12 5
11
7
11 11
10 9
1 Right side cover plate 7 High-frequency board

2 Inverter power card 8 IGBT module
3 Panel connectors 9 Current sensor
4 SMPS fuse and fan fuse 10 Fan assembly
5 Upper capacitor bank assembly 11 Lower capacitor bank assembly (some power sizes have a blank plate)
6 DC bus fuses 12 Gatedrive card
Illustration 11.1 F1–F13 Inverter Module (Exploded View)

Module Disassembly/Reassemb... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
11.1.1 Power Card Replacement
When installing the power card, ensure that the insulator sheet is installed between the power card and the mounting plate.
Follow the fastener torque values as described in
1. Unplug the power card connectors.
1a For F1–F4 or F10–13 enclosures, unplug
1. Insert the scaling card into the standoffs on the
MK102, FK103, MK104, MK105, MK106,
new power card. Make sure that the current
MK107, MK109, MK110, and MK112.
scaling card is secure.
Refer to Illustration 11.2.
2. Place the power card onto the plastic standoff at
1b For F8/F9 enclosures, unplug MK102,
the top right corner of the power card.
FK103, MK104, MK105, MK106, MK107,
MK108, MK109, MK110, and MK112. 3. Secure the power card using the 7 power card
mounting screws (T25).
2. Remove the 7 power card mounting screws (T25).
4. Plug in the power card connectors.
3. Remove the power card from the plastic standoff.
4a For F1–F4 or F10–13 enclosures, connect
4. Remove, but do not discard, the scaling card by
MK102, FK103, MK104, MK105, MK106,
pushing in the retaining clips on the standoffs.
MK107, MK109, MK110, and MK112.
NOTICE Refer to Illustration 11.2.
PARTS REUSE 4b For F8–F9 enclosures, connect MK102,
A replacement scaling card is not included with the FK103, MK104, MK105, MK106, MK107,
replacement power card. Retain the scaling card so it can MK108, MK109, MK110, and MK112.
be reinstalled on the new power card.
11 11

130BX172.10
3
4
2 5
16
15
14
12
10 8
11 11
13
11 9 7
1 Power card 9 MK106

2 Mounting plate 10 MK100
3 MK110 11 MK109
4 MK102 12 FK102
5 MK104 13 MK112 terminals 4,5,6
6 MK105 14 MK112 terminals 1,2,3
7 MK107 15 Current scaling card
8 FK103 16 Current scaling card standoff
Illustration 11.2 Power Card, F1–F13

11.1.2 Upper Capacitor Bank Assembly Replacement (without removing power card)
NOTICE
POWER CARD
The power card can remain attached to the capacitor bank cover during removal. If desired, remove the power card in
accordance with instructions provided.
1. Unplug the following power card connectors:
1a MK105
1. Reinstall the capacitor bank assembly in its
1b MK107 original location.
1c MK109 2. Secure the capacitor bank assembly using 4
2. Remove the 2 red wires from the 15 A fuse block retaining nuts (10 mm).
attached to the cover plate flange. 3. Secure the electrical connection using 6 electrical
3. Free the cable with the 2 red wires attached to it connection nuts (8 mm).
by disconnecting the 10-pin connector next to 4. Reinstall MK102 to the power card and ground
the fuse block on the cover plate flange. lug.
4. Disconnect the 2 white wires from the 4 A fuse 5. Reinstall the cable with the 2 white wires by
block attached to the cover plate flange and free reconnecting the 6-pin connector on the opposite
the cable by disconnecting the 6-pin connector end of cable. Reattach the 2 white wires from the
on the opposite end of the cable. 4 A fuse block that attach to the cover plate
5. Remove MK102 from the power card and ground flange.
lug. The power card can now remain fastened to 6. Reinstall the cable with the 2 red wires by
the capacitor bank assembly. reconnecting it to the 10-pin connector next to
6. Remove the 6 electrical connection nuts (8 mm) the fuse block on the cover plate flange.
securing the electrical connection of the 7. Reattach the 2 red wires to the 15 A fuse block,
11 11 assembly. These nuts are recessed in the gap
between the upper and lower capacitor banks.
which is attached to the cover plate flange.
8. Plug in the following power card connectors:
7. Remove the 4 retaining nuts (10 mm) securing
8a MK105
the capacitor bank assembly.
8b MK107
8. Remove the capacitor bank assembly.
8c MK109
NOTICE
CAPACITOR ASSEMBLY WEIGHT
The capacitor bank assembly weighs 9 kg (20 lb).

1 2
130BX274.12
3
4
4
11 11
6
5
1 Upper capacitor bank assembly 4 Electrical connection nut (8 mm)

2 Inverter power card 5 Lower capacitor bank assembly
3 Retaining nut (10 mm) 6 IGBT gatedrive card
Illustration 11.3 Upper Capacitor Bank Assembly, F1–F13

11.1.3 Lower Capacitor Bank Assembly Replacement
For some power sizes, there is a blank plate in place of the lower capacitor bank assembly.
1. Disconnect the cables from the following
gatedrive card connectors:
1. Reinstall the capacitor bank assembly in its
1a MK100
original location.
1b MK102
2. Secure the capacitor bank assembly using 4
1c MK103 retaining nuts (10 mm).
1d MK104 3. If there is a blank plate instead of a lower
1e MK106 capacitor bank assembly, skip this step.
Otherwise, secure the electrical connection using
1f MK105 (if the unit has a brake option)
6 electrical connection nuts (8 mm).
NOTICE 4. Connect the following cables to the gatedrive
If there is a blank plate instead of a lower capacitor bank card:
assembly, skip the next step.
4a MK100
2. Remove the 6 electrical connection nuts (8 mm)
that secure the capacitor bank assembly. These 4b MK102
nuts are recessed in the gap between the upper 4c MK103
and lower capacitor banks.
4d MK104
3. Remove the 4 retaining nuts (10 mm) securing
capacitor bank assembly. 4e MK106
4. Remove the capacitor bank assembly. 4f MK105 (if the unit has a brake option)
NOTICE
CAPACITOR ASSEMBLY WEIGHT
11 11 The capacitor bank assembly weighs 9 kg (20 lb).

1 2
130BX264.12
3
3
4 4
11 11
6 5
1 Upper capacitor bank assembly 4 Retaining nut (8 mm)

2 Inverter power card 5 Lower capacitor bank assembly
3 Electrical connection nut (8 mm) 6 IGBT gatedrive card
Illustration 11.4 Lower Capacitor Bank Assembly, F1–F13

11.1.4 High-frequency Board Replacement
1. Remove the upper capacitor bank assembly.
Refer to chapter 11.1.2 Upper Capacitor Bank
Assembly Replacement (without removing power 1. Reinstall the high-frequency board to its original
card). position within the module. Secure the board to
the standoff with the 1 nut (8 mm).
2. Disconnect cable from connector MK100 on the
high-frequency board. 2. Reinstall the 2 screws (T25) at each end of the
high-frequency board.
3. Remove the 2 screws (T25) from the high-
frequency board. 3. Reconnect the cable to the MK100 connector on
the high-frequency board.
4. Remove the 1 nut (8 mm) from the high-
frequency board standoff and remove the board. 4. Reinstall the upper capacitor bank assembly.
130BX258.12
1
11 11 2
1 Retaining nut (8 mm) 3 T25 screw

2 High-frequency board
Illustration 11.5 High-frequency Board

11.1.5 Current Sensor Replacement
NOTICE 7. Remove the bus bar and slide off the current
sensor.
RETROFITTING CURRENT SENSORSDrives built
between week 1, 2014 – week 16, 2016 require 8. For 1000 A units only, remove the mounting plate
retrofitting of the current sensors and related parts. For from the back of the current sensor by removing
more information, see chapter 11.1.6 Current Sensor 4 screws (8 mm). Retain the screws and mounting
Retrofit. plate for reassembly.
Reassembly
Disassembly The 6 screws (T30) connecting the bus bar to the IGBT
There are 2 sizes of current sensors (500 A or 1000 A), module must be tightened to 4 Nm (35 in-lb). For other
depending on the size of the drive. Use the following steps fastener torque values, refer to the standard torque values
to replace the current sensors. There is an extra step for in chapter 1.6 General Torque Tightening Values.
1000 A current sensors.
1. For 1000 A sensors only, reinstall the mounting
1. Remove the lower capacitor bank assembly. plate onto the back of the current sensor using 4
Refer to chapter 11.1.3 Lower Capacitor Bank screws (8 mm).
Assembly Replacement.
2. Slide the new current sensor onto the bus bar.
2. Remove 6 screws (T30) connecting the bus bar to
3. Secure the current sensor base to the back panel
the IGBT module at the IGBT end of the bus bar.
using 2 nuts (7 mm).
3. Remove 3 standoff nuts (7 mm) from the IGBT
4. Reconnect the wire to the current sensor.
end of the bus bar.
5. Secure the output bus bar to the current sensor
4. Remove 1 screw (T40) from the opposite end of
bus bar using 1 screw (T40).
the bus bar that is attached to the output bus
bar. 6. Secure the IGBT end of the bus bar to the 3
standoffs using 3 nuts (7 mm).
5. Unplug the wire from the current sensor.
7. Secure the IGBT end of the bus bar to the IGBT
6. Remove 2 nuts (7 mm) that attach the base of
module using 6 screws (T30).
the current sensor to the back panel.
8. Reinstall the lower capacitor bank assembly.
11 11

130BX320.11
1
1 Current sensor 4 Screw (T40)

11 11 2 Screw (T30) 5 Mounting plate (1000 A sensor)
3 Nut (7 mm) – –
Illustration 11.6 Current Sensor Assembly

11.1.6 Current Sensor Retrofit
NOTICE
RETROFITTING CURRENT SENSORS
Drives built between week 1, 2014 – week 16, 2016 require retrofitting of the current sensors and related parts.
Disassembly
To retrofit the current sensors and related parts in the inverter module, use the following procedure. Refer to Illustration 11.7.
1. Remove the inverter module from the frequency converter. Refer to chapter 10.2.6 Inverter Module Replacement.
2. To remove the cover plate, unfasten 4 nuts (M6), 1 from each corner of the cover plate.
130BF142.10
1
2
4
11 11
1 Cover plate 3 Lower capacitor bank assembly

2 Upper capacitor bank assembly 4 Current sensor
Illustration 11.7 Inverter Module


3. Disconnect the cables from the following
gatedrive card connectors: 4. Remove the 6 recessed connection nuts (M5) that
secure the capacitor bank assembly. These nuts
3a MK100
are found in the gap between the upper and
3b MK102 lower capacitor banks.
3c MK103 5. Remove the 4 nuts (M6) securing the lower
3d MK104 capacitor bank assembly. The gatedrive card can
remain in place on the assembly.
3e MK106
6. Lift the capacitor bank assembly from the unit.
130BF143.10
1
4
2
5
11 11
3
1 Upper capacitor bank assembly 4 Power card

2 Recessed connection nuts (M5) 5 Nut (M6)
3 Lower capacitor bank assembly 6 Gatedrive card
Illustration 11.8 Capacitor Bank Assembly, F1–F2

7c Detach the cable from the 3-pin

7. Remove the wire harness using the following
connector on the high frequency card.
steps:
7d Detach the cable from each current
7a Unplug the 16-pin cable from the
sensor.
MK102 connector on the power card.
7e Detach any cable ties that secure the
7b Remove the screw (M5) attaching the
wire harness, and remove the wire
ring terminal ground to the power card.
harness from the unit.
1 2 3 4
130BF201.10
5
11 11
1 Power card 4 3-pin connector

2 16-pin cable connector (MK102) 5 High frequency card
3 Ring terminal ground (M5) – –
Illustration 11.9 Power Card

8c Remove 1 screw (M8) from the opposite

8. Remove the current sensors and bus bars using
end of the bus bar where it connects to
the following steps:
the output bus bar.
8a Remove 6 screws (M6) connecting the
8d Remove 2 nuts (M4) that attach the
bus bar to the IGBT module at the IGBT
base of the current sensor to the back
end of the bus bar.
panel.
8b Remove 3 standoff nuts (M4) from the
8e Remove the bus bar and current sensor.
IGBT end of the bus bar.
130BF200.10
1
4
5
11 11
6
1 Screw (M6) 4 Nut (M4)

2 Standoff nut (M4) 5 Current sensor
3 Bus bar 6 Nut (M8)
Illustration 11.10 Current Sensor Assembly

Reassembly 1c Attach the cable to the 3-pin connector

on the high frequency card.
1. Install the new current sensor wire harness using
the following steps: 1d Attach cable ties securing the wire
harness in the unit.
1a Plug the 16-pin cable into the MK102
connector on the power card.
1b Secure the screw (M5) attaching the ring
terminal ground to the power card.
130BF202.10
8
5
10
11
6
11 11
12
7
1 16-pin cable connector (MK102) 7 Nut (M8)

2 M5 ring terminal ground 8 3-pin connector on high frequency card
3 Power card 9 Upper capacitor bank assembly
4 Screw (M6) 10 Bus bar
5 Nut (M4) 11 Cable connector
6 Current sensor 12 Wire harness
Illustration 11.11 Current Sensors, Bus bars, and Wire Harness

2. Install the 3 current sensors and bus bars using

the following steps:
2a Slide the new current sensor onto the
new bus bar and place it in the unit.
Position the sensor with the arrow on
the sensor facing away from the IGBTs.
See Illustration 11.11.
2b Secure the current sensor base to the
back panel using 2 nuts (M4).
2c Reconnect the wire harness to the
current sensor.
2d Secure the output bus bar to the
current sensor bus bar using 1 screw
(M8).
2e Attach the end of the bus bar to the 3
standoffs using 3 nuts (M4).
2f Secure the IGBT end of the bus bar to
the IGBT module using 6 screws (M6).
2g Repeat steps the steps for each current
sensor.
3. Place the lower capacitor bank assembly in its
original position.
4. Secure the capacitor bank assembly using 4 nuts
(M6).
5. Secure the capacitor bank using 6 recessed nuts
(M5).
11 11 6. Connect the cables to the following connectors
on the gatedrive card:
6a MK100
6b MK102
6c MK103
6d MK104
6e MK106
7. Install the cover plate using the following steps:
7a Place the cover plate in its original
position.
7b Secure 4 nuts (M6), 1 in each corner of
the cover plate.
7c Install the inverter module in the
frequency converter. Refer to
chapter 10.2.6 Inverter Module
Replacement.

11.1.7 Brake IGBT Module Replacement
NOTICE
The brake IGBT is an option and is not present on all units.
Follow the special torque requirements on the instructions
1. Remove both the upper and lower capacitor bank
included with the replacement module.
assemblies. Refer to chapter 11.1.2 Upper Capacitor
Bank Assembly Replacement (without removing 1. Reinstall the brake IGBT to the back panel using
power card) and chapter 11.1.3 Lower Capacitor the 4 mounting screws per brake IGBT.
Bank Assembly Replacement. 2. Place the IGBT-inductor bus bar assembly to its
2. Remove the high-frequency board. Refer to original position.
chapter 11.1.4 High-frequency Board Replacement. 3. Connect the IGBT-inductor base bar assembly to
3. Unplug the brake IGBT cable from the connector the 2 DC bus bars from the inductor. Secure the
on each of the 2 brake IGBT modules. assembly using 4 retaining nuts (13 mm).
4. Remove the bus bar that is attached to the left 4. Place the 3 IGBT bus bars back to their original
side of the panel and to the left most brake IGBT position.
by removing 2 nuts at each end of the bus bar. 5. Reinstall the 9 snubber capacitors on top of the
5. Remove the jumper bus bar between the 2 brake IGBT bus bars. Secure the snubber capacitors
IGBTs by removing the retaining nut on each end using 2 screws (T30) per snubber capacitor.
of the jumper bus bar. 6. Secure the IGBT-inductor bus bar assembly to
6. Remove the 2 screws (T30) connecting the IGBT- each brake IGBT module using 2 screws (T30).
inductor bus bar assembly to each brake IGBT 7. Reinstall the jumper bus bar between the 2 brake
module. IGBTs using a retaining nut at each end of the
7. Remove the 9 snubber capacitors by removing 2 jumper bus bars.
screws (T30) from each capacitor. 8. Reinstall the bus bar to the left side of the panel
11 11
8. Remove the 3 IGBT bus bars under the snubber and to the left most brake IGBT using 2 nuts at
capacitors. each end of the bus bar.
9. Remove the 4 retaining nuts (13 mm) connecting 9. Reconnect the brake IGBT cable to the connector
the IGBT-inductor base bar assembly to the 2 DC on each of the 2 brake IGBT modules.
bus bars from the inductor. 10. Reinstall the high-frequency board.
10. Remove the IGBT-inductor bus bar assembly. 11. Reinstall both the upper and lower capacitor
11. Remove the brake IGBT by removing the 4 bank assemblies.
mounting screws that attach each brake IGBT to
the back panel.

130BX321.11
1
3
4
1 5
10
1 Attaching nut 6 Brake IGBT cable

11 11 2 Left attached bus bar 7 Brake IGBT module
3 Jumper bus bar between brakes 8 IGBT-inductor bus bar assembly
4 Attaching nut 9 Snubber capacitor
5 IGBT-inductor bus bar assembly 10 IGBT capacitor bus bar
Illustration 11.12 Brake IGBT Module

11.1.8 IGBT Module Replacement
Follow the special torque requirements on the instructions
1. Remove both the upper and lower capacitor bank
included with the replacement module.
assemblies. Refer to chapter 11.1.2 Upper Capacitor
Bank Assembly Replacement (without removing 1. Reinstall the IGBT module to the back panel using
power card) and chapter 11.1.3 Lower Capacitor the 8 retaining screws (T25).
Bank Assembly Replacement. 2. Place the IGBT-inductor bus bar assembly to its
2. Remove the high-frequency board. Refer to original position.
chapter 11.1.4 High-frequency Board Replacement. 3. Connect the IGBT-inductor base bar assembly to
3. Remove the 3 current sensors. Refer to the 2 DC bus bars from the inductor. Secure the
chapter 11.1.5 Current Sensor Replacement. assembly using 4 retaining nuts (13 mm).
4. If the optional brake IGBT is present, complete 4. Place the 3 IGBT bus bars back to their original
this step. Otherwise, continue to the next step. position.
4a Remove the bus bar attached to the left 5. Reinstall the 9 snubber capacitors on top of the
side of the panel and to the left most IGBT bus bars. Secure the snubber capacitors
brake IGBT by removing 2 nuts at each using 2 screws (T30) per snubber capacitor.
end of the bus bar. Refer to 6. If the optional brake IGBT is present, complete
chapter 11.1.7 Brake IGBT Module this step. Otherwise, continue to the next step.
Replacement.
6a Connect the IGBT-inductor bus bar
4b Remove the 2 screws (T30) connecting assembly to each brake IGBT module
the IGBT-inductor bus bar assembly to using 2 screws (T30).
each brake IGBT module.
6b Reinstall bus bar to left side of panel
5. Remove the 9 snubber capacitors by removing 2 and to left most brake IGBT using 2 nuts
screws (T30) for from each capacitor. at each end of bus bar.
6. Remove the 3 IGBT capacitor bus bars under the 7. Reinstall the high-frequency board.
snubber capacitors.
7. Remove the 4 retaining nuts (13 mm) connecting
8. Reinstall both the upper and lower capacitor
bank assemblies.
11 11
the IGBT-inductor bus bar assembly to the 2 DC
bus bars from the inductor. NOTICE
8. Remove the IGBT-inductor bus bar assembly. Connect the temperature sensor cable from the
gatedrive card MK100 to the center IGBT module
9. Remove the IGBT module by removing the 8 connector (MK103).
retaining screws (T25) that secure the IGBT
module to the back panel.

130BX259.12
2
11 11
1 IGBT module 4 Snubber capacitor

2 High-frequency board 5 IGBT capacitor bus bar
3 IGBT-inductor bus bar assembly 6 Current sensor
Illustration 11.13 IGBT Module

11.1.9 Gatedrive Card Replacement
1. Unplug the gatedrive card connectors.
1a For F1–F4 or F10–13 enclosures, unplug
1. Reinstall the new gatedrive card to its original
MK100, MK102, MK103, MK104, and
position within the module. Secure the card to
MK106. If the unit has a brake option,
the standoffs with 6 screws (T25).
unplug MK105. Refer to Illustration 11.2.
2. Plug in the cables to the gatedrive card
1b For F8–F9 enclosures, unplug MK100,
connectors.
MK101, MK102, MK103, MK104, and
MK106. If the unit has a brake option, 2a For F1–F4 or F10–13 enclosures, connect
unplug MK105. MK100, MK102, MK103, MK104, and
2. Remove the gatedrive card by removing the 6
connect MK105. Refer to Illustration 11.2.
mounting screws (T25) from the standoffs.
2b For F8–F9 enclosures, connect MK100,
MK101, MK102, MK103, MK104, and
connect MK105.
130BX256.12
1 2 3 4 5
11 11
1 MK104 4 MK100
2 MK103 5 MK105 (optional)
3 MK102 6 MK106
Illustration 11.14 Gatedrive Card, F1–F13

11.2 Rectifier Module
CAUTION
TRAINING REQUIRED
Only certified technicians who are trained by Danfoss are permitted to test and repair module components. Repair work
conducted by non-certified technicians can result in personal injury or equipment damage.
1. Remove the rectifier module from the frequency converter. Refer to chapter 10.2.5 Rectifier Module Replacement.
2. Remove the right side panel from the rectifier module by removing 6 nuts (T25) and 1 nut (8 mm).
130BX335.12
2 3
4
5
1
7
12
11
11 11
10
1 Rectifier module cover plate 7 Soft charge cards

2 Power card 8 Soft charge card mounting plate
3 Panel connectors 9 SCR module
4 SMPS fuse 10 Fan assembly
5 Power card mounting plate flange 11 Diode module
6 Power card mounting plate 12 Soft charge resistor
Illustration 11.15 Exploded View of Rectifier Module, F1–F4

130BX420.11
2
11 11
6 5
1 MPIC card 5 Diode

2 Rectifier module cover plate 6 SCR
3 Power card 7 Fan assembly
4 Soft charge resistor 8 Soft charge card

130BX421.11
1
8 2
11 11
1 Rectifier module cover plate 5 Diode

2 Power card 6 SCR
3 Soft charge card 7 Fan assembly
4 Soft charge resistor 8 Transformer

11.2.1 Power Card Replacement
These instructions are the same for 6-pulse and 12-pulse units, with the exception that 12-pulse units can vary in the
number of SCR and diode modules. F8–F9 enclosures contain an extra MPIC card that is connected to the power card to
provide control to the extra SCRs.
NOTICE
The power card can remain installed if the power card mounting plate is removed to access the soft charge boards.
Remember to disconnect the cables.
1. Disconnect the following cables from the power
card:
1. Verify that the insulation sheet is in place on the
1a MK100
module.
1b MK102
2. Place the new power card on top of the
1c MK103 insulation sheet and align the power card
1d MK104 openings with the screw holes.
1e MK105 3. Attach the plastic standoff to the power card.
1f MK106 4. Secure the power card using 7 screws (T25).
1g MK107 (F8–F13 only) 5. Reconnect the following cables to the power

card:
1h MK108
5a MK100
1i MK110
5b MK102
1j MK112
5c MK103
1k FK102
5d MK104
2.
1l FK103 (F8–F13 only)
Remove the power card by removing 7 screws
5e MK105 11 11
(T25) and detaching the plastic standoff at the 5f MK106
top right corner of the power card. 5g MK107 (F8–F13 only)
3. The insulation sheet behind the power card can 5h MK108
be left in place. Ensure the sheet is in place for
5i MK110
reassembly.
5j MK112
5k FK102

130BX323.12
1
11 11
1 Power card
2 Power card mounting plate
3 Power card attaching screw
Illustration 11.18 Power Card

11.2.2 12-pulse MPIC Replacement
The 12-pulse F8–F9 enclosures have a multi-pulse interface card (MPIC) mounted on the power card mounting plate.
NOTICE
The MPIC can remain installed if the power card mounting plate is removed to access the soft charge boards.
1. Disconnect the following cables from the MPIC:
1a MK100
1. Verify that the insulation sheet is in place on the
1b MK102 module.
1c MK104 2. Place the new MPIC on top of the insulation
1d MK105 sheet and align the MPIC openings with the
screw holes.
1e MK106
3. Secure MPIC using 4 screws (T25).
1f MK110
4. Reconnect the following cables to the MPIC:
2. Remove the MPIC by removing 4 screws (T25).
4a MK100
3. The insulation sheet behind the MPIC can be left
in place. Ensure that the sheet is in place for 4b MK102
reassembly. 4c MK104
4d MK105
4e MK106
4f MK110
11 11

130BX431.12
3
1
5
11 11
1 MK110 5 MK104
2 MPIC 6 MK102
3 MK106 7 MK101
4 MK105
Illustration 11.19 Multi-pulse Interface Card (MPIC)

11.2.3 Power Card Mounting Plate Disassembly/Reassembly
1. Disconnect the 2 fast-on connectors from the
fuse block that is attached to the power card
mounting plate flange. 1. Position the mounting plate on the module and
secure with 4 retaining nuts (8 mm).
2. Disconnect the following cables from the power
card: 2. Reconnect the 3 cable connectors (6-pin, 8-pin,
and 12-pin) to the back side of the flange.
2a MK100
3. Reconnect the following cables to the power
2b MK103
card:
2c MK104
3a MK100
2d MK105
3b MK103
2e MK106
3c MK104
2f MK110
3d MK105
3. Disconnect the 3 cable connectors (6-pin, 8-pin,
3e MK106
and 12-pin) from the power card mounting panel
flange. The cable connectors disconnect from the 3f MK110
back side of the flange. 4. Reconnect the 2 fast-on connectors to the fuse
4. Remove the power card mounting plate by block.
removing the 4 retaining nuts (8 mm) that secure
the plate.
NOTICE
The soft charge cards are accessible now for changing
fuses. There is 1 soft charge card per inverter module.
11 11

130BX322.12
1 2 3
5
6
11 11
1 Power card mounting plate 4 Fuse block

2 Power card 5 Power card mounting plate flange
3 Cable connectors 6 Retaining nuts (8 mm)
Illustration 11.20 Power Card Mounting Plate

11.2.4 Soft Charge Card Replacement
1. Remove the power card mounting plate.
Refer to chapter 11.2.3 Power Card Mounting Plate
Disassembly/Reassembly. 1. Verify that the insulation sheet is in place on the
power card mounting plate.
2. Disconnect the following cables from the soft
charge card: 2. Place the new soft charge card on the insulation
sheet and align the card with the screw holes in
2a MK1
the mounting plate.
2b MK2
3. Secure the soft charge card using 4 screws (T25).
2c MK3
4. Reconnect the following cables from the soft
2d MK4 charge card:
3. Remove the soft charge card from the mounting 4a MK1
plate by removing the 4 screws (T25) securing
4b MK2
the card to the mounting plate. Note the
insulation sheet below the soft charge card. 4c MK3
Remove and keep the insulation sheet for 4d MK4
reinstallation.
5. Reinstall the power card mounting plate.
11 11

130BX316.12
1
2
11 11 2
1 Soft charge card

2 Attaching screw
Illustration 11.21 Soft Charge Card

11.2.5 Soft Charge Card Mounting Plate Disassembly/Reassembly
Disassembly/Reassembly. 1. Secure the soft charge mounting plate with 4
nuts (8 mm).
2. Remove the R (red), S (white), and T (black) ring
lugs from the input power bus bar. There is 1 soft 2. Reconnect the MK3 and MK4 cables to each soft
charge card per inverter module. charge card.
3. Disconnect the MK3 and MK4 cables from each 3. Reinstall the R (red), S (white), and T (black) ring
soft charge card. lugs to the input power bus bar. There is 1 soft
charge card per inverter module.
4. Remove the soft charge card mounting plate by
removing the 4 nuts (8 mm) that secure the 4. Reinstall the power card mounting plate.
mounting plate. The soft charge cards can remain
attached to the mounting plate.
11 11

130BX315.12
1
11 11
1 Soft charge card

2 Soft charge card mounting plate
3 Attaching nut (8 mm)
Illustration 11.22 Soft Charge Card Mounting Plate

11.2.6 Soft Charge Resistor Replacement
Units with 2 inductors contain 2 resistors, 1 on each side of the mounting plate. Units with 3 inductors contain an extra
resistor.
Disassembly/Reassembly. 1. Secure the new soft charge resistor with a nut
(8 mm) on the top of the soft charge resistor.
2. Remove the soft charge mounting plate.
Refer to chapter 11.2.5 Soft Charge Card Mounting 2. Tighten the nut (8 mm) on the bottom of the
Plate Disassembly/Reassembly. resistor.
3. Loosen the nut (8 mm) on the bottom of the soft 3. Reinstall the soft charge mounting plate.
charge resistor. 4. Reinstall the power card mounting plate.
4. Remove the nut (8 mm) on the top of the
resistor.
11 11

130BX317.12
1
11 11
1 Top nut (8 mm)

2 Soft charge resistors
3 Bottom nut (8 mm)
Illustration 11.23 Soft Charge Resistor for a Unit Containing 3 Inverters

11.2.7 SCR Module Replacement
Disassembly/Reassembly. 1. Attach the SCR module to the heat sink back
panel with 4 mounting screws (T30) and washers.
Refer to chapter 11.2.5 Soft Charge Card Mounting 2. Reattach the gate lead to the SCR module. If
Plate Disassembly/Reassembly. reassembling more than 1 SCR module, make
sure that the gate leads are reattached in their
3. Remove the 6 nuts (13 mm) that secure the SCR
original positions.
modules to the (+) DC bus bar.
3. Secure the SCR modules to the AC input bus bar
4. Remove the 2 nuts (17 mm) that secure the (+)
with 6 nuts (13 mm), 2 for each SCR module.
DC bus bar to the output bus bar and remove
the (+) DC bus bar. 4. Attach the (+) DC bus bar to the output bus bar
with 2 nuts (17 mm).
5. Remove 6 nuts (13 mm), 2 from each SCR
module, from the AC input bus bar. 5. Secure the SCR modules to the (+) DC bus bars
with 6 nuts (13 mm), 2 for each SCR module.
6. If removing more than 1 SCR module, note which
gate lead attaches to which module. Unplug gate 6. Reinstall the soft charge mounting plate.
lead from SCR module. 7. Reinstall the power card mounting plate.
7. Remove the 4 mounting screws (T30) and
washers attaching the SCR module to the heat
sink back panel.
11 11

130BE360.10
2
3
1 (+) DC bus bar 4 Retaining nuts (13 mm)

2 Retaining nuts (17 mm) 5 SCR module
3 AC input bus bar
Illustration 11.24 SCR Module, F1 and F3
130BX324.13
1 2
11 11 3
5
6
1 AC input bus bar 5 Retaining nut (17 mm)

2 Retaining nut (13 mm) 6 Retaining nut (13 mm)
3 (+) DC bus bar 7 SCR module
4 Output bus bar
Illustration 11.25 SCR Module, F2 and F4

11.2.8 Diode Module Replacement
Disassembly/Reassembly. 1. Secure the new diode to the module using 4
retaining screws (T30) and washers.
Refer to chapter 11.2.5 Soft Charge Card Mounting 2. Secure the diode module to the bus bars using 1
Plate Disassembly/Reassembly. mounting nut (17 mm) on the AC input side and
1 mounting nut (17 mm) on the (-) DC side of the
3. Remove the 2 mounting nuts (17 mm) from the
module.
diode module, 1 on the AC input side and 1 on
the (-) DC side of module. 3. Reinstall the soft charge mounting plate.
4. Remove the diode module by removing 4 4. Reinstall the power card mounting plate.
retaining screws (T30) and washers from the
corners of module.
11 11

130BE380.10
1
1 Retaining nut (17 mm) 3 Diode module

2 Screws (T30)
Illustration 11.26 Diode Module, F1 and F3
130BX314.13
11 11 1
3
2
1 Retaining nut (17 mm) 3 Diode module

2 Screws (T30)
Illustration 11.27 Diode Module, F2 and F4

11.2.9 Heat Sink Thermal Sensor Replacement
Disassembly/Reassembly. 1. Attach the new heat sink thermal sensor to the
heat sink using 1 screw (T20).
Refer to chapter 11.2.5 Soft Charge Card Mounting 2. Reinstall the soft charge mounting plate.
Plate Disassembly/Reassembly. 3. Reinstall the power card mounting plate.
3. Remove the heat sink thermal sensor by
removing the 1 screw (T20) securing the sensor
to the heat sink.
11 11

Power-dependent Specificati... VLT® Drives FC Series, F1–F4/F8–F13 Enclosures
12 Power-dependent Specifications
12.1 F1-F4 Enclosures

12.1.1 FC 102, 380–480 V
FC 102 P500 P560 P630 P710 P800 P1M0

Normal load* NO NO NO NO NO NO
Typical shaft output at 400 V [kW] 500 560 630 710 800 1000
Typical shaft output at 460 V [hp] 700 750 900 1000 1200 1350
Enclosure size F1, F3 F2, F4
Output current
Continuous (at 3x380–440 V) [A] 880 990 1120 1260 1460 1720
Intermittent (at 3x380–440 V) [A] 968 1089 1232 1386 1606 1892
Continuous (at 3x441–480 V) [A] 780 890 1050 1160 1380 1530
Intermittent (at 3x441–480 V) [A] 858 979 1155 1276 1518 1683
Continuous kVA (at 400 V AC) [kVA] 610 686 776 873 1012 1192
Continuous kVA (at 460 V AC) [kVA] 621 709 837 924 1100 1219
Maximum input current
Continuous (3x380–440 V) [A] 857 964 1090 1227 1422 1675
Continuous (3x441–480 V) [A] 159 867 1022 1129 1344 1490
Maximum pre-fuses1) [A] 1600 2000 2500
Maximum cable cross-section2)
Motor [mm2 (AWG)] 8x150 (8x300 mcm) 12x150 (12x300 mcm)
Mains [mm2 (AWG)] 8x240 (8x500 mcm)
Load share [mm2 (AWG)] 4x120 (4x350 mcm)
Brake [mm2 (AWG)] 4x185 (4x350 mcm) 6x185 (6x350 mcm)
Other information
Weight, enclosure IP21/IP54 [kg (lb)] 1017/1318 (2242/2905) 1260/1561 (2778/3441)
12 12 Heat sink overtemperature trip [°C (°F)] 95 (203)
Power card ambient trip [°C (°F)] 85 (185)
*Normal overload=110% current for 60 s
Table 12.1 Technical Specifications, F1–F4, Mains Supply 3x380–480 V AC

1) For type of fuse, consult the operating intructions.
2) The 3 values for the maximum cable cross-section are for single core, flexible wire, and flexible wire with sleeve, respectively.

Power-dependent Specificati... Service Guide
12.1.2 FC 102, 525–690 V
FC 102 P710 P800 P900 P1M0 P1M2 P1M4

Normal load* NO NO NO NO NO NO
Output current
Continuous (at 550 V) [A] 763 889 988 1108 1317 1479
Intermittent (60 s overload) (at 550 V) [A] 839 978 1087 1219 1449 1627
Continuous (at 575/690 V) [A] 730 850 945 1060 1260 1415
Intermittent (60 s overload) (at 575/690 V) [kVA] 803 935 1040 1166 1386 1557
Continuous kVA (at 550 V) [kVA] 727 847 941 1056 1255 1409
Continuous (at 550 V) [A] 743 866 962 1079 1282 1440
Continuous (at 575 V) [A] 711 828 920 1032 1227 1378
Continuous (at 690 V) [A] 711 828 920 1032 1227 1378
Maximum external mains fuses1) [A] 1600 2000 2500
Mains [mm2 (AWG)] 8x240 (8x500 mcm) 8x240 (8x500 mcm)
Load share [mm2 (AWG)]
4x185 (4x350 mcm) 6x185 (6x300 mcm)
Brake [mm2 (AWG)]
Other information
1017/1038 1260/1561 1294/1595
Weight, enclosure IP21/IP54 [kg (lb)]
(2242/2288) (1278/3441) (2853/3516)
Heat sink overtemperature trip [°C (°F)] 95 (203) 105 (221) 95 (203) 105 (221) 95 (203)
*Normal overload=110% current for 60 s.
12 12

12.1.3 FC 202, 380–480 V
FC 202 P500 P560 P630 P710 P800 P1M0

High/normal load* HO NO HO NO HO NO HO NO HO NO HO NO
Typical shaft output at 400 V [kW] 450 500 500 560 560 630 630 710 710 800 800 1000
Typical shaft output at 460 V [hp] 600 650 650 750 750 900 900 1000 1000 1200 1200 1350
Output current
Continuous (at 3x380–440 V) [A] 800 880 880 990 990 1120 1120 1260 1260 1460 1460 1720
Intermittent (at 3x380–440 V) [A] 1200 968 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892
Continuous (at 3x441–480 V) [A] 730 780 780 890 890 1050 1050 1160 1160 1380 1380 1530
Intermittent (at 3x441–480 V) [A] 1095 858 1170 979 1335 1155 1575 1276 1740 1518 2070 1683
Continuous kVA (at 400 V AC) [kVA] 554 610 610 686 686 776 776 873 873 1012 1012 1192
Continuous (3x380–440 V) [A] 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675
Continuous (3x441–480 V) [A] 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490
Maximum pre-fuses1) [A] 1600 2000 2500
Mains, F1 and F2 [mm2 (AWG)] 8x240 (8x500 mcm)
Other information
Weight, rectifier module [kg (lb)] 102 (224) 136 (299)
Weight, inverter module [kg (lb)] 102 (224) 136 (299) 102 (224)
Heat sink overtemperature trip [°C
95 (203)
(°F)]
12 12 *High overload=150% current for 60 s, normal overload=110% current for 60 s


12.1.4 FC 202, 525–690 V
FC 202 P710 P800 P900

High/normal load* HO NO HO NO HO NO
Enclosure size F1, F3
Output current
Continuous (at 550 V) [A] 659 763 763 889 889 988
Continuous (at 575/690 V) [A] 630 730 730 850 850 945
Continuous (at 550 V) [A] 642 743 743 866 866 962
Continuous (at 575 V) [A] 613 711 711 828 828 920
Continuous (at 690 V) [A] 613 711 711 828 828 920
Maximum external mains fuses1 [A] 1600
Motor [mm2 (AWG)] 8x150 (8x300 mcm)
Mains, F1 [mm2 (AWG)] 8x240 (8x500 mcm)
Brake [mm2 (AWG)] 4x185 (4x350 mcm)
Other information
Weight, enclosure IP21/IP54 [kg (lb)] 1017/1318 (2242/2905)
Weight, rectifier module [kg (lb)] 102 (224)
Weight, inverter module [kg (lb)] 102 (224) 136 (299)
Heat sink overtemperature trip [°C (°F)] 95 (203) 105 (221)
85 (185)
95 (203) 12 12
Power card ambient trip [°C (°F)]
*High overload=150% current for 60 s, normal overload=110% current for 60 s.


FC 202 P1M0 P1M2 P1M4

Output current
Continuous (at 550 V) [A] 988 1108 1108 1317 1317 1479
Continuous (at 575/690 V) [A] 945 1060 1060 1260 1260 1415
Continuous (at 550 V) [A] 962 1079 1079 1282 1282 1440
Continuous (at 575 V) [A] 920 1032 1032 1227 1227 1378
Continuous (at 690 V) [A] 920 1032 1032 1227 1227 1378
Other information
Heat sink overtemperature trip [°C (°F)] 95 (203) 105 (221) 95 (203)
12 12 *High overload=150% current for 60 s, normal overload=110% current for 60 s.


12.1.5 FC 302, 380–500 V
FC 302 P450 P500 P560 P630 P710 P800

Output current
Continuous (at 400 V) [A] 800 880 880 990 990 1120 1120 1260 1260 1460 1460 1720
Intermittent (60 s overload)
1200 968 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892
(at 400 V) [A]
Continuous (at 460/500 V) [A] 730 780 780 890 890 1050 1050 1160 1160 1380 1380 1530
1095 858 1170 979 1335 1155 1575 1276 1740 1518 2070 1683
(at 460/500 V) [A]
Continuous kVA (at 400 V) [kVA] 554 610 610 686 686 776 776 873 873 1012 1012 1192
Continuous kVA
632 675 675 771 771 909 909 1005 1005 1195 1195 1325
(at 500 V) [kVA]
Continuous (at 400 V) [A] 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675
Continuous (at 460/500 V) [A] 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490
Other information
Weight, rectifier module [kg (lb)]
Weight, inverter module [kg (lb)] 102 (225)
102 (225)
136 (300)
136 (300)
102 (225)
12 12
110 (230)
(°F)]
Control card ambient trip [°C (°F)] 85 (185)
* High overload=160% torque during 60 s, normal overload=110% torque during 60 s.
Table 12.6 Technical Specifications, F8–F13, Mains Supply 380–500 V AC


12.1.6 FC 302, 525–690 V
FC 302 P630 P710 P800

Output current
Continuous (at 550 V) [A] 659 763 763 889 889 988
Continuous (at 575/690 V) [A] 630 730 730 850 850 945
Intermittent (60 s overload) (at 575/690 V) [A] 945 803 1095 935 1275 1040
Continuous (at 550 V) [A] 642 743 743 866 866 962
Continuous (at 575 V) [A] 613 711 711 828 828 920
Continuous (at 690 V) [A] 613 711 711 828 828 920
Other information
12 12 Power card ambient trip [°C (°F)]

85 (185)


FC 302 P900 P1M0 P1M2

Output current
Continuous (at 550 V) [A] 988 1108 1108 1317 1317 1479
Continuous (at 575/690 V) [A] 945 1060 1060 1260 1260 1415
Intermittent (60 s overload) (at 575/690 V) [A] 1418 1166 1590 1386 1890 1557
Continuous (at 550 V) [A] 962 1079 1079 1282 1282 1440
Continuous (at 575 V) [A] 920 1032 1032 1227 1227 1378
Continuous (at 690 V) [A] 920 1032 1032 1227 1227 1378
Other information
* High overload=160% torque during 60 s, normal overload=110% torque during 60 s. 12 12

12.2 F8-F9 and F10-F13 Enclosures

12.2.1 FC 102, 380–480 V
FC 102 P315 P355 P400 P450 P500 P560 P630 P710 P800 P1M0
Normal overload 110% for 1 minute NO NO NO NO NO NO NO NO NO NO
Typical shaft output [kW] at 400 V 315 355 400 450 500 560 630 710 800 1000
Typical shaft output [hp] at 460 V 450 500 550/600 600 650 750 900 1000 1200 1350
Enclosure size F8, F9 F10, F11 F12, F13
Output current
Continuous (at 380–440 V) 600 658 745 800 880 990 1120 1260 1460 1720
Intermittent (60 s overload at 380–440
V) 660 724 820 880 968 1089 1232 1386 1606 1892
Continuous (at 400 V) 416 456 516 554 610 686 776 873 1012 1192
Intermittent (60 s overload at 460–500
V) 457 501 568 610 671 754 854 960 1113 1311
Continuous (at 441–500 V) 540 590 678 730 780 890 1050 1160 1380 1530
(at 441–500 V) 594 649 746 803 858 979 1155 1276 1518 1683
Continuous (at 460 V) 430 470 540 582 621 709 837 924 1100 1219
Continuous (at 500 V) 473 517 594 640 684 780 920 1017 1209 1341
Continuous (3x380–440 V) [A] 590 647 733 787 857 964 1090 1227 1422 1675
Continuous (3x441–480 V) [A] 531 580 667 718 759 867 1022 1129 1344 1490
Maximum external mains fuses1)[A] 700 900 1500
Motor [mm2 (AWG)] 12x150
8x150 (8x300 mcm)
(12x300 mcm)
Regeneration terminals [mm2 (AWG)] 4x120 (4x250 mcm)
12 12 Other information
Weight enclosure IP21/IP54 [kg (lb)] 263 270 272 313
1004 (2214) 1246 (2748)
(580) (595) (600) (690)
110 (230) 95 (203)
(°F)]


12.2.2 FC 102, 525–690 V
FC 102 P450 P500 P560 P630 P710 P800 P900 P1M0 P1M2 P1M4
Normal overload 110% for 1 minute NO NO NO NO NO NO NO NO NO NO
Typical shaft output [hp] at 525–550 V 355 400 450 500 560 670 750 850 1000 1100
Typical shaft output [kW] at 690 450 500 560 630 710 800 900 1000 1200 1400
Typical shaft output [hp] at 575 450 500 600 650 750 950 1050 1150 1350 1550
Enclosure size F8, F9 F10, F11 F12, F13
Output current
Continuous (6x525–550 V) [A] 470 523 596 630 763 889 988 1108 1317 1479
Intermittent (6x550 V) [A] 515 575 656 693 839 978 1087 1219 1449 1627
Continuous (6x551–690 V) [A] 450 500 570 630 730 850 945 1060 1260 1415
Intermittent (6x551–690 V) [A] 495 550 627 693 803 935 1040 1166 1386 1557
Continuous kVA (550 V) [kVA] 448 498 568 600 727 847 941 1056 1255 1409
Continuous (6x550 V) [A] 453 504 574 607 743 866 962 1079 1282 1440
Continuous (6x575 V) [A] 434 482 549 607 711 828 920 1032 1227 1378
Continuous (6x690 V) [A] 434 482 549 607 711 828 920 1032 1227 1378
Maximum external mains fuses1) [A] 630 900 1600 2000 2500
Regeneration terminals [mm2 (AWG)] 4x120 (4x250 mcm)
Other information
Weight enclosure IP21/IP54 [kg (lb)] 440/656 (880/1443) 880/1096 (1936/2471) 1022/1238 (2248/2724)
Heat sink overtemperature trip [°C 105 105
110 (230) 95 (203) 95 (203) 95 (203) 95 (203)
(°F)] (221) (221)
Table 12.10 Technical Specifications, F8–F13, Mains Supply 525–690 V AC 12 12


12.2.3 FC 202, 380–480 V
FC 202 P315 P355 P400 P450

High/normal load* HO NO HO NO HO NO HO NO
Typical shaft output at 400 V [kW] 250 315 315 355 355 400 400 450
Typical shaft output at 460 V [hp] 350 450 450 500 500 600 550 600
Output current
Continuous (at 400 V) [A] 480 600 600 658 658 745 695 800
Intermittent, 60 s overload (at 400 V) [A] 720 660 900 724 987 820 1043 880
Continuous (at 460/480 V) [A] 443 540 540 590 590 678 678 730
Intermittent, 60 s overload (at 460/480 V) [A] 665 594 810 649 885 746 1017 803
Continuous kVA (at 400 V AC) [kVA] 333 416 416 456 456 516 482 554
Continuous kVA (at 460 V AC) [kVA] 353 430 430 470 470 540 540 582
Continuous (400 V) [A] 472 590 590 647 647 733 684 787
Continuous (460/480 V) [A] 436 531 531 580 580 667 667 718
Maximum external main fuses1) [A]
Mains [mm2 (AWG)] 4x90 (4x3/0) 4x240 (4x500 mcm)
Other information
Heat sink overtemperature trip [°C (°F)] 110 (230)
*High overload=150% current for 60 s, normal overload=110% current for 60 s

12 12

FC 202 P500 P560 P630 P710 P800 P1M0

Output current
Continuous (at 400 V) [A] 800 880 880 990 990 1120 1120 1260 1260 1460 1460 1720
Intermittent, 60 s overload
1200 968 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892
(at 400 V) [A]
Continuous (at 460/480 V) [A] 730 780 780 890 890 1050 1050 1160 1160 1380 1380 1530
Intermittent, 60 s overload 1095 858 1170 979 1335 1155 1575 1276 1740 1518 2070 1683
(at 460/480 V) [A]
Continuous (400 V) [A] 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675
Continuous (460/480 V) [A] 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490
Maximum external main fuses1) [A] 900 1500
Other information
95 (203)
(°F)]
*High overload=150% current for 60 s, normal overload=110% current for 60 s

1) For type of fuse, consult the operating intructions. 12 12

12.2.4 FC 202, 525–690 V
FC 202 P450 P500 P560 P630

Output current
Continuous (at 550 V) [A] 395 470 429 523 523 596 596 630
Intermittent (60 s overload) (at 550 V) [A] 593 517 644 575 785 656 894 693
Continuous (at 575/690 V) [A] 380 450 410 500 500 570 570 630
Intermittent (60 s overload) 570 495 615 550 750 627 855 693
(at 575/690 V) [kVA]
Continuous kVA (at 550 V) [kVA] 376 448 409 498 498 568 568 600
Continuous (at 550 V) [A] 381 453 413 504 504 574 574 607
Continuous (at 575 V) [A] 366 434 395 482 482 549 549 607
Continuous (at 690 V) [A] 366 434 395 482 482 549 549 607
Maximum external mains fuses1) [A] 630
Mains [mm2 (AWG)] 4x85 (4x3/0)
Other information
Heat sink overtemperature trip [°C (°F)] 110 (230)
12 12 Table 12.13 Technical Specifications, F8–F13, Mains Supply 525–690 V AC


FC 202 P710 P800 P900

Output current
Continuous (at 550 V) [A] 659 763 763 889 889 988
Continuous (at 575/690 V) [A] 630 730 730 850 850 945
Continuous (at 550 V) [A] 642 743 743 866 866 962
Continuous (at 575 V) [A] 613 711 711 828 828 920
Continuous (at 690 V) [A] 613 711 711 828 828 920
Other information

12 12

FC 202 P1M0 P1M2 P1M4

Output current
Continuous (at 550 V) [A] 988 1108 1108 1317 1317 1479
Continuous (at 575/690 V) [A] 945 1060 1060 1260 1260 1415
Continuous (at 550 V) [A] 962 1079 1079 1282 1282 1440
Continuous (at 575 V) [A] 920 1032 1032 1227 1227 1378
Continuous (at 690 V) [A] 920 1032 1032 1227 1227 1378
Other information
Weight, rectifier module [kg (lb)] 136 [300]
12 12 Table 12.15 Technical Specifications, F8–F13, Mains Supply 525–690 V AC


12.2.5 FC 302, 380–500 V
FC 302 P250 P315 P355 P400

Output current
Continuous (at 400 V) [A] 480 600 600 658 658 745 695 800
720 660 900 724 987 820 1043 880
(at 400 V) [A]
Continuous (at 460/500 V) [A] 443 540 540 590 590 678 678 730
665 594 810 649 885 746 1017 803
(at 460/500 V) [A]
Continuous (at 400 V) [A] 472 590 590 647 647 733 684 787
Continuous (at 460/500 V) [A] 436 531 531 580 580 667 667 718
Mains [mm2 (AWG)] 4x90 (4x3/0) 4x90 (4x3/0) 4x240 (4x500 mcm) 4x240 (4x500 mcm)
Motor [mm2 (AWG)] 4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm) 4x240 (4x500 mcm)
Brake [mm2 (AWG)] 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)
Other information
110 (230)
(°F)]
Control card ambient trip [°C (°F)] 85 (185)
12 12

FC 302 P450 P500 P560 P630 P710 P800

Output current
Continuous (at 400 V) [A] 800 880 880 990 990 1120 1120 1260 1260 1460 1460 1720
1200 968 1320 1089 1485 1232 1680 1386 1890 1606 2190 1892
(at 400 V) [A]
Continuous (at 460/500 V) [A] 730 780 780 890 890 1050 1050 1160 1160 1380 1380 1530
1095 858 1170 979 1335 1155 1575 1276 1740 1518 2070 1683
(at 460/500 V) [A]
Continuous (at 400 V) [A] 779 857 857 964 964 1090 1090 1227 1227 1422 1422 1675
Continuous (at 460/500 V) [A] 711 759 759 867 867 1022 1022 1129 1129 1344 1344 1490
Maximum external mains fuses1) [A] 900 1500
Other information
Weight, enclosure IP21/IP54 [kg] 1017/1319 (2242/2908) 1261/1562 (2780/3444)
95 (203)
(°F)]
12 12 * High overload=160% torque during 60 s, normal overload=110% torque during 60 s.


12.2.6 FC 302, 525–690 V
FC 302 P355 P400 P500 P560

Output current
Continuous (at 550 V) [A] 395 470 429 523 523 596 596 630
Intermittent (60 s overload) (at 550
593 517 644 575 785 656 894 693
V) [A]
Continuous (at 575/690 V) [A] 380 450 410 500 500 570 570 630
Intermittent (60 s overload) (at
570 495 615 550 750 627 855 693
575/690 V) [A]
Continuous (at 550 V) [A] 381 453 413 504 504 574 574 607
Continuous (at 575 V) [A] 366 434 395 482 482 549 549 607
Continuous (at 690 V) [A] 366 434 395 482 482 549 549 607
Mains [mm2 (AWG)] 4x85 (4x3/0)
Brake [mm2 (AWG)] 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm) 2x185 (2x350 mcm)
Other information
110 (230)
(°F)]
Power card ambient trip [°C (°F)]
85 (185)
12 12

FC 302 P630 P710 P800

High/normal load HO NO HO NO HO NO
Output current
Continuous (at 550 V) [A] 659 763 763 889 889 988
989 839 1145 978 1334 1087
(at 550 V) [A]
Continuous (at 575/690 V) [A] 630 730 730 850 850 945
945 803 1095 935 1275 1040
(at 575/690 V) [A]
Continuous (at 550 V) [A] 642 743 743 866 866 962
Continuous (at 575 V) [A] 613 711 711 828 828 920
Continuous (at 690 V) [A] 613 711 711 828 828 920
Other information
Power heatsink overtemperature trip
95 (203) 105 (221) 95 (203)
[°C (°F)]
12 12 Power card ambient trip [°C (°F)]

* High overload=160% torque during 60 s, normal overload=110% torque during 60 s
85 (185)


FC 302 P900 P1M0 P1M2

Output current
Continuous (at 550 V) [A] 988 1108 1108 1317 1317 1479
1482 1219 1662 1449 1976 1627
(at 550 V) [A]
Continuous (at 575/690 V) [A] 945 1060 1060 1260 1260 1415
1418 1166 1590 1386 1890 1557
(at 575/690 V) [A]
Continuous (at 550 V) [A] 962 1079 1079 1282 1282 1440
Continuous (at 575 V) [A] 920 1032 1032 1227 1227 1378
Continuous (at 690 V) [A] 920 1032 1032 1227 1227 1378
Other information
Weight, enclosure IP21/IP 54 [kg (lb)] 1261/1562 (2780/3444) 1295/1596 (2855/3519)
Power heat sink overtemperature trip
95 (203) 105 (221) 95 (203)
[°C (°F)]
12 12


12.3 Ratings Tables

12.3.1 Warning and Alarm Trip Points
The frequency converter is protected against short circuits with current measurement in each of the 3 motor phases (250–
1400 kW (350–1550 hp)). A short circuit between 2 output phases causes an overcurrent in the frequency converter. The
frequency converter turns off the IGBTs individually when the short-circuit current exceeds the permitted value (alarm 16,
Trip Lock).
380–480 V AC FC 102/FC 202 P500 P560 P630 P710 P800 P1M0

380–500 V AC FC 302 P450 P500 P560 P630 P710 P800
Overcurrent warning [Arms] 1777 1777 2338 2580 2666 3507
Overcurrent alarm1) (1.5 s delay) [Arms] 1777 1777 2338 2580 2666 3507
Ground fault alarm [Arms] 400 440 495 560 630 730
Short circuit alarm [Arms] 2260 2260 2974 3281 3390 4460
Heat sink overtemperature [°C] 95 (203)
Heat sink under temperature
[°C (°F)] 0 (32)
warning
Power card ambient overtem-
75 (167)
perature [°C (°F)]
Power card ambient under
-20 (-4)
temperature [°C (°F)]
Mains phase warning (30 s delay) DC Bus Ripple Vpkpk 30
Mains phase alarm (60 s delay) DC Bus Ripple Vpkpk 30
Table 12.21 Warning and Alarm Trip Points, 380–500 V AC

1) Based on crest factor of 1.414.
525–690 V AC FC 102/FC 202 P710 P800 P900 P1M0 P1PM2 P1M4

525–690 V AC FC 302 P630 P710 P800 P900 P1M0 P1M2
Overcurrent warning [Arms] 1648 1974 2338 2472 2961 3507
Overcurrent alarm1) (1.5 s delay) [Arms] 1648 1974 2338 2472 2961 3507
12 12 Ground fault alarm

Short circuit alarm
[Arms]
[Arms]
330
2096
382
2511
445
2974
494
3144
554
3766
659
4460
Heat sink overtemperature [°C (°F)] 95 105 95 95 105 95
Heat sink under temperature
[°C (°F)] 0 (32)
warning
Power card ambient
75 (167)
overtemperature [°C (°F)]
Power card ambient
-20 (-4)
under temperature [°C (°F)]
Mains phase warning (30 s delay) DC Bus Ripple Vpkpk 50
Mains phase alarm (60 s delay) DC Bus Ripple Vpkpk 50
Table 12.22 Warning and Alarm Trip Points, 525–690 V AC

1) Based on crest factor of 1.414.

12.3.2 DC Voltage Levels
380–480 V units 380–500 V units 525–690 V units

Inrush circuit enabled [V DC] 370 370 550
Inrush circuit disabled [V DC] 395 395 570
Inverter undervoltage disabled [V DC] 373 373 553
Undervoltage warning [V DC] 410 410 585
Inverter undervoltage re-enabled 413 413 602
(warning reset) [V DC]
Overvoltage warning (without brake) 778 817 1084

[V DC]
Dynamic brake turned on [V DC] 778 810 1099
Inverter overvoltage re-enabled 786 821 1099
(warning reset) [V DC]
Overvoltage warning (with brake) 810 828 1109
[V DC]
Overvoltage trip [V DC] 820 855 1130
Table 12.23 DC Voltage Levels
12 12

13 13
196
OPTION CABINET RECTIFIER CABINET INVERTER CABINET
DOOR INTERLOCK DOOR INTERLOCK DOOR INTERLOCK
- + - + - +
Block Diagrams
BLK CBL21 DOOR INTERLOCKS

BLK BLK WHT BLK WHT
2
WHT
2
1 1
WHT
SPLICE
- + 2 2
24 V DC POWER SUPPLY LOCATED IN RECTIFIER CABINET: CBL23 CBL23
PS1 24V DC POWER SUPPLY BLK BLK
1 1
L N Pin 8 1 P2 (RECTIFIER MODULE)
3 3 WHT
GRN/YEL Pin 1 3 P2 (RECTIFIER MODULE)
BLK BLK
13 Block Diagrams
WHT WHT
BLK WHT
1 2 3 1 2 3
1 2 3
+
-
+
-
+
-
MK1 MK1
MK1
C M F IL T E R
C M F IL T E R
C M F IL T E R
BLK
MK 5
MK 7
MK 6
MK5
MK 7
MK 6
MK 5
MK 7
MK 6
BLK WHT CBL20 A1/C2 RFI
LOCATED IN OPTIONS CABINET
LOCATED IN RECTIFIER CABINET: 400VA TRANSFORMER
X1 X2
400VA
13.1 Block Diagrams for F1–F4 Enclosures
TRANSFORMER T1 H1 H2
CBL20
FU-DISC
FU1 BLK
6A
MK3
MK3
MK1
MK2
MK1
MK2
MK3
S
MK1
MK2
WHT
FU2 TB3 T
6A
T BLK
FU3 TB3 S
6A
S WHT
FU4
6A DIFF. MODE DIFF. MODE
LOCATED IN RECTIFIER CABINET: FUSIBLE DISCONNECT DIFF. MODE
T FILTER FILTER FILTER
FOUR-POLE
FUSIBLE
DISCONNECT BLK WHT
Danfoss A/S © 07/2019 All rights reserved.

TB CONTACTOR
M1
R MAINS FUSES
L1 91 14 11
OF1 DISCONNECT
DS1
FU1 R
S
FU2 S
L2 92 TO RECTIFIER CABINET
FU3 T
T
L3 93
C1 C13 C14 BLK WHT

WHT LOCATED IN OPTIONS CABINET: CB, DISCONNECT AND CONTACTOR
GND 94 MX C2 BLK C1 C2
TB5 BLK
WHT C21 C22
BLK
SHUNT TRIP
WHT A2
WHT
A1 * A1 A2 C21 C22 C13 C14
BLK CIRCUIT BREAKER

TB4 *Note 1: Contactor coil connection without Emergency Stop
CBL20 MAINS OPTION BLOCK DIAGRAM CB1
e30bd939.11
Illustration 13.1 Block Diagram, F1–F4 Options Cabinet
MG90K502
MG90K502
PILZ_STO 14
PILZ_STO A2
PILZ_STO S12
*178N0149
TO PILZ_STO
Block Diagrams
CURRENT CURRENT CURRENT

SCALING SCALING SCALING
CARD
CBL19 CARD CARD
MK 1 0 0
MK107
MK108
MK109
130B0057
FC-X02 INV1 INV2 INV3
CBL18 MDCIC CARD

177G0542
MK106
PCA13
1 FK100 44 1 FK102 44
LCP
ANALOG I/O 10 9 8 7 6
MK111
RS-485 5 4 3 2 1
61 68 69
39 42 50 53 54 55
S + -
DIGITAL INPUTS
12 13 18 19 27 29 32 33 20 37 1 FK101 44 1 FK103 44
MK101 MK102
CAN CAN
6 5 4 3 2 1 6 5 4 3 2 1
BLK LOAD SHARE

WHT TERMINALS
RFI KLIXON RED
JUMPER IS INSTALLED LOAD SHARE

IN CASE OF NO (UNIDIRECTIONAL)
OPTIONS CABINET
2 2
CBL1
177G0528
177G4749 1 1
LOCATED IN
RECTIFIER CABINET
BLK 2 2 BLK
WHT 1 1 WHT HEAT SINK/DOOR HEAT SINK/DOOR

S1 S2 FAN TRANSFORMER S1 S2 FAN TRANSFORMER
177G0686
CBL9 CBL10
177G0240
KLIXON IS INSTALLED IN CASE THERE IS AN OPTION CABINET 177G0240 177G0562
177G0562
F1 F2 F1 F2
WHT 16051 WHT
16051 RED BLK 16052 RED BLK
16052 177G0539 177G0540 REGEN
2 3 1 2 3 1
TERMINALS
106 104 2 3 1 2 3 1
177G0468
Service Guide
TB3 WHT
CBL3
RECTIFIER CABINET DOOR FAN 177G0534
177G0534
L
BLK FAN-
CBL3
FAN+ N
GND PE
INVERTER CABINET DOOR FAN LOCATED IN
SCR DIS/ENA TERMINAL BLOCKS
CBL2 FAN- INVERTER CABINET
LOCATED IN RECTIFIER CABINET 177G0687 FAN+
GND
177G0538 CBL3
BLK FAN- L CBL3
FAN+ N
177G0687 177G0534
GND PE
177G0534
WHT WHT BLK FAN-
FAN+
GND
CBL23 177G0687
OPTION CABINET DOOR FAN 177G0687
177G0528 RED INVERTER CABINET DOOR FAN
Pin 1 (RFI SWITCH) BLK CBL4 CBL3
2
177G0751 177G0534
WHT UDC P5
P5
2
Pin 3 (RFI SWITCH) 177G0520
P3 177G0520 CBL7 P2
P2 P6 NOT USED BLK WHT P2 177G0533 BLK WHT NOT USED
177G0529 P1 P1
CBL1 1 4 3 6 44 1
5 1 8 7 6 3 10 11 3 1 8 7 6 11 10 9 1 4 3 6 44 1 8 7 6 8 7 6 11 10 9
P4 11 10 9
6-Pin WHT
14-Pin 6-Pin 16-Pin BLK FU5 6-Pin 16-Pin WHT FU7 16-Pin
DC-Link
8
RFI/CAN/SCR DIS/ENA Aux 2 Aux 1 DC-Link Aux 2 Aux 1 Aux 2 Aux 1
INVERTER Relay Relay Relay Relay Relay Relay
5
DC-Link WHT
Not used BLK
5 4
BLK
8-Pin
5 10
10
BLK
WHT
1
-SCR RED
10-Pin
7
RED
10-Pin
7
CBL7 WHT
2
WHT
2
1 177G0533 FU6
FU4 BLK
1
BLK
1
DC+ DC+

177G0470 P4
+SCR P7 P4 177G0470 177G0470
177G0473
177G0473
POWER CARD
RECTIFIER INVERTER 1 INVERTER 2 177G0473
30
TE S T C ON N E C TOR
1
1 1
177G0753 P6
20
DC- RED
DC- P6
6
RED R'
6
R'
POWER CARD
WHT
POWER CARD
WHT 30 S'
2
S' 30
8-Pin
2 5
8-Pin
R' S' T'
T'
5
T'
12-Pin 44
BLK
3
P1
3
BLK
4
4
7 9 11 8 10 12 2 4 6 BRAKE BRAKE
7
7
TERMINALS TERMINALS
8
8
P5
P3 R+ P3 R+
R- R-
*Note 1: For MK111 on the MDCIC the harness
CBL8 W1 W2 178N0149 is used on all FC 302 drives in this
177G0531/532
MOTOR TERMINALS
frame size, as well as FC1 02 and FC 202 with SAFE
V1 MOTOR TERMINALS V2
STOP option. For FC 102 and FC 202 drives without
U1 U2 SAFE STOP option, a jumper connector (P/N
R
178N0167) will be connected to MK111 of the MDCIC
FROM OPTIONS CABINET
IF OPTIONS CABINET S
PRESENT T
e30bd940.11
Illustration 13.2 Block Diagram, F1/F3 Top Level
197
13 13
13 13
198
PILZ_STO 14
PILZ_STO A2
PILZ_STO S12
*178N0149
TO PILZ_STO
*Note 1: For MK111 on the MDCIC the harness
178N0149 is used on all FC-302 drives in this
CURRENT CURRENT CURRENT
frame size, as well as FC102 and FC202 with SAFE SCALING SCALING SCALING
CARD CARD
CBL19 CARD
Block Diagrams
MK 1 0 0
MK107
MK108
MK109
STOP option. For FC102 and FC202 drives without 130B0057
INV1 INV2 INV3
FC-X02
SAFE STOP option, a jumper connector (P/N
178N0167) will be connected to MK111 of the MDCIC
CBL18
177G0542
MK106
1 FK100 44 1 FK102 44
MDCIC CARD
LCP PCA13
10 9 8 7 6
ANALOG I/O 5 4 3 2 1
RS-485
MK111
61 68 69
39 42 50 53 54 55
S + -
DIGITAL INPUTS
12 13 18 19 27 29 32 33 20 37 1 FK101 44 1 FK103 44
MK101 MK102
CAN CAN
6 5 4 3 2 1 6 5 4 3 2 1
BLK LOAD SHARE

WHT TERMINALS
RFI KLIXON RED
JUMPER IS INSTALLED LOAD SHARE

IN CASE OF NO
(UNIDIRECTIONAL)
OPTIONS CABINET
2 2
CBL1
177G0528
177G4749 1 1
LOCATED IN RECTIFIER CABINET
BLK 2 2 BLK
HEATSINK/DOOR
WHT 1 1 WHT HEATSINK/DOOR HEATSINK/DOOR FAN TRASNFORMER
S1 S2 FAN TRASNFORMER
S1 S2 FAN TRASNFORMER S1 S2
177G0686
CBL9 CBL10 CBL11 177G0240
177G0240
KLIXON IS INSTALLED IN CASE THERE IS AN OPTION CABINET 177G0240 177G0562
177G0562
177G0562
F1 F2 F1 F2 F1 F2
WHT 16051 WHT 16051
16051 RED BLK
RED BLK 16052 RED BLK 16052
16052 177G0539 177G0540 177G0541 2 3 1 REGEN
2 3 1 2 3 1
2 3 1
TERMINALS
106 104 2 3 1 2 3 1
177G0468
TB3 WHT
CBL3
RECTIFIER CABINET DOOR FAN 177G0534
177G0534
L
BLK FAN-
CBL3
FAN+ N
GND PE
INVERTER CABINET DOOR FAN LOCATED IN INVERTER
SCR DIS/ENA TERMINAL BLOCKS
CBL2 FAN- CABINET
LOCATED IN RECTIFIER CABINET 177G0687 FAN+
CBL17
GND
177G0538 CBL3 177G0537
BLK FAN- L CBL3
FAN+ N
177G0687 177G0534
BLK GND PE
177G0534
WHT WHT FAN-
FAN+
GND
CBL23 177G0687
OPTION CABINET DOOR FAN 177G0687
177G0528 RED INVERTER CABINET DOOR FAN
Pin 1 (RFI SWITCH) BLK CBL4 CBL3
2
177G0751 177G0534
WHT UDC P5
P5 P5
2
Pin 3 (RFI SWITCH) 177G0520 177G0520
P3 177G0520 CBL7 P2 P2
P2 NOT USED BLK P2 177G0533 BLK WHT NOT USED BLK WHT P1 NOT USED
177G0529 P6 WHT P1 P1
CBL1 1 4 3 6 44 1 1 4 3 6 44 1
5 1 8 7 6 3 10 11 3 1 8 7 6 1 4 3 6 44 1 8 8 7 6 11 10 9 8 7 6 11 10 9
11 10 9 P4 7 6 11 10 9
6-Pin WHT 6-Pin
14-Pin 6-Pin 16-Pin BLK FU5 6-Pin 16-Pin WHT FU7 16-Pin FU9 DC-Link 16-Pin
DC-Link
8
RFI/CAN/SCR DIS/ENA Aux 2 Aux 1 DC-Link Aux 2 Aux 1 Aux 2 Aux 1 Aux 2 Aux 1
INVERTER Relay Relay Relay Relay
WHT Relay Relay Relay Relay
DC-Link Not used BLK
5 4
BLK
8-Pin
5 10
5 10
BLK
WHT
1
-SCR RED
10-Pin
RED
10-Pin
7
10-Pin
7
CBL7 WHT
7 2
WHT FU8
2
1 177G0533 FU6
2
BLK

FU4
1
BLK
1
DC+
1
DC+ DC+
177G0470 P4
+SCR P7 P4 177G0470 177G0470
RECTIFIER 177G0473 INVERTER 1 INVERTER 2 INVERTER 3 P4
177G0473
POWER CARD
177G0473
30
1
1 1 1
177G0753 P6
DC- DC- P6 DC- P6
20 RED RED
6
RED R' R'
6
R'
POWER CARD
WHT
POWER CARD
WHT
POWER CARD
WHT 30 S' S'
2
S'
30 30
8-Pin
6 2 5
8-Pin
2 5
8-Pin
R' S' T'
T' T'
5
T'
BLK BLK
3
12-Pin 44 P1 BLK
4
3 4
3 4
7 9 11 8 10 12 2 4 6 BRAKE BRAKE BRAKE
7
7
TERMINALS TERMINALS TERMINALS
8
8
P5
P3 R+ P3 R+ P3 R+
R- R- R-
CBL8 W1 W2 W3
177G0531/532
MOTOR TERMINALS V2 MOTOR TERMINALS V3 MOTOR TERMINALS
V1
U1 U2 U3
R
FROM OPTIONS CABINET
IF OPTIONS CABINET S
PRESENT T
e30bd941.11
Illustration 13.3 Block Diagram, F2/F4 Top Level
MG90K502
MG90K502
P2 P3
Block Diagrams
P4
P1 P6 TO CUSTOMER AUX RELAY TERMINALS TO FAN AUTOTRANSFORMER TO RECTIFIER MODULE
TO MDCIC BOARD TEST CONNECTOR 16-Pin 10-Pin
8-Pin
3 5 10 4 8 7 6 9 2 1
8 7 1 4 3 6 2 5
8 7 6 11 10 9 3 5 10 4 8 7 6 9 2 1
8 7 1 4 3 6 2 5
44-pin Panel 30-pin Panel
Mount Connector BLK BLK
Mount Connector RED WHT BLK
WHT BLK RED
WHT WHT
BLK RED
WHT WHT Fu1 (15A) CBL35
WHT
RED BLK 177G0521
BLK
WHT
CBL33
BLK
177G0527 CBL34
177G0523 AUX FAN
CBL34 CBL34
1 2 3 4 5 6 13 11 4 5 3 12 9 16 1 8 6 5 4 3 2 1 FAN ASSEMBLY
5 10 3 8 1 6 177G0523
177G0523 177G0516
105
1
NO
CBL32 C NO NC C NO NC L1 L2 L1 L2 L1 L1
AUX_S
AUX_T
AUX_S
AUX_T
R S T HEATSINK FAN
AUX 2 FANS X2 X1
177G0515 AUX 1 102 100
C
2
103 101
104
RELAY RELAY
FK102
S AUX_S T AUX_T WHT BLU 1 1
MK107 MAINS
MK112 FK103 BLK BLK 2 2
106
1
NC
MK106
SPLICE BRN 3 3
GRN/YEL 4 4
CBL31 CBL37
MK104
177G0514 177G0517/518
F5-F8
29 HF SWITCH
BLK
+
VDD 14 C1
HF SW
-
POWER CARD RL2 15 WHT WHT
1 VDD 12 HEATSINK
PCA12 RFI FAN
FANO 13 FAN CAPACITOR
WHT
GND 9
SENS 10
CUR DET
MK102 11
CURRENT
SENSORS
VPOS 1
IU' IU1 2
VNEG 3
VPOS 4
IV' IV1 5
VNEG
MK110
6
VPOS 7
MK105 IW' IW1 8
VNEG 16
43 +DC -DC
MK109
A B TB3
CBL44 81 R-
177G0526 RED E1/C2 BRAKE IGBT
BRC BLK E2
BRC 82
MK1
BRK
6 4 1
GATE DRIVE BOARD G2

R+
7 5 10
BRN
COL
MK106 BRN
BRK
Fu2 (4A) PCA5
MK105
GBP
WHT BRAKE GATE
IGBT4 EXT BRAKE
Service Guide
1 2 6
GBP RES CARD
GATE
RESISTOR
MK102 MK103 MK104 MK100 PCA14
6-Pin CONNECTIONS
EM
U V W NTC
GUP
EUP
GUP
EUP
GUP
EUP
GUP
GUN
GUN
EUP
EUN
EUN
GUP
GUN
EUP
EUN
GUN
EUN
GUP
GUN
GUN
EUP
EUN
EUN
TMP+
TMP-
1
1
1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 3
RED E1/C2 BRAKE IGBT
BLK
BLK E2
MK1
6 4 1
BRK
WHT G2
2
2
COL
BLK CBL43
190864 CBL42 CBL41 CBL40 BRAKE GATE
190864 190808 IGBT5
4
4
190864 RES CARD
GATE
BLK
PCA15
EM
3
3
P5 WHT
CBL39
190861
5
5
4 5 8 1 1 2 3 4 5 8 1 1 2 3 4 5 8 1 1 2 3
WHT UDC- UDC+
NTC1
NTC2
NTC1
EUP1
NTC1
NTC2
ELO1
EUP1
GLO1
NTC2
GUP1
ELO1
EUP1
GLO1
GUP1
ELO1
GLO1
GUP1
6
6
WHT U NTC V NTC W NTC
MK100 MK103 MK100 MK103 MK100 MK103
GATE RESISTOR CARD GATE RESISTOR CARD GATE RESISTOR CARD

NTC NTC NTC
PCA6 PCA7 PCA8
IN
IN
IN
OUT
OUT
OUT
177G0520 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3
CBL35
177G0519
PCA9 CBANK1 LOWER CBANK2 UPPER
HF CARD DC CAP BANK DC CAP BANK
+
+DC UDC+ UDC+
IU
L2 TB2
CS1
96 U

+ M -
C2 C3 C4 C5 C6 C7 C8 C9 C10
+ NTC NTC
+ NTC
- - CUP1 UP CUP2 UP CUP3 UP CUP1 VP CUP2 VP CUP3 VP CUP1 WP CUP2 WP CUP3 WP

IV
GUP1 GUP2 GUP3 GUP1 GUP2 GUP3 GUP1 GUP2 GUP3
L3
EUP1 EUP2 EUP3 EUP1 EUP2 EUP3 EUP1 EUP2 EUP3
CS2 97 V
A A
+ M -
B B
MK1
MK1
C C
BAL CKT
BAL CKT
GLO1 GLO2 GLO3 GLO1 GLO2 GLO3 GLO1 GLO2 GLO3
ELO1 ELO2 ELO3 ELO1 ELO2 ELO3 ELO1 ELO2 ELO3
UN UN UN VN VN VN WN WN WN IW
L4
ECONOPACK+ MODULE ECONOPACK+ MODULE ECONOPACK+ MODULE 98 W

+
CS3
+
IGBT1 IGBT2 IGBT3
+ M -
- -
+
2
MK100
-
1
UDC- UDC-
-
-DC BLK
WHT
F-FRAME IGBT USAGE IGBT'S GATE RESISTOR CARDS
+
T5 450, 500, 710 KW: 177G0782 (DSP GEN 3), 177G2046 (DSP GEN 4), 177G3401 (INF GEN 4) 130B6879 (DSP GEN 3), 130B6836 (DSP GEN 4, INF GEN 4)
HF SWITCH
-
560, 630, 800 KW: 177G0783 (DSP GEN 3), 177G2047 (DSP GEN 4), 177G3404 (INF GEN 4) 130B6880 (DSP GEN 3), 130B6837 (DSP GEN 4, INF GEN 4)
CBL37 177G0517/518 T7 630, 900 KW 177G7085 (DSP GEN 3), 177G3407 (INF GEN 3) 130B6881 (DSP AND INF GEN 3)
710, 800 KW, 1M0, 1M2 177G0784 (DSP GEN 3), 177G3410 (INF GEN 3) 130B6881 (DSP AND INF GEN 3)
e30bd942.11
Illustration 13.4 Block Diagram, F1–F4 Inverter Module
199
13 13
13 13
200
P2 P3 P6 P4
P7 TO INVERTER DC-LINK TO INVERTER 1
TO OPTION AND INVERTER CABINETS NOT USED
TEST CONNECTOR 14-PIN 16-PIN 6-PIN 8-PIN
30-pin Panel Mount Connector
1 2 3 4 5 6 8 5 4 1
6 7 5 8 11 10 3
6 7 5 1 8 10 3 8 7 6 11 10 9
Block Diagrams
11 1 2 3 4 5 6 8 5 4 1
29 1 BLK WHT BLK WHT BLK BLK

RED WHT RED BLK WHT
BLK RED
WHT WHT BLK WHT
RED BLK SPLICE
TEMP SWITCH/SCR Disable RFI SWITCH Fu1 (4A)
CBL54 SPLICE CBL58
WHT FAN ASSEMBLY
177G0512 CBL55 177G0513 177G0516
177G0527 CBL56 177G0508 CBL58 HEAT SINK FAN
177G0513 WHT BLU 1 1
CBL51 3
1
2
9
1 2 3
7
8
2 4 5 6 CBL57
3
5
6
4
1
11
13
10
15
12
16
14
1 1 2 3 B A BLK BLK 2 2
177G0515 177G0509/510
C NO NC SPLICE BRN
IV1
3
RL2
IU1
3
IW1
VDD
C NO NC
DET
GND
VDD
FANO
VNEG
VNEG
VNEG
+DC
VPOS
SENS
VPOS
-DC
VPOS
CAN 10 GRN/YEL
105 R RED 4 4
106 104 AUX 2 AUX 1 MK105 5
NC C NO MK108 RELAY
IV'
IU'
IW'
RELAY
8
CUR
HF SW
RFI FAN
MK104
MK106 S WHT
FK102 3
MK112
M AI N S
CURRENT 6
SENSORS T BLK
1
MK102
29 BLK C1
1 WHT HEAT SINK
FAN CAPACITOR
WHT
POWER CARD CBL57

177G0509/510
MK110
PCA12
1
43
1
6
6
MK100
SCR
GATE DRIVER MK103 RED
RECTIFIER HS
TEMP SENSOR
R S T
GND
TMP
4
4
P1
CBL52 3 6 2 5 1 4 1 2 3
WHT
177G0514
WHT WHT WHT
20 BLK BLK
CBL53 BLK BLK BLK
2
2
WHT
177G0502/503 R' S' T' 177G0507
RED R
CBL67 +SCR A
177G0511
+SCR MK2 CBL60
1
1
MK3
WHT S MK1 -SCR C

+

+
-SCR - +SCR
BLK T SOFTCHARGE BOARD 1
177G0753
3
3
PCA16
SCR1 SCR2 SCR3 RS+ A
43 BLK BLK BLK R1
MK4
RS- B
P5
1 2
12-PIN
WHT
11
11
WHT WHT
CBL61
1 2
177G0506 RED
9
9
WHT
TO INVERTERS 1, 2, & 3
R S BLK
7
7
T CBL68
1900800 R' S' T'
CBL62
R RED
R +SCR A
177G0507
5
5
TH1 MK2
WHT
MK3
HEATSINK NTC S -SCR C

MK1
+
BLK -SCR - +SCR

T
12
12
S SOFTCHARGE BOARD 3
PCA17
RS+ A
R2
10
10
RS-
MK4
B
T Heatsink Temp Sensor
CBL63
8
8
177G0506
RED
WHT

BLK
R' S' T'

CBL64
RED 177G0507
R +SCR A
MK2
WHT
MK3
S -SCR C
MK1
+
-SCR - +SCR
D1 D2 D3 -SCR T SOFTCHARGE BOARD 2
PCA18
-
- RS+ A
R3
RS-
MK4
BLK CBL65
177G0506
CBL66
177G0504/505
e30bd943.11
Illustration 13.5 Block Diagram, F1–F4 Rectifier Module
MG90K502
MG90K502
Block Diagrams
TB3 RT2b
TB3 PS2
PS2
BLK
WHT
PS2 -
PS2 +
177G0486
BLK
WHT
PS2 PS2
177G0468
RT2 RT2
- +
177G0440 24 V DC POWER SUPPLY 24V CUSTOMER
Service Guide
177A0023 POWER SUPPLY

177G0713 TB3
177G0467 OPTION
+24 +24b RET RETb
L N
LOCATED IN RECTIFIER CABINET: T1 (400VA
TRANSFORMER) AND FU-DISC (FOUR-POLE FUSIBLE
DISCONNECT)
LOCATED IN RECTIFIER CABINET: CUSTOMER CONNECTION Note: Transformer wiring is the same for
GRN/YEL all line voltages.
BLK (L)

WHT (N)
177G0687
T1 X1
T1 X2
LOCATED IN RECTIFIER CABINET:

INTERNAL AND CUSTOMER POWER SUPPLIES
e30bd944.11
Illustration 13.6 Block Diagram, F1–F4 Customer 24 V Supply Option
201
13 13
13 13
202
LOCATED IN RECTIFIER CABINET: 700VA TRANSFORMER AND HEATERS
HEATERS 230V CONFIGURATION 700VA

177G0465 TRANSFORMER LOCATED IN RECTIFIER CABINET: 115V/230V LIGHT
177G0466 T2* 177G0485
177G0966
TB3 H1
Block Diagrams
TEMP-SW 2 H-230V
177G0710 L1 177G0711
3H1 GND L1 N
1H1
660V H2 BLK
H1 TB3 H2 R R
690V N GND
GRN
230V BLK
BRW
575V H3 TB3 H3
R = 150 Ohms
BLU
CONFIGURATION GRN/YEL
FAN ASSEMBLY 177G0687
525V H4 BLK
177G1117 TB3 H4
X1 BLK
1H2 3H2 TB3 X1
FAN- L 230V
FAN+ N 177G0965 177G0965 460V H5 BLK
TB3 LT
TB3 H5
TB3 LT
GND PE 2H2 4H2
TB3 REF
TB3 GND
177G0687 BLK
TB3 REF
400V H6 TB3 H6
0V 0V H7 WHT
2H1 4H1
TB3 X4 TB3 H7 230V LIGHT 115V LIGHT
177G0966
X4
LT-230V LT-115V
REF
TB9 REF
700VA
TRANSFORMER T2 177G0485
TB3 H1
HEATERS 115V CONFIGURATION
177G0465
H-115V 177G0466
BLK
LOCATED IN RECTIFIER CABINET: TERMINAL BLOCKS
4H1 4H2 660V H2
H1 TB3 H2
177G0965 177G0965
R = 150 Ohms 690V
575V H3 BLK
3H1 3H2 TB3 H3
177G0966 177G0966
525V H4 BLK
BLK X3 TB3 H4
1H1 1H2 TB3 X3 115V
177G0965 460V H5 BLK
177G0965 TB3 H5
2H1 2H2
LT-230V GND
H/LT 14
H/LT 22
T2* X1
T2 X3
T2 X4/T2* X4
T2 H7/T2* H7
T2 H6/T2* H6
T2 H5/T2* H5
T2 H4/T2* H4
T2 H3/T2* H3
T2 H2/T2* H2
T2 H1/T2* H1
FU-DISC FU3
400V H6 BLK
177G0687
TB3 H6
177G0968 WHT
L
WHT
PE
0V H7
GRN
WHT
RED
BLK
BLK
WHT
WHT
BLK
BLK
BLK
BLK
BLK
BLK
BLK
TB3 X4 0V
TB3 H7
GND
FAN-
FAN+
REF
X4
WHT
177G0436
GND 14 22 X1 X3 X4 H7 H6 H5 H4 H3 H2 H1 S

FAN ASSEMBLY 115V 177G0468
177G1117
TB3 REF
177G0440
CONFIGURATION
177A0023
177G0713
TB3
GND 1 LT 230V 115V REF T 400V 460V 525V 575V 660V 690V S
LOCATED IN RECTIFIER CABINET: HEATER/LIGHT SWITCH GRN/YEL

177G0687 NOTE: CUSTOMER CONNECT
LOCATED IN RECTIFIER CABINET: TEMPERATURE SWITCH TO CORRECT TAB
BLK
BLK
BLU
WHT
WHT
HEATERS/LIGHT SWITCH
TEMPERATURE SWITCH 21 22
H/LT-SW
Note: Tempearture setting = 50F DOOR OPEN RED
TB3 22
Differential setting = 10F 177G0712
(Heaters will turn off at 50F+10F)

13 14
4 WHT
TEMP-SW TB3 14
1 50F DOOR CLOSED
TEMP-SW 1
177G0447
FU-DISC FU2
2
H/LT-SW 13/21
H/LT-SW 13/21
LT-115V N OR LT-230V N
LT-115V L1 OR LT-230V L1
H-115V REF OR H-230V REF
177G0967 BLK
TB3 115V OR TB3 230V
BLK
TB3 1
e30bd945.11
Illustration 13.7 Block Diagram, F1–F4 Cabinet Heater and Service Lights Option
MG90K502
LOCATED IN INVERTER CABINET: SAFE STOP AND TEMPERATURE MONITORING DEVICES
MG90K502
LOCATED ON RECTIFIER
OR OPTIONS
CABINET DOOR 1 3 1 3 1 3 177G0477
177G0478 See important notes on the CI45 units in the lower left
3-POSITION corner of this page
RUN
RESET
SWITCH
E-STOP
TB2 24+b
TB2 S31
***
TB2 13
Block Diagrams
TB2 S32
TB2 S11
TB2 S12
TB4 37
PUSHBUTTON BACK VIEW
177G0702
PILZ S12
****
PILZ S11
177G0480 2 4 2 4 2 4 *
PILZ 37
177G0481 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8
177G0482
WHT
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
LOCATED IN OPTIONS FC X02
PMA PMA PMA PMA PMA
1
2
CABINET PILZ BLK WHT WHT
TB3 S01
ANALOG I/O
2
1
BLK
CN1 **
TB3 S02 RS-485
WHT BLK
C21 C22 RET
A1 S31 S32 S11 S12 BLK TB1 RET 61 68 69
WHT 39 42 50 53 54 55
TB3 OPT +24V S + -
1 2 WHT BLK WHT BLK WHT TB1 24V
1 2
C13 C14 BLK DIGITAL INPUTS

13 37 TB3 NEGb
12 13 18 19 27 29 32 33 20 37
A1 A2 S11 S12 PB1 PB2 PB3 PB4 RS1 RS2 Rn1 Rn2 SO1 SO2 24+ NEG
PILZ CI45 CI45 CI45 CI45 CI45 177G1322
GND A1 C13 C14 C21 C22 PNOZ XV2P
ON CONTACTOR 37 A2
14 24
ASSEMBLY POWER 37 47 TB2
START 11 12 13 14 11 12 13 14 11 12 13 14 11 12 13 14 11 12 13 14
6A 6A
TB4 CH.1 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18
38 48 CH. 1[t]
CH.2
SS1
SS2
CH. 2[t] S11 S12 S21 S22 S31 S32 S34 24+ b NEGb
A1 C14 C21 S33
C21 14 S54 S55 13
GND C13
*****CUSTOMER +230V
TB1
TB1
*****CUSTOMER RETURN 14 38
BLK
*****CUSTOMER GND
WHT
A2 Y39 Y40 S21 S22 S33 S34
WHT
SS3
SS4
177G0468
177G0440
TB1
TB1
177A0023
177G0713
be installed between
177G0467
BLK
terminals S11and S12
PILZ 38
TB2 C21
130G0080
PILZ S33
177G0436
P8
10-Pin PANEL MOUNT CONNECTOR
PILZ 14
PILZ 13
PILZ A1
PILZ A2
TB4 C21
PILZ S34
1
PILZ S21
PILZ S22
PILZ S31
PILZ S32
1
TB1 RET
TB2 14
9
RET
TB4 A1
9
TB2 S34
TB2 S21
TB4 S33
TB2 S22
6
TB2 NEGb
6
PILZ WITH CONTACTOR TB1 24V 24V

4
4
Service Guide
8
7
PILZ LOCATED IN OPTIONS CABINET IF OPTIONS

3
CABINET PRESENT OTHERWISE LOCATED IN OR OPTIONS

CABINET DOOR 1 3 1 3 1 3 177G0477
WHT
10
INVERTER CABINET 177G0478

10
TB1 SS2 WHT

CI45 18
FC-X02 13
FC-X02 37
CI45 17
TB3 SI2
CN1 RET
CN1 24V
3-POSITION
2
RUN
TB2 24+b
TB2 S31
TB2 13
TB2 S32
RESET
TB2 S11
TB2 S12
E-STOP BLK
5
SWITCH
5
PUSHBUTTON BACK VIEW TB1 SS3 TB3 SJ1

B LK
WH T
BLK
B LK
PILZ S12
WH T
177G0482 2 4 2 4 2 4
PILZ S11
177G0480
WHT
177G0481
24V
RET
RET
RET
SS4
SS3
SS1
SS2
PILZ 177G0468
1
2
BLK WHT WHT 177G0440
TB3 S01 P9 177A0023
2
1
BLK
16-Pin PANEL MOUNT CONNECTOR
A1 S31 S32 S11 S12 TB3 S02 TB1 177G0713
1
WHT
1
BLK 177G0467
WHT
TB3 OPT
2
13 1 2 WHT BLK WHT BLK

2
37 1 2
RET
RET
24V
RET
SS4
SS3
SS1
SS2
BLK
3
TB3 NEGb
3
WHT
4
PILZ S11 S12 PB1 PB2 PB3 PB4 RS1 RS2 Rn1 Rn2 SO1 SO2 24+ NEG
B LK
WH T
PNOZ XV2P
5
14 24
6
1
6
6
5
POWER 37 47
10
START
7

TB2
8
CH.1 BLK
P8
P8
P8
P8
38 48 CH. 1[t] PILZ_STO TB3 RT1

BLK
9
CH.2 178n0166
9
CH. 2[t] A2
10
10
S11 S12 S21 S22 S31 S32 S34 S33 14 S54 S55 13 24+ b NEGb
11
*Note 1: There is a factory installed jumper between 14 38

12
terminals 1 and 3 of the CI45 units. Customer must

A2 Y39 Y40 S21 S22 S33 S34
13
remove jumper.
BLK
WHT
14
**Note 2: Connector CN1 used to bring 24V to PMA

15
devices. Connector should be removed to accomodate WHT

16
communication device. PILZ_STO WHT

TB3 PS1
178n0166
BLK
***Note 3: MCB112 available for up to 3 PTCs in series. A1
Jumper must always

be installed between
terminals S11and S12
MCB114 available for up to 3 PT100/PT1000.
PILZ 14
PILZ 13
PILZ A1
PILZ A2
****Note 4: Safe Stop is standard for FC 302. Safe
PILZ S21
PILZ S22
PILZ S32
PILZ S31
PILZ S33
PILZ S34
TB2 14
PILZ WITH/WITHOUT CONTACTOR,
TB2 S34
TB2 S21
TB4 S33
TB2 S22
Stop must be ordered separately for FC 102 and FC 202.
TB2 NEGb
*****Note 5: Contactor coil connection with Emergency Stop.
THERMAL MONITORS BLOCK DIAGRAM
PILZ WITHOUT CONTACTOR
e30bd946.11
Illustration 13.8 Block Diagram, F1–F4 Pilz Relay/Thermal Monitor Option
203
13 13
13 13
204
LOCATED IN RECTIFIER CABINET: MANUAL MOTOR STARTERS AND 30A CUSTOMER FUSE OPTION JUMPER PRESENT IF
LOCATED IN INVERTER CABINET: PILZ RELAY FOR STO (PILZ_STO) NO OPTIONS CABINET TB2 SO1 P8 5
TB2 SO2 24V FROM PS1

WHT BLK
Block Diagrams
MAINS AFTER JUMPER PRESENT IF MMS

-
P9-8
+
P8-1
P9-16
P8-6
30A CUSTOMER OPTION INSTALLED WITH
CONTACTOR WHT +
NO SAFE STOP OPTION BLK
AND FUSES FUSES - TB3

RED
AND NO OPTIONS CABINET
(3FT1) (3FB1)
R F30A RP SO1 SJ1 SO2 PS1 PS1 RT1 RT1 PS2 PS2
CUSTOMER RT2 RT2 104 106
WHT (3FT2) (3FB2)
S F30B SP TERMINALS 177G0468
BLK (3FT3) (3FB3) 177G0440
T F30C TP 177A0023
177G0713
* 177G0467
*
SM1 SM2 SI2 OPT INV NEG NEGb +24 +24b RET RETb 104 106
MMS2
WH T
WH T
B LK
177G0969 FUSES
RED (2FB1) (2FT1) (L1)
R 177G0974
10
FXA SPLICE
WHT WHT
WHT (2FB2) (2FT2) (L2)
S FXB
TB2 24+
P8
BLK
TB2 NEG
(2FB3) (2FT3) (L3)

T FXC MMS1 MMS1
BLK BLK
177G0974
MAINS AFTER WHT JUMPER PRESENT
(55) (56) (44) (43)
CONTACTOR IF NO MMS OPTION
O.L AUX
AND FUSES MMS2 MMS2
BLK
RED (L1)
MMS2 (2FB1)
MMS1 FUSES (2FT1)
(55) (56) (44) (43) R
MAINS AFTER FXA
O.L AUX WHT (2FB2) (2FT2) (L2)
2.5-4.0A CONTACTOR S FXB
AND FUSES BLK (2FB3) (2FT3) (L3)
4.0-6.3A T FXC
6.3-10A T3 T1 177G0969
10-16A T2 MDCIC MK111
PIN 6 MMS1
WHT
P9 16 S12 S22 Y6
WHT 2.5-4.0A
178N0149 Y4 S34
A1 S11

CUSTOMER T2 4.0-6.3A
SUPPLIED AC T3 T1 PILZ
PNOZ E1.1P 6.3-10A
MOTOR 1
10-16A
POWER
CH.1 T3 T1
MMS: 177G0449-2/177G0450-2/177G0451-2/177G0452-2 CH.2
FUSE: 177G0703/177G0704/177G0705/177G0706/177G0707/177G0708
177G0454-2
T2
177G0455-2
MDCIC MK111
177G0694-2 PIN 8 A2 S35 S36 Y32
WHT
178N0149
14 24 S21 Y5 CUSTOMER
*Note 1: There are only 2 combinations: *
PILZ_STO SUPPLIED AC
2 manual motor starters or 1 manual motor starter 178N0082 T2
178N0149
and the 30A customer fuse terminals. MOTOR 2 T3 T1
BLK
RED
*Note 2: The Pilz relay for STO is a standard

P9 8
components for FC 302 drives in this enclosure size, as

PIN 10
well as FC 102 and FC 202 with SAFE STOP option.

It will not be present for FC 102 and FC 202
drives, without SAFE STOP option. Instead jumper
MDCIC MK111
(p/n: 178N0167) will be inserted on the MDCIC, MK111
e30bd947.11
Illustration 13.9 Block Diagram, F1–F4 Manual Motor Starters/30 A Customer Fuse Terminal, Pilz for STO
MG90K502
TB7 LOCATED IN INVERTER CABINET: NAMUR TERMINALS, CONTROL CARD, MCB 112, MCB 113 MCB 113 EXTENDED I/O
X45
1
NAMUR TERMINALS TB7 60
2
TB7 61
MG90K502
3
TB7 62 TB8
1
1
4
CUSTOMER SUPPLIED 24V RET CONTROL CARD PIN 20 TB7 63
1
1
AUX RELAYS 1 & 2
Block Diagrams
TERMINALS JUMPERED TOGETHER X58
1
1
01 02 03 04 05 06
2
2
CUSTOMER SUPPLIED 24V 0.8 AMP
X46
3
3
1
TB7 10
3
2
3
TERMINALS JUMPERED TOGETHER
3
3
TB7 11
01 02 03 04 05 06
10
10
MCB 113 PIN X46/1
5
TB7 12
FC-X02
11
11
6
MCB 113 PIN X46/3
12
12
MCB 113 PIN X46/5 TB7 13
TB7 32
TB7 33
TB7 31
TB7 30
13
13
MCB 113 PIN X46/7 ANALOG I/O
9
RS-485 TB7 14
14
14
MCB 113 PIN X46/9
10
61 68 69 39 42 50 53 54 55
15
15
11
MCB 113 PIN X46/11 S + - TB7 15
12
16
16
MCB 113 PIN X46/13 TB7 51
13
TB7 16
17
17
MCB 113 PIN 12 TB7 50
14
DIGITAL INPUTS
18
18
CONTROL CARD PIN 37
X47
30
30
TB11 PIN 01 12 13 18 19 27 29 32 33 20 37 1 2 3 4 5 6 7 8 9 10 11 12
Service Guide
31
31
TB11 PIN 02
32
32
TB11 PIN 04
33
33
TB11 PIN 05
TB7 34
TB7 36
TB7 35
TB7 37
TB7 39
TB7 38
TB7 40
TB7 42
TB7 41
34
34
MCB 113 PIN X47/1
35
35
MCB 113 PIN X47/3 ID NAME Setup 1 Setup 2 Setup 3 Setup 4
300 Reference Range Min - Max Min - Max Min - Max Min - Max
36
36
MCB 113 PIN X47/2
315 Reference Resource 1 Analog Input 53 Analog Input 53 Analog Input 53 Analog Input 53
TB10 1
TB10 18
37
37
MCB 113 PIN X47/4 316 Reference Resource 2 Digital pot.meter Digital pot.meter Digital pot.meter Digital pot.meter
317 Reference Resource 3 No function No function No function No function
38
38
MCB 113 PIN X47/6
391 Ramp Time 5 5 5 5
39
39
MCB 113 PIN X47/5 394 Minimum Limit 0 0 0 0
MCB 112 PTC 410 Motor Speed Direction Both Directions Both Directions Both Directions Both Directions
40
40
MCB 113 PIN X47/7
511 Terminal 19 Digital Input No Operation No Operation No Operation No Operation

41
41
MCB 113 PIN X47/9 512 Terminal 27 Digital Input No Operation No Operation No Operation No Operation
CUSTOMER CONNECTIONS TO NAMUR TERMINALS

42
42
MCB 113 PIN X47/8
PTC T1
PTC T2
NC
NC
NC
NC
NC
NC
NC
LOGIC OUT
LOGIC COM
SAFETY STOP
514 Terminal 32 Digital Input PTC Card 1 PTC Card 1 PTC Card 1 PTC Card 1
1 2 3 4 5 6 7 8 9 10 11 12
50
50
CONTROL CARD PIN 53 519 Terminal 37 Safe Stop PTC & Safe Stop Alarm PTC & Safe Stop Alarm PTC & Safe Stop Alarm PTC & Safe Stop Alarm
520 Terminal X46/1 Digital Input Start Latched Start Latched Start Latched Start
51
51
CONTROL CARD PIN 55 521 Terminal X46/3 Digital Input Stop Inverse Stop Inverse Stop Inverse Stop Inverse
60
60
MCB 113 PIN X45/1 522 Terminal X46/5 Digital Input DigiPot Increase DigiPot Increase DigiPot Increase DigiPot Increase
523 Terminal X46/7 Digital Input DigiPot Decrease DigiPot Decrease DigiPot Decrease DigiPot Decrease
61
61
MCB 113 PIN X45/2 524 Terminal X46/9 Digital Input Reset Reset Reset Reset
TB7 17
525 Terminal X46/11 Digital Input Coast Inverse Coast Inverse Coast Inverse Coast Inverse
62
62
MCB 113 PIN X45/3
TB7 90
TB7 91
526 Terminal X46/13 Digital Input Reversing Reversing Reversing Reversing
63
63
MCB 113 PIN X45/4 540.0 Function Relay Drive Ready Drive Ready Drive Ready Drive Ready
540.1 Function Relay VLT Running VLT Running VLT Running VLT Running
90
90
MCB 112 PIN 1
540.2 Function Relay Alarm Alarm Alarm Alarm
91
91
MCB 112 PIN 2 540.3 Function Relay Reverse Reverse Reverse Reverse
540.4 Function Relay Run on ref/no warn Run on ref/no warn Run on ref/no warn Run on ref/no warn
177G0468 612 Terminal 53 Low Current 4 4 4 4
177G0440 670 Terminal X45/1 Output Output frequency Output frequency Output frequency Output frequency
177G0441 680 Terminal X45/3 Output Motor current Motor current Motor current Motor current
177G0713
177G0467 e30bd948.11
Illustration 13.10 Block Diagram, F1–F4 NAMUR Terminals Option
205
13 13
13 13
206
LOCATED IN OPTION CABINET: INSULATION MONITORING DEVICES (BENDER) LOCATED IN INVERTER CABINET: SAFE STOP
Block Diagrams
FC-X02
TB3 NEG
TB3 SO2
TB3 SO1
TB3 OPT
ANALOG I/O
RS-485
616869 3942 50 535455
S + -
BLK
WHT
WHT
BLK
DIGITAL INPUTS
12 13 18 19 27 29 32 33 20 37
SO2
TB2 24+b
SO1 24+ NEG
TB2 NEGb
BLK
WHT
TB2 177G0446
*
S01 SO2 24+b NEGb

A1/+ A2/- k1 I
TB7 SI2
TB7 SJ1
BLK
B1 A2/-
B1 C11 WHT BENDER
B1 A1/+
B1 C12 RCMS460-D-1
C11 C12 k1 I
LOCATED IN RECTIFIER CABINET
B2 11
B2 12
B1
B2 A2/-
B2 A1/+
JUMPER
PRESENT IF
NO OPTIONS
CABINET.
W120 I
TB2 SO1
TB2 SO2
W120 k1
B2 L1
B2 L2
24V FROM PS1
TB2 24+b
TB2 NEGb
177G0445 WHT
TB2 SO1
R S
*Note: W120 required for use with
Bender RCMS460-D-1. W120 should be BLK
P9-8
P8-1
P9-16
P8-6
A1/+ A2/- L1 L2 KE TB2 SO2

installed on mains cables R, S, and T
BLK
WHT
near the input bus bars. WHT + BLK

BENDER FC-X02 13 -
TB6 W120 not supplied by Danfoss + -
IRDH275B-427

SO1 SJ1 SO2 PS1 PS1 RT1 RT1 PS2 PS2 RT2 RT2 104 106
11 12
R S
177G0468
177G0440
177G0441 TB3
B2 177G0713
177G0467
S
R
RS BUS BARS
GROUND BAR
NEAR INPUT
TB2 SO2
TB2 SO1
BLK
BUS BARS
WHT
177G1012
JUMPER
GND PRESENT
IF NO MMS.
TB2 OPT
TB2 NEG
FC-X02 37
e30bd949.11
Illustration 13.11 Block Diagram, F1–F4 IRM/RCD Options
MG90K502
2 2 BLK 2 2 BLK
177G4749
1 1 WHT 1 1 WHT
44
TB8
note 1 AUX RELAYS 1 & 2
C1 C2 FC-X02
01 02 03 04 05 06
FK100
MG90K502
SCR DIS/ENA TERMINAL BLOCKS Sh5, TB3 107
1
LOCATED IN RECTIFIER CABINET Sh5, TB3 105
01 02 03 04 05 06
LCP
Block Diagrams
RFI_1 CBL11 ANALOG I/O

BLK
177G0542 RS-485
3 3
61 68 69
39 42 50 53 54 55
S + -
Sh4, RFI_1 2 2
WHT DIGITAL INPUTS
1 1
12 13 18 19 27 29 32 33 20 37
CBL13
177G0842
3 3
Sh4, RFI_2 2 2
1 1
RFI_2
CBL12 177G1155
CBL14
HEAT SINK/DOOR FAN TRANSFORMER

177G0538
CBL15 TR1
WHT
OPTIONS CABINET RED BLK
DOOR FAN 2 3 1
RED FAN- L 2 3 1
TB5
F3 FAN+ N
WHT GND PE
BLK
REG+ REGEN
177G2236 L2
L1
13.2 Block Diagrams for F8–F9 Enclosures
TERMINALS
2
REG-
32uH FAN-
2
1
FAN+
Service Guide
F1 GND
RECTIFIER CABINET
DOOR FAN INVERTER
FAN- L DOOR FAN
FAN+ N
F4 GND PE
WHT
177G2150
BLK
CBL14 BLK 177G2151 BLK
WHT
WHT CBL16 RED 177G2152
177G0520
BLK
UDC Not used BLK WHT RED WHT
WHT
CBL17
5 1 8 7 6 3 10 11 3 1 8 7 6 11 10 9 1 4 3 6 44 1 8 7 6 11 10 9
14-Pin 6-Pin 16-Pin 6-Pin 16-Pin

RFI/CAN/SCR DIS/ENA INVERTER AUX2 AUX1 Fan AUX2 AUX1
DC-Link Relay RELAY POWER Relay RELAY BLK
P2
5 10
8-Pin
-L1
-L2
BLK
+L1
+L2
P6 P3 P4 P5 P1 P2
8 6 5 4 31
RED
P4
WHT
10-Pin
BLK
7 2 1
1
BLK
DC+
6 GND

P7 WHT
INVERTER 1 5 CAN_H
4 CAN_L RED
30
POWER CARD
P7 3
TEST CONNECTOR
DC- 2 VDD
1 1 RFI_2
12-P 1
P5 20 RED
P1 R’
WHT
R’ S’ T’ S’ P6
BLK
T’
RECTIFIER 177G0753
8-Pin
12 Pin 44 30
POWER CARD
7 9 11 8 10 12 2 4 6
TEST CONNECTOR
BRAKE
P3
6 2 5 3 4 7 8
R1 S1 T1 R2 S2 T2
TERMINALS
R+
R-
W1
INV 1 MOTOR
V1
TERMINALS
U1 Note 1 :
MAINS FUSES MAINS FUSES
T’
BLK If no option cabinet, installed jumper
S’
WHT
91 R2 91-1 R’ else, Disconnect Interlock Aux Contacts
R1 FU1 FU4 RED
8-Pin
FU2 92-1 FU5

Klixon etc.
S1 92 S2 INV 2
CBL18 Not Used
6 2 5 3 4 7 8
T1 93 FU3 T2 93-1 FU6

177G0531
GND 94 GND 94 2 inverter
TB1 TB2 e30bd950.11
Illustration 13.12 Block Diagram, F8–F9 Top Level
207
13 13
13 13
208
P4
HEAT SINK/DOOR
FAN TRANSFFORMER
TO CABINET DOOR FAN /

TRx
INDUCTOR CABINET FAN
WHT
RED
P7 P1 P2 2 3 1
P3 P6 2 3 1

Block Diagrams
TEST CONNECTOR TO OPTION AND 8-PIN

177G0753 NOT USED TO INVERTER DC-LINK
20
INVERTER CABINETS
1
30-pin Panel Mount Connector 6-PIN
14-PIN 16-PIN
1
43
1 2 3 4 5 6 8 7 5 4 3 1
6 7 5 8 11 10 3 6 2
6 7 5 1 8 10 3 8 7 6 11 10 9
11 1 2 3 4 5 6 Fu1 (15A) 8 7 6 5 4 3 2 1
29 1
RED WHT BLK WHT BLK RED WHT BLK RED WHT BLK
BLK RED
TEMP WHT WHT BLK WHT
SWITCH/SCR RED BLK BLK
Disable RFI SWITCH Fu1 (4A)
CBL202 WHT
177G0512 CBL203
WHT
HEAT SINK FAN
177G0527 CBL204 177G2801 WHT
BLK 1 1
177G0514 43
1
2
9
1 2 3
7
8
5
4
1 2 3 4 5 6
11
13
10
15
12
16
14
1 2 3 B A 13 11 4 5 3 12 9 16 1 8 BLK 2 2
177G0515 C NO NC C NO NC SPLICE
IV1
RL2
3
IU1
3
IW1
VDD
L1 L2 L1 L2 L1 L1
DET
GND
VDD
FANO
VNEG 3
VNEG 6
VNEG
VPOS
SENS
VPOS
VPOS
CBL201 -DC +DC
AUX_S
AUX_T
AUX_S
AUX_T
MPIC CAN FANS
GRN/YEL 4 4
CBL200 AUX 2 AUX 1 X2 X1 CBL205
106 104 105
IV'
IU'
IW'
RELAY RELAY
CUR
HF SW
RFI FAN
MK108 MK105
NC C NO MK107 177G2552
CURRENT MK112
MK110
SENSORS
10 FK102
2
R3 C1
13
MK102
5
S3 1
MAINS
8 HEAT SINK
MK107
16
T3 1 1 1 FAN CAPACITOR
RED 1 177G2546 POWER CARD

R2
9
WHT 4
12
S2
MAINS
CBL207 CBL219
MK105
MK104
MK104
BLK 7
MK106
15
T2
29 29 29 10
R RED
5
8
TMP TMP S WHT
1 WHT WHT MK100 3
MK100 MK102 FK103 RED
MAINS
6
6
MK106
GND 2 BLK 177G2559 BLK GND T BLK
CBL208 SCR 1
SCR
MK103
Rectifier HS NTC
Highest HS
GATE DRIVER
TEMP SIGNAL
1 2 3
MK110
GATE DRIVER LOGIC CKT. 3 RED RED
AUX S, AUX T
R2 S2 T2
RECTIFIER HS
R3 S3 T3 R2 S2 T2 N1 N2 N3 SNS
TEMP SENSOR
WHT
4
3 6 2 5 1 4
102
100
103
101
7 14 6 13 5 12 3 10 2 9 1 8 1 5 2 6 3 7 4 8
WHT
Chassis Gnd Chassis Gnd WHT WHT WHT
WHT WHT
BLK BLK BLK BLK
BLK BLK
CBL210 177G2845 CBL213 BLK
2
CBL209
177G2547 177G2548
CBL211
1
+
177G2549 +L1
+
+L2
3
SCR1 SCR2 SCR3

SCR4 SCR5 SCR6 BLK BLK BLK
BLK BLK BLK 1 2 3
1 2 3 WHT WHT WHT
11
WHT WHT 1 2 3
WHT
P5
1 2 3 177G2856
12-PIN
R' S' T'

9
RED R
CBL215
177G2618 1 +SCR A
3 2 1
WHT
MK3
CBL214 S 2 -SCR C
7
MK1
177G2618 MK2
+
R1 BLK T -L1 - +L1

CBL212 3
R2
N1 RS+ A
5
N2 HEAT SINK NTC SOFTCHARGE BOARD 1

R1
MK4
HEATSINK NTC RS- B

S1 RED
12
S2 CBL216
T5 177G0506
WHT
HEAT SINK TEMP SENSOR T7 177G0608
10
T2 T1
BLK
8
RED
R'
3 3
S' WHT
2 2
T'
D1 D2 D3 1 1
D4 D5 D6 -
-
-
-
-L1
-L2
CBL217 RED CBL219
WHT
177G2846 BLK 177G2560
177G0507
R' S' T'
CBL206

RED 3 2 1
R 1 +SCR A
MK2
WHT CBL218
MK3
S 2 -SCR C BLK
MK1
+
-L2 - +L2 WHT
BLK 177G2550
T 3 RED
RS+ A R' RED

R2
SOFTCHARGE BOARD 2 S'
MK4
RS- B WHT
PCA17
BLK 10 R'
T' R 5
CBL220 8 S'
S 3
6 T'
T5 177G0506 CBL209 T 1
T7 177G0608 177G2547 NOT USED
e30bd951.11
Illustration 13.13 Block Diagram, F8–F9 Rectifier Module
MG90K502
MG90K502
TO CUSTOMER AUX RELAY TERMINALS TO FAN AUTOTRANSFORMER TO RECTIFIER MODULE
TO MDCIC BOARD TEST CONNECTOR USED 16-Pin 10-Pin 8-Pin
3 5 10 4 8 7 6 9 2 1 6 5 1 2 3 5 6
8 7 1 4 3 2 4
8 7 6 11 10 9 3 5 10 4 8 7 6 9 2 1 6 2 3 4 5 6
8 7 1 4 3 2 5 1
Block Diagrams
44-pin Panel 30-pin Panel P3 177G2619

Mount Connector Mount Connector BLK BLK RED WHT BLK
WHT BLK RED CBL305
P2 P4 WHT WHT GDB, MK101,Pin1
BLK RED P7
WHT WHT Fu1 (15A) WHT
CBL304
P6 RED BLK 177G0521 GDB, MK101,Pin2
P1 BLK
WHT
CBL302
BLK
177G0527
CBL303 177G0523 AUX FAN CBL303
1 2 3 4 5 6 13 11 4 5 3 12 9 16 1 8 6 5 4 3 2 1 BLK 177G0523 177G0523 FAN ASSEMBLY
5 10 3 8 1 6
3
1 GND 177G0516
AUX_S
AUX_T
AUX_S
AUX_T
R S T HEAT SINK FAN
FANS
2
177G0515 AUX 2 X2 X1 102 100
AUX 1 103 101 CAN_L
RELAY RELAY S AUX_S T AUX_T WHT BLU 1 1
MAINS WHT
MK107
1
BLK BLK
MK108
CAN_H 2 2
MK112 FK103 SPLICE BRN 3
MK106 RED 3
CAN GRN/YEL 4 4
3
CBL300
105
NO
MK104
177G0514
C
2
104
F5-F8
FK102
29
106
NC
C1
POWER CARD WHT
1 HEAT SINK
BLK HF SWITCH
+
VDD 14 FAN CAPACITOR
HF SW WHT
-
RL2 15 WHT
VDD 12
RFI FAN
FANO 13 177G0517/518
GND 9
SENS 10
CUR DET 11
CBL306
VPOS 1
IU1 2
MK110
IU'
VNEG 3
MK102
VPOS 4
MK105 IV' IV1 5
VNEG 6
CURRENT SENSORS
43 +DC -DC VPOS 7
IW' IW1 8
MK109 VNEG
A B 16
TB3
CBL307 81 R-
BRC BLK E2
BRC 82
MK1
BRK
6 4 1
GATE DRIVE BOARD G2
R+
BRN
COL
BRN
BRK
1
Fu2 (4A) P7, Pin 1 RFI_RL2 MK106 BRAKE GATE
GBP
WHT
MK105
IGBT4 EXT BRAKE
1 2 6 7 5 10
GBP RES CARD
GATE
RESISTOR
2
P7, Pin 2 VDD MK102 MK103 MK104 MK100 PCA14
6-Pin CONNECTIONS
EM
MK101
U V W NTC
3
GUP
EUP
GUP
EUP
GUP
EUP
GUP
GUN
EUP
EUN
GUN
EUN
GUP
GUN
EUP
EUN
GUN
EUN
GUP
GUN
EUP
EUN
GUN
EUN
TMP+
TMP-
1
1
1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 3
BLK
BLK E2
MK1
BRK
6 4 1
WHT G2
2
2
COL
BLK CBL308 CBL308 CBL309

P5 CBL308 BRAKE GATE
190864 190864 190864 190808 IGBT5
4
Service Guide
4
RES CARD
GATE
BLK
PCA15
177G0520
EM
3
3
WHT
CBL310
190861
5
5
4 5 8 1 1 2 3 4 5 8 1 1 2 3 4 5 8 1 1 2 3
WHT UDC- UDC+
NTC1
NTC1
NTC2
NTC1
EUP1
NTC2
ELO1
GLO1
EUP1
NTC2
ELO1
GUP1
EUP1
GLO1
ELO1
GUP1
GLO1
GUP1
6
6
MK100 MK103 MK100 MK103 MK100 MK103
GATE RESISTOR CARD NTC
IN
IN
IN
OUT
OUT
OUT
CBL311 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3
177G0519

+ UDC+
+DC UDC+
IU
L2 TB2
CS1
96 U
+ M -
C2 C3 C4 C5 C6 C7 C8 C9 C10
+ NTC NTC
+ NTC
- - CUP1 UP CUP2 UP CUP3 VP CUP1 VP CUP2 WP CUP3 WP CUP1 VP CUP2 WP CUP3 WP

IV
L3
CS2 97 V
A A
+ M -
B B

MK1
MK1
C C
BAL CKT
BAL CKT
UN UN VN VN WN WN VN WN WN IW
L4

+
CS3
+
IGBT1 IGBT2 IGBT3 + M -
- -
+
2
MK100
-
1
UDC- UDC-
-DC - BLK
WHT
+
HF SWITCH
-
CBL312 177G0517/518
e30bd952.11
209
13 13
13 13
LOCATED IN RECTIFIER CABINET: 400VA TRANSFORMER, FUSIBLE DISCONNECT AND 24V DC POWER SUPPLY
210
RECTIFIER/ INVERTER
OPTION CABINET CABINET DOOR
DOOR INTERLOCK INTERLOCK
BLK
Sh5, TB3 RT1 - + - +
WHT
177G0709
Sh5, TB3 PS1
177G0709
DOOR INTERLOCKS
BLK 2 2
1 1
Block Diagrams
RED
SPLICE RFI_1
- + - +
24 V DC POWER SUPPLY
PS1 RED 2
BLK
L N Rectifier RFI_1
177G0486 1
WHT
GRN/YEL 3
177G0687
BLK WHT
1 2 3
+
-
CBL400 MK1
CM FILTER
177G0484 RFI
LOCATED IN OPTIONS CABINET
MK5
MK7
MK6
BLK WHT
CBL401
T1 177G3175
400VA X1 X2
TRANSFORMER
H1 H2
FU-DISC FU3 CBL402

177G0850
FU1 BLK
6A
MK3
S
MK1
MK2
WHT
FU2
6A
T BLK
FU3 TB3 T, Sheet 6
6A
S FU4
WHT
6A
TB3 S, sheet 6 DIFF. MODE
T 177G0475 FILTER
177G0703
4-POLE FUSIBLE
DISCONNECT RED WHT
TB2
R2 DISCONNECT 2
L1-2 91-2 0022118
FU1 R
S2
FU2 S TO RECTIFIER CABINET
L2-2 92-2
FU3 T

T2
L3-2 93-2
WHT 23 MAINS FUSES
Aux 1 contact *Note 1: Contactor coil connection without Emergency Stop
00020220 LOCATED IN OPTIONS CABINET: DISCONNECT
GND 94 177G3114 00020208
RED 24
13 Aux 2 contact
WHT
14 177G3114
00013137
BLK RFI_2
BLK 2
CBL403 Sh1 C1
177G0850 Thermal Switch 1
WHT 2
WHT Rectifier RFI_2

177G0696 1
140 C
TB1 3
RED
R1 DISCONNECT 1
L1-1 91-1 0022118
FU1 R
RFI
S1 92-1 FU2 LOCATED IN OPTIONS CABINET S TO RECTIFIER CABINET
L2-1 Same as RFI Above
FU3 T
T1 93-1
L3-1 MAINS FUSES
23 00020220
Aux 1 contact
00020208
94 177G3114
24
GND
WHT 13
Aux 2 contact
RED 14 177G3114
e30bd953.11
MG90K502
LOCATED IN INVERTER CABINET: SAFE STOP AND TEMPERATURE MONITORNG DEVICES
MG90K502
FC-X02 13 (RCM,IRM)
SO1-SO2 JUMPER
P8-5 (mms) ***
PRESENT IF NO OPTIONS CABINET
****
See notes on the CI45 units in the lower left
(SCR dis/en)
(SCR dis/en)
Block Diagrams
corner of this page

FC-X02
ANALOG I/O
TB2 SO1 177G0702 * RS-485
5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8 5 6 7 8
TB2 SO2 61 68 69 39 42 50 53 54 55
Sh4, PS1-
Sh4, PS1+
P8-6 (TM)
P8-1 (TM)
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 S + -
Sh 1, P2, pin7
Sh 1, C2, pin1
WHT BLK
WHT BLK PMA PMA PMA PMA PMA
Sh7, TB7 51 (NAMUR)
+ -
CN1** Sh7, TB7 50 (NAMUR)
BLK
RET DIGITAL INPUTS
177G0468 TB1 RET
+24V
177G0440 WHT TB1 24V
+24V
+24V
177A0023
TB3 177G0713 12 13 18 19 27 29 32 33 20 37
177G0467
CI45 CI45 CI45 CI45 CI45 177G1322
WHT
WHT
WHT
BLK
BLK
11 12 13 14 11 12 13 14 11 12 13 14 11 12 13 14 11 12 13 14
15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18 15 16 17 18
P8-10 (mms)
FC-X02 37 (IRM, RCM)
TB2 24+
TB2 24+
TB2 NEG
TB2 NEG
TB3 SI2
TB1 SS1
TB3 SJ1
TB1 SS2
(PILZ)
(PILZ)
Sh7, TB7 1
Sh7, TB7 18
(TM)
(RCM,IRM)
(RCM,IRM)
(TM)
TB1 SS4
TB1 SS3
(IRM, RCM)
OR OPTIONS
(NAMUR)
(IRM, RCM)
CABINET DOOR
(NAMUR)
WHT
177G0477
WHT 1 3 1 3 1 3 177G0478
E-STOP
PUSHBUTTON 3-POSITION
RUN
RESET
177G0480 SWITCH
177G0481 BLK
Service Guide
2 4 2 4 2 4
BLK
TB2 24+
TB2 S31
TB2 13
TB2 S32
TB2 S11
TB2 S12
1
2
WHT
TB3 S01
CI45 18
CI45 17
FC-X02 13
FC-X02 37
CN1 RET
CN1 24V
177G0482 BLK
WHT
2
1
TB3 S02
WHT 10-Pin PANEL MOUNT CONNECTOR
TB3 INV
BLK
WHT
BLK
WHT
PILZ RS RN
PILZ S11
PILZ S11
BLK
TB3 NEGb P8
1
1
24V
RET
RET
RET
SS4
RET WHT
SS3
SS1
BK
SS2
WHT
TB3 SO1 TB1 RET TB3 RT1
9
177G0468
WHT
BK
A1 TB3 SO2
6
S31 S12
6
S32 S11 24V 177G0440

BLK
TB1 24V TB3 PS1
4
WHT 177A0023
TB3 OPT
13
8
37 TB1 177G0713
BLK
TB3 NEG
7
177G0467
3
S11 S12 PB1 PB2 PB3 PB4 RS1 RS2 Rn1 Rn2 SO1 SO2 24+ NEG SO1 SO2 24+ NEG
RET
RET
RET
24V
SS4
SS3
SS1
SS2
PILZ LOCATED IN OPTIONS CABINET IF OPTIONS PILZ WHT WHT

10
10
PNOZ XV2P TB1 SS2 TB3 SI2

2
CABINET PRESENT OTHERWISE LOCATED IN 14 24 WHT

POWER 37
5
BLK BLK
BLK
WHT
INVERTER CABINET TB1 SS3 TB3 SJ1

START TB2
CH.1
38 48 CH. 1[t]
CH.2 S11 S12 S21 S22 S31 S32 S34 S33 14 S54 S55 13 24+ Neg SO1 SO2 24+b Negb
P8 1
P8 6

P8 5
P8 10
CH. 2[t]
Sh 6, B1 A2/- or
BLK
Sh 6, B2 A2/-
BLK
14 38
WHT
Sh 6, B1 A1/+ or
WHT
A2 Y39 Y40 S21 S22 S33 S34 Sh 6, B2 A1/+
Sh 6, B1 C11 or
Sh 6, B2 11
Sh 6, B1 C12 or
Sh 6, B2 12
PILZ 14
PILZ 13
PILZ A1
PILZ A2
PILZ S21
PILZ S22
PILZ S31
PILZ S32
PILZ S34
PILZ S33
BLK
*Note 1: There is a factory installed jumper between
terminals 1 and 3 of the CI45 units. Customer must
remove jumper.
TB2 14
TB2 S34
TB2 S21
TB4 S33
TB2 S22
TB2 Neg
**Note 2: Connector CN1 used to bring 24V to PMA
devices. Connector should be removed to accomodate
communication device.
***Note 3: MCB112 available for up to 3 PTCs in
series. MCB114 available for up to 3 PT100/PT1000.
****Note 4: Safe Stop is standard for FC-302. Safe

Stop must be ordered separately for FC102 and FC202
e30bd954.11
Illustration 13.16 Block Diagram, F8–F9 Pilz Relay with No Contactor/Thermal Monitor
211
13 13
13 13
212
LOCATED IN OPTION CABINET: INSULATION MONITORING DEVICES (BENDER)
Block Diagrams
Note: The following terminal blocks are associated

with the IRM/RCM optional feature:
TB2: S01/S01, SO2/SO2, 24+/24+b, & NEG/NEGb
FC X02: 12 and 37
See Block Diagram, F8–F9 Pilz Relay with No Contactor/Thermal Monitor
Sh5, TB2 24+b

Sh5, TB2 NEGb
BLK
WHT
177G0446
*
A1/+ A2/- k1 I
BENDER
RCMS460-D-1
C11 C12 k1 I
B1
W120 I
W120 k1
Gnd -> Ground Bar
Gnd -> Ground Bar

Sh5, TB2 SO1
Sh5, TB2 SO2
Sh5, TB2 24+b

Sh5, TB2 NEGb
177G0445

R S
A1/+ A2/- L1 L2 KE
BENDER *Note: W120 required for use with Bender

TB6 RCMS460-D-1. W120 should be installed
IRDH275B-427
on mains cables R, S, and T near the
11 12
R S input bus bars.
W120 not supplied by Danfoss.
B2
R
R & S BUS BARS
NEAR INPUT
BUS BARS
Sh5,TB2 SO2
Sh5, TB2 SO1
e30bd955.11
MG90K502
MG90K502
LOCATED IN INVERTER CABINET: NAMUR TERMINALS, CONTROL CARD, MCB 112, MCB 113
Block Diagrams
MCB 113 EXTENDED I/O

X45
1
TB7 60
2
TB7 61
3
TB7 62 TB8
TB7
4
TB7 63
AUX RELAYS 1 & 2
NAMUR TERMINALS X58
1
01 02 03 04 05 06
1
CUSTOMER SUPPLIED 24V RET Sh5, FC-X02 PIN 20 X46
1
TERMINALS JUMPERED TOGETHER TB7 10
1
3
TB7 11
2
CUSTOMER SUPPLIED 24V 0.8 AMP 01 02 03 04 05 06
3
3
5
TB7 12
3
3
7
TB7 13
3
3
TB7 32
TB7 33
TB7 31
8
TB7 30
10
10
MCB 113 PIN X46/1
9
TB7 14
11
11
10
MCB 113 PIN X46/3
12
12
MCB 113 PIN X46/5 TB7 15
13
13
MCB 113 PIN X46/7
TB7 16
14
14
MCB 113 PIN X46/9
11 12 13 14
15
15
MCB 113 PIN X46/11 X47
16
16
1 2 3 4 5 6 7 8 9 10 11 12
MCB 113 PIN X46/13
17
17
Service Guide
MCB 113 PIN 12
18
18
Sh5, FC-X02 PIN 37
30
30
TB11 PIN 01
TB7 41
TB7 40
TB7 42
TB7 38
TB7 37
TB7 35
TB7 39
TB7 34
TB7 36
31
31
TB11 PIN 02
32
32
TB11 PIN 04 ID NAME Setup 1 Setup 2 Setup 3 Setup 4
33
33
TB11 PIN 05
315 Reference Resource 1 Analog Input 53 Analog Input 53 Analog Input 53 Analog Input 53
34
34
MCB 113 PIN X47/1 316 Reference Resource 2 Digital pot.meter Digital pot.meter Digital pot.meter Digital pot.meter
35
35
MCB 113 PIN X47/3 317 Reference Resource 3 No function No function No function No function
391 Ramp Time 5 5 5 5
36
36
37
37
MCB 113 PIN X47/4 410 Motor Speed Direction Both Directions Both Directions Both Directions Both Directions
38
38
MCB 113 PIN X47/6

39
39
MCB 112 PTC 514 Terminal 32 Digital Input PTC Card 1 PTC Card 1 PTC Card 1 PTC Card 1
40
40
MCB 113 PIN X47/7 PTC & Safe Stop Alarm
519 Terminal 37 Safe Stop PTC & Safe Stop Alarm PTC & Safe Stop Alarm PTC & Safe Stop Alarm
41
41
MCB 113 PIN X47/9 520 Terminal X46/1 Digital Input Start Latched Start Latched Start Latched Start

521 Terminal X46/3 Digital Input Stop Inverse Stop Inverse Stop Inverse Stop Inverse
42
42
MCB 113 PIN X47/8
LOGIC OUT
LOGIC COM
SAFETY STOP
NC
NC
NC
NC
NC
NC
PTC T1
PTC T2
NC
522 Terminal X46/5 Digital Input DigiPot Increase DigiPot Increase DigiPot Increase DigiPot Increase
1 2 3 4 5 6 7 8 9 10 11 12
50
50
Sh 5, FC-X02 PIN 53 523 Terminal X46/7 Digital Input DigiPot Decrease DigiPot Decrease DigiPot Decrease DigiPot Decrease
51
51
Sh 5, FC-X02 PIN 55 524 Terminal X46/9 Digital Input Reset Reset Reset Reset
525 Terminal X46/11 Digital Input Coast Inverse Coast Inverse Coast Inverse Coast Inverse
60
60
MCB 113 PIN X45/1 526 Terminal X46/13 Digital Input Reversing Reversing Reversing Reversing
61
61
MCB 113 PIN X45/2 540.0 Function Relay Drive Ready Drive Ready Drive Ready Drive Ready
TB7 17
540.1 Function Relay VLT Running VLT Running VLT Running VLT Running
62
62
TB7 91
TB7 90
MCB 113 PIN X45/3 Alarm Alarm Alarm
540.2 Function Relay Alarm
63
63
MCB 113 PIN X45/4 540.3 Function Relay Reverse Reverse Reverse Reverse
540.4 Function Relay Run on ref/no warn Run on ref/no warn Run on ref/no warn Run on ref/no warn
90
90
MCB 112 PIN 1
Sh5, FC-X02 32
612 Terminal 53 Low Current 4 4 4 4
91
91
MCB 112 PIN 2 670 Terminal X45/1 Output Output frequency Output frequency Output frequency Output frequency
680 Terminal X45/3 Output Motor current Motor current Motor current Motor current
e30bd956.11
Illustration 13.18 Block Diagram, F8–F9 NAMUR Terminals
213
13 13
13 13
214
JUMPER PRESENT IF
LOCATED IN RECTIFIER CABINET: MANUAL MOTOR STARTERS AND 30A CUSTOMER FUSE OPTION
NO OPTIONS CABINET
TB2 SO1 P8 5
TB2 SO2 24V FROM PS1

WHT BLK
JUMPER PRESENT IF MMS TB3
+ -
OPTION INSTALLED WITH
Block Diagrams
NO SAFE STOP OPTION
AND NO OPTIONS CABINET 177G0468
MAINS AFTER 177G0440
CONTACTOR 30A CUSTOMER 177A0023

177G0713
AND FUSES FUSES 177G0467
RED (3FT1) (3FB1)

R F30A RP
CUSTOMER SM1 SM2 SI2 OPT INV NEG NEGb +24 +24b RET RETb 105 107
WHT (3FT2) (3FB2)
S F30B SP TERMINALS.
BLK (3FT3) (3FB3)
BLK
WHT
WHT
T F30C TP
*
177G0974
10
SPLICE
WHT WHT
P8
TB2 24+
*
TB2 NEG
MMS1 MMS1
BLK BLK
JUMPER PRESENT
MMS2 (55) (56) (44) (43)
IF NO MMS OPTION
177G0969 FUSES O.L AUX
RED (2FB1) (2FT1) (L1) MMS1
R FXA
WHT (2FB2) (2FT2) (L2) FUSES
S FXB RED (2FB1) (2FT1) (L1)
BLK (2FB3) (2FT3) (L3) WHT MAINS AFTER R FXA
T FXC WHT (2FB2) (2FT2) (L2)
CONTACTOR S FXB
MAINS AFTER MMS2 MMS2 AND FUSES BLK (2FB3) (2FT3) (L3)
BLK
T FXC
CONTACTOR
AND FUSES. (55) (56) (44) (43) 177G0969
O.L AUX
MMS2 MMS1
2.5-4.0A 177G0974 2.5-4.0A
4.0-6.3A 380 - 500V drives 4.0-6.3A
6.3-10A MMS Range MMS Part Number Fuse selected MMS setting
T3 T1 2.5A - 4A 177G0449 6 3.3 6.3-10A
10-16A 4A - 6.3A 177G0450 10 4.6
T2 6.3A - 10A 177G0451 15 7.3
10-16A
10A - 16A 177G0452 25 13.4

T3 T1
525 - 690V drives T2
MMS Setting MMS Part Number Fuse selected MMS setting
CUSTOMER T2 2.5A - 4A 177G0449 10 3.7
T3 T1 4A - 6.3A 177G0450 15 5.8
SUPPLIED AC 6.3A - 10A 177G0451 20 8.6
MOTOR 1 10A - 16A 177G0452 20 10.5
CUSTOMER T2
SUPPLIED AC T3 T1
MMS:177G0449-2/177G0450-2/177G0451-2/177G0452-2 MOTOR 2
FUSE:177G0703/177G0704/177G0705/177G0706/177G0707/177G0708
177G0454-2
177G0455-2
*Note 1: There are only 2 combinations: 177G0694-2
2 manual motor starters or 1 manual motor starter MANUAL MOTOR STARTERS/30A CUSTOMER FUSE TERMINAL BLOCK DIAGRAM
and the 30A customer fuse terminals.
e30bd957.11
Illustration 13.19 Block Diagram, F8–F9 Manual Motor Starters/30 A Customer Fuse Terminal
MG90K502
MG90K502
PILZ_STO 14
PILZ_STO A2
CBL101 CURRENT CURRENT CURRENT
SCALING SCALING SCALING PILZ_STO S12
CARD CARD CARD
01 02 03 04 05 06
MK100
130B0057
MK107
MK108
*178N0149
MK109
FC X02 INV1 INV2 INV3 TO PILZ_STO
TB8
177G0842 2i
Block Diagrams
AUX RELAYS 1 & 2
MK106
01 02 03 04 05 06
1 FK100 44 1 FK102 44 177G0843 3i

LCP CBL100
177G2167
ANALOG I/O 10 9 8 7 6
RS-485 5 4 3 2 1
61 68 69
39 42 50 53 54 55
MK111
MDCIC CARD
S + -
PCA13
DIGITAL INPUTS
177G0842 44 FK103 44
12 13 18 19 27 29 32 33 20 37 1 FK101 1
MK101 MK102
CAN CAN
CBL13
6 5 4 3 2 1 6 5 4 3 2 1
BLK
WHT
RED
BLK
WHT
RED
CBL104
177G1155
CBL102 CBL103
SCR DIS/ENA TERMINAL BLOCKS 177G4749
2
BLK
JUMPER IS INSTALLED 2 2 177G1440
LOCATED IN RECTIFIER CABINET 177G1440
IN CASE THERE IS 1 1
WHT
1
BLK NO OPTION CABINET
2 2
HEAT SINK/DOOR
1 1
HEAT SINK/DOOR HEAT SINK/DOOR
C2 FAN TRANSFORMER
177G4749
FAN TRANSFORMER FAN TRANSFORMER
WHT
C1 TR3
TR1 TR2
WHT WHT
WHT BLK RECT2 RED BLK
RED BLK RED BLK
2 3 1
RECT1 F1 F2 2 3 1 2 3 1
F1 F2 OPTIONS CABINET RED
OPTIONS CABINET 2 3 1 TB5
DOOR FAN DOOR FAN 2 3 1 2 3 1
WHT WHT
WHT WHT REG+
FAN- L FAN- L REGEN
L1 F5 FAN+ N
L2 F6 FAN+ N
GND PE
BLK GND PE
TERMINALS
107 105
REG-
106 104 177G0534
S2 FAN-
S1 BLK CBL107 S1 S2 CBL110 FAN-
FAN+
FAN+
UDC UDC F3 F4 GND
GND
177G2151 177G2151 CBL113
CBL106 CBL109
1
1
2
2
2 2 177G2245 INVERTER CABINET INVERTER CABINET 177G0537
177G2245 WHT
2 2 DOOR FAN DOOR FAN
1 1 BLK
1
1
2
2
1 1 BLK
RECTIFIER CABINET 3 3 WHT BLK
RECTIFIER CABINET
3 3 WHT DOOR FAN DOOR FAN CBL111
13.3 Block Diagrams for F10-F13 Enclosures
RFI2
Service Guide
RFI1 RED FAN- L FAN- L

177G2152
FAN+ N FAN+ N
CBL112
F1 GND
F2 GND
PE PE
CBL108 177G2152
CBL105 BLK BLK BLK
WHT
177G3202 RED
177G2244 WHT WHT
RED WHT BLK BLK WHT BLK WHT

BLK Not used BLK BLK WHT NOT USED NOT USED
Not used
1 4 3 6 44 1 1 4 3 6 44 1
1 8 7 6 3 10 11 3 1 5 1 8 7 6 3 10 11 3 1 8 7 6 1 4 3 6 44 1 8 8 7 6 11 10 9 8 7 6 11 10 9
5 8 7 6 11 10 9 11 10 9 7 6 11 10 9
8
WHT
8
14-Pin 16-Pin 14-Pin 6-Pin 16-Pin 6-Pin P1 16-Pin WHT
6-Pin 16-Pin FU9 6-Pin 16-Pin
6-Pin FU5 FU7 DC-Link P1 DC-Link P1
RFI/CAN/SCR DIS/ENA Aux 2 Aux 1 RFI/CAN/SCR DIS/ENA Aux 2 Aux 1 DC-Link Aux 2 Aux 1 Aux 2 Aux 1 Aux 2 Aux 1
INVERTER Relay Relay INVERTER Relay Relay Relay Relay
Relay Relay Relay Relay
6 5
DC-Link
6 5
DC-Link P5
BLK
8-Pin
P4 P5 P5
5 10
5 10
P2 P3 P4 P2 P3 BLK P2 P2
P2
4 3
P6
4 3
-SCR P6 -SCR FU4
RED
10-Pin
7
RED
1
10-Pin
1
7
10-Pin
7
WHT
2
WHT FU8
2
FU6
2
P4 P4 BLK P4
1
BLK
1
1
1 DC+ DC+
1 DC+
+SCR +SCR P7 INVERTER 1 INVERTER 2 INVERTER 3
P7
See F10-F13 Inverter Module Block Diagram See F10-F13 Inverter Module Block Diagram See F10-F13 Inverter Module Block Diagram
POWER CARD
30
RECTIFIER 1 RECTIFIER 2 1
POWER CARD
30
1 1
1
F10: 1 Soft Charge Circuit (177G2851) 1 F10: 1 Soft Charge Circuit (177G2851) DC- DC-
3 P6
F12: 1 Soft Charge Circuit (177G2851) F12: 2 Soft Charge Circuits (177G2852) DC-
20 BLK P6 RED P6
18
6
P1 J2 BLK
T' T' R'
P1 20
POWER CARD
WHT
POWER CARD
P5 WHT
POWER CARD
J1 P5 WHT 30 S' S'
6 2
S'
177G0753 30 30
6 2 5
8-Pin
2 5
8-Pin
R' S' T'
R' S' T' R' T'
5
177G2376 R'
12-Pin 12-Pin P3 RED 3 BLK P3
44 RED P3
44
8-Pin
3 4
3 4
7 9 11 8 10 12 2 4 6 7 9 11 8 10 12 2 4 6 BRAKE BRAKE BRAKE
7
7
TERMINALS TERMINALS TERMINALS
8
8
R1 S1 T1 S2 T2

CBL114 R+ R+ R+
R- R- R-
177G2367 W2 W3
W1
V1 MOTOR TERMINALS V2 MOTOR TERMINALS V3 MOTOR TERMINALS
MAINS FUSES MAINS FUSES

U1 U2 U3
FU1 95
R1 91 R2 FU4
92 FU2 S2 96 FU5
S1
CBL115
93 T2 97 FU6
T1 FU3
177G2367 2-inverter
GND 94 GND 98
177G2366 3-inverter
TB1 TB2
*Note 1: For MK111 on the MDCIC, the wire harness (178N0149) is used on all FC 302 drives in this enclosure size as well as FC 102 and FC 202 with Safe Stop option.
For FC 102 and FC 202 drives without Safe Stop option, a jumper connector (178N0167) is connected to MK111 of the MDCIC.
e30bd958.11
Illustration 13.20 Block Diagram, F10–F13 Top Level
215
13 13
13 13
216
HEAT SINK/DOOR
FAN TRANSFORMER
Block Diagrams
TRx TO CABINET DOOR FAN/

44-pin Panel Mount Connector INDUCTOR CABINET FAN
Rectifier 1 has both jumpers
WHT
Rectifier 2 has 1-20 jumper only P2 RED P4
P6 2 3 1
20 1
P7 P3
J1 TO OPTION AND 2 3 1 8-PIN
TO INVERTER DC-LINK CBL205
18 3 NOT USED
P1 177G2376
INVERTER CABINETS
TEST CONNECTOR 14-PIN 16-PIN 6-PIN 177G2552
43
1
1 2 3 4 5 6 8 7 6 5 4 3 2 1
6 7 5 8 11 10 3
6 7 5 1 8 10 3 8 7 6 11 10 9
11 1 2 3 4 5 6 8 7 6 5 4 3 2 1
Fu1 (15A)
29 1 BLK WHT BLK WHT BLK RED
RED WHT RED
BLK
WHT BLK
Temp Sw / RED
WHT WHT BLK WHT
SCR disable
RED BLK
FK103
FK103
FK103
FK103
Pin 103
Pin 101
Pin 100
Pin 102
Fu1 (4A) BLK
CBL202 RFI switch
CBL203 WHT
177G0512 177G0527
CBL200 CBL201 WHT HEAT SINK FAN
CBL204 177G2801 WHT
BLK 1 1
177G0514 177G0515 1 3 3
1
2
9
2 2 4
7
8
5 6
3
5
6
1
11
13
10
15
12
16
14
1 1 2 3 B A 13 11 4 5 3 12 9 16 1 8 BLK 2
CBL206 2
C NO NC SPLICE
IV1
3
RL2
IU1
3
IW1
VDD
C NO NC L1 L1
DET
L1 L2 L2 L1
GND
VDD
FANO
VNEG
VNEG
VNEG
VPOS
SENS
VPOS
VPOS
-DC +DC
AUX_S
AUX_T
AUX_S
AUX_T
177G2552
CAN GRN/YEL 4 4
106 104 105 AUX 2 AUX 1 FANS X2 X1
NC C NO
IV'
IU'
IW'
RELAY RELAY MK105
CUR
MK108
HF SW
RFI FAN
MK107
FK102 CURRENT MK112
MK104
SENSORS
29 MK102 C1
1
HEAT SINK
FAN CAPACITOR
POWER CARD
MK110
PCA12
CBL207
10
R RED
43 5
8
S WHT
6
6
MK100 MK103 FK103 3
M AI N S
6
MK106
SCR RECTIFIER HS T BLK
TEMP SENSOR 1
GATE DRIVER Auxs, AuxT RED
TMP
GND
R S T
4
4
3 6 2 5 1 4 1 2 3 WHT
102
100
101
103
WHT WHT WHT
BLK BLK
BLK BLK BLK CBL208 P4 pin5
2
2
WHT
177G0502 P4 pin6 R' S' T' CBL210
CBL209 177G2856
P4 pin 4 RED R +SCR A
177G0511 P4 pin 3 MK2
1
1
WHT
MK3
S -SCR C
+
MK1
+
-SCR - +SCR
BLK T SOFTCHARGE BOARD 1
3
3
PCA16
SCR1 SCR2 SCR3 +SCR RS+ A
BLK BLK BLK R1
MK4
RS- B
1 2
WHT
11
11
WHT WHT
1 2
P5
CBL211
12-PIN
9
9
177G0506
7
7
CBL212
R 1900800
5
5
TH1
HEATSINK NTC

12
12
S
R'
10
10
T S'
Heatsink Temp Sensor
8
T'
8
CBL207
177G0509
D1 D2 D3 -SCR
-
-
CBL213
177G2550
e30bd959.11
Illustration 13.21 Block Diagram, F10–F13 Rectifier with 1 Soft Charge Circuit
MG90K502
MG90K502
HEAT SINK/DOOR
FAN TRANSFORMER
Block Diagrams
TO CABINET DOOR FAN/

TRx
INDUCTOR CABINET FAN
WHT
44-pin Panel Mount Connector P2 RED P4

P6 2 3 1
20 1
P7 P3
TO OPTION AND 2 3 1 8-PIN
P1 TO INVERTER DC-LINK
177G0753 INVERTER CABINETS NOT USED
J2 TEST CONNECTOR 6-PIN
14-PIN 16-PIN
43
1
30-pin Panel Mount Connector 2 3 4 5 6 8 5 4 3 1
8 1 7 6 2
6 7 5 11 10 3
6 7 5 1 8 10 3 8 7 6 11 10 9
11 1 2 3 4 5 6 8 7 6 5 4 3 2 1
Fu1 (15A)
29 1 BLK WHT BLK WHT BLK RED
RED WHT RED
WHT BLK
BLK RED
WHT WHT BLK WHT CBL304
RED BLK
FK103
FK103
FK103
FK103
Pin 101
RFI SWITCH
Pin 100
Pin 103
Pin 102
TEMP SWITCH/SCR Disable CBL302 Fu1 (15A) BLK

CBL300 177G0512
CBL3xx WHT
177G0514 177G0527 HEAT SINK FAN
WHT
CBL303 177G2801 WHT
BLK 1 1
CBL301
1
1 3 3
2
9
2
7
8
2 4
3
5
6
5 6
4
1
11
13
10
15
12
16
14
1 1 2 3 B A 13 11 4 5 3 12 9 16 1 8 BLK 2
2
177G0515 177G2552
C NO NC SPLICE
IV1
3
RL2
3
IU1
C
VDD
IW1
NO NC L1 L1
DET
L1 L2 L2 L1
GND
VDD
FANO
VNEG
VNEG
VNEG
VPOS
SENS
VPOS
VPOS
-DC +DC
AUX_S
AUX_T
AUX_S
AUX_T
106 104 105
CAN FANS
GRN/YEL 4 4
AUX 2 AUX 1 X2 X1
NC C NO
IV'
IU'
IW'
RELAY RELAY MK105
CUR
HF SW
RFI FAN
MK108 MK107
MK104
FK102 CURRENT MK112
SENSORS
29 MK102 C1
1
HEAT SINK
FAN CAPACITOR
POWER CARD
PCA12
MK110
177G0509
CBL307 CBL307
10 177G0509
R RED
43 5
8
FK103 S WHT
6
6
MK103 3
M AI N S
MK100 6
MK106
SCR RECTIFIER HS T BLK
1
GATE DRIVER TEMP SENSOR AuxS, AuxT RED
GND
S
TMP
R T
4
4
3 6 2 5 1 4 1 2 3 WHT
102
100
101
103
WHT WHT WHT
Service Guide
BLK BLK
CBL305 BLK BLK BLK P4 pin5
2
2
WHT
177G0502 P4 pin6 R' S' T' 177G2856 CBL308
CBL306 P4 pin 4 RED R +SCR A
MK2
177G0511 P4 pin 3
1
1
MK3
WHT S -SCR C
MK1
+
+
SOFTCHARGE -SCR - +SCR

BLK T
BOARD 1
3
3
SCR1 SCR2 SCR3 +SCR PCA16 RS+ A

BLK BLK BLK R1
MK4
RS- B
1 2
WHT
11
11
WHT WHT
P5
12-PIN
1 2
177G0506
9
9
CBL309
7
7
CBL310
R 1900800
5
5
TH1
HEATSINK NTC
12
12
S
10
10

T Heatsink Temp Sensor
8
8
RED
WHT
BLK
R' S' T' CBL311 177G2856

RED
R +SCR A
MK2
WHT
MK3
S -SCR C
MK1
+
BLK -SCR - +SCR

D1 D2 D3 -SCR T SOFTCHARGE
- BOARD 2
- RS+ A
PCA18 R3
MK4
RS- B
BLK
CBL313
177G0506
CBL312
177G0504
e30bd960.11
Illustration 13.22 Block Diagram, F10–F13 Rectifier with 2 Soft Charge Circuits
217
13 13
13 13
218
Block Diagrams
TO CUSTOMER AUX RELAY TERMINALS TO FAN AUTOTRANSFORMER TO RECTIFIER MODULE

TO MDCIC BOARD TEST CONNECTOR USED 16-Pin 10-Pin 8-Pin
3 5 10 4 8 7 6 9 2 1
8 7 1 4 3 6 2 5
8 7 6 11 10 9 3 5 10 4 8 7 6 9 2 1
8 7 1 4 3 6 2 5
44-pin Panel 30-pin Panel P3
Mount Connector Mount Connector BLK BLK RED WHT BLK
WHT BLK RED
WHT WHT
P2 BLK RED P4
P1 P6 WHT WHT Fu1 (15A) CBL404
WHT
RED BLK 177G0521
BLK
WHT
CBL402
177G0527 BLK
CBL403
177G0523 AUX FAN
1 2 3 4 5 6 13 11 4 5 3 12 9 16 1 8 6 5 4 3 2 1
CBL405 CBL405 FAN ASSEMBLY
5 10 3 8 1 6
177G0523 177G0523 177G0516
105
1
NO
AUX_S
AUX_T
AUX_S
AUX_T
R S T HEAT SINK FAN
177G0515 FANS X2 X1 102 100
C
2
AUX 2 AUX 1 103 101
104
RELAY RELAY S AUX_S T AUX_T WHT BLU 1 1
MAINS
FK102
MK107 BLK BLK 2 2
106
NC
MK112 FK103 SPLICE BRN 3 3
MK106
GRN/YEL 4 4
CBL400 CBL406
MK104
177G0514 177G0517/518
F5-F8
29 HF SWITCH
BLK
+
VDD 14 C1
HF SW
-
POWER CARD RL2 15
WHT WHT
1 PCA12 VDD 12 HEAT SINK
RFI FAN
FANO 13 FAN CAPACITOR
WHT
GND 9
SENS 10
CUR DET 11
VPOS 1
IU' IU1 2
SENSORS
CURRENT
VNEG
MK102
3
VPOS 4
MK110
IV' IV1 5
VNEG 6
VPOS 7
MK105 IW' IW1 8
VNEG 16
43 +DC -DC
MK109
A B TB3
CBL44 81 R-
BRC
BLK E2
BRC
82
BRK
MK1
R+
6 4 1
GATE DRIVE CARD
7 5 10
BRN G2
COL
PCA5 BRN
BRK
Fu2 (4A) MK106 GBP WHT BRAKE GATE
IGBT4
MK105
EXT BRAKE
1 2 6
GBP RES CARD
GATE
RESISTOR
MK102 MK103 MK104 MK100 PCA14
P5 6-Pin CONNECTIONS
EM
U V W NTC
GUP
EUP
GUP
EUP
GUP
EUP
GUP
GUN
EUP
EUN
GUN
EUN
GUP
GUN
GUN
EUP
EUN
EUN
GUP
GUN
EUP
EUN
GUN
EUN
TMP+
TMP-
1
1
1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 6 7 4 5 9 10 1 2 3
BLK
BLK E2
BRK
6 4 1
MK1
WHT G2
2
2
COL
BLK CBL408 CBL410 CBL411

190864 CBL409 BRAKE GATE
190864 190808 IGBT5
4
4
190864 RES CARD
GATE
BLK
PCA15
177G0520
EM
3
3
WHT
CBL412
190861
5
5
4 5 8 1 1 2 3 4 5 8 1 1 2 3 4 5 8 1 1 2 3
WHT UDC- UDC+
NTC1
NTC1
NTC2
EUP1
NTC1
NTC2
ELO1
EUP1
NTC2
GLO1
GUP1
ELO1
EUP1
GLO1
ELO1
GUP1
GLO1
GUP1
6
6
MK100 MK103 MK100 MK103 MK100 MK103
PCA6 PCA7 PCA8
IN
IN
IN
OUT
OUT
OUT
CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3 CUP1 GUP1 EUP1 GLO1 ELO1 CUP2 GUP2 EUP2 GLO2 ELO2 CUP3 GUP3 EUP3 GLO3 ELO3
CBL407
177G0519

+
+DC UDC+ UDC+
IU
L2 TB2
CS1
96 U
+ M -
C2 C3 C4 C5 C6 C7 C8 C9 C10
+ NTC NTC
+ NTC
- - CUP1 UP CUP2 UP CUP3 VP CUP1 VP CUP2 WP CUP3 WP CUP1 VP CUP2 WP CUP3 WP

IV
L3
CS2 97 V
A A
+ M -
B B
MK1
MK1
C C
BAL CKT
BAL CKT
UN UN VN VN WN WN VN WN WN IW
L4

+
CS3
+
IGBT1 IGBT2 IGBT3 + M -
- -
+
2
MK100
-
1
UDC- UDC-
-
-DC BLK
WHT
+
HF SWITCH
-
CBL37 177G0517/518
e30bd961.11
MG90K502
OPTION CABINET RECTIFIER CABINET INVERTER CABINET
BLK
DOOR INTERLOCK DOOR INTERLOCK DOOR INTERLOCK
Sh8, TB3 RT1 - - -
+ + +
WHT
Sh8, TB3 PS1
CBL500
BLK
MG90K502
BLK BLK WHT BLK WHT
DOOR INTERLOCKS
WHT
2 2
1 1
RED
RFI_2
Block Diagrams
- + - +
24 V DC POWER SUPPLY
PS1 RED 2
BLK
L N Rectifier, RFI_2
1
WHT
GRN/YEL 3
BLK BLK
WHT WHT
BLK WHT
1 2 3 1 2 3
1 2 3
+
-
+
-
+
-
MK1 MK1
MK1
C M FILTER
C M FILTER
C M FILTER
RFI
BLK LOCATED IN OPTIONS CABINET
MK 5
MK 7
MK 6
MK5
MK 7
MK 6
MK 5
MK 7
MK 6
BLK WHT
CBL501
X1 X2
400VA
TRANSFORMER T1 H1 H2
CBL502
BLK
FU1
6A
MK3
MK1
MK3
MK2
MK1
MK2
MK3
S
MK1
MK2
WHT
FU2 TB3 T, Sheet 6
6A
T BLK
FU3 TB3 S, sheet 6
6A
S WHT
FU4
6A DIFF. MODE DIFF. MODE DIFF. MODE
Service Guide
T FILTER FILTER FILTER

FU-DISC
4-POLE
FUSIBLE
FU3 RED WHT
DISCONNECT
TB2
R2
DISCONNECT 2
91-2
L1-2
FU1 R
92-2 FU2 S TO RECTIFIER CABINET

S2
L2-2
FU3 T
93-2 Aux 1
T2
23 MAINS FUSES
L3-2
GND 94-2 24

Aux 2
RED 13
Aux contact
WHT 14
BLK BLK
RFI_1
2
1
CBL503 WHT Rectifier C1
WHT 2 2 2
1 1
Rectifier
CBL504 1 RFI_1
WHT Thermal Switch 140 C
TB1 3
R1 DISCONNECT 1
91-1
L1-1
FU1 R
RFI
S1 91-1 FU2 LOCATED IN OPTIONS CABINET S TO RECTIFIER CABINET
L2-1 Same as RFI Above
FU3 T
Aux 2
T1 23
93-1
L3-1 MAINS FUSES
24
GND 94-1
Aux 1
13
Aux contact
14
e30bd962.11
219
13 13
13 13
220
Block Diagrams
TB3 RT2b
TB3 PS2
PS2
BLK
WHT
PS2 -
PS2 +
BLK
WHT
PS2 PS2 RT2 RT2
- +
24 V DC POWER SUPPLY 24V CUSTOMER
TB3 POWER SUPPLY
OPTION
+24 +24b RET RETb
L N
T1 (400VA TRANSFORMER) AND FU-DISC (4-POLE FUSIBLE DISCONNECT)
CUSTOMER CONNECTION
Note: Transformer wiring is the same for all line voltages.
GRN/YEL

BLK (L)
WHT (N)
T1 X1
T1 X2

INTERNAL AND CUSTOMER POWER SUPPLIES
e30bd963.11
Illustration 13.25 Block Diagram, F10–F13 Customer 24 V Supply
MG90K502
HEATERS 230V CONFIGURATION 700VA
177G0465 TRANSFORMER
177G0466 T2* 177G0485
MG90K502
177G0966
TB3 H1
TEMP-SW 2 H-230V
177G0710 L1 177G0711
1H1 3H1 GND L1 N
660V H2 BLK
Block Diagrams
H1 TB3 H2 R R
690V N GND
230V H3 BLK
GRN
BRW
575V TB3 H3
R = 150 Ohms CONFIGURATION
BLU
GRN/YEL
FAN ASSEMBLY 177G0687
525V H4 BLK
177G1117 TB3 H4
X1 BLK
1H2 3H2 TB3 X1
FAN- L 230V
FAN+ N 177G0965 177G0965 460V H5 BLK
TB3 LT
GND PE 2H2 4H2

TB3 H5
TB3 LT
TB3 REF
TB3 GND
177G0687 400V H6 BLK
TB3 REF
TB3 H6
0V 0V H7 WHT
2H1 4H1
TB3 X4 TB3 H7
X4 230V LIGHT 115V LIGHT
177G0966
LT-230V LT-115V
REF
TB9 REF
LOCATED IN RECTIFIER CABINET: 700VA TRANSFORMER AND HEATERS
700VA
TRANSFORMER T2 177G0485
TB3 H1
HEATERS 115V CONFIGURATION
177G0465
LT-230V GND
T2 H1/T2* H1
FU-DISC FU3
T2 H7/T2* H7
T2 H6/T2* H6
T2 H3/T2* H3
T2 H2/T2* H2
H/LT 22
T2* X1
T2 X3
T2 X4/T2* X4
T2 H5/T2* H5
T2 H4/T2* H4
H/LT 14
H-115V 177G0466
4H1 4H2 660V H2 BLK
H1 TB3 H2
177G0965 177G0965
R = 150 Ohms 690V
575V H3 BLK
3H1 3H2 TB3 H3
BLK
BLK
WHT
BLK
BLK
BLK
BLK
BLK
GRN
BLK
RED
BLK
WHT
WHT
Service Guide
177G0966 177G0966
525V H4 BLK
BLK X3 TB3 H4
1H1 1H2 TB3 X3 177G0436
115V GND 22 X1 X3 X4 H7 H6 H5 H4 H3 H2 H1 S
14
177G0965 460V H5 BLK
177G0965 TB3 H5
2H1 2H2
177G0468
400V H6 BLK 177G0440
177G0687
TB3 H6 177A0023
177G0968 WHT
177G0713
TB3
L
WHT
PE
0V H7
TB3 X4 0V
TB3 H7
GND
FAN-
FAN+
REF
X4 GND 1 230V 115V REF T 400V 460V 525V 575V 660V 690V S1
WHT
LT
GRN/YEL
NOTE: CUSTOMER CONNECT
BLU
177G0687
WHT
TO CORRECT TAB
BLK
BLK
FAN ASSEMBLY
WHT
115V
177G1117
TB3 REF
CONFIGURATION

LOCATED IN RECTIFIER CABINET: TERMINAL BLOCKS
TEMP-SW 1
FU-DISC FU2
H/LT-SW 13/21
H/LT-SW 13/21
HEATERS/LIGHT SWITCH
DOOR OPEN
TEMPERATURE SWITCH 21 22
LT-115V N OR LT-230V N
H/LT-SW TB3 22
LT-115V L1 OR LT-230V L1
RED
H-115V REF OR H-230V REF
Note: Tempearture setting = 50F

Differential setting = 10F 177G0712
(Heaters will turn off at 50F+10F)

13 14
4 WHT
TEMP-SW TB3 14
1 50F DOOR CLOSED
177G0447
2
177G0967 BLK
TB3 115V OR
TB3 230V
BLK
TB3 1
LOCATED IN RECTIFIER CABINET: 115V/230V LIGHT
e30bd964.11
Illustration 13.26 Block Diagram, F10–F13 Cabinet Heater and Service Lights Option
221
13 13
13 13
222
JUMPER PRESENT IF
LOCATED IN RECTIFIER CABINET: MANUAL MOTOR STARTERS AND 30A CUSTOMER FUSE OPTION
NO OPTIONS CABINET TB2 SO1 P8 5
24V FROM PS1
TB2 SO2
WHT BLK
Block Diagrams
+ -
P9-16
P8-6
P8-1
P9-8
WHT BLK
JUMPER PRESENT IF MMS + -
MAINS AFTER TB3
30A CUSTOMER OPTION INSTALLED WITH
CONTACTOR
FUSES NO SAFE STOP OPTION SO1 SJ1 SO2 PS1 PS1 RT1 RT1 PS2 PS2 RT2 RT2 104 106 105 107
AND FUSES AND NO OPTIONS CABINET
RED (3FT1) (3FB1)
R F30A RP
CUSTOMER
WHT (3FT2) (3FB2)
S F30B SP TERMINALS
BLK (3FT3) (3FB3)
T F30C TP
SM1 SM2 SI2 OPT INV NEG NEGb +24 +24b RET RETb 104 106 105 107
*
WH T
WH T
B LK
177G0468
* 177G0440
177A0023
177G0713
177G0974
WHT
SPLICE
WHT 10 177G0467
MMS2
P8
TB2 24+
TB2 NEG
177G0969 FUSES MMS1 MMS1

RED (2FB1) (2FT1) (L1) BLK BLK
R FXA JUMPER PRESENT
WHT (2FB2) (2FT2) (L2) (55) (56) (44) (43)
S FXB 177G0974 IF NO MMS OPTION
WHT
O.L AUX
BLK (2FB3) (2FT3) (L3)
T FXC MMS1
MMS2 RED
FUSES (2FT1) (L1)
MAINS AFTER MMS2 (2FB1)
BLK MAINS AFTER R FXA
CONTACTOR WHT (2FB2) (2FT2) (L2)
CONTACTOR S FXB
AND FUSES (55) (56) (44) (43)
AND FUSES BLK (2FB3) (2FT3) (L3)
O.L AUX T FXC
MMS2 MDCIC MK111 177G0969
PIN 6
WHT
2.5-4.0A 178N0149
P9 16 WHT S12 S22 Y6
4.0-6.3A 178N0149 A1 Y4 S11 S34

6.3-10A T3 T1 MMS1
10-16A PILZ
T2 PNOZ E1.1P
2.5-4.0A
POWER
T3 T1
CH.1
4.0-6.3A
CH.2
T2
6.3-10A
CUSTOMER T2 MDCIC MK111 10-16A
SUPPLIED AC T3 T1 PIN 8 A2 S35 S36 Y32
WHT
178N0149
MOTOR 1 14 24 S21 Y5
*
PILZ_STO CUSTOMER T2
178N0082 SUPPLIED AC T3 T1
178N0149
MMS: 177G0449-2/177G0450-2/177G0451-2/177G0452-2
BLK
*Note 1: There are only 2 combinations: FUSE: 177G0703/177G0704/177G0705/177G0706/177G0707/177G0708 MOTOR 2

RED
2 manual motor starters, or 1 manual motor starter 177G0454-2

P9 8
177G0455-2
and the 30A customer fuse terminals.
PIN 10
177G0694-2
*Note 2: The Pilz relay for STO is a standard component for FC 302
drives in this enclosure size, as well as FC 102 and FC 202 with
MDCIC MK111
Safe Stop option. It is not present for FC 102 and FC 202 drives
without Safe Stop option. Instead, jumper (178N0167) is
inserted on the MDCIC, connector MK111.
e30bd965.11
Illustration 13.27 Block Diagram, F10–F13 Manual Motor Starter/30 A Customer Fuse Terminal
MG90K502
MG90K502
LOCATED IN INVERTER CABINET: NAMUR TERMINALS, CONTROL CARD, MCB 112, MCB 113 MCB 113 EXTENDED I/O
X45
TB7 60
Block Diagrams
TB7 TB7 61
NAMUR TERMINALS TB7 62
TB8
1 2 3 4
TB7 63
X58
AUX RELAYS 1& 2
1
CUSTOMER SUPPLIED 24V RET CONTROL CARD PIN 20
01 02 03 04 05 06
1 2
1
X46
1
TB7 10
2
CUSTOMER SUPPLIED 24V
3
3
TB7 11
01 02 03 04 05 06
3
3
TB7 12
3
MCA 113 PIN X46/1 TB7 13
TB7 30
TB7 31
TB7 32
TB7 33
MCA 113 PIN X46/3

MCA 113 PIN X46/5 TB7 14
MCA 113 PIN X46/7

FC X02
TB7 15
MCA 113 PIN X46/9
ANALOG I/O
MCA 113 PIN X46/11 TB7 16
RS-485
1 2 3 4 5 6 7 8 9 10 11 12 13 14
MCA 113 PIN X46/13
61 61 61 X47
S + - 39 42 5053 54 55
MCA 113 PIN 12 1 2 7
3 4 5 6 8 9 10 11 12
TB7 51
CONTROL CARD PIN 37
TB11 PIN 01 TB7 50
DIGITAL INPUTS
TB11 PIN 02 TB7 34
TB7 36
TB7 35
TB7 37
TB7 39
TB7 38
TB7 40
TB7 42
TB7 41
12 13 18 19 27 29 32 3320 37
TB11 PIN 04
Service Guide
TB11 PIN 05
ID NAME Setup 1 Setup 2 Setup 3 Setup 4
MCB 113 PIN X47/1
MCB 113 PIN X47/3 315 Reference Resource 1 Analog Input 53 Analog Input 53 Analog Input 53 Analog Input 53
316 Reference Resource 2 Digital pot.meter Digital pot.meter Digital pot.meter Digital pot.meter
MCB 113 PIN X47/2
317 Reference Resource 3 No function No function No function No function
MCB 113 PIN X47/4 391 Ramp Time 5 5 5 5
TB7 1
TB7 18
410 Motor Speed Direction Both Directions Both Directions Both Directions Both Directions

MCB 113 PIN X47/9 514 Terminal 32 Digital Input PTC Card 1 PTC Card 1 PTC Card 1 PTC Card 1
MCB 112 PTC
MCB 113 PIN X47/8 519 Terminal 37 Safe Stop PTC & Safe Stop Alarm PTC & Safe Stop Alarm PTC & Safe Stop Alarm PTC & Safe Stop Alarm
520 Terminal X46/1 Digital Input Start Latched Start Latched Start Latched Start
CONTROL CARD PIN 53 521 Terminal X46/3 Digital Input Stop Inverse Stop Inverse Stop Inverse Stop Inverse
PTC T1
PTC T2
NC
NC
NC
NC
NC
NC
NC
LOGIC OUT
SAFETY STOP
LOGIC COM
CONTROL CARD PIN 55 522 Terminal X46/5 Digital Input DigiPot Increase DigiPot Increase DigiPot Increase DigiPot Increase
1 2 3 4 5 6 7 8 9 10 11 12 DigiPot Decrease DigiPot Decrease DigiPot Decrease DigiPot Decrease
523 Terminal X46/7 Digital Input
MCB 113 PIN X45/1 Reset Reset Reset
524 Terminal X46/9 Digital Input Reset

MCB 113 PIN X45/2 525 Terminal X46/11 Digital Input Coast Inverse Coast Inverse Coast Inverse Coast Inverse
526 Terminal X46/13 Digital Input Reversing Reversing Reversing Reversing
MCB 113 PIN X45/3
540.0 Function Relay Drive Ready Drive Ready Drive Ready Drive Ready
VLT Running
TB7 17
MCB 113 PIN X45/4 540.1 Function Relay VLT Running VLT Running VLT Running
540.2 Function Relay Alarm Alarm Alarm Alarm
TB7 90
TB7 91
MCB 112 PIN 1
540.3 Function Relay Reverse Reverse Reverse Reverse
3 10 11 12 13 14 15 16 17 18 30 31 32 33 34 35 36 37 38 39 40 41 42 50 51 60 61 62 63 90 91
10 11 12 13 14 15 16 17 18 30 31 32 33 34 35 36 37 38 39 40 41 42 50 51 60 61 62 63 90 91
MCB 112 PIN 2 540.4 Function Relay Run on ref/no warn Run on ref/no warn Run on ref/no warn Run on ref/no warn
612 Terminal 53 Low Current 4 4 4 4
670 Terminal X45/1 Output Output frequency Output frequency Output frequency Output frequency
177G0469 Motor current
680 Terminal X45/3 Output Motor current Motor current Motor current
177G0440
177G0441
177G0713
177G0467
e30bd966.11
Illustration 13.28 Block Diagram, F10–F13 NAMUR Terminals
223
13 13
13 13
224
Block Diagrams
10-PIN PANEL MOUNT CONNECTOR
16-PIN PANEL MOUNT CONNECTOR

e30bd967.11
Illustration 13.29 Block Diagram, F10–F13 Pilz Relay No Contactor
MG90K502
MG90K502
LOCATED IN OPTION CABINET: INSULATION RESISTANCE MONITORING DEVICE OR RESIDUAL CURRENT MONITORING DEVICE (BENDER) LOCATED IN RECTIFIER CABINET
Block Diagrams
B1 OR B2 MAY BE INSTALLED, NOT BOTH. JUMPER PRESENT IF

NO OPTIONS CABINET
TB2 24+b
TB2 NEGb
TB2 S02 WHT
PS1 +
PS1-
BLK
WHT
P9-8
P8-1
P9-16
P8-6
BLK
GROUND BAR
GROUND BAR
TB2 S01
BLK
*
WHT
WHT BLK
+ -
k1 I FC-X02 13 + -
A1/+ A2/-
SO1 SJ1 SO2 PS1 PS1 RT1 RT1 PS2 PS2 RT2 RT2 104 106 105 107
TB2 24+b
TB2 NEGb
177G1012
BENDER 177G0468
RCMS460-D-1 177G0440
R S
177G0445
C11 C12 k1 I 177G0446 177G0441
A1/+ A2/- L1 L2 KE 177G0713
177G0467
TB6 BENDER OR B1 SM1 SM2 SI2 OPT INV NEG NEGb +24 +24b RET RETb 104 106 105 107
IRDH275B-427
11 12
R S
BLK
WHT
TB3
W120 I
JUMPER
TB2 SO2
TB2 SO1
W120 k1
B2
PRESENT
R
Service Guide
W120 IF NO MMS
TB2 24+
TB2 NEG
FC-X02 37
RS BUS BARS
NEAR INPUT
TB2 SO2
TB2 SO1
BUS BARS *Note: W120 required for use with Bender RCMS460-D-1. W120
should be installed on mains cables R, S, and T near the input bus bars.
W120 not supplied by Danfoss.
TB3 SO2
TB3 SO1
TB3 OPT
TB3 NEG
SO1 SO2 24+ NEG

177G0468
177G0440
177A0023
TB2 177G0713
177G0467
SO1 SO2 24+ b NEGb
B1 or B2 12
B1 or B2 11
B1 or B2 A2/-
B1 or B2 A1/+
e30bd968.11
225
13 13
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to
products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed. All trademarks in this material are property
of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
Danfoss A/S
Ulsnaes 1
DK-6300 Graasten
vlt-drives.danfoss.com
130R0364 MG90K502 07/2019
*MG90K502*

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ENGINEERING TOMORROW

4 Operator Interface and Drive Control 31

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 1

4.2.3 Parameter Settings 34

5 Internal Frequency Converter Operation 43

2 Danfoss A/S © 07/2019 All rights reserved. MG90K502

6.5.4 Incorrect Motor Operation 56

7 Frequency Converter and Motor Applications 71

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 3

8.6.6 Fan Continuity Test 6 92

9 Special Test Equipment 101

10 Top-level Component Disassembly/Reassembly 105

4 Danfoss A/S © 07/2019 All rights reserved. MG90K502

11 Module Disassembly/Reassembly 133

12 Power-dependent Specifications 174

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 5

12.2.6 FC 302, 525–690 V 191

13 Block Diagrams 196

6 Danfoss A/S © 07/2019 All rights reserved. MG90K502

1.1 Purpose • The VLT® AQUA Drive FC 202, 110–1400 kW

The guide provides the following information:

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 7

1 1 1.3 Abbreviations 1.4 Conventions

ACP Application control processor - Cross-reference.

ESD Electrostatic discharge • An asterisk (*) indicates default setting of a

UM,N Nominal motor voltage

Table 1.1 Abbreviations

8 Danfoss A/S © 07/2019 All rights reserved. MG90K502

1.6 General Torque Tightening Values 1 1

Shaft Torx/hex Class A Class B

Table 1.4 Torque Values Standard Thread

Shaft Torx drives Class A Class B

Table 1.5 Torque Values for Thread-cutting into Metal

Shaft Torx drives Class A Class B

Table 1.6 Torque Values for Thread-forming into Plastic

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 9

10 Danfoss A/S © 07/2019 All rights reserved. MG90K502

Table 2.1 Discharge Time WARNING

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 11

2.5 Electrostatic Discharge

Many electronic components within the frequency

12 Danfoss A/S © 07/2019 All rights reserved. MG90K502

3.1 Product Overview For example, T4 for FC 102 and FC 202

VLT® AutomationDrive series frequency converters are 1 2 3 4 5

applications and incorporate a wide range of control and

3.2 Service Report CAUTION:

Report the serial number (S/N) of the frequency converter

1a Product group and frequency converter

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 13

3.3.1 T4 (380–480 V AC) Voltage Rating

Power FC Enclosure Enclosure size with

3.3.2 T5 (380–500 V AC) Voltage Rating

Power FC Enclosure Enclosure size with

14 Danfoss A/S © 07/2019 All rights reserved. MG90K502

3.3.3 T7 (525–690 V AC) Voltage Rating

Power FC Enclosure Enclosure size with

Power FC Enclosure Enclosure size with

MG90K502 Danfoss A/S © 07/2019 All rights reserved. 15

3.4 Exploded Views, F1–F4 Enclosures