Service Manual: VLT HVAC Basic Drive FC 101

MAKING MODERN LIVING POSSIBLE
Service Manual
VLT® HVAC Basic Drive FC 101
Contents VLT® HVAC Basic Drive Service Manual
Contents
1 Introduction 6
1.1 Purpose 6
1.2 Product Overview 6
1.3 Safety 6
1.4 Electrostatic Discharge (ESD) 6
1.5 Tools Required 9
1.6 Electrical Installation in General 10
1.7 Exploded Views – H Frame Size 11
1.8 Exploded Views - I Frame Size 14
1.9 Ratings Tables 17
1.9.1 Short Circuit and Over-current Trips 17
1.9.2 DC Voltage Levels 17
2 Frequency Converter Control 18

2.1 Introduction 18
2.2 Status Messages 18
2.3 Frequency Converter Inputs and Outputs 18
2.3.1 Input signals 18
2.3.2 Output Signals 19
2.4 Service Functions 19
2.5 Control Terminals 19
2.6 Control Terminal Functions 20
2.7 Earthing Shielded Cables 22
3 Internal Frequency Converter Operation 23

3.1 General 23
3.2 Description of Operation 23
3.2.1 Logic section 23
3.2.2 Logic to Power Interface 24
3.2.3 Power Section 24
3.3 Sequence of Operation 24
3.3.1 Rectifier Section 24
3.3.2 Intermediate Section 26
3.3.3 Inverter Section 28
3.3.4 Fan Speed Control 30
4 Troubleshooting 31
4.1 Troubleshooting Tips 31
4.2 Exterior Fault Troubleshooting 31
4.3 Fault Symptom Troubleshooting 31
MG90X202 - VLT® is a registered Danfoss trademark 1

4.4 Visual Inspection 32

4.5 Fault Symptoms 33
4.5.1 No Display 33
4.5.2 Intermittent Display 33
4.5.3 Display (Line2) Flashing 33
4.5.4 WRONG or WRONG LCP Displayed 33
4.5.5 Motor Will Not Run 33
4.5.6 Incorrect Motor Operation 34
4.6 Warnings and Alarms 34
4.6.1 Alarms 34
4.6.2 Warnings 35
4.6.3 Warning And Alarm Messages 35
4.7 After Repair Tests 39
5 Frequency Converter and Motor Applications 41

5.1 Torque Limit, Current Limit, and Unstable Motor Operation 41
5.1.1 Overvoltage Trips 41
5.1.2 Mains Phase Loss Trips 41
5.1.3 Control Logic Problems 42
5.1.4 Programming Problems 42
5.1.5 Motor/Load Problems 43
5.2 Internal Frequency Converter Problems 43
5.2.1 Current Sensor Faults 43
5.2.2 Signal and Power Wiring Considerations for Electromagnetic Compatibility 43
5.2.3 Effect of EMI 43
5.2.4 Sources of EMI 44
5.2.5 EMI Propagation 44
5.2.6 Preventive Measures 45
6 Test Procedures 46
6.1 Non-repairable Units 46
6.2 Introduction 48
6.3 Static Test Procedures 48
6.3.1 Pre-requisite 48
6.3.2 Rectifier Circuit Test 49
6.3.3 Inverter Section Tests 49
6.3.4 Intermediate Section Tests 50
6.3.5 Location of UDC Terminals 50
6.4 Dynamic Test Procedures 52
6.4.1 No Display Test (Display is Optional) 53
6.4.2 Input Voltage Test 53
2 MG90X202 - VLT® is a registered Danfoss trademark

6.4.3 Basic Control Card Voltage Test 53

6.4.4 Input Imbalance of Supply Voltage Test 54
6.4.5 Input Waveform Test 54
6.4.6 Output Imbalance of Motor Supply Voltage Test 55
6.4.7 Input Terminal Signal Tests 55
6.5 Initial Start Up Or After Repair Drive Tests 56
7 H-Frame Size Disassembly and Assembly Instructions 57

7.1 Electrostatic Discharge (ESD) 57
7.2 General Disassembly Procedure 57
7.3 H6 Frame Size Disassembly and Assembly Instructions 57
7.3.1 Control Card and Control Card Mounting Plate 57
7.3.2 Heatsink Fan Assembly 58
7.3.3 DC Coil 59
7.3.4 DC Link Card 59
7.3.5 RFI Filter 60
7.3.6 Power Card 60
7.4.2 Power Card 62
7.4.3 Inrush Card 62
7.4.4 RFI Filter 63
7.4.5 Relay Transducer Card 63
7.4.6 Rectifier Modules 64
7.4.7 IGBT 64
7.4.9 DC Coil 65
7.4.10 Capacitor Bank 66
7.5.2 Power Card 67
7.5.5 RFI Filter 69
7.5.7 IGBT 70
7.5.9 DC Coil 72

7.6.2 Power Card Cover 73

7.6.3 Power Card 74
7.6.4 Heatsink and DC Coils 74
8 I-Frame Size Disassembly and Assembly Procedures 76

8.1 General Disassembly Procedure 76
8.2 I6 Frame Size Disassembly and Assembly Instructions 76
8.2.2 Cable Mounting Plate 77
8.2.4 SMPS Card 78
8.2.5 Bus Bar Unit 78
8.2.6 Power Card 79
8.2.7 DC Coil 79
8.2.8 RFI Filter 80
8.3 I7 Frame Size Disassembly and Assembly Instructions 80
8.3.2 Power Card 81
8.3.3 Power Card Mounting Plate 82
8.3.5 Bus Bar 83
8.3.6 RFI Filter 83
8.3.8 Fan 84
8.3.9 Terminal Plate 85
8.3.10 DC Bus Bar Assembly 85
8.3.13 DC Coil 87
8.3.14 IGBT 87
8.3.15 Thyristor 88
8.4 I8 Frame Size Disassembly and Assembly Procedure 88
8.4.2 Power Card 89
8.4.3 Power Card Mounting Plate 90
8.4.5 Bus Bar 91
8.4.6 RFI Filter 91
8.4.8 Terminal Plate 92

8.4.9 DC Bus Bar Assembly 93

8.4.12 DC Coil 94
8.4.13 IGBT 95
8.4.14 Thyristor 95
9 Block Diagrams 96
9.1.1 H6 Frame Size 96
9.1.2 I6 Frame Size 97
9.1.3 H7, H8, I7, I8 Frame Size 98
Index 101

Introduction VLT® HVAC Basic Drive Service Manual
1 1 1 Introduction
1. DO NOT touch electrical parts of the frequency

converter when connected to mains. Also make
1.1 Purpose sure that other voltage inputs have been discon-
This manual provides detailed technical information and nected (linkage of DC intermediate circuit). Be
instructions to enable a qualified technician to identify aware that there may be high voltage on the DC
faults and perform repairs on H and I frames frequency link even when the LEDs are turned off. Before
converters. touching any potentially live parts of the
frequency converter, wait at least as stated in
Table 1.1.
It provides the reader with a general view of the unit's
main assemblies, and a description of the internal 2. Before conducting repair or inspection,
processing. This information gives technicians a better disconnect mains.
understanding of the frequency converter's operation to 3. [Off] on the LCP does not disconnect mains.
assist in troubleshooting and repair.
4. During operation and while programming
parameters, the motor may start without warning.
This manual provides instructions for the frequency
Press [Stop] when changing data.
converter models and voltage ranges described in Table 1.2
to Table 1.4. 5. When operating on a PM motor, disconnect
motor cable.
1.2 Product Overview Voltage [V] Power Range [kW]

Minimum waiting
time [min]
FC 101 frequency converters are designed for the Heating, 3x200 0.25–3.7 4
Ventilation, and Air-Conditioning (HVAC) markets. They 3x200 5.5–11 15
operate in variable torque mode, and include features
3x400 0.37–7.5 4
suited for fan and pump applications within the HVAC
3x400 11–90 15
market.
3x600 2.2–7.5 4
3x600 11–90 15
1.3 Safety
Table 1.1 Discharge Time
CAUTION
Frequency converters contain dangerous voltages when 1.4 Electrostatic Discharge (ESD)
connected to mains. Only a trained technician should carry
out the service. See also warnings in 2.1 Introduction.
CAUTION
When performing service, use proper Electrostatic
CAUTION Discharge (ESD) procedures to prevent damage to sensitive
components.
For dynamic test procedures, main input power is required
and all devices and power supplies connected to mains are
energized at rated voltage. Take extreme caution when Many electronic components within the frequency
conducting tests in a powered frequency converter. converter are sensitive to static electricity. Voltages so low
Contact with powered components could result in that they cannot be felt, seen, or heard can reduce the life,
electrical shock and personal injury. affect performance, or completely destroy sensitive
electronic components.

1.4.1 Frame Size Definitions 1 1

Model HP @200–240 V AC kW @200–240 V AC Frame Size IP Rating Repairable Yes/No
PK25 0.33 0.25 H1 IP20 No
PK37 0.5 0.37 H1 IP20 No
PK75 1.0 0.75 H1 IP20 No
P1K5 2.0 1.5 H1 IP20 No
P2K2 3.0 2.2 H2 IP20 No
P3K7 5.0 3.7 H3 IP20 No
P5K5 7.5 5.5 H4 IP20 No
P7K5 10.0 7.5 H4 IP20 No
P11K 15.0 11.0 H5 IP20 No
P15K 20.0 15.0 H6 IP20 Yes
P18K 25.0 18.5 H6 IP20 Yes
P22K 30.0 22.0 H7 IP20 Yes
P30K 40.0 30.0 H7 IP20 Yes
P37K 50.0 37.0 H8 IP20 Yes
P45K 60.0 45.0 H8 IP20 Yes
Table 1.2 FC 101 Frequency Converters 200-240 V AC

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

PK37 0.5 0.37 H1 IP20 No
PK75 1.0 0.75 H1 IP20 No
P1K5 2.0 1.5 H1 IP20 No
P2K2 3.0 2.2 H2 IP20 No
P3K0 4.0 3.0 H2 IP20 No
P4K0 5.0 4.0 H2 IP20 No
P5K5 7.5 5.5 H3 IP20 No
P7K5 10.0 7.5 H3 IP20 No
P11K 15.0 11.0 H4 IP20 No
P15K 20.0 15.0 H4 IP20 No
P18K 25.0 18.0 H5 IP20 No
P22K 30.0 22.0 H5 IP20 No
P30K 40.0 30.0 H6 IP20 Yes
P37K 50.0 37.0 H6 IP20 Yes
P45K 60.0 45.0 H6 IP20 Yes
P55K 70.0 55.0 H7 IP20 Yes
P75K 100.0 75.0 H7 IP20 Yes
P90K 125.0 90.0 H8 IP20 Yes
PK75 1.0 0.75 I2 IP54 No
P1K5 2.0 1.5 I2 IP54 No
P2K2 3.0 2.2 I2 IP54 No
P3K3 4.0 3.3 I2 IP54 No
P4K0 5.0 4.0 I2 IP54 No
P5K5 7.5 5.5 I3 IP54 No
P7K5 10.0 7.5 I3 IP54 No
P11K 15.0 11.0 I4 IP54 No
P15K 20.0 15.0 I4 IP54 No
P22K 25.0 18.0 I4 IP54 No
P11K 15.0 11.0 I5 IP54 No
P15K 20.0 15.0 I5 IP54 No
P22K 25.0 18.0 I5 IP54 No
P22K 30.0 22.0 I6 IP54 Yes
P30K 40.0 30.0 I6 IP54 Yes
P37K 50.0 37.0 I6 IP54 Yes
P45K 60.0 45.0 I7 IP54 Yes
P55K 70.0 55.0 I7 IP54 Yes
P75K 100.0 75.0 I8 IP54 Yes
P90K 125.0 90.0 I8 IP54 Yes
Table 1.3 FC 101 Frequency Converters 380-480 V AC

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

P2K2 3.0 2.2 H9 IP20 No
P3K0 4.0 3.0 H9 IP20 No
P5K5 7.5 5.5 H9 IP20 No
P7K5 10.0 7.5 H9 IP20 No
P11K 15.0 11.0 H10 IP20 Yes
P15K 20.0 15.0 H10 IP20 Yes
P22K 30.0 22.0 H6 IP20 Yes
P30K 40.0 30.0 H6 IP20 Yes
P45K 60.0 45.0 H7 IP20 Yes
P55K 70.0 55.0 H7 IP20 Yes
P75K 100.0 75.0 H8 IP20 Yes
P90K 125.0 90.0 H8 IP20 Yes
Table 1.4 FC 101 Frequency Converters 525–600 V AC
1.5 Tools Required

Quick Guide for HVAC Basic Drive, MG18A.
ESD Protection Kit Wrist strap and Mat

Metric socket set 7 to 19 mm
Socket extensions 100 to 150 mm (4 in and 6 in)
Torx driver set T10-T50
Needle nose pliers
Magnetic sockets
Ratchet
Screwdrivers Standard and Philips
Table 1.5 Required Tools
Additional Tools Recommended for Testing

• Digital voltmeter/ohmmeter (must be rated for
1000 V DC for 600 V units)
• Analog voltmeter
• Oscilloscope
• Clamp-on style ammeter

1 1 1.6 Electrical Installation in General

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

Frame IP class 3x200-240 V 3x380-480 V Line Motor DC Control Earth Relay
connection terminals
H1 IP20 0.25-1.5 0.37-1.5 1.4 0.8 0.8 0.5 0.8 0.5
H2 IP20 2.2 2.2-4 1.4 0.8 0.8 0.5 0.8 0.5
H3 IP20 3.7 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
H4 IP20 5.5-7.5 11-15 1.2 1.2 1.2 0.5 0.8 0.5
H5 IP20 11 18.5-22 1.2 1.2 1.2 0.5 0.8 0.5
H6 IP20 15-18 30-45 4.5 4.5 - 0.5 3 0.5
H7 IP20 22-30 55 10 10 - 0.5 3 0.5
H7 IP20 - 75 14 14 - 0.5 3 0.5
H8 IP20 37-45 90 242 242 - 0.5 3 0.5
Table 1.6

Frame IP class 3x380-480 V Line Motor DC connection Control Earth Relay
terminals
I2 IP54 0.75-4.0 1.4 0.8 0.8 0.5 0.8 0.5
I3 IP54 5.5-7.5 1.4 0.8 0.8 0.5 0.8 0.5
I4 IP54 11-18.5 1.4 0.8 0.8 0.5 0.8 0.5
I5 IP54 11-18.5 1.8 1.8 - 0.5 3 0.6
I6 IP54 22-37 4.5 4.5 - 0.5 3 0.6
I7 IP54 45-55 10 10 - 0.5 3 0.6
I8 IP54 75-90 14/241 14/241 - 0.5 3 0.6
Table 1.7

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

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

1.7 Exploded Views – H Frame Size 1 1

NOTE
Non-repairable units are not shown with exploded views.
130BC341.10
13 14
12
11
10
9
7 15
3
4
2
6
5
16
17
1 18
Illustration 1.1 Exploded View - H6 Frame Size
1 Blind cover 10 Filter protection cover

2 Front cover LCP 11 RFI filter
3 Cradle 12 EMC shield
4 Control card 13 Bus bar unit
5 Control card mounting plate 14 Heatsink fan assembly
6 DC coils 15 Connector
7 Coil mounting plate 16 DC coil cover
8 Coil mounting plate 17 Capacitor bank metal cover
9 DC link card 18 Capacitor vibration support
Table 1.9

1 1 17 18
130BC342.10
14 16
15
12 19
13
11
9 10 20
8
7
3 5 22
21
6
4
2
23
24
1 Blind cover 13 Relay/transducer card mounting plate

2 LCP 14 DC coil cover plate
3 Front cover 15 Bus bar
4 EMC shield 16 Plastic cover
5 Cradle 17 Rectifier modules
6 Control card 18 Heatsink fan assembly
7 Control card mounting plate 19 DC coils
8 Power card 20 Capacitors
9 Power card mounting plate 21 Bottom plate
10 RFI filter 22 Relay/transducer card
11 EMC shield 23 IGBT
12 Inrush card 24 Cable mounting plate
Table 1.10

1 1
130BC214.11
19
18
20
17
16
15
14
21
13
12
11
22
10
7
6
5
2
3
1
4
1 LCP 12 SMPS card

2 Front cover 13 Cable mounting plate
3 Cradle, control card and mounting plate 14 IGBT
4 EMC shield 15 Relay/transducer card mounting plate
5 Power card 16 Relay/transducer card
6 Power card mounting plate 17 Bus bar
7 Support bracket 18 Rectifier modules
8 Plastic cover 19 Heatsink fan assembly
9 RFI filter 20 Capacitors
10 DC coil cover plate 21 Bottom cover
11 Bus bar unit 22 Connection terminals
Table 1.11

1 1
1.8 Exploded Views - I Frame Size
130BC046.11
10
7 9
8
5
6
4
2 3
13
14 12
15
11
16
Illustration 1.4 Exploded View - I6 Frame Size
1 Local Control Panel (LCP) 9 DC coil

2 Front cover 10 Heatsink
3 Cradle 11 Fan assembly
4 Control card 12 Cable mounting plate
5 Control card mounting plate 13 RFI filter
6 Fan 14 Connectors
7 Bus bar unit 15 EMC shield
8 Power card 16 Cable entry
Table 1.12

1 1
130BC215.11
16
15
14
13
12
17
11
10
9 18
8
19
7
20
6 21
5
4
3
22
2
1
23
24
25
1 Local Control Panel (LCP) 14 DC coil

2 Front door 15 Thyristors
3 Cradle 16 Back plate
4 Control card 17 IGBT
5 Control card mounting plate 18 Capacitor
6 Terminal plates 19 Heatsink fan
7 Support bracket 20 Bus bar unit
8 RFI filter 21 Relay/transducer card
9 Inrush card 22 Relay card mounting plate
10 Terminal connectors 23 Power card
11 Cable mounting plate 24 Power card mounting plate
12 Bus bar 25 Cable entry
13 Bracket
Table 1.13

1 1
130BC216.11
11
10
6 7 8
2 4 5
3 12
1
14
13
18
16 15
17
19
1 LCP 11 DC coil
2 Front cover 12 Rectifier modules
3 Cradle 13 IGBTs
4 LCP gasket 14 Capacitors
5 Control card 15 Heatsink fan assembly
6 Control card mounting plate 16 Fan
7 Support bracket 17 Cable mounting plate
8 RFI filter 18 Relay/transducer card with mounting plate
9 Power Card 19 Cable entry
10 Power card mounting plate
Table 1.14

1.9 Ratings Tables 1 1

1.9.1 Short Circuit and Over-current Trips
The frequency converter is protected against short circuits inverter turns off the IGBTs individually when the short
with current measurement in each of the three motor circuit current exceeds the permitted value (Alarm 16 Trip
phases or in the DC link. A short circuit between two Lock).
output phases causes an over current in the inverter. The
1.9.2 DC Voltage Levels
200-240 V AC 380-480 V AC 525-600 V AC

H1–H5 H6–H8 H1–H5 H6–H8 H6–H10
I2–I3–I4 I5–I8
Inrush circuit enabled
Inrush circuit disabled 202 184 314 372 532
Under voltage 202 184 314 372 532
Under voltage re-enable 202+15 184+16 314+30 372+24 532+20
Over voltage 410 412 800 800 976
Over voltage re-enable 410-15 412-16 800-30 800-24 976-20
IT-Grid Turn on 410+25 412+25 800+35 800+35 976+35
Table 1.15 DC Voltage Levels

Frequency Converter Control VLT® HVAC Basic Drive Service Manual
2 Frequency Converter Control

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

control cable is run between frequency converters, and not 14-28 Production Settings and 14-29 Service Code, are the
between frequency converters and other devices. relevant service parameters.
Parameters for configuring the input and output using Parameter settings are displayed by pressing [Main Menu] 2 2
NPN and PNP. on the LCP.
These parameters cannot be changed while the motor is Use the navigation keys [▲], [▼], [►] and [◄] to scroll
running. through parameters.
2.3.2 Output Signals See the FC 101 Quick Guide, MG18A for detailed
information on accessing and displaying parameters, and
The frequency converter also produces output signals that for descriptions and procedures for service information
are carried either through the RS-485 serial bus or terminal available in parameter group 6-** Analog In/Out.
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
2.5 Control Terminals
24 V DC. In addition, a pulse reference can be provided on Control terminals must be programmed. Each terminal has
terminals 27 and 29. Output analog signals generally specific functions and a numbered parameter associated
indicate the frequency, current, torque, and so on, to an with it, see Table 2.2. The setting selected in the parameter
external controller or system. Digital outputs can be enables the function of the terminal.
control signals used to open or close a damper, or send a
start or stop command to auxiliary equipment.
It is important to confirm that the control terminal is
programmed for the correct function.
Additional terminals are Form C relay outputs on terminals
01, 02, and 03, and terminals 04, 05, and 06.
Parameter settings are displayed by pressing [Main Menu].
Terminals 12 and 13 provide 24 V DC low voltage power,

Use [▲], [▼], [►] and [◄] to scroll through parameters.
often used to supply power to the digital input terminals
(18-33). Those terminals must be supplied with power from
either terminal 12 or 13, or from a customer supplied See the HVAC Basic Drive FC 101 Quick Guide, MG18A for
external 24 V DC power source. Improperly connected details on changing parameters and the functions available
control wiring is a common service issue for a motor not for each control terminal.
operating or the frequency converter not responding to a
remote input. In addition, the input terminal must be receiving a signal.
Confirm that the control and power sources are wired to
Number of digital outputs 2 the terminal. Then check the signal.
Terminal number 42, 451)
Voltage level at digital output 17 V Signals can be checked in two ways. Digital Input can be
selected for display by pressing [Display Mode], or a
Max. output current at digital output 20 mA
voltmeter can be used to check for voltage at the control
Max. load at digital output 1 kΩ
terminal.
Table 2.1 Digital Output
1) Terminals 42 and 45 can also be programmed as analog output.
In summary, for proper frequency converter functioning,
the frequency converter input control terminals must be:
2.4 Service Functions • Wired properly
Service information for the frequency converter can be • Powered

shown in display lines 1 and 2. 24 different items can be • Programmed correctly for the intended function
accessed. Included in the data are
• counters that tabulate operating hours, etc.
• fault logs that store frequency converter status

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

2.6 Control Terminal Functions Terminal Function

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

130BB626.10
L1 U
2 2
L2 V
3 Phase
power L3 W
input
PE PE
Motor
UDC-
Not present on all power sizes
UDC+
50 (+10V OUT) relay2

+10Vdc
06
0-10Vdc- 53 (A IN) 240V AC 3A
0/4-20 mA 05
0-10Vdc- 54 (A IN) 04
0/4-20 mA
55 (COM A IN/OUT) relay1
42 0/4-20mA A OUT / DIG OUT 03
240V AC 3A
45 0/4-20mA A OUT / DIG OUT 02
Bus ter. 01
12 (+24V OUT) ON=Terminated
ON
1 2
OFF=Unterminated
18 (DIGI IN)
24V (NPN)
OV (PNP)
19 (DIGI IN)
24V (NPN)
20 (COM D IN) OV (PNP)
Bus ter.
27 (DIGI IN)
24V (NPN) RS-485 (N PS-485) 69
OV (PNP) RS-485
29 (DIGI IN) Interface
24V (NPN) (P RS-485) 68
OV (PNP) Do not connect shield to
(Com RS-485 ) 61 61 on 116,117 and 118 unites
(PNP)-Source
(NPN)-Sink
Illustration 2.1 Control Terminal Electrical Overview
Control terminals must be programmed. Each terminal has

specific functions and a numbered parameter associated
with it. The setting selected in the parameter enables the
function of the terminal. See the HVAC Basic Drive FC 101
Quick Guide, MG18A for details.

2.7 Earthing Shielded Cables

Connect the screened control cables to the metal cabinet
2 2 of the frequency converter with cable camps at both ends.
Table 2.3 shows earth cabling for optimal results.
Correct earthing Control cables and cables for serial communication must be fitted with cable
clamps at both ends to ensure the best possible electrical connection.
Incorrect earthing Do not use twisted cable ends (pigtails) since they increase screen
impedance at high frequencies.
Earth potential protection When the earth potential between the frequency converter and the
PLC or other interface device is different, electrical noise may occur that can disturb the entire
system. This can be resolved by fitting an equalizing cable next to the control cable. Minimum
cable cross section is 8 AWG.
50/60 Hz earth loops When using very long control cables, 50/60 Hz earth loops may occur
that can disturb the entire system. This can be resolved by connecting one end of the screen
with a 100 nF capacitor and keeping the lead short.
Serial communication control cables Low frequency noise currents between frequency
converters can be eliminated by connecting one end of the screened cable to frequency
converter terminal 61. This terminal connects to earth through an internal RC link. It is
recommended to use twisted-pair cables to reduce the differential mode interference between
conductors.
Table 2.3 Earthing Screened Cables

Internal Frequency Converte... VLT® HVAC Basic Drive Service Manual
3 Internal Frequency Converter Operation
A custom integrated circuit generates a pulse width

modulation (PWM) waveform, which is then sent to the
3.1 General interface circuitry located on the power card. 3 3
This section provides an operational overview of the main
assemblies and circuitry in the frequency converter.
130BC343.10
Control Card Power
3.2 Description of Operation

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

Standard I/O
into four main sections.
Digital Analog
LCP RS485
Input I/O
1. Rectifier
2. Intermediate Circuit Illustration 3.1 Logic Section
3. Inverter
4. Control and Regulation
The PWM waveform is improved through the Voltage
The main frequency converter components are grouped Vector Control Scheme, VVCplus. VVCplus provides variable
into three categories. They are: frequency and voltage to the motor matching the motor
requirements. Also available is the continuous pulsing
1. Control Logic Section SFAVM PWM. The dynamic response of the system
2. Logic to Power Interface changes to meet the variable requirements of the load.
3. Power Section
Another part of the logic section is the removable LCP or
In 3.3 Sequence of Operation, these three sections are display mounted on the front of the frequency converter.
covered in greater detail while describing how power and The LCP provides the interface between the internal digital
control signals move throughout the frequency converter. logic and the operator.
3.2.1 Logic section All programmable parameter settings can be uploaded into
the EEPROM of the LCP. This function helps in maintaining
The control card includes most of the logic section (see a back-up frequency converter profile and parameter set.
Illustration 3.2). The primary logic element of the control Its download function can be used in programming other
card is a microprocessor, which supervises and controls all frequency converters or restoring a program to a repaired
functions of frequency converter operation. In addition, a unit. The LCP is removable during operation to prevent
separate PROM contains the parameters to provide the undesired program changes. With the addition of a remote
user with programmable options. These parameters are mounting kit, the LCP can be mounted in a remote
programmed to enable the frequency converter to meet location.
specific application requirements. This data is stored in an
EEPROM providing security during power-down and also Control terminals, with programmable functions, are
allows the flexibility to change the operational character- provided for input commands such as run, stop, forward,
istics of the frequency converter. reverse and speed reference. Additional output terminals
are provided to supply signals to run peripheral devices or
for monitoring and reporting status.

The control card logic 7 V DC, 6 V DC, and 3.3 V DC operating voltage. SMPS
powers the logic and interface circuitry. SMPS is supplied
• communicates via serial link with outside devices by the DC bus voltage. The secondary SMPS provides
such as personal computers or Programmable power to the logic circuitry with main input disconnected.
Logic Controllers (PLC). It can keep units with communication options live on a
network when the frequency converter is not powered
3 3 • provides two voltage supplies for use from the
control terminals.
from the mains.
24 V DC is used for switching functions such as start, stop, Circuitry for controlling speed of the cooling fans is also
and forward/reverse. The 24 V DC supply also supplies 200 provided on the power card.
mA of power, which can partly be used to power external
encoders or other devices. A 10 V DC supply rated at 17
mA is also available for use with speed reference circuitry.
3.2.3 Power Section
The DC coil is a single unit with two coils wound on a

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

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

The logic circuitry on the control card allows for adding:
of the output to measure motor current.
• option modules for synchronizing control
130BC330.10
• serial communications Rectifier Intermediate
(SCR/Diodes) circuit
Inverter
section (IGBTs)
• additional relays
• cascade pump controller

L1 T1
• custom operating software L2 T2
L3 T3
3.2.2 Logic to Power Interface
The logic to power interface isolates the high voltage Illustration 3.2 Typical Power Section
components of the power section from the low voltage
signals of the logic section. The interface consists of two
sections.
3.3 Sequence of Operation
• Power Card
3.3.1 Rectifier Section
• Gate Driver
The control card handles much of the fault processing for Depending on size of the frequency converters, the
output short circuit and ground fault conditions. The rectifier section is built on either six or three diodes and
power card provides conditioning of these signals. Scaling three thyristors.
of current feedback and voltage feedback is accomplished
on the interface sections before processing by the control Inrush current in units with a normal 6-diode rectifier is
card. limited with a simple PTC and relay circuit.
The power card contains a Switch Mode Power Supply Phase controlling the thyristors (active inrush control)
(SMPS). The SMPS provides the unit with 24 V DC, 16 V DC, limits the inrush current in units with diodes and thyristors.

The low voltage power supplies are activated when the DC ripple voltage is present on the DC bus, the actual DC
bus reaches approximately 50 V DC less than the alarm value is closer to V ACx1.38 under unloaded conditions
voltage low for the DC bus (see rating tables in and may drop to V ACx1.32 while running under load. For
1 Introduction). After a short delay, an inrush enable signal example, a frequency converter connected to a nominal
is sent from the control card to the power card SCR gating 460 V line, while sitting idle, the DC bus voltage is approxi-
circuit. The SCRs are automatically gated when forward mately 635 V DC (460x1.38).
biased, as a result acting similar to an uncontrolled 3 3
rectifier. As long as power is applied to the frequency converter,
this voltage is present in the intermediate circuit and the
When the DC bus capacitors are fully charged, the voltage inverter circuit. It is also fed to the Switch Mode Power
on the DC bus is equal to the peak voltage of the input AC Supply (SMPS) on the power card and is used for
line. Theoretically, this can be calculated by multiplying the generating all other low voltage supplies.
AC line value by 1.414 (V ACx1.414). However, since AC
130BC134.10
Brake not connected to terminal on FC 101
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS
Motor
L2 x3 RFI _ RL 2 x3 A V
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
Tmp_ VGDS
P_BRF
7 xGD
RL 2
SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
Control Card UINV_P SAFE _ FB
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
Isol. RS 485 FAN 1 Int.
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
VGD +/- 15 /UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
”Internal Communication”
control
panel ”Internal supply bus”
Illustration 3.3 Example of H6 Power and Control Section

130BC135.10
Thyristor x3 AC / DC Brake not connected to terminal on FC 101
BR DC /AC
RFI (variations)
A
U
Motor
L1
3 3
x3
V
MAINS
A
L2 W
A
L3 o
C
RFI _RL 1 BR BR INV Temp.

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1
uC+ RL 1
Tmp_VGDS
P _BRF
7 xGD
EEP RL 2
RL 2
RFI _ RL 1
RFI _ RL 2 VDD (GND ) 24V
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB
VDD (GND) 24V Imax 2 comp.

E _FAN Level
E _FFB Shift
LCP ACP MCP Ext.

Display CAN
fans
control ”Internal supply bus”
panel
Illustration 3.4 Example of H7, H8, I7, I8 Power and Control Section
3.3.2 Intermediate Section capacitor. It also provides a current path for discharging
the capacitors once power has been removed from the
Following the rectifier section, voltage passes to the frequency converter.
intermediate section. An LC filter circuit consisting of the
DC bus inductor and the DC bus capacitor bank smooths Also located in the intermediate section is the High
the rectified voltage. Frequency (HF) filter film capacitors. These capacitors
reduce the common mode noise caused by switching into
The DC bus inductor provides series impedance to stray capacitors to earth in cable and motor.
changing current. This impedance aids the filtering process
while reducing harmonic distortion to the input AC current In some units, RFI relay 2 can be opened to minimize
waveform normally inherent in rectifier circuits. voltage charge up.
The DC capacitor bank assembly consists of up to six If DC-link increases above a certain level specified in EE-
capacitors arranged in series/parallel configuration. A prom for each unit, RFI relay 2 opens automatically.
bleeder circuit maintains equal voltage drops across each

130BC335.10
3 3
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS
Motor
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
Tmp_ VGDS
P_BRF
7 xGD
RL 2
SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
Shift
LCP ACP MCP
Display
CAN
control
Illustration 3.5 Example of H6 Intermediate Section
130BC336.10
BR DC /AC
RFI (variations)
A
U
Motor
L1 x3
V
MAINS
A
L2 W
A
L3 o
C

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1
uC+ RL 1
Tmp_VGDS
P _BRF
7 xGD
EEP RL 2
RL 2
RFI _ RL 1
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

E _FAN Level
E _FFB Shift
LCP ACP MCP Ext.

Display CAN
fans
panel
Illustration 3.6 Example of H7, H8, I7, I8 Intermediate Section

3.3.3 Inverter Section Hall effect current sensors monitor the output current and
deliver proportional signals to the power card where they
In the inverter section (see Illustration 3.8), gate signals are are buffered and delivered to the control card. The control
delivered from the control card, through the power card to card logic uses these current signals to determine proper
the gates of the IGBTs. The series connection of each set of waveform compensations based on load conditions. They
IGBTs is delivered to the output, first passing through the further serve to detect over current conditions, including
3 3 current sensors. earth faults and phase-to-phase shorts on the output.
Once a run command and speed reference are present, the During normal operation, the power card and control card
IGBTs begin switching to create the output waveform, as are monitoring various functions within the frequency
shown in Illustration 3.8. Looking at the phase-to-phase converter. The current sensors provide current feedback
voltage waveform with an oscilloscope shows that the information. The DC bus voltage and mains voltage are
Pulse Width Modulation (PWM) principal creates a series of monitored as well as the voltage delivered to the motor. A
pulses which vary in width. Basically, the pulses are thermal sensor mounted inside the sixpack IGBT module
narrower as zero crossing is approached and wider the provides heatsink temp feedback for the inverter. This
farther from zero crossing. The pulse duration of applied applies to unit up to and including H6 and I6 frame sizes.
DC voltage controls the width. Although the voltage For H7-H8 and I7-I8 frame sizes, the inverter consists of 3
waveform is a consistent amplitude, the inductance within dual IGBT modules and the thermal sensor is mounted
the motor windings serve to average the voltage delivered separately on the heatsink.
and so. As the pulse width of the waveform varies, the
average voltage seen by the motor varies as well. This then
130BX136.10
equates to the resultant current waveform which takes on
the sine wave shape expected in an AC system. The pulse
rate determines the waveform frequency waveform. By
employing a sophisticated control scheme, the frequency
converter can deliver a current waveform that nearly
replicates a true AC sine wave.
Illustration 3.7 Output Voltage and Current Waveforms
This waveform, as generated by the Danfoss VVCplus PWM
principle at the control card, provides optimal performance
and minimal losses in the motor.

130BC337.10
3 3
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS
Motor
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
Tmp_ VGDS
P_BRF
7 xGD
RL 2
SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
VCX (GX ) 5V
Tmp _VGDS
D-I /O
UINV_N VCC
A-I /O VCC (GND) 5V
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
Shift
LCP ACP MCP
Display
CAN
control
Illustration 3.8 Example of H6 Inverter Section
130BC338.10
BR DC /AC
RFI (variations)
A
U
Motor
L1 x3
V
MAINS
A
L2 W
A
L3 o
C

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1
uC+ RL 1
Tmp_VGDS
P _BRF
7 xGD
EEP RL 2
RL 2
RFI _ RL 1
Inrush
SMPS SAFE _ FB
Control Card UINV_P
Tmp _ VGDS
D-I/O
UINV_N
VCX (GX) 5V VCC
Int.
A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

E _FAN Level
E _FFB Shift
LCP ACP MCP Ext.

Display CAN
fans
panel
Illustration 3.9 Example of H7, H8, I7, I8 Inverter Section

3.3.4 Fan Speed Control
IP20 IP20
Enclosure H6 H7 H8 Enclosure H9 H10 H6 H7 H8
Voltage T2 T2 T2 T2 T2 T2 Voltage T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6 T6
3 3 Power Rating
(kW)
15 18. 5 22 30 37 45
Power
Rating 2.2 3.0 5.5 7.5 11 15 22 30 45 55 75 90
FAN start (kW)
45 45 45 45 45 45
temperature °C FAN start
FAN max speed tempera- 35 35 35 35 45 45 45 45 40 40 40 40
60 60 60 60 60 60
temperature °C ture °C
FAN stop FAN max
36 36 36 36 36 36
temperature °C speed
55 55 55 55 60 60 60 60 55 55 55 55
tempera-
Table 3.1 Fan Speed Control, IP20, H6-H8, T2 ture °C
FAN stop
IP20 tempera- 31 31 31 31 36 41 41 41 30 30 30 30
Enclosure H6 H7 H8 ture °C
Voltage T4 T4 T4 T4 T4 T4
Power Rating Table 3.4 Fan Speed Control, IP20, H9-H10 and H6-H8, T6
30 37 45 55 75 90
(kW)
FAN start
45 45 45 40 40 40
temperature °C
FAN max speed
60 60 60 55 55 55
temperature °C
FAN stop
41 41 41 30 30 30
temperature °C
Table 3.2 Fan Speed Control, IP20, H6-H8, T4
IP54
Enclosure I6 I7 I8
Voltage T4 T4 T4 T4 T4 T4 T4
Power Rating
22 30 37 45 55 75 90
(kW)
FAN start
45 45 45 40 40 40 40
temperature °C
FAN max speed
60 60 60 55 55 55 55
temperature °C
FAN stop
35 35 35 30 30 30 30
temperature °C
Table 3.3 Fan Speed Control, IP54, I6-I8

Troubleshooting VLT® HVAC Basic Drive Service Manual
4 Troubleshooting
CAUTION
4.1 Troubleshooting Tips Never assume that a motor is wired properly after a service
of the frequency converter. There is a risk of overlooking
Before repairing a frequency converter, read and
for example, loose connections, improper programming, or
understand the following instructions.
added equipment.
4 4
1. Note all warnings concerning voltages present in
It is best to develop a detailed approach, beginning with a
the frequency converter. Always verify the
physical inspection of the system. See Table 4.1 for items
presence of AC input voltage and DC bus voltage
to examine.
before working on the unit. Some points in the
frequency converter are referenced to the
negative DC bus. They are at bus potential even 4.3 Fault Symptom Troubleshooting
though it may appear on diagrams to be a
neutral reference. This troubleshooting section is divided into sections based
on the symptom being experienced. To start, Table 4.1,
CAUTION provides a visual inspection check list. Often, wrong instal-
Voltage can be present for as long as 20 minutes on lation or wiring of the frequency converter cause the
frequency converters after removing power from the unit. problem. The check list provides guidance through various
See the label on the front of the frequency converter door items to inspect during any frequency converter service
and Table 1.1 for the specific discharge time. process.
2. Never apply power to a unit that is suspected of
being faulty. Many faulty components within the Next, symptoms are approached as the technician most
frequency converter can damage other commonly discovers them: reading an unrecognized
components when power is applied. Always frequency converter display, problems with motor
perform the procedure for testing the unit after operation, or a warning or alarm displayed by the
repair as described in 4.7 After Repair Tests. frequency converter. Remember, the frequency converter
processor monitors inputs and outputs as well as internal
3. Never attempt to defeat any fault protection
frequency converter functions. Thus, an alarm or warning
circuitry within the frequency converter, as this
does not necessarily indicate a problem within the
results in unnecessary component damage and
frequency converter itself.
can cause personal injury.
4. Always use factory approved replacement parts. Each incident has further descriptions on how to
The frequency converter is designed to operate troubleshoot that particular symptom. When necessary,
within certain specifications. Incorrect parts can further referrals are made to other parts of the manual for
affect tolerances and result in further damage to additional procedures. 5 Frequency Converter and Motor
the unit. Applications presents detailed discussions on areas of
5. Read the instruction manual. A thorough frequency converter and system troubleshooting that an
understanding of the unit is the best approach. If experienced repair technician must understand for
ever in doubt, consult the factory or authorized effective analysis.
repair center for assistance.
Finally, a list of tests, 4.7 After Repair Tests is provided.
Always perform these tests under the following conditions:
4.2 Exterior Fault Troubleshooting
There may be slight differences in servicing a frequency • Starting a frequency converter for the first time.
converter that has been operational for some extended
time compared to a new installation. When using proper
• Approaching a frequency converter that is
suspected of being faulty.
troubleshooting procedures, make no assumptions.
• After a repair to the frequency converter.

4.4 Visual Inspection

Visually inspect the conditions in Table 4.1 as part of any
initial troubleshooting procedure.
Inspect For Description

Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on
4 4 input power side of frequency converter or output side to motor. Examine operation and condition of
these items as possible causes for operational faults. Check function and installation of pressure sensors
or encoders (etc.) used for feedback to frequency converter.
Cable routing Avoid routing motor wiring, AC line wiring, and signal wiring in parallel. If parallel routing is
unavoidable, try to maintain a separation of 150–200 mm (6-8 inches) between the cables or separate
them with a grounded conductive partition. Avoid routing cables through free air.
Control wiring Check for broken or damaged wires and connections. Check the voltage source of the signals. Though
not always necessary depending on the installation conditions, the use of shielded cable or a twisted
pair is recommended. Ensure the shield is terminated correctly.
Frequency converter cooling Check operational status of all cooling fans. Check door filters on NEMA 12 (IP54) units. Check for
blockage or constrained air passages. Verify bottom gland plate is installed.
Frequency converter display Warnings, alarms, frequency converter status, fault history and many other important items are available
through the display on the local control panel of frequency converter.
Frequency converter interior Frequency converter interior must be free of dirt, metal chips, moisture, and corrosion. Check for burnt
or damaged power components or carbon deposits that were the result of a catastrophic component
failure. Check for cracks or breaks in the housings of power semiconductors, or pieces of broken
component housings loose inside the unit.
EMC considerations Check for proper installation with regard to electromagnetic capability. Refer to the frequency converter
instruction manual and this chapter for further details.
Environmental conditions Under specific conditions these units can be operated within a maximum ambient of 50°C (122°F).
Humidity levels must be less than 95% non-condensing. Check for harmful airborne contaminates such
as sulfur based compounds.
Grounding The frequency converter requires a dedicated ground wire from its chassis to the building ground. It is
also suggested that the motor be grounded to the frequency converter chassis as well. The use of
conduit or mounting of the frequency converter to a metal surface is not considered a suitable ground.
Check for good ground connections that are tight and free of oxidation.
Input power wiring Check for loose connections. Check for proper fusing. Check for blown fuses.
Motor Check nameplate ratings of motor. Ensure that motor ratings coincide with frequency converters. Ensure
frequency converter's motor parameters (1–20 to 1–25) are set according to motor ratings.
Output to motor wiring Check for loose connections. Check for switching components in output circuit. Check for faulty contacts
in switch gear.
Programming Ensure frequency converter parameter settings are correct according to motor, application, and I/O
configuration.
Proper clearance These frequency converters require top and bottom clearance adequate to ensure proper air flow for
cooling in accordance with the frequency converter size. frequency converters with exposed heat sinks
out the back of the frequency converter must be mounted on a flat solid surface.
Vibration Though somewhat subjective look for an unusual amount of vibration that the frequency converter may
be subjected to. The frequency converter should be mounted solidly or the use of shock mounts
employed.
Table 4.1 Visual Inspection

4.5 Fault Symptoms 4.5.3 Display (Line2) Flashing

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

converter starts immediately.
On
4.5.4 WRONG or WRONG LCP Displayed
Warn. If the message WRONG or WRONG LCP appears, it is due
to a faulty LCP or the use of an incorrect LCP.
Alarm
Illustration 4.1 Replace the LCP with a correct and functioning one.
Be certain, however, that the display is dark. Having a

NOTE
Error 84 appears if the LCP cannot communicate with
single character in the upper corner of the LCP or just a
FC 101.
dot indicates that communications may have failed with
the control card. This situation typically appears when a
serial bus communication option has been installed in the 4.5.5 Motor Will Not Run
frequency converter and is either not connected properly
or is malfunctioning. If this symptom is detected, verify that the unit is properly
powered up (display is lit) and that there are no warning
If neither indication is available, then the source of the or alarm messages displayed. The most common cause of
problem is elsewhere. Proceed to 6.4.1 No Display Test this problem is either incorrect control logic or an
(Display is Optional) to carry out further troubleshooting incorrectly programmed frequency converter. Such
steps. occurrences result in one or more of the following status
messages being displayed.
4.5.2 Intermittent Display
LCP Stop
[Off] has been pressed. Line 2 of the display also flashes
Cutting out or flashing of the entire display and power
when this situation occurs.
LED indicates that the power supply (SMPS) is shutting
down as a result of being overloaded. The overload may Press [Auto On] or [Hand On]. Refer to the Input Terminal
be due to improper control wiring or a fault within the Signal Test.
frequency converter itself. Standby
This message indicates that there is no start signal at
The first step is to rule out a problem in the control wiring. terminal 18.
To do so, disconnect all control wiring by unplugging the
Ensure that a start command is present at terminal 18.
control terminal blocks from the control card.
Refer to the Input Terminal Signal Test.
If the display stays lit, the problem is in the control wiring Unit ready
(external to the frequency converter). Check all control Terminal 27 is low (no signal).
wiring for shorts or incorrect connections. Ensure that terminal 27 is logic “1”. Refer to the Input
Terminal Signal Test.
If the display continues to cut out, follow the procedure Run OK, 0 Hz
for 4.5.1 No Display as though the display was not lit at all. This message indicates that a run command has been
given to the frequency converter but the reference (speed
command) is zero or missing.

Check control wiring to ensure that the proper reference NOTE

signal is present at the input terminals. Also check that the Motor may also stall when loaded or the frequency
unit is properly programmed to accept the signal provided. converter may trip occasionally on Alarm 13.
Refer to the Input Terminal Signal Test.
Off 1 (2 or 3) Check setting of all motor parameters, see 6.4.6 Output
This message indicates that bit #1 (or #2, or #3) in the Imbalance of Motor Supply Voltage Test.
control word is logic “0”. This situation only occurs when
the frequency converter is being controlled via the If output voltage is unbalanced, see 6.4.6 Output Imbalance
4 4 fieldbus.
A correct control word must be transmitted to the
of Motor Supply Voltage Test.
frequency converter over the communication bus. Motor draws high current but cannot start
STOP Possible open winding in motor or open connection to
One of the digital input terminals 16, 17, 27, 29, 32, or 33 motor.
is programmed for “Stop Inverse” and the corresponding Perform 6.4.6 Output Imbalance of Motor Supply Voltage Test
terminal is low (logic “0”). to ensure that frequency converter is providing correct
Ensure that the above parameters are programmed output (see Motor Runs Rough above).
correctly and that any digital input programmed for “Stop Check motor for open windings. Check all motor wiring
Inverse” is high (logic “1”). connections.
Display Indication that the unit is functioning, but there is Run an AMA to check the motor for open windings and
no output. unbalanced resistance. Inspect all motor wiring
Check that parameter 620 is not set to “Run With Inverter connections.
Disabled”.
If the unit is equipped with external 24 V DC option, check 4.6 Warnings and Alarms
that the main power is applied to the frequency converter.
When the frequency converter fault circuitry detects a fault
NOTE condition, or a pending fault, a warning, or alarm is issued.
In this case, the display alternately flashes Warning 8. A flashing display on the LCP indicates an alarm or
warning condition and the associated number code on line
4.5.6 Incorrect Motor Operation 2. Sometimes a warning precedes an alarm. defines
whether a warning precedes an alarm and whether the
Occasionally, a fault can occur where the motor continues frequency converter suspends operations (trips).
to run, but not in the correct manner. The symptoms and
causes may vary considerably. Many of the possible 4.6.1 Alarms
problems are listed below by symptom along with
recommended procedures for determining their causes. An alarm causes the frequency converter to trip (suspend
operation). The frequency converter has three trip
Wrong speed/unit does not respond to command conditions which are displayed on line 1:
Possible incorrect reference (speed command).
Ensure that the unit is programmed correctly according to TRIP (AUTO RESTART): The frequency converter is
the reference signal being used, and that all reference programmed to restart automatically after the fault is
limits are set correctly as well. Perform 6.4.7 Input Terminal removed. The number of automatic reset attempts can be
Signal Tests to check for faulty reference signals. continuous or limited to a programmed number of
attempts. If the selected number of automatic reset
Motor speed unstable
attempts is exceeded, the trip condition changes to TRIP
Possible incorrect parameter settings, faulty current
(RESET).
feedback circuit, loss of motor (output) phase.
Check settings of all motor parameters, including all motor
TRIP (RESET): Requires resetting of the frequency converter
compensation settings (Slip Compensation, Load Compen-
before operation after a fault is cleared. The frequency
sation, etc.). For Closed Loop operation, check PID settings.
converter can be reset manually by pressing [Reset], a
Perform 6.4.7 Input Terminal Signal Tests to check for faulty
digital input, or a serial bus command. For FC 101
reference signals. Perform Output Phase Imbalance Test to
frequency converters, the stop and reset are the same key.
check for loss of motor phase.
If [Stop/Reset] is used to reset the frequency converter,
Motor runs rough [Start] must be pressed to initiate a run command in either
Possible over magnetization (incorrect motor settings), or local or remote.
an IGBT misfiring.

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

• 24-09 FM Alarm Handling
are correctly transferred into the exchange unit.
• Press [Reset]
• A digital reset input

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

code in the display signal a warning or an alarm.
No. Description Warning Alarm Trip Lock Parameter Reference

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

No. Description Warning Alarm Trip Lock Parameter Reference

24 Fan Fault (Only on 400 V (X) 14–53
30-90 kW)
30 Motor phase U missing (X) (X) 4–58
31 Motor phase V missing (X) (X) 4–58
32 Motor phase W missing (X) (X) 4–58
38 Internal fault (X) (X)
44 Earth fault 2 (X) (X)
4 4 47
48
Control Voltage Fault
VDD1 Supply Low
(X)
(X)
(X)
(X)
50 AMA Calibration Failed (X)
51 AMA check Unom and Inom (X)
52 AMA low Inom (X)
53 AMA motor too big (X)
54 AMA motor too small (X)
55 AMA Parameter out of (X)
range
56 AMA interrupted by user (X)
57 AMA timeout (X)
58 AMA internal fault (X) (X)
59 Current limit (X)
60 External Interlock (X)
66 Heat sink Temperature Low (X)
69 Pwr Card Temperature (X) (X) (X)
79 Illegal PS config (X) (X)
80 Drive Initialized to Default (X)
Value
87 Auto DC Braking (X)
95 Broken Belt (X) (X) 22–6*
201 Fire Mode (X)
202 Fire M Limits Exceeded (X)
250 New spare parts (X) (X)
251 New Type Code (X) (X)
Table 4.2 Alarm/Warning Code List
(X) Dependent on parameter. A trip is the action when an WARNING/ALARM 2, Live zero error
alarm has appeared. The trip coasts the motor and can be This warning or alarm only appears if programmed by the
reset by pressing [Reset] or make a reset by a digital input user in 6-01 Live Zero Timeout Function. The signal on one
(parameter group 5-1* Digital Inputs [1]). The original event of the analog inputs is less than 50% of the minimum
that caused an alarm cannot damage the frequency value programmed for that input. Broken wiring or faulty
converter or cause dangerous conditions. A trip lock is an device sending the signal can cause this condition.
action when an alarm occurs, which can damage the Troubleshooting
frequency converter or connected parts. A trip lock Check connections on all the analog input
situation can only be reset by a power cycling. terminals. Control card terminals 53 and 54 for
signals, terminal 55 common. MCB 101 terminals
Warning Yellow 11 and 12 for signals, terminal 10 common. MCB
Alarm Flashing red 109 terminals 1, 3, 5 for signals, terminals 2, 4, 6
common).
Table 4.3 LED Indication
Check that the frequency converter programming
The alarm words, warning words and extended status and switch settings match the analog signal type.
words can be read out via serial bus or optional fieldbus Perform Input Terminal Signal Test.
for diagnosis.

WARNING/ALARM 4, Mains phase loss when the motor runs with more than 100% overload for
A phase is missing on the supply side, or the mains too long.
voltage imbalance is too high. This message also appears Troubleshooting
for a fault in the input rectifier on the frequency converter. Check for motor overheating.
Options are programmed at 14-12 Function at Mains
Imbalance. Check if the motor is mechanically overloaded
Troubleshooting Check that the motor current set in 1-24 Motor

Check the supply voltage and supply currents to the Current is correct.
frequency converter.
WARNING/ALARM 7, DC overvoltage
Ensure that Motor data in parameters 1-20
through 1-25 are set correctly. 4 4
If the intermediate circuit voltage exceeds the limit, the If an external fan is in use, check in 1-91 Motor
frequency converter trips after a time. External Fan that it is selected.
Troubleshooting Running AMA in 1-29 Automatic Motor Adaptation
Extend the ramp time (AMA) tunes the frequency converter to the
Change the ramp type motor more accurately and reduces thermal
loading.
Increase 14-26 Trip Delay at Inverter Fault
WARNING/ALARM 11, Motor thermistor over temp
WARNING/ALARM 8, DC under voltage
Check whether the thermistor is disconnected. Select
If the intermediate circuit voltage (DC link) drops below
whether the frequency converter issues a warning or an
the under voltage limit, the frequency converter checks if a
alarm in 1-90 Motor Thermal Protection.
24 V DC backup supply is connected. If no 24 V DC backup
supply is connected, the frequency converter trips after a Troubleshooting
fixed time delay. The time delay varies with unit size. Check for motor overheating.
Troubleshooting Check if the motor is mechanically overloaded.

Check that the supply voltage matches the When using terminal 53 or 54, check that the
frequency converter voltage. thermistor is connected correctly between either
Perform input voltage test. terminal 53 or 54 (analog voltage input) and
terminal 50 (+10 V supply). Also check that the
Perform soft charge circuit test.
terminal switch for 53 or 54 is set for voltage.
WARNING/ALARM 9, Inverter overload Check 1-93 Thermistor Source selects terminal 53
The frequency converter is about to cut out because of an or 54.
overload (too high current for too long). The counter for
When using digital inputs 18 or 19, check that
electronic, thermal inverter protection issues a warning at
the thermistor is connected correctly between
98% and trips at 100%, while giving an alarm. The
either terminal 18 or 19 (digital input PNP only)
frequency converter cannot be reset until the counter is
and terminal 50. Check 1-93 Thermistor Source
below 90%.
selects terminal 18 or 19.
The fault is that the frequency converter has run with
more than 100% overload for too long.
Troubleshooting
WARNING/ALARM 13, Over current
Compare the output current shown on the LCP
The inverter peak current limit (approximately 200% of the
with the frequency converter rated current.
rated current) is exceeded. The warning lasts about 1.5 s,
Compare the output current shown on the LCP then the frequency converter trips and issues an alarm.
with measured motor current. Shock loading or fast acceleration with high inertia loads
Display the Thermal Drive Load on the LCP and can cause this fault.
monitor the value. When running above the Troubleshooting:
frequency converter continuous current rating, Remove power and check if the motor shaft can
the counter increases. When running below the be turned.
frequency converter continuous current rating,
Check that the motor size matches the frequency
the counter decreases.
converter.
WARNING/ALARM 10, Motor overload temperature
Check parameters 1-20 through 1-25 for correct
According to the electronic thermal protection (ETR), the
motor data.
motor is too hot. Select whether the frequency converter
issues a warning or an alarm when the counter reaches
100% in 1-90 Motor Thermal Protection. The fault occurs

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

Check for proper fan operation. 2822 USB port overflow
3072-5122 Parameter value is outside its limits
Cycle power to the frequency converter and
5123 Option in slot A: Hardware incompatible with
check that the fan operates briefly at start-up.
control board hardware
Check the sensors on the heatsink and control 5124 Option in slot B: Hardware incompatible with
card. control board hardware
ALARM 30, Motor phase U missing 5125 Option in slot C0: Hardware incompatible with
Motor phase U between the frequency converter and the control board hardware
motor is missing. 5126 Option in slot C1: Hardware incompatible with
control board hardware
Remove power from the frequency converter and check
5376-6231 Internal fault. Contact your Danfoss supplier or
motor phase U.
Danfoss Service Department.
ALARM 31, Motor phase V missing
Motor phase V between the frequency converter and the Table 4.4 Internal Fault Codes
motor is missing.
Remove power from the frequency converter and check ALARM 44, Earth fault II
motor phase V. There is a discharge from the output phases to earth,
either in the cable between the frequency converter and
the motor or in the motor itself.

Troubleshooting Troubleshooting:
Turn off the frequency converter and remove the
The heatsink temperature measured as 0 °C could indicate
earth fault.
that the temperature sensor is defective, thus causing the
Measure the resistance to ground of the motor fan speed to increase to the maximum. If the sensor wire
leads and the motor with a megohmmeter to between the IGBT and the gate drive card is disconnected,
check for earth fault in the motor. this warning is produced. Also, check the IGBT thermal
WARNING 47, 24 V supply low sensor.
The 24 V DC is measured on the control card. The external ALARM 79, Illegal power section configuration
24 V DC backup power supply may be overloaded,
otherwise contact the Danfoss supplier.
The scaling card is the incorrect part number or not
installed. Also MK102 connector on the power card could
4 4
WARNING 48, 1.8 V supply low not be installed.
The 1.8 V DC supply used on the control card is outside of ALARM 80, Drive initialised to default value
allowable limits. The power supply is measured on the Parameter settings are initialised to default settings after a
control card. Check for a defective control card. If an manual reset. Reset the unit to clear the alarm.
option card is present, check for an overvoltage condition.
ALARM 95, Broken belt
ALARM 51, AMA check Unom and Inom Torque is below the torque level set for no load, indicating
The settings for motor voltage, motor current, and motor a broken belt. 22-60 Broken Belt Function is set for alarm.
power are wrong. Check the settings in parameters 1-20 to Troubleshoot the system and reset the frequency converter
1-25. after the fault has been cleared.
ALARM 52, AMA low Inom WARNING 200, Fire mode
The motor current is too low. Check the setting in This warning indicates the frequency converter is operating
4-18 Current Limit. in fire mode. The warning clears when fire mode is
ALARM 53, AMA motor too big removed. See the fire mode data in the alarm log.
The motor is too big for the AMA to operate. WARNING 202, Fire mode limits exceeded
ALARM 54, AMA motor too small While operating in fire mode one or more alarm conditions
The motor is too small for the AMA to operate. have been ignored which would normally trip the unit.
Operating in this condition voids unit warranty. Cycle
ALARM 55, AMA parameter out of range power to the unit to remove the warning. See the fire
The parameter values of the motor are outside of the mode data in the alarm log.
acceptable range. AMA does not run.
WARNING 250, New spare part
56 ALARM, AMA interrupted by user The power card or switch mode power supply has been
The user has interrupted the AMA. exchanged. The frequency converter type code must be
ALARM 57, AMA internal fault restored in the EEPROM. Select the correct type code in
Try to restart AMA again. Repeated restarts can over heat 14-23 Typecode Setting according to the label on the unit.
the motor. Remember to select ‘Save to EEPROM’ to complete.
ALARM 58, Internal fault WARNING 251, New typecode
Contact your Danfoss supplier. The frequency converter has a new type code.
WARNING 59, Current limit
The current is higher than the value in 4-18 Current Limit. 4.7 After Repair Tests
Ensure that Motor data in parameters 1-20 to 1-25 are set
correctly. Possibly increase the current limit. Be sure that Following any repair to a frequency converter or testing of
the system can operate safely at a higher limit. a frequency converter suspected of being faulty, the
following procedure must be followed. Following the
WARNING 60, External interlock
procedure will ensure that all circuitry in the frequency
A digital input signal is indicating a fault condition external
converter is functioning properly before putting the unit
to the frequency converter. An external interlock has
into operation.
commanded the frequency converter to trip. Clear the
external fault condition. To resume normal operation,
apply 24 V DC to the terminal programmed for external 1. Perform visual inspection procedures as described
interlock. Reset the frequency converter. in Table 4.1.
WARNING 66, Heatsink temperature low 2. Perform static test procedures to ensure that
This warning is based on the temperature sensor in the frequency converter is safe to start.
IGBT module. 3. Disconnect motor leads from output terminals (U,
V, W) of frequency converter.

4. Apply AC power to frequency converter.

5. Give the frequency converter a run command
and slowly increase reference (speed command)
to approximately 40 Hz.
6. Using an analog volt meter or a DVM capable of
measuring true RMS, measure phase-to-phase
output voltage on all three phases: U to V, U to
W, V to W. All voltages must be balanced within
4 4 8 V. If unbalanced voltage is measured, refer to
6.4.2 Input Voltage Test.
7. Stop frequency converter and remove input
power. Allow 20 minutes for DC capacitors to
fully discharge.
8. Reconnect motor leads to frequency converter
output terminals (U, V, W).
9. Reapply power and restart frequency converter.
Adjust motor speed to a nominal level.
10. Using a clamp-on style ammeter, measure output
current on each output phase. All currents must
be balanced.

Frequency Converter and Mot... VLT® HVAC Basic Drive Service Manual
5 Frequency Converter and Motor Applications
5.1.1 Overvoltage Trips

5.1 Torque Limit, Current Limit, and
Overvoltage trip occurs when the DC bus voltage reaches
Unstable Motor Operation its DC bus alarm voltage high (see 1.9.1 Short Circuit and
Excessive loading of the frequency converter can result in Over-current Trips). Before tripping, the frequency converter
warning or tripping on torque limit, over current, or displays a high voltage warning. Mostly, fast deceleration
inverter time. Avoid this situation by sizing the frequency ramps with respect to load inertia causes an over voltage
converter properly for the application and ensuring that condition. During deceleration of the load, inertia of the
intermittent load conditions cause anticipated operation in system acts to sustain the running speed. Once the motor
frequency drops below the running speed, the load begins
5 5
torque limit or an occasional trip. However, specific
parameters that are improperly set, can cause nuisance or overhauling the motor. The motor then becomes a
unexplained occurrences. The following parameters are generator and starts returning energy to the frequency
important in matching the frequency converter to the converter. This is called regenerative energy. Regeneration
motor for optimum operation. occurs when the speed of the load is greater than the
commanded speed. The diodes in the IGBT modules rectify
this return and raises the DC bus. If the amount of
Parameters 1-20 to 1-25 configure the frequency converter
returned voltage is too high, the frequency converter trips.
for the connected motor. These are motor power, voltage,
frequency, current, and rated motor speed. It is important
to set these parameters accurately. Enter the motor data
required as listed on the motor nameplate. For effective There are a few ways to overcome this situation. One
and efficient load control, the frequency converter relies method is to reduce the deceleration rate so it takes
on this information for calculating the output waveform in longer for the frequency converter to decelerate. A rule of
response to the changing demands of the application. thumb is that the frequency converter can only decelerate
the load slightly faster than it would take for the load to
naturally coast to a stop. A second method is to allow the
1-29 Automatic Motor Adaption (AMA) activates the
over voltage control function (2-17 Over-voltage Control) to
Automatic Motor Adaptation (AMA) function. When AMA is
take care of the deceleration ramp. When enabled, the
performed, the frequency converter measures the electrical
overvoltage control function regulates deceleration at a
characteristics of the motor and sets various frequency
rate that maintains the DC bus voltage at an acceptable
converter parameters based on the findings. Two key
level. One caution with over voltage control is that it does
parameter values set by this function are stator resistance
not make corrections to unrealistic ramp rates.
and main reactance, 1-30 Stator Resistance (Rs) and
1-35 Main Reactance (Xh). If unstable motor operation is
experienced, perform AMA if this operation has not already For example, the deceleration ramp has to be 100 seconds
been performed. AMA can only be performed on single due to the inertia, and the ramp rate is set at 3 seconds.
motor applications within the programming range of the Over voltage control initially engages, then disengages and
frequency converter. Consult the Quick Guide for HVAC allows the frequency converter to trip. This is purposely
Basic Drive, MG18A for more information on this function. done so the unit's operation is not misinterpreted.
As stated, the AMA function must be set 1-30 Stator The FC 101 has an AC brake which increases magnetisation
Resistance (Rs) and 1-35 Main Reactance (Xh). The values for current to increase loss in motor and reduce DC-link
these parameters can either be supplied by the motor voltage. If the DC-link voltage exceeds a certain voltage,
manufacturer, or contain factory default values. the overvoltage control increases the frequency.
NOTE 5.1.2 Mains Phase Loss Trips

Never adjust these parameters to random values even
The frequency converter actually monitors phase loss by
though it seems to improve operation. Such adjustments
monitoring the amount of ripple voltage on the DC bus.
can result in unpredictable operation under changing
Ripple voltage on the DC bus is a product of a phase loss.
conditions.
The main concern is that ripple voltage causes overheating
in the DC bus capacitors and the DC coil. If the ripple
voltage on the DC bus is left unchecked, the lifetime of
the capacitors and DC coil would be drastically reduced.

When the input voltage becomes unbalanced or a phase This data can also be read in parameter group 16-6* Inputs
disappears completely, the ripple voltage increases. This and Outputs.
situation causes the frequency converter to trip and issue
Alarm 4, Mains Phase Loss. In addition to missing phase If there is no correct indication, check if the signal is
voltage, a line disturbance or imbalance can cause an present at the input terminals of the frequency converter.
increased bus ripple. Line disturbances can be caused by Use a voltmeter or oscilloscope in accordance with
line notching, defective transformers, or other loads that 6.4.7 Input Terminal Signal Tests.
can affect the form factor of the AC waveform. Mains
imbalances which exceed 3% cause sufficient DC bus
If the signal is present at the terminal, the control card is
ripple to initiate a trip.
defective and must be replaced. If the signal is not
present, the problem is external to the frequency
Output disturbances can have the same effect of increased
5 5 ripple voltage on the DC bus. A missing or lower than
converter. The circuitry providing the signal along with its
associated wiring must then be checked.
normal output voltage on one phase can cause increased
ripple on the DC bus. When a mains imbalance trip occurs,
it is necessary to check both the input and output voltage
5.1.4 Programming Problems
of the frequency converter.
Difficulty with frequency converter operation can be a
result of improper programming of the frequency
Severe imbalance of supply voltage or phase loss can
converter parameters. Three areas where programming
easily be detected with a voltmeter. View line disturbances
errors can affect frequency converter and motor operation
through an oscilloscope. Conduct tests for input imbalance
are motor settings, references and limits, and I/O configu-
of supply voltage, input waveform, and output imbalance
ration. See 2.3 Frequency Converter Inputs and Outputs.
of supply voltage as described in 4 Troubleshooting.
The frequency converter must be set up correctly for the

5.1.3 Control Logic Problems motor(s) connected to it. Parameters must have data from
the motor nameplate entered into the frequency converter.
Problems with control logic can often be difficult to These data enables the frequency converter processor to
diagnose, since there is usually no associated fault match the frequency converter to power characteristics of
indication. The typical complaint is simply that the the motor. The most common result of the inaccurate
frequency converter does not respond to a given motor data is that the motor drawing higher than normal
command. There are two basic commands that must be amounts of current must perform the task expected of it.
given to any frequency converter to obtain an output. In such cases, setting the correct values to these
Commands provided to the frequency converter to obtain parameters and performing the Automatic Motor
an output: Adaptation (AMA) function usually solves the problem.
• Start Command: to execute. Any references or limits set incorrectly result in less than
• Reference or Speed Command: to identify the acceptable frequency converter performance. For instance,
speed of execution. if maximum reference is set too low, the motor is unable
to reach full speed. These parameters must be set
The frequency converters are designed to accept various
according to the requirements of the particular installation.
signals. First determine which of these signals the
References are set in parameter group 3-0* Reference Limits.
frequency converter is receiving
Incorrectly set I/O configuration usually results in the

• Digital inputs (18, 19, 27, 29)
frequency converter not responding to the function as
• Analog outputs (42, 45) commanded. Remember that for every control terminal
• 10 V output input or output there are corresponding parameter
settings. These settings determine how the frequency
• Analog inputs (53, 54)
converter responds to an input signal or the type of signal
• Serial communication bus (68, 69) present at that output. Utilizing an I/O function involves a
The presence of a correct reading indicates that the two-step process. The desired I/O terminal must be wired
microprocessor of the frequency converter has detected properly, and the corresponding parameter must be set
the desired signal. See 2.3 Frequency Converter Inputs and accordingly. Control terminals are programmed in
Outputs. parameter groups 5-0* Digital I/O Mode and 6-0* Analog I/O
Mode.

5.1.5 Motor/Load Problems frequency converter display. With the motor disconnected,
the current should be zero. A frequency converter with a
Problems with the motor, motor wiring, or mechanical load defective current sensor indicates some current flow. An
on the motor can develop in a number of ways. The motor indication of a fraction of one amp is tolerable. However,
or motor wiring can develop a phase-to-phase or phase-to- that value should be considerably less than one amp. If the
earth short resulting in an alarm indication. Checks must display shows more than one amp of current, there is a
be made to determine whether the problem is in the defective current sensor. All three current sensors in
motor wiring or the motor itself. FC 101 units are mounted on one circuit board (either
power card, SMPS card, or current transducer card). The
A motor with unbalanced, or unsymmetrical, impedances repair procedure is to replace all three current sensors at
on all three phases can result in uneven or rough the same time.
5 5
operation, or unbalanced output currents. For
measurements, use a clamp-on style ammeter to 5.2.2 Signal and Power Wiring
determine whether the current is balanced on the three Considerations for Electromagnetic
output phases. See 6.4.6 Output Imbalance of Motor Supply Compatibility
Voltage Test.
This section provides an overview of general signal and
Usually a current limit warning indicates an incorrect power wiring considerations when addressing the Electro-
mechanical load. If possible, disconnect the motor from magnetic Compatibility (EMC) concerns for typical
the load to determine if the load is incorrect. commercial and industrial equipment. Only certain high-
frequency phenomena (such as RF emissions, RF immunity)
Quite often, the indications of motor problems are similar are discussed. Low-frequency phenomena (such as
to those of a defect in the frequency converter itself. To harmonics, mains voltage imbalance, notching) are not
determine whether the problem is internal or external to covered.
the frequency converter, disconnect the motor from the
frequency converter output terminals. Perform 6.4.6 Output NOTE
Imbalance of Motor Supply Voltage Test procedure on all Special installations or compliance to the European CE
three phases with an analog voltmeter. If the three voltage EMC directives require strict adherence to relevant
measurements are balanced, the frequency converter is standards and are not discussed here.
functioning correctly. Hence, the problem is external to the
frequency converter. 5.2.3 Effect of EMI
If the voltage measurements are not balanced, the While electromagnetic interference (EMI) related distur-
frequency converter is malfunctioning. This typically means bances to frequency converter operation are uncommon,
that one or more output IGBTs are not switching on and the following detrimental EMI effects may be seen:
off correctly. This can be a result of a defective IGBT or
gate signal.
• Motor speed fluctuations
• Serial communication transmission errors

5.2 Internal Frequency Converter Problems
• Frequency converter CPU exception faults
If an over temperature indication is displayed, determine • Unexplained frequency converter trips
whether this condition actually exists within the frequency
A disturbance resulting from other nearby equipment is
converter or whether the thermal sensor is defective. If
more common. Generally, other industrial control
not, the temperature sensor must be checked.
equipment has a high level of EMI immunity. However,
non-industrial, commercial, and consumer equipment is
5.2.1 Current Sensor Faults often susceptible to lower levels of EMI. Detrimental effects
to these systems may include the following:
When a current sensor fails, it is indicated sometimes by
an over-current alarm that cannot be reset, even with the
motor cables disconnected. However, the frequency
• Pressure/flow/temperature signal transmitter
signal distortion or aberrant behaviour
converter experiences frequent false earth fault trips. This
is due to the DC offset failure mode of the sensors. • Radio and TV interference
• Telephone interference
The simplest method of determining whether a current
sensor is defective is to disconnect the motor from the
• Computer network data loss
frequency converter. Then observe the current in the • Digital control system faults

5.2.4 Sources of EMI frequency, and variable voltage PWM waveform. This high
rate of voltage change [dU/dt] is the primary source of the
Modern frequency converters (see Illustration 5.1) utilize frequency converter generated EMI.
IGBTs to provide an efficient and cost effective means to
create the Pulse Width Modulated (PWM) output waveform The high rate of voltage change caused by the IGBT
necessary for accurate motor control. These devices rapidly switching creates high frequency EMI.
switch the fixed DC bus voltage creating a variable
130BX137.10
Rectifier DC Bus Inverter
Filter reactor
5 5 AC Line Motor
IGBT
Filter capacitor
Sine wave
PWM waveform
Illustration 5.1 Frequency Converter Functionality Diagram
5.2.5 EMI Propagation within the frequency converter itself. However,

imperfections in the frequency converter earthing or the
Frequency converter generated EMI is both conducted to equipment earth system can cause some of the currents to
the mains and radiated to nearby conductors. See travel out to the power network.
Illustration 5.2.
2
130BC154.10
4
1 3
130BC344.10
2 4
1 3
5 5
5
6
6
9 7
8
7
Illustration 5.2 Earth Currents
Illustration 5.3 Signal Conductor Currents
CAUTION NOTE
Stray capacitance between the motor conductors, Unprotected or poorly routed signal conductors located
equipment earth, and other nearby conductors results in close to or in parallel to motor and mains conductors are
induced high frequency currents. susceptible to EMI.
High earth circuit impedance at high frequencies results in Signal conductors are especially vulnerable when they are
an instantaneous voltage at points reputed to be at earth run in parallel to the power conductors for any distance.
potential. This voltage can appear throughout a system as EMI coupled into these conductors can affect either the
a common mode signal that can interfere with control frequency converter or the interconnected control device.
signals. See Illustration 5.4.
Theoretically, these currents return to the DC bus via the While these currents tend to travel back to the frequency
earth circuit and a high frequency (HF) bypass network converter, imperfections in the system cause some current

to flow in undesirable paths, thus exposing other locations be terminated in a manner that is appropriate for the
to the EMI. connected equipment. Avoid terminating the screen
through a pigtail connection as it increases the high
frequency impedance and spoils the effectiveness of the
2
130BC345.10
screen.
4
1 3
A simple alternative is to twist the existing single
conductors to provide a balanced capacitive and inductive
coupling. This operation cancels differential mode
interference. While not as effective as true twisted-pair
cable, it can be implemented in the field using the
5
6 materials on hand.
Motor cable selection
Motor conductors have the greatest influence on the EMI
5 5
Illustration 5.4 Alternate Signal Conductor Currents characteristics of the system. These conductors must
receive the highest attention whenever EMI is a problem.
Single conductor wires provide the least protection from
NOTE EMI emissions. Often, if these conductors are routed
High frequency currents can be coupled into the mains separately from the signal and mains wiring, then no
supplying the frequency converter when the mains further consideration is needed. If the conductors are
conductors are located close to the motor cables. routed close to other susceptible conductors, or if the
system is suspected to cause EMI problems, consider
5.2.6 Preventive Measures alternate motor wiring methods.
Installing screened power cable is the most effective
EMI-related problems are more effectively alleviated during means to alleviate EMI problems. The cable screen forces
the design and installation phases rather than after the the noise current to flow directly back to the frequency
system is in service. Many of the listed steps can be converter before it gets back into the power network or
implemented at a relatively low cost compared to the cost takes other undesirable high frequency paths. Unlike most
of identifying and fixing the problem later. signal wiring, the screening on the motor cable must be
terminated at both ends.
Earthing If a screened motor cable is not available, then three-phase
Earth the frequency converter and motor solidly to the conductors along with earth in a conduit provides some
equipment frame. A good high frequency connection is degree of protection. This technique is not as effective as
necessary to allow the high frequency currents to return to screened cable due to the unavoidable contact of the
the frequency converter rather than to travel through the conduit with various points within the equipment.
power network. The earth connection is ineffective if it has
Serial communications cable selection
high impedance to high frequency currents. Therefore it
There are various serial communication interfaces and
must be as short and direct as practical. Flat-braided cable
protocols in the market. Each of these interfaces
has lower high-frequency impedance than round cable.
recommends one or more specific types of twisted-pair,
Simply mounting the frequency converter or motor onto a
screened twisted-pair, or proprietary cables. Refer to the
painted surface does create an effective earth connection.
manufacturer’s documentation when selecting these
In addition, running a separate earth conductor directly
cables. Similar recommendations apply to serial communi-
between the frequency converter and the running motor is
cation cables as to other signal cables. Using twisted-pair
recommended.
cables and routing them away from power conductors is
Cable routing encouraged. While screened cable provides additional EMI
Avoid routing motor wiring, mains wiring, and signal protection, the screen capacitance may reduce the
wiring in parallel. If parallel routing is unavoidable, try to maximum allowable cable length at high data rates.
maintain a separation of 200 mm (6–8 inches) between the
cables or separate them with an earthed conductive
partition. Avoid routing cables through free air.
Signal cable selection
Single conductor 600 V rated wires provide the least
protection from EMI. Twisted-pair and screened twist-pair
cables are available which are designed to minimize the
effects of EMI. While unscreened twisted-pair cables are
often adequate, screened twisted-pair cables provide
another degree of protection. The signal cable screen must

Test Procedures VLT® HVAC Basic Drive Service Manual
6 Test Procedures
130BC299.10
6.1 Non-repairable Units
H1-H5 and I2-I4 are non-repairable units and should not be
repaired. The information about Line/Motor/UDC+-
terminals is useful to verify what went wrong with these
1
frequency converters, for statistics and WIIS purposes, but
8
also to avoid replacing a frequency converter that is
actually not defective. 7
6 6 130BB634.10 3
1
4
MAINS
2
4
Motor Illustration 6.2 I2 Frame
IP54 380-480 V, 0.75-4.0 kW
U V W
-DC+DC
2
1 RS-485
2 Line in
3 3 Earth
4 Wire clamps
5 Motor
6 UDC
7 Relays
8 I/O
Illustration 6.1 H1-H5 Frame
Table 6.2
IP20 200-240 V, 0.25-11 kW and IP20 380-480 V, 0.37-22 kW
1 Line
2 Earth
3 Motor
4 Relays
Table 6.1

130BC201.10
130BD011.10
6 6
Illustration 6.4 I4 Frame

IP54 380-480 V, 0.75-4.0 kW
Illustration 6.3 I3 Frame
IP54 380-480 V, 5.5-7.5 kW
1 RS-485
2 Line in
1 RS-485
3 Earth
2 Line in
4 Wire clamps
3 Earth
5 Motor
4 Wire clamps
6 UDC
5 Motor
7 Relays
6 UDC
8 I/O
7 Relays
8 I/O Table 6.4
Table 6.3

6.2 Introduction • Digital voltmeter/ohmmeter capable of reading

real RMS
WARNING • Analog voltmeter
DISCHARGE TIME! • Oscilloscope
Frequency converters contain DC-link capacitors that can
remain charged even when the frequency converter is not
• Current meter
powered. To avoid electrical hazards, disconnect AC mains,

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

Static tests are performed without applying power to the
This section contains detailed procedures for testing frequency converter.
frequency converters. Previous sections of this manual
provide symptoms, alarms, and other conditions which
require additional test procedures to diagnose the
WARNING
Whenever power is applied to the frequency converter,
frequency converter further. The results of these tests
never disconnect the input cable. Disconnecting the input
indicate the appropriate repair actions. Again, because the
cable could result in electrical shock, personal injury, and
frequency converter monitors input and output signals,
death.
motor conditions, AC, and DC power and other functions,
the source of fault conditions may exist outside of the
frequency converter. Testing described here isolates many The purpose of performing static test is to check for any
of these conditions as well. Disassembly and Assembly possibility of short circuit of the power components.
Instructions (H or I-frame sizes frequency converters,
respectively), describes detailed procedures for removing 6.3.1 Pre-requisite
and replacing frequency converter components.
• Prepare the work area according to the ESD
Frequency converter testing is divided into Static Tests, and regulations. Ground ESD mat and wrist strap.
Dynamic Tests. Static tests are conducted without power Ensure that the ground connection between
applied to the frequency converter. Most frequency body, the ESD mat and the frequency converter is
converter problems can be diagnosed simply with these always present while servicing the drive. Handle
tests. Static tests are performed with little or no disassembled electronic parts carefully and always
disassembly. The purpose of static testing is to check for ESD protected.
shorted power components. Perform these tests on any
• Perform the static test before powering up the
unit suspected of containing faulty power components fault unit.
before applying power.
• Perform static test after completing the repair
and assembly of the frequency converter.
CAUTION • Connect the frequency converter to the mains
For dynamic test procedures, main input power is required. only after completion of static tests.
All devices and power supplies connected to mains are
energized at rated voltage. Use extreme caution when • All necessary precautions for system startup must
be completed before applying power to
conducting tests on a powered frequency converter.
frequency converter.
Contact with powered components could result in
electrical shock and personal injury.
Dynamic tests are performed with power applied to the

frequency converter. Dynamic testing traces signal circuitry
to isolate faulty components.

6.3.2 Rectifier Circuit Test 6.3.3 Inverter Section Tests
Pay close attention to the polarity of the meter leads to The inverter section is primarily made up of the IGBTs used
ensure the identification of any faulty component, in case for switching the DC bus voltage to create the output to
an incorrect reading appears. the motor. The frequency converter also has clamping
capacitors between +UDC and -UDC on the IGBT.
Described next is the procedure to conduct the static test
on the rectifier.
CAUTION
Disconnect motor leads when testing inverter section. With
NOTE leads connected, a short circuit in one phase reads in all
In H6 units the +/-UDC terminals are not readily accessible. phases, making isolation difficult.
Find terminals K601 (+) and K611 (-) between the DC
capacitors.
Before starting tests, ensure that meter is set to diode
In H7-H8 units the +/-UDC terminals are directly accessible
scale.
on MK900 on the power card.
In I7-I8 units the +/-UDC terminals are accessible on MK900
6 6
on the power card or on MK3 on the current sensor board. Inverter test part I
For further details, see 6.3.5 Location of UDC Terminals 1. Connect the positive (+) meter lead to the (+)
before measuring) positive DC bus terminal.
2. Connect the negative (–) meter lead to terminals
Rectifier test part I U, V, and W in sequence.
1. Connect the negative terminal of the multimeter Each reading must show infinity. The meter starts at a low
lead to the positive DC Bus. value and slowly climbs toward infinity due to capacitance
2. Connect the positive terminal of the multimeter within the frequency converter being charged by the
lead to the input terminal L1, L2, L3 in turn. The meter.
multimeter indicates Rectifier open.
Rectifier test part II Inverter test part II
3. Reverse the meter leads. That is, connect the 1. Reverse the meter leads by connecting the
positive terminal of the multimeter lead to the negative (–) meter lead to the positive (+) DC bus
positive DC Bus. terminal.
4. Connect the negative terminal of the multimeter 2. Connect the positive (+) meter lead to U, V, and
lead to the input terminal L1, L2, L3 in turn. The W in sequence. Each reading should show a
multimeter indicates Diode open. diode drop.
Rectifier test part III Inverter test part III

5. Connect the positive terminal of the multimeter 1. Connect the positive (+) meter lead to the
lead to the negative DC Bus. negative (-) DC bus terminal.
6. Connect the negative terminal of the multimeter 2. Connect the negative (–) meter lead to terminals
lead to the input terminal L1, L2, L3 in turn. The U, V, and W in sequence. Each reading should
multimeter indicates a diode drop of 0.4 V~0.6 V show a diode drop.
(depending on the power size) on the three Inverter test part IV
terminals. 1. Reverse the meter leads by connecting the
Rectifier test part IV negative (–) meter lead to the negative (-) DC bus
7. Reverse the meter leads. That is, connect the terminal.
negative terminal of the multimeter lead to the 2. Connect the positive (+) meter lead to U, V, and
negative DC Bus. W in sequence.
8. Connect the positive terminal of the multimeter Each reading should show infinity. The meter starts at a
lead to the input terminal L1, L2, L3 in turn. The low value and slowly climb toward infinity due to
multimeter indicates Diode open. capacitance within the frequency converter being charged
by the meter.

6.3.4 Intermediate Section Tests 6.3.5 Location of UDC Terminals
NOTE H6
This test is applicable for H7, H8, I7, and I8 units only. Remove the IP20 front cover, then remove the capacitor
vibration support. The terminals K601 (+UDC) and K611
(-UDC) are located between the 4 capacitors on the circuit
The intermediate section of the frequency converter is
board. Remove the metal cover to access these terminals.
made up of the DC bus capacitors, the DC coils, and the
balance circuit for the capacitors.
130BC352.10
1. Test for short circuits with the ohmmeter set on
Rx100 scale or, for a digital meter, select diode.
2. Measure across the positive (+) DC terminal and
the negative (–) DC terminal. Observe the meter
polarity.
6 6 3. The meter starts out with low ohms and then
move towards infinity as the meter charges the
capacitors.
4. Reverse meter leads.
5. The meter pegs at zero while the meter
discharges the capacitors. The meter then begins
moving slowly toward two diode drops as the
meter charges the capacitors in the reverse
Illustration 6.5 UDC Terminals Location on H6 Frequency
direction. Although the test does not ensure that
Converter
the capacitors are fully functional, it ensures that
no short circuits exist in the intermediate circuit.
Incorrect reading
A short circuit could be caused by a short in the inrush
130BC353.10
circuit, rectifier or inverter section. Be sure that the tests
for these circuits have already been performed successfully.
A failure in one of these sections could be read in the
intermediate section since they are all routed via the DC
bus.
The only other likely cause would be a defective capacitor
within the capacitor bank.
There is not an effective test of the capacitor bank when it
is fully assembled. If suspecting a failure within the
capacitor bank, replace the entire bank. Replace the
capacitor bank in accordance with the disassembly
procedures.
Illustration 6.6 Metal Cover over Terminals

130BC356.10
130BC354.10
Illustration 6.9 +/- UDC Terminals
6 6
H9
The UDC terminals are available on connectors at the
bottom of the frequency converter. Static measurements
can be done directly from here.
Illustration 6.7 The UDC Terminals on the Circuit Board
130BC351.10
H7 and H8
Remove the IP20 front cover to access the terminals
directly on the power card MK900.
130BC355.10
W V U
L3 L2 L1 DC+ DC-

Converter
Illustration 6.8 Power Card

H10
130BC358.10
Remove the front terminal cover to access the connectors.
The UDC terminals are located inside the frequency
converter.
130BC351.10
W V U
Illustration 6.13 +/- UDC Terminals on Current Sensor Board

6 6
L3 L2 L1 DC+ DC-
130BC359.10
Converter
I7 and I8
Remove the IP54 front cover to access the +/- UDC
terminals, either on the power card MK900 or on MK3 on
the current sensor board.
130BC356.10
Illustration 6.14 +/- UDC Terminals on Current Sensor Board -

Close-up View
6.4 Dynamic Test Procedures

NOTE
Test procedures in this section are numbered for reference
only. Tests do not need to be performed in this order.
Perform tests only as necessary.
Illustration 6.12 +/- UDC Terminals on Power Card
WARNING
Never disconnect the input cabling to the frequency
converter with power applied due to danger of severe
injury or death.
CAUTION
Take all the necessary safety precautions for system start-
up before applying power to the frequency converter.
Dynamic tests are conducted with the power applied to

the medium power size frequency converter.

Dynamic tests are performed without the motor being L1 to L3

connected to UVW connector. Program the frequency L2 to L3
converter to approximately 50 Hz on start. For 380 V frequency converters, all measurements must be
within the range of 342–550 V AC. Readings of less than
Dynamic tests can indicate if one of the IGBT does not 342 V AC indicate problems with the input mains voltage.
switch, and the output voltage drops on the fault terminal, For 525–600 V frequency converters, all measurements
UVW. must be within the range of 446–600 V AC. Readings of
less than 446 V AC indicate problems with the input mains
Dynamic tests are conducted to check the IGBT. Conduct voltage.
the test without the motor being connected to the
frequency converter. Program the multimeter to AC 1000 In addition to the actual voltage reading, the balance of
V. the voltage between the phases is also important. The
frequency converter can operate within specifications as
Described next is the procedure to conduct the dynamic long as the imbalance of supply voltage is not more than
test on the IGBT. 3%.
6 6
1. Connect the positive terminal of the multimeter Danfoss calculates mains imbalance per an IEC specifi-
lead to the U connector, and connect the cation.
negative terminal to the V terminal.
2. Connect the positive terminal of the multimeter Imbalance=0.67 X (Vmax–Vmin)/Vavg
lead to the U connector, and connect the For example, if three phase readings were taken and the
negative terminal to the W terminal. results were 500 V AC, 478.5 V AC, and 478.5 V AC; then
3. Connect the positive terminal of the multimeter 500 V AC is Vmax, 478.5 V AC is Vmin, and 485.7 V AC is Vavg,
lead to the V connector, and connect the resulting in an imbalance of 3%.
negative terminal to the W terminal.
Although the frequency converter can operate at higher
The meter reading is 450 V ±25 V when performing the
mains imbalances, the lifetime of components, such as DC
dynamic test at 400 V mains, and 50 Hz/1500 RPM output
bus capacitors, is shortened.
depending on the instrument used.
Incorrect reading
The reading must be within ±1.5%.
CAUTION
6.4.1 No Display Test (Display is Optional) Open (blown) input fuses or tripped circuit breakers
usually indicate a more serious problem. Before replacing
A frequency converter with no display in the LCP can be fuses or resetting breakers, perform static tests.
the result of several causes. First, verify that there is no
display. A single character in the display or a dot in the An incorrect reading here requires further investigation of
upper corner of the display indicates a communication the main supply. Typical items to check would be:
error. Check that all option cards are properly installed.
When this condition occurs, the green power-on LED is
• Open (blown) input fuses or tripped circuit
illuminated. breakers
If the LCD display is dark and the green power-on LED is

• Open disconnects or line side contactors
not lit, proceed with the following tests. • Problems with the power distribution system
If the Input Voltage Test was successful check for voltage to
First test for proper input voltage. the control card.
6.4.2 Input Voltage Test 6.4.3 Basic Control Card Voltage Test
1. Apply power to frequency converter. 1. Measure the control voltage at terminal 12 with
2. Use the DVM to measure the input mains voltage respect to terminal 20. The meter must read
between the frequency converter input terminals 21-27 V DC.
in sequence: An incorrect reading here could indicate that a fault in the
L1 to L2 customer connections loads down the supply. Disconnect

control wiring and repeat the test. If this test is successful, 6. Reapply power to the frequency converter and
then continue. Remember to check the customer place it in run.
connections. If still unsuccessful, change the control card. 7. Repeat the current measurements.
If the imbalance of supply voltage moves with swapping
2. Measure the 10 V DC control voltage at terminal
the leads, the mains supply is suspect. Otherwise, it may
50 with respect to terminal 55. The meter must
indicate a problem with the gating of the rectifiers.
read between 9.2 and 11.2 V DC.
An incorrect reading here could indicate that a fault in the
6.4.5 Input Waveform Test
customer connections loads down the supply. Disconnect
control wiring and repeat the test. If this test is successful,
Testing the current waveform on the input of the
then continue. Remember to check the customer
frequency converter can assist in troubleshooting mains
connections. If still unsuccessful, change the control card.
phase loss conditions or suspected problems with the SCR/
diode modules. Phase loss caused by the mains supply can
Replace the LCP with a known good one. If the problem be easily detected. In addition, the SCR/diode modules
6 6 persists, replace the control card in accordance with the
disassembly procedures.
control the rectifier section. If one of the SCR/diode
modules become defective or the gate signal to the SCR
lost, the frequency converter responds the same as loss of
6.4.4 Input Imbalance of Supply Voltage one of the phases.
Test
The following measurements require an oscilloscope with
Theoretically, the current drawn on all three input phases voltage and current probes.
must be equal. Some imbalance may be seen, however,
due to variations in the phase to phase input voltage, and
Under normal operating conditions, the waveform of a
single phase loads within the frequency converter.
single phase of input AC voltage to the frequency
converter appears as in Illustration 6.15.
A current measurement of each phase reveals the
balanced condition of the line. To obtain an accurate Input A
130BX142.10
reading, the frequency converter must run at its rated
load, or at a load of not less than 40%.
1. Perform the input voltage test before checking
the current, in accordance with procedure.
Voltage imbalances automatically result in a
corresponding current imbalance.
2. Apply power to the frequency converter and 0.0 ms 5 ms/Div.
place it in run. Illustration 6.15 Normal AC Input Voltage Waveform

3. Using a clamp-on ammeter (analog preferred),
read the current on each of three input lines at
L1(R), L2(S), and L3(T). The waveform shown in Illustration 6.16 represents the
Typically, the current should not vary from phase input current waveform for the same phase as shown in
to phase by more than 5%. Should a greater Illustration 6.15 while the frequency converter is running at
current variation exist, it indicates a possible 40% load. The two positive and two negative jumps are
problem with the mains supply to the frequency typical of any 6-diode bridge. It is the same for frequency
converter, or a problem within the frequency converters with SCR/diode modules.
converter. One way to determine if the mains
supply is at fault is to swap two of the incoming Input B
130BX143.10
phases. This assumes that two phases read one

current while the third deviates by more than 5%.
If all three phases are different from one another,
swap the phase with the highest current with the
phase with the lowest current.
4. Remove power to frequency converter.
5. Swap the phase that appears to be incorrect with 0.0 ms 5 ms/Div.
one of other two phases. Illustration 6.16 AC Input Current Waveform with Diode Bridge

With a phase loss, the current waveform of the remaining 1. Using a voltmeter, measure AC output voltage at
phases would take on the appearance shown in frequency converter motor terminals 96 (U), 97
Illustration 6.17. (V), and 98 (W). Measure phase-to-phase checking
U to V, then U to W, and then V to W.
Input B
130BX144.10
All three readings must be within 8 V AC of each other.
The actual value of the voltage depends on the speed at
which the frequency converter is running. The volts/hertz
ratio is relatively linear (except in VT mode) so at 60 Hz the
voltage should be approximately equal to the mains
voltage applied. At 30 Hz, it is about half of that, and so
on, for any other speed selected. The exact voltage
reading is less important than balance between phases.
0.0 ms 5 ms/Div.
Illustration 6.17 Input Current Waveform with Phase Loss.

2. Next, monitor three output phases at the motor
Always verify the condition of the input voltage waveform

terminals 96 (U), 97 (V), and 98 (W) with the
clamp on the ammeter. An analog device is 6 6
preferred. To achieve an accurate reading, run the
before forming a conclusion. The current waveform follows
frequency converter above 40 Hz as this is
the voltage waveform. If the voltage waveform is incorrect,
normally the frequency limitation of such meters.
proceed to investigate the reason for the AC supply
problem. If the voltage waveform on all three phases is The output current must be balanced from phase to phase
correct, but the current waveform is not, the input rectifier and no phase must be more than 2-3% different from
circuit in the frequency converter is suspect. Perform the another. If these tests are successful, the frequency
static soft charge and rectifier tests and also the dynamic converter is operating normally.
diode module test.
3. If a greater imbalance exists than described
6.4.6 Output Imbalance of Motor Supply above, disconnect the motor cables and repeat
Voltage Test the voltage balance test.
Since the current follows the voltage, it is necessary to
Check the balance of the output voltage and current to differentiate between a load problem and a frequency
measure the electrical functioning between the frequency converter problem. Should a voltage imbalance in the
converter and the motor. In testing the phase-to-phase output be detected with the motor disconnected, it is
output, both voltage and current are monitored. Conduct necessary to test the gate drive circuits for proper firing. If
static tests on the inverter section of the frequency output voltage is unbalanced, measure from ±UDC to the
converter before this procedure. output phases U, V and W respectively, to find out which
IGBT is not firing correctly. Then replace the power card to
If the voltage is balanced but the current is not, it determine if there is a gate firing problem. This applies for
indicates the motor is drawing an uneven load. This could frequency converters with separate IGBT modules. For
be the result of a defective motor, a poor connection in frequency converters with IGBTs on the power card, the
the wiring between the frequency converter and the solution may already be found.
motor, or a defective motor overload.
If the voltage was balanced, but the current imbalanced
If the output current is unbalanced as well as the voltage, when the motor was connected, the load is suspect. There
the frequency converter is not gating the output properly. could be a faulty connection between the frequency
It could be the result of a defective power card or an converter and motor or a defect in the motor itself. Look
improper connection of the output circuitry. for bad connections at any junctions of the output wires
including connections made to contactors and overloads.
NOTE Also, check for burned or open contacts in such devices.
Use an analog voltmeter for monitoring output voltage.
Digital voltmeters are sensitive to waveform and switching 6.4.7 Input Terminal Signal Tests
frequencies and commonly return erroneous readings.
The presence of signals on either the digital or analog
The initial test can be made with the motor connected and input terminals of the frequency converter can be verified
running its load. If suspect readings are recorded, on the frequency converter display. Digital or analog input
disconnect the motor cables to isolate the problem further. status can be selected or read in parameters 16-60 to
16-64.

Digital Inputs For analog input terminals 53 and 54, a DC voltage

With digital inputs displayed, control terminals 18, 19, 27, between 0 and +10 V DC must be read to match the
and 29 are shown left to right, with a 1 indicating the analog signal sent to the frequency converter. Or a reading
presence of a signal. of 0.9 to 4.8 V DC corresponds to a 4-20 mA signal.
If the desired signal is not present in the display, the
problem is either in the external control wiring to the NOTE
frequency converter or a faulty control card. To determine A (-) minus sign preceding any reading above indicates a
the fault location, use a voltmeter to test for voltage at the reversed polarity. In this case, reverse the wiring to the
control terminals. analog terminals.
Verify that the control voltage power supply is correct as

6.5 Initial Start Up Or After Repair Drive
follows.
1. Use a voltmeter for measuring voltage at control Tests
card terminal 12 and 13 with respect to terminal
Following any repair to a frequency converter or testing of
6 6 20. The meter should read 21-27 V DC.
If the 24 V supply voltage is not present, test the control
a frequency converter suspected of being faulty, the
following procedure must be followed. Following this
card in 6.2.1 Introduction. procedure will ensure that all circuitry in the frequency
converter is functioning properly before putting it into
If 24 V is present, proceed with checking the individual operation.
inputs as follows.
2. Connect the (-) negative meter lead to reference 1. Perform visual inspection procedures as described
terminal 20. in Table 4.1.
3. Connect the (+) positive meter lead to the 2. Perform static test procedures to ensure that the
terminals in sequence. frequency converter is safe to start.
The presence of a signal at the desired terminal must 3. Disconnect motor cables from output terminals
correspond to the digital input display readout. A reading (U, V, W) of the frequency converter.
of 24 V DC indicates the presence of a signal. A reading of
4. Apply AC power to frequency converter.
0 V DC indicates no signal is present.
5. Give the frequency converter a run command
and slowly increase reference (speed command)
Analog Inputs
to approximately 40 Hz.
The value of signals on analog input terminals 53 and 54
can also be displayed. The voltage or current in mA, 6. Using an analog volt meter or a DVM capable of
depending on the switch setting, is shown in line 2 of the measuring true RMS, measure phase-to-phase
display. output voltage on all three phases: U to V, U to
W, V to W. All voltages must be balanced within
If the desired signal is not present in the display, the
8 V. If measuring unbalanced voltage, refer to
problem is either in the external control wiring to the
6.4.2 Input Voltage Test.
frequency converter, or a faulty control card. To determine
the fault location, use a voltmeter to test for a signal at 7. Stop the frequency converter and remove input
the control terminals. power. Allow 20 minutes for DC capacitors to
fully discharge.
Verify that the reference voltage power supply is correct
as follows. 8. Reconnect motor cables to frequency converter
1. Use a voltmeter for measuring the voltage at output terminals (U, V, W).
control card terminal 50 with respect to terminal 9. Reapply power and restart frequency converter.
55. The meter must read between 9.2 and 11.2 V Adjust motor speed to a nominal level.
DC.
10. Using a clamp-on style ammeter, measure output
If the 10 V supply voltage is not present, conduct current on each output phase. All currents must
6.4.3 Basic Control Card Voltage Test earlier in this section. be balanced.
If 10 V is present, proceed with checking the individual

inputs as follows.
2. Connect the (-) negative meter lead to reference
terminal 55.
3. Connect the (+) positive meter lead to desired
terminal 53 or 54.

H-Frame Size Disassembly a... VLT® HVAC Basic Drive Service Manual
7 H-Frame Size Disassembly and Assembly Instructions
7.1 Electrostatic Discharge (ESD) 7.3 H6 Frame Size Disassembly and

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

Use correct ESD procedures to prevent damage to 7. Remove screws (T20) in cover plate.
sensitive components when servicing the frequency
8. Remove the control card mounting plate.
converter.
Reinstall in the reverse order.
NOTE
Frame size is used throughout this manual where ever
procedures or components differ between frequency
converters based upon the unit's physical size. Refer to
1.4.1 Frame Size Definitions to determine frame size
definitions.
7.2 General Disassembly Procedure

This procedure explains how to remove the outer parts of
the frequency converter that are common for H frame
sizes. When this procedure is completed, the inside
components are accessible.
1. Remove the plastic cover beneath the LCP with a

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

7.3.2 Heatsink Fan Assembly
130BC108.11
1
1. Unplug the fan cable

2 2. Remove 4 screws on fan cover plate.
3. Remove the fan.
3 Reinstall in the reverse order.
130BC113.11
4 1
7 7
3
Illustration 7.1 Control Card and Control Card Mounting Plate

Illustration 7.2 Heatsink Fan Assembly
1 LCP
2 Cradle 1 Fan cover plate
3 Control card 2 Screws
4 Control card mounting plate 3 Fan assembly
Table 7.1 Table 7.2

7.3.3 DC Coil 7.3.4 DC Link Card
1. Remove the 4 screws on the DC coil cover to 1. Remove the 6 screws on coil mounting plate.
access the DC coils.
2. Remove the coil mounting plate.
2. Remove the 4 screws to loosen the cables from
3. Loosen the 4 screws from the DC Link card.
the DC Link card.
4. Press one of the barbs to loosen the link card.
3. Remove the 6 screws on the DC coils (3 screws
on each coil). 5. Unplug the 10-pin ribbon cable and the filter
cable.
4. Remove the coils.
6. Remove the DC Link card.
Reinstall in the reverse order. Join the mounting snaps.
130BC109.11
1
130BC110.11
1
7 7
2
2
Illustration 7.3 DC Coil

Illustration 7.4 DC Link Card
1 DC coil cover
2 DC coils 1 Coil mounting plate
2 Capacitor bank metal cover
Table 7.3 3 DC link card
Table 7.4

7.3.5 RFI Filter 7.3.6 Power Card
1. Remove the protection cover. 1. Remove the 3 screws on the U V W cable

2. Remove the 6 distance bushes. connector.
3. Remove the 2 screws on the frame side. 2. Remove the connector.
4. Remove the 3 screws from U V W cables. 3. Remove the 3 small screws (T10) from the power
card.
5. Press the barbs on the side of the filter.
NOTE
6. Remove the RFI filter.
If it is difficult to get out the screws, use a magnet.
Reinstall in the reverse order. 4. Remove the 6 remaining screws (T20).
5. Lift the power card and slide it out of the frame.
130BC111.11
NOTE
If it is difficult to remove the power card, it is helpful to
7 7 press the frame sides outwards while pressing the barbs

on the side of the power card.
2
130BC112.11
1

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

130BC108.11
1
7.4 H7 Frame Size Disassembly and
2
7.4.1 Control Card and Control Card
Mounting Plate
1. Remove the LCP by pressing the barbs on the 3

side.
2. Remove the foil.
3. Remove the 3 screws (T10).
4
4. Gently, lift off the control card.
5. Press the barb on the LCP ribbon cable and pull
it out of the control card mounting plate.
6. Remove the mounting plate.
7 7
1 LCP
2 Cradle
3 Control card
4 Control card mounting plate
Table 7.7

7.4.2 Power Card 7.4.3 Inrush Card
1. Remove the LCP ribbon cable from the power 1. Remove the 2 screws (T20) from the filter shield.
card.
2. Remove the shield.
2. Unplug all other cables from the power card,
3. Remove the 4 screws (T20) from the power card
including the 3 gate cables at the bottom of the
mounting plate.
card.
4. Remove the power card mounting plate.
3. Remove the 3 screws (T20) from the mounting
plate. 5. Unplug all cables from the inrush card.
4. Remove the power card by pushing in the 6 6. Remove the 6 screws (T20) from the inrush card.
retaining clips. 7. Remove the inrush card.
NOTE Reinstall in the reverse order.
Use a screwdriver if the retaining clips are hard to reach.
5. Slide the power card out and remove it.
130BC346.10
1
7 7
130BC125.11
Illustration 7.9 Inrush Card
Illustration 7.8 Power Card 1 EMC shield

3 Inrush card
1 Power card
Table 7.9
Table 7.8

7.4.4 RFI Filter 7.4.5 Relay Transducer Card
1. Remove the red/black cables from the filter cable. 1. Unplug cables on the relay transducer card.
2. Remove the protective foil. 2. Loosen the right cable connector using a hex 5
3. Remove the 3 filter cables screws using a hex 8 key.
key. 3. Open the plastic clamp to remove the cables
4. Remove the 2 screws (T20) from the EMC shield. from the connector.
5. Remove the EMC shield. 4. Remove the 2 screws (T20) from the holding
bracket.
6. Remove the 8 screws (T20) on the filter cable
cover. 5. Remove the holding bracket.
7. Loosen the left cable connector using a hex 5 key 6. Remove the 3 cable screws (T20).
7. Remove the 3 screws on relay card (T20).
8. Remove the entire filter assembly.
8. Remove the Relay card by pushing in the
retaining clips on the standoffs. Use a screwdriver
if necessary.
7 7
130BC126.11
1
9. Remove the mounting plate.
2
130BC127.11
1
Illustration 7.10 RFI Filter
1 RFI filter
2 Screws Illustration 7.11 Relay or Transducer Card
3 EMC shield
Table 7.10
1 Relay transducer card
2 Relay card mounting plate
Table 7.11

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

connector plate.
2. Remove the cable connector plate.
3. Loosen the coil cables (T20).
7 7 4. Unplug the cables.

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

9. Remove the 2 screws (T20) from each IGBT.
1 Cable mounting plate
10. Remove the IGBTs. 2 IGBT
CAUTION 3
4
Bus bar
Capacitor
The IGBTs and the heatsink have thermal paste on them.
Be careful not to touch the paste directly as it is Table 7.12
poisonous.
11. Remove the thermal paste from the IGBT.
12. Clean the heatsink.

7.4.8 Heatsink Fan Assembly 7.4.9 DC Coil
1. Remove the 4 screws (T20) from the fan cover 1. Remove the 4 screws (T20) from the DC coil
plate. cover plate.
2. Press the fan cover plate outwards using a 2. Remove the 4 screws (T20) from the heatsink.
screwdriver.
3. Remove the heatsink.
3. Remove the fans and the fan cover plate.
4. Remove 4 screws (T20) from each of the 2 DC
Reinstall in the reverse order. Coils.
5. Remove the coils.
130BC132.11
130BC133.12
1 1
2
7 7
3
1 Fan cover
2 Fan assembly
Table 7.13
1 DC coil cover plate

2 Heatsink
3 DC coil
Table 7.14

7.4.10 Capacitor Bank

1. Remove the foil.
2. Remove the 6 screws on the bottom plate.
3. Remove the bottom plate. 7.5.1 Control Card and Control Card
Mounting Plate
4. Remove the 4 screws (T20) from the capacitor
mounting plate.
1. Remove the LCP by pressing the barbs on the
5. Remove the mounting plate. side.
6. Turn the capacitor bank upside-down. 2. Remove the foil.
7. Remove the hex nut with a hex 19 key. 3. Remove the 3 screws (T10).
8. Remove the capacitor. 4. Gently, lift off the control card.
Reinstall in the reverse order. 5. Press the barb on the LCP ribbon cable and pull
it out of the control card mounting plate.
1 6. Remove the mounting plate.
130BC348.10
7 7 Reinstall in the reverse order.
Illustration 7.15 Capacitor Bank
1 Foil
2 Bottom plate
3 Capacitor bank
Table 7.15

7.5.2 Power Card
130BC108.11
1
1. Remove 2 screws (T20) from the EMC shield.
2. Remove cables from EMC shield.
2
3. Remove the EMC shield.
4. Remove the LCP ribbon cable from the power
3 card.
5. Unplug all other cables from the power card.
6. Remove the 3 screws (T20) from the mounting
plate.
4 7. Remove the power card by pushing in the 6
retaining clips.
NOTE
Use a screwdriver if the retaining clips are hard to reach.
8. Slide the power card out and remove it.
Reinstall in the reverse order. 7 7
130BC125.11
1
1 LCP
2 Cradle
3 Control card
Table 7.16
1 Power card
Table 7.17

7.5.3 Inrush Card 7.5.4 Rectifier Modules
1. Remove the 4 screws (T20) from the power card

mounting plate.
CAUTION
Wear protective gloves when cleaning up the thermal
2. Remove the power card mounting plate. paste as it is poisonous.
3. Unplug all cables from the inrush card.
4. Remove the 6 screws (T20) from the inrush card. 1. Remove cables and foil.
5. Remove the inrush card. 2. Remove coil cords (T20).
Reinstall in the reverse order. 3. Remove 6 screws (T25).

4. Remove screws in coil cables (T20).
5. Remove the 6 screws (T25) from the bar.
130BC346.10
1
6. Remove the bar.

7. Loosen and remove the 3 cables using a hex 10
key.
7 7 8.
9.
Remove the plastic cover.
Remove the 2 screws (T20) on each of the
rectifier modules
2 10. Remove the thermal paste paper.
11. Clean up any excessive thermal paste.
3
Illustration 7.18 Inrush Card
1 EMC shield
3 Inrush card
Table 7.18

7.5.5 RFI Filter
130BC128.11
1
1. Remove the 3 screws (T20) from the small EMC

2 shield.
2. Remove the EMC shield.
3. Loosen left cable connector using a hex 8 key.
3 4. Remove the 4 screws (T20) from the filter.
4
5. Remove the entire filter assembly.
130BC126.11
1
2
3 7 7
Illustration 7.19 Rectifier Modules
1 Foil Illustration 7.20 RFI Filter

2 Bus bar
3 Plastic cover
4 Rectifier modules 1 RFI filter
2 Screws
Table 7.19 3 EMC shield
Table 7.20

7.5.6 Relay Transducer Card 7.5.7 IGBT
1. Remove the 4 screws (T20) on the plate.

CAUTION
2. Carefully remove cables before removing the Wear protective gloves when cleaning up the thermal
plate. paste as it is poisonous.
3. Loosen the cables in the right cable connector
using a hex 8 key. 1. Remove the 2 screws from the cable retaining
4. Pull out the cables. guide.
5. Remove the 3 screws (T30) on the relay card. 2. Remove the cable retaining guide.
6. Remove the 2 10-pin ribbon cables. 3. Remove the 4 screws (T20) from the cable
connector plate.
7. Remove the 3 screws (T20) from the relay card.
4. Remove the cable connector plate.
8. Press the 3 retaining clips.
5. Remove the 2 cable screws (T20)
9. Remove the relay card.
6. Remove the 2 screws (T30) in each of the 2
10. Remove the relay card mounting plate. capacitors.
7 7 Reinstall in the reverse order. 7. Remove the capacitors.
8. Remove the 2 screws (T30) from the bus bar.
130BC127.11
1
9. Remove the 4 screws (T20) holding the
capacitors.
10. Remove the bus bar.
2
11. Remove the gate cables from the IGBTs.
12. Remove the 4 screws from each IGBT.
13. Remove the thermal paper.
14. Remove the thermal paste from the IGBTs and
the heatsink.
Illustration 7.21 Relay Transducer Card

2 Relay card mounting plate
Table 7.21

1 7.5.8 Heatsink Fan Assembly
130BC131.11
1. Remove the 4 screws (T20) from the fan cover
plate.
2. Press the fan cover plate outwards using a
4 screwdriver.
3. Remove the fans and the fan cover plate.
3
2
130BC132.11
2
1
7 7
Illustration 7.22 IGBT


2 IGBT 1 Fan cover
3 Bus bar 2 Fan assembly
4 Capacitor
Table 7.23
Table 7.22

7.5.9 DC Coil 7.5.10 Capacitor Bank
1. Remove the 4 screws (T20) from the DC coil 1. Remove the foil.
cover plate. 2. Remove the 4 screws from the bottom plate.
2. Remove the 4 screws (T20) from the heatsink. 3. Remove the bottom plate.
3. Remove the heatsink. 4. Remove the 4 screws from the capacitor bank
4. Remove 4 screws (T20) from each of the 2 DC assembly.
Coils. 5. Remove the assembly.
5. Remove the coils. 6. Turn the assembly upside-down.
Reinstall in the reverse order. 7. Remove the 2 hex nuts with a hex 19 key.
8. Remove the 2 capacitors.
130BC133.12
2
130BC348.10
7 7
3
1 DC coil cover plate

2 Heatsink
3 DC coil Illustration 7.25 Capacitor Bank
Table 7.24
1 Foil
2 Bottom plate
3 Capacitor bank
Table 7.25

7.6.2 Power Card Cover

1. Press and loosen the 3 barbs at the bottom, and
Assembly Instructions the 3 barbs at the top.
7.6.1 Control Card and Control Card 2. Remove the power card cover.
Mounting Plate Reinstall in the reverse order. Join the mounting snaps.
1. Remove the LCP cradle. LCP cradle can be

1
130BC103.11
removed by hand.
2. Remove 3 screws (T10) securing the control card
mounting plate to the control assembly support
bracket.
3. Carefully lift out the control card.
Reinstall in the reverse order. 130BC101.11
7 7
1
3
Illustration 7.27 Power Card Cover
1 Power card cover
Table 7.27
1 LCP
3 Control card
Table 7.26

7.6.3 Power Card 7.6.4 Heatsink and DC Coils
1. Remove the 4 screws (T10) for the DC coil cables. 1. Remove the 7 mounting screws from top surface.
2. Remove the 5 screws (T10) for the heatsink. 2. Press and loosen the 3 barbs at the bottom.
3. Remove the 4 IGBT screws (T25). 3. Unplug the DC coil cables.
4. Unplug fan cable connector. 4. Remove the heatsink.
CAUTION 5. Lift out the DC coils.
The power card and the heatsink have thermal paste on Reinstall in the reverse order.
them. Wear protective gloves as the paste is poisonous.
5. Lift out the power card.
130BC105.11
6. Remove the capacitor bank gasket.
130BC104.11
7 7 1
Illustration 7.29 Heatsink

1 Heatsink
Table 7.29
1 Power card
130BC106.11
Table 7.28
1 DC coil
Table 7.30

7.6.5 Heatsink Fan Assembly
1. Remove 2 screws (T10) on the DC coil mounting

plate
2. Remove the plate.
3. Press and loosen the 2 barbs on the fan.
4. Remove the fan.
130BC107.11
7 7
1
1 Heatsink fan
2 Fan mounting plate
Table 7.31

I-Frame Size Disassembly an... VLT® HVAC Basic Drive Service Manual
8 I-Frame Size Disassembly and Assembly Procedures
130BC059.11
1
8.1 General Disassembly Procedure

This procedure explains how to remove the outer parts of 2
the frequency converter that are common for all I frame

sizes. When this procedure is completed, the inside
components are accessible. 3
4
1. Loosen and remove the 4 screws (T20) from the
5
front cover.
2. Remove the front cover.
3. Remove the screw and sheet metal next to the
EMC shield.
4. Loosen and remove the 4 screws (T20) from the
cable entry.
8 8 5. Remove the cable entry.
8.2 I6 Frame Size Disassembly and

8.2.1 Control Card and Control Card
Mounting Plate
1. Remove LCP cradle. Illustration 8.1
2. Remove 3 screws (T12) on the control board.

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


8.2.2 Cable Mounting Plate 8.2.3 Heatsink Fan Assembly
1. Remove the ribbon cable. 1. Unplug cable from power card.

2. Remove 1 screw (T20) from shield metal. 2. Remove 2 screws (T20) from the fan mounting
3. Use a flat screwdriver to release the retainers and plate.
connection terminals. 3. Push the cable downwards. Use a screwdriver to
4. Use a hex 4 key to loosen the screws in the cable press the gasket down through the entry.
connector. 4. Pull out fan assembly.
5. Pull out the cables. Reinstall in the reverse order.
6. Slide the connector to the side and remove it.
130BC064.11
7. Remove 2 screws (T20) from the mounting plate.
130BC060.11 2
8 8
2
1
1 Fan cover
Illustration 8.2 Cable Mounting Plate 2 Fan assembly
Table 8.3
1 EMC shield
Table 8.2

8.2.4 SMPS Card 8.2.5 Bus Bar Unit
1. Remove the 3 black plastic covers. 1. Remove the 2 screws from the snubber capacitor
2. Unplug and remove the fan. on the bus bar unit.
3. Unplug all other cables. 2. Remove the snubber capacitor.
4. Remove the 2 screws (T20) at MK101. 3. Use a Hex 8 key to remove 2 screws from the bus
bar unit.
5. Remove the 3 screws (T20) at K103A, K104A, and
K105A. 4. Remove the 6 small screws (T10).
6. Remove the 4 screws (T20) and from the SMPS 5. Remove the remaining 9 screws (T20).
card. 6. Unplug cables.
7. Lift off the SMPS card. 7. Lift out the bus bar unit.
Reinstall in the reverse order. Reinstall in the reverse order.
1
130BC061.11
130BC062.11
1
8 8
Illustration 8.4 SMPS Card
1 SMPS card
Table 8.4
Illustration 8.5 Bus Bar Unit
1 Fan
2 Bus bar unit
Table 8.5

8.2.6 Power Card 8.2.7 DC Coil
1. Remove 7 screws (T20) 1. Remove 4 screws (T20) from the coil.

2. Remove 5 screws (T10) on the Power Card. 2. Lift the coil.
3. Lift out the power card. Reinstall in the reverse order.
130BC065.11
130BC063.11
1
Illustration 8.7 8 8
1 DC coil
1 Power card
Table 8.7
Table 8.6

8.2.8 RFI Filter

1. Remove 2 screws (T20) from the filter.
2. Lift out the filter.
Reinstall in the reverse order. 8.3.1 Control Card and Control Card
Mounting Plate
130BC066.11
1. Remove 2 screws (T20) from the 2 cover plates.
1
2. Remove the LCP cradle.
3. Remove 3 screws (T10) from the control card.
5. Remove 2 screws (T20) from the bracket next to
the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8 8 Illustration 8.8
1 RFI filter
Table 8.8

8.3.2 Power Card
130BC059.11
1
1. Unplug and remove the LCP ribbon cable.

2
3. Remove 3 screws (T20) on the power card.
3
4. Remove the power card.
5
130BC070.11
1
8 8
Illustration 8.10
Illustration 8.9 Control Card Mounting Plate
1 Power card
1 LCP and cradle
2 Control card and mounting plate Table 8.10
3 EMC shield
Table 8.9

8.3.3 Power Card Mounting Plate 8.3.4 Inrush Card
1. Remove 4 screws (T20) from the power card 1. Unplug all cables.
mounting plate.
2. Remove 6 screws (T20) from the inrush card.
2. Remove the power card mounting plate with the
3. Remove the inrush card.
fan attached.
130BC072.11
1
130BC071.11
1
8 8
Illustration 8.12
Illustration 8.11
1 Inrush card
Table 8.12
Table 8.11

8.3.5 Bus Bar 8.3.6 RFI Filter
1. Unplug and remove the red/black cable. 1. Unplug the 3 filter cables from the thyristors
2. Remove the black plastic cover. using a hex 8 key.
3. Remove 8 screws (T20) from the support bracket. 2. Loosen the 3 cables from the cable connector
using a hex 5 key.
4. Remove the bus bar assembly.
3. Remove 3 screws (T20) from the support bracket.
4. Remove support bracket.
5. Remove 4 screws (T20) from the RFI Filter.
130BC073.11
1
6. Remove the entire assembly.
130BC076.11
1
8 8
Illustration 8.13
1 Bus bar
Table 8.13 Illustration 8.14
1 RFI filter
Table 8.14

8.3.7 Relay Transducer Card 8.3.8 Fan
1. Remove the 3 clamps on each side of the 2 cable 1. Remove 2 screws (T20) on the fan bracket.
connectors. 2. Remove 2 screws (T20) from the fan.
2. Remove the cable connector with no cables 3. Remove the fan.
attached.
3. Remove 3 screws (T20) from the support bracket.
4. Loosen the 3 cables from the relay transducer 1
130BC077.10
card.
5. Remove the cable connector with cables and
retaining guide attached.
6. Unplug all other cables from the relay transducer
card.
7. Remove the 3 screws (T20)
8. Remove the relay transducer card.
8 8
130BC075.11
Illustration 8.16
1 Fan
Table 8.16
Illustration 8.15
Table 8.15

8.3.9 Terminal Plate 8.3.10 DC Bus Bar Assembly
1. Remove the black plastic cover. 1. Remove 2 screws (T20) from the 2 snubbers.
2. Remove 4 screws (T20) on the cover plate. 2. Remove the snubbers.
3. Remove the terminal plate. 3. Loosen and remove cables from bus bar assembly
Reinstall in the reverse order. and DC coil.
4. Remove 6 screws (T20) from the bus bar
assembly.
130BC078.11
1 5. Remove the bus bar assembly.
130BC080.11
1
8 8
Illustration 8.17
1 Terminal plate
Table 8.17 Illustration 8.18 DC Bus Bar Assembly
1 DC bus bar assembly
Table 8.18

8.3.11 Heatsink Fan Assembly 8.3.12 Capacitor Bank
1. Remove gate cables from IGBTs. 1. Remove 4 screws (T20) from each of the
2. Remove 2 screws (T20) from the heatsink fan capacitors.
assembly. 2. Remove the capacitors.
3. Push the fan cable down through the gasket. Reinstall in the reverse order.
4. Carefully press the gasket down with a
130BC081.11
screwdriver.
1
5. Remove the fan assembly.
130BC350.10
2
1
8 8 Illustration 8.20 Capacitors
1 Capacitors
Illustration 8.19 Table 8.20
1 Fan cover plate

2 Fan assembly
Table 8.19

8.3.13 DC Coil 8.3.14 IGBT
1. Remove 5 screws (T20) on the potted coil. 1. Remove 2 screws (T20) from each of the 3 IGBTs.
2. Remove the DC coil.
CAUTION
Reinstall in the reverse order. The IGBTs and the heatsink have thermal paste on them.
Wear protective gloves as the paste is poisonous.
2. Remove all IGBTs.
130BC082.11
1
130BC083.11
2
1
Illustration 8.21 DC Coil 8 8

1 Bus bar
2 DC coil
Table 8.21
1 IGBT
Table 8.22

8.3.15 Thyristor
1. Remove 2 screws (T20) from each of the 3
thyristors.
Assembly Procedure
CAUTION 8.4.1 Control Card and Control Card

Mounting Plate
The thyristors and the heatsink have thermal paste on
them. Wear protective gloves as the paste is poisonous.
1. Remove 2 screws (T20) from the 2 cover plates.
2. Remove the thyristors.
2. Remove the LCP cradle.
3. Remove 3 screws (T10) from the control card.
130BC074.11
1
5. Remove 2 screws (T20) from the bracket next to

the control card mounting plate.
6. Remove 4 screws (T20) to remove the control
card mounting plate.
7. Unplug the LCP ribbon cable.
8 8 Reinstall in the reverse order.
Illustration 8.23 Thyristor
1 Thyristor
Table 8.23

8.4.2 Power Card
130BC059.11
1
1. Unplug and remove the LCP ribbon cable.

2
3. Remove 3 screws (T20) on the power card.
3
4. Remove the power card.
5
130BC070.11
1
8 8
Illustration 8.25
Illustration 8.24 Control Card Mounting Plate
1 Power card
1 LCP and cradle
2 Control card and mounting plate Table 8.25
3 EMC shield
Table 8.24

8.4.3 Power Card Mounting Plate 8.4.4 Inrush Card
1. Remove 4 screws (T20) from the power card 1. Unplug all cables.
mounting plate.
2. Remove 6 screws (T20) from the inrush card.
2. Remove the power card mounting plate with the
3. Remove the inrush card.
fan attached.
130BC072.11
1
130BC071.11
1
8 8
Illustration 8.27
Illustration 8.26
1 Inrush card
Table 8.27
Table 8.26

8.4.5 Bus Bar 8.4.6 RFI Filter
1. Unplug and remove the red/black cable. 1. Unplug the 3 filter cables from the thyristors
2. Remove the black plastic cover. using a hex 8 key.
3. Remove 6 screws (T20) and 2 screws (T30) from 2. Loosen the 3 cables from the cable connector
the support bracket. using a hex 5 key.
4. Remove the bus bar assembly. 3. Remove 3 screws (T20) from the support bracket.
Reinstall in the reverse order. 4. Remove support bracket.

5. Remove 4 screws (T20) from the RFI Filter.
6. Remove the entire assembly.
130BC073.11
1
130BC076.11
1
8 8
Illustration 8.28
1 Bus bar
Illustration 8.29
Table 8.28
1 RFI filter
Table 8.29

8.4.7 Relay Transducer Card 8.4.8 Terminal Plate
1. Remove 2 screws (T20) from each of the 2 cable 1. Remove 4 screws (T20) on the cover plate.
connectors.
2. Remove the complete terminal plate including
2. Remove the cable connector. cable connector.
3. Remove 3 screws (T20) from the support bracket. Reinstall in the reverse order.
4. Loosen the 3 cables (T30) from the relay
transducer card.
130BC078.11
1
5. Unplug all other cables from the relay transducer
card.
6. Remove the 3 screws (T20).
7. Remove the relay transducer card.
Reinstall in the reverse order. 130BC075.11
8 8 Illustration 8.31
1 Terminal plate
Table 8.31
Illustration 8.30 Relay Transducer Card
Table 8.30

8.4.9 DC Bus Bar Assembly 8.4.10 Heatsink Fan Assembly
1. Remove 2 screws (T30) from each of the 2 1. Remove 4 screws (T20) from the heatsink fan
snubbers. assembly.
2. Remove the snubbers. 2. Push the cables down through the gaskets.
3. Loosen and remove the 2 cables from bus bar 3. Carefully press the gaskets down with a
assembly and DC coil. screwdriver.
4. Remove 2 screws (T30). 4. Remove the fan assembly.
5. Remove 8 screws (T20) on top of the bus bar Reinstall in the reverse order.
assembly.
6. Remove the bus bar assembly.
130BC094.11
1
130BC080.11
2
8 8
1 Fan cover plate

2 Heatsink fan
Illustration 8.32 DC Bus Bar Assembly Table 8.33
1 Bus bar assembly
Table 8.32

8.4.11 Capacitor Bank 8.4.12 DC Coil
1. Remove 4 screws (T20) from each of the 1. Remove 5 screws (T20) on the potted coil.
capacitors.
2. Remove the DC coil.
2. Remove the capacitors.
130BC082.11
1
130BC081.11
1
8 8 Illustration 8.34 Capacitors

1 Bus bar
1 Capacitors 2 DC coil
Table 8.34 Table 8.35

8.4.13 IGBT 8.4.14 Thyristor
1. Remove 4 screws (T20) from each of the 3 IGBTs. 1. Remove 2 screws (T20) from each of the 3
thyristors.
CAUTION
The UGBTs and the heatsink have thermal paste on them. CAUTION
Wear protective gloves as the paste is poisonous. The thyristors and the heatsink have thermal paste on
2. Remove all IGBTs. them. Wear protective gloves as the paste is poisonous.
2. Remove the thyristors.
130BC083.11
1
130BC074.11
1
8 8

Illustration 8.37 Thyristor
1 IGBT
1 Thyristor
Table 8.36
Table 8.37

Block Diagrams VLT® HVAC Basic Drive Service Manual
9 Block Diagrams
9.1.1 H6 Frame Size
130BC339.10
AC / DC BR DC /AC
RFI (variations)
Inrush
L1 A
U
MAINS
Motor
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
Tmp_ VGDS
P_BRF
7 xGD
RL 2
SMPS EEP RL 2
RFI _RL 1
RFI _ RL 2 VGD +/- 15 /UDC -/-5
Inrush
VCX (GX ) 5V
Tmp _VGDS
D-I /O
9 9
UINV_N VCC
A-I /O VCC (GND) 5V
FFB 1 fans
VDD (GND) 24V
Imax2 comp.
Shift
LCP ACP MCP
Display
CAN
control
Illustration 9.1

Block Diagrams
Brake not connected to terminal on FC101
AC /DC BR DC /AC 130BC137.10

9.1.2 I6 Frame Size
RFI (variations)
Inrush A
L1 U
x3 RFI _ RL 2 x3 A
L2 V
Motor
MAINS
L3 W
o A
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
RL 2
EEP P_ BRF
7 xGD
SMPS
RL 2
RFI _ RL 1
Tmp _ VGDS

Inrush
Control Card
VLT® HVAC Basic Drive Service Manual
SAFE _ FB
UINV_ P VCX (GX ) 5V
MG90X202 - VLT® is a registered Danfoss trademark

Tmp _VGDS
D-I/O
A-I/O UINV_ N VCC
VCC (GND ) 5V
FFB 1 fans
VDD (GND ) 24V
Ext. Imax2 comp.
FAN 2
FFB 2 fans Level
Shift
LCP ACP MCP
Display
CAN
control
Illustration 9.2
97
9 9
9 9
98
Thyristor x3 AC /DC Brake not connected to terminal on FC 101
Block Diagrams
BR DC /AC
130BC340.10
RFI (variations)
A
U
L1 x3 A V
Motor
L2 W
o A
MAINS
L3 C
9.1.3 H7, H8, I7, I8 Frame Size

FB GD GD conv.
RFI _ RL 2
Inrush GD
Supply
Pulse
RL 1
uC+ RL 1
RL 2
EEP
7 xGD
RFI _ RL 1 P _BRF
Tmp _VGDS
RL 2
Inrush
SMPS SAFE _ FB
Control Card UINV_ P
Tmp _ VGDS
UINV_N VCC
Int.
D-I/O VCX (GX) 5V

A-I/O fans
FAN
Isol. RS 485
VCC (GND) 5V FFB

E _FAN Level
E _FFB Shift
LCP ACP MCP Ext.

Display CAN
fans
panel
Illustration 9.3
Block Diagrams
Brake not connected to terminal on FC101
130BC136.10
AC/DC BR DC /AC
RFI (variations)
Inrush
9.1.4 H9 Frame Size
A
L1 U
x3 RFI _ RL 2 x3 A
L2 V
Motor
MAINS
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
uC+ RL 1
EEP RL 2
P _BRF
7 xGD
SMPS
RL 2
RFI _ RL 1
Tmp_VGDS
RFI _ RL 2
VGD+/- 15/UDC-/-5
Inrush
Control Card UINV _ P SAFE _ FB
VCX (GX ) 5V
Tmp_VGDS

D-I/O UINV _ N
VCC ( GND) 5V VCC
A-I/O
FAN 1 Int.
Isol. RS 485
FFB 1 fans
VDD ( GND ) 24V
Imax2 comp.
VGD +/- 15/UDC -/-5 Level
Shift
LCP ACP MCP
Display
CAN
panel
Illustration 9.4
99
9 9
9 9
100
Block Diagrams
AC /DC BR DC /AC 130BC138.10

RFI (variations)
Inrush
9.1.5 H10 Frame Size
A
L1 U
x3 RFI _ RL 2 x3 A
L2 V
Motor
MAINS
L3 A W
o
C
RFI _ RL 1
BR BR INV Temp.
FB GD GD conv.
GD
Supply
RL 1
RL 1
uC+
RL 2
EEP P_ BRF
7 xGD
SMPS
RL 2
RFI _ RL 1
Tmp _ VGDS
RFI _ RL 2 VGD +/- 15/UDC -/-5

Inrush
SAFE _ FB
Control Card UINV _ P VCX ( GX) 5V

Tmp _ VGDS
D-I/O

UINV _ N VCC
A-I/O VCC (GND ) 5V
FAN 1 Int.
Isol. RS 485
FFB 1 fans
VDD (GND ) 24V
Imax2 comp.
VGD +/- 15/UDC-/-5 Level
Shift
LCP ACP MCP
Display
CAN
control
panel
”Internal supply bus”
Illustration 9.5
Index VLT® HVAC Basic Drive Service Manual
Index
H
Heatsink........ 11, 12, 13, 28, 58, 64, 65, 70, 72, 74, 75, 77, 86, 93,
A 95
AMA........................................................................ 34, 36, 37, 39, 41, 42
Analog
Inputs................................................................................................... 36 I
Output........................................................................................... 19, 42 IGBT...................................... 12, 13, 16, 24, 28, 34, 41, 43, 44, 49, 53
Signal............................................................................... 19, 20, 36, 56 Impedance.................................................................. 22, 26, 43, 44, 45
Signals.................................................................................................. 18
Input
Cabling................................................................................................. 52
C Signal............................................................................... 18, 20, 39, 42
Cable Cross Section............................................................................. 22 Terminals............................................................................................. 36
Capacitor Inverter Time.......................................................................................... 41

Capacitor......... 12, 13, 15, 16, 22, 24, 25, 40, 41, 49, 50, 57, 64
Bank............................................................................................... 26, 50
L
Circuitry..................................... 18, 23, 24, 31, 34, 39, 42, 48, 55, 56 LCP......................... 15, 16, 18, 19, 23, 33, 34, 54, 57, 61, 66, 67, 76
Control LED................................................................................... 6, 33, 35, 36, 53
Card............................................... 20, 23, 24, 25, 33, 36, 42, 53, 56
Terminal....................................... 18, 19, 20, 21, 23, 33, 36, 42, 56
Wiring....................................................................... 18, 19, 33, 34, 56 M
Current Main Assemblies............................................................................... 6, 23
Rating................................................................................................... 37 Motor
Waveform............................................................................. 26, 28, 54 Current................................................................................................. 39
Data................................................................................................ 37, 39
Power................................................................................................... 39
D
DC
Bus Capacitor..................................................................................... 53 O
Bus Inductor....................................................................................... 26 Output
Capacitor............................................................................................. 56 Output...... 17, 18, 19, 20, 23, 24, 28, 31, 32, 34, 35, 38, 39, 41,
Coil...................................................................... 14, 15, 16, 24, 41, 50 42, 44, 48, 49, 53, 55, 56
Deceleration Rate................................................................................. 41 Current................................................................................................. 37
Short Circuit....................................................................................... 24
Digital
Signal...................................................................................... 19, 24, 48
Input....................................................................................... 18, 20, 37
Voltage....................................................... 18, 34, 40, 42, 53, 55, 56
Output.................................................................................... 19, 20, 24
Over
Diode............................................................... 24, 41, 48, 49, 50, 54, 55
Current.......................................................................................... 17, 41
Display Line............................................................................................ 19 Temperature............................................................................... 35, 43
Over-current........................................................................................... 35
E
Earth Cabling.......................................................................................... 22
P
Electrical Installation In General...................................................... 10 Peak Voltage........................................................................................... 25
EMC......................................................................... 32, 38, 43, 63, 67, 69 Phase Loss................................................................... 35, 37, 41, 42, 54
Power
Card.... 12, 13, 14, 15, 16, 20, 23, 24, 25, 50, 55, 60, 62, 67, 68,
F 79, 81, 82, 89, 90
Form
Cardcontrol Card.............................................................................. 28
A............................................................................................................. 20
Component................................................................................. 32, 48
C Relay........................................................................................... 19, 20
Programming......................................................................................... 36
Pulse Reference..................................................................................... 19
G
Gate Signal................................................................................ 28, 43, 54 PWM............................................................................................ 23, 28, 44
Gating Circuit......................................................................................... 25
R
Reference Signal................................................................................... 34

Relay......................................................... 12, 13, 15, 16, 24, 26, 63, 70

Remote Input.................................................................................. 18, 19
Reset................................................................................................... 37, 39
RFI Relay................................................................................................... 26
RS-485......................................................................................... 18, 19, 20
S
SCR...................................................................................................... 25, 54
Serial Bus...................................................................... 18, 19, 33, 34, 36
Short Circuit................................................................ 17, 38, 48, 49, 50
Signal Conductor.................................................................................. 44
Status
Line........................................................................................................ 18
Messages...................................................................................... 18, 33
Switch................................................................................................ 24, 32
Switching Function.............................................................................. 24
T
Thermal Sensor............................................................................... 28, 43
Thyristor................................................................................................... 24
Torque Limit.................................................................................... 41, 43
Trip
Condition............................................................................................ 34
Lock................................................................................................ 35, 36
V
Voltage
Imbalance............................................................................. 37, 43, 55
Waveform.................................................................................... 28, 55
W
Waveform............................................... 23, 26, 28, 41, 42, 44, 54, 55


www.danfoss.com/drives
130R0242 MG90X202 Rev. 2012-05-22
*MG90X202*

Service Manual: VLT HVAC Basic Drive FC 101

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MAKING MODERN LIVING POSSIBLE

2 Frequency Converter Control 18

3 Internal Frequency Converter Operation 23

MG90X202 - VLT® is a registered Danfoss trademark 1

4.4 Visual Inspection 32

5 Frequency Converter and Motor Applications 41

2 MG90X202 - VLT® is a registered Danfoss trademark

6.4.3 Basic Control Card Voltage Test 53

7 H-Frame Size Disassembly and Assembly Instructions 57

MG90X202 - VLT® is a registered Danfoss trademark 3

7.6.2 Power Card Cover 73

8 I-Frame Size Disassembly and Assembly Procedures 76

4 MG90X202 - VLT® is a registered Danfoss trademark

8.4.9 DC Bus Bar Assembly 93

MG90X202 - VLT® is a registered Danfoss trademark 5

1. DO NOT touch electrical parts of the frequency

1.2 Product Overview Voltage [V] Power Range [kW]

6 MG90X202 - VLT® is a registered Danfoss trademark

1.4.1 Frame Size Definitions 1 1

Table 1.2 FC 101 Frequency Converters 200-240 V AC

MG90X202 - VLT® is a registered Danfoss trademark 7

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

Table 1.3 FC 101 Frequency Converters 380-480 V AC

8 MG90X202 - VLT® is a registered Danfoss trademark

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

Table 1.4 FC 101 Frequency Converters 525–600 V AC

1.5 Tools Required

ESD Protection Kit Wrist strap and Mat

Table 1.5 Required Tools

Additional Tools Recommended for Testing

• Clamp-on style ammeter

MG90X202 - VLT® is a registered Danfoss trademark 9

1 1 1.6 Electrical Installation in General

Power [kW] Torque [Nm]

Power [kW] Torque [Nm]

Power [kW] Torque [Nm]

Table 1.8 Details of Tightening Torques

10 MG90X202 - VLT® is a registered Danfoss trademark

1.7 Exploded Views – H Frame Size 1 1

Illustration 1.1 Exploded View - H6 Frame Size

1 Blind cover 10 Filter protection cover

MG90X202 - VLT® is a registered Danfoss trademark 11

Illustration 1.2 Exploded View - H7 Frame Size

1 Blind cover 13 Relay/transducer card mounting plate

12 MG90X202 - VLT® is a registered Danfoss trademark

Illustration 1.3 Exploded View - H8 Frame Size

1 LCP 12 SMPS card

MG90X202 - VLT® is a registered Danfoss trademark 13

Illustration 1.4 Exploded View - I6 Frame Size

1 Local Control Panel (LCP) 9 DC coil

14 MG90X202 - VLT® is a registered Danfoss trademark

Illustration 1.5 Exploded View - I7 Frame Size

1 Local Control Panel (LCP) 14 DC coil

MG90X202 - VLT® is a registered Danfoss trademark 15

Illustration 1.6 Exploded View - I8 Frame Size

16 MG90X202 - VLT® is a registered Danfoss trademark

1.9 Ratings Tables 1 1

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

Table 1.15 DC Voltage Levels