VACON NX SERVICE MANUAL Appendix FR5 PDF
VACON NX SERVICE MANUAL Appendix FR5 PDF
VACON NX SERVICE MANUAL Appendix FR5 PDF
Appendix FR5
1 Table of content
B-
POW
B+ / R+
R-
J1
U_HI
V_HI
W_HI
J3
DC +
X3
L1 U / T1
X4
L2 V / T2
X5
MiniSkiip
L3 W / T3
Main Circuit Diagrams
X10
INTEGRATED C
DC -
W_LO
INPUT MODULE
U_LO
V_LO
BRK
J2
TERM
3. MECHANICAL CONSTRUCTION
*NOTE! CHECK THE RIGHT SPARE PARTS FROM THE SPARE PART LIST, WHICH IS AVAILABLE
ON THE PRODUCERS EXTRANET.
60FR05003
60FR00015
60FR00016
60FR00050
60PP05052
60PP01002*
60FR05031
60FR05002
60PP05000
60FR05029
60CP01307*
60VB00313
60VB00613
60FR05052
60FR05001
60PP01043
60FR05015
60FR05009
60FR05000
60PP01061
Also, make sure that the working environment is safe and will not cause personal
injury, damage to the unit, or to the environment. If repairs are being carried out
in the field, make sure that the supply voltage cannot be switched on during ser-
vice, and the action of the service personnel will not cause unnecessary distur-
bance or interruption to the process.
• Open back plate by lifting it from its lower side up and pull back plate down-
wards.
• Remove the control unit's fixing screws from the lower corners and from under-
neath the panel.
• Check for possible burn marks, broken components or foil on the power board.
Replace the board without testing if it is badly burnt.
• Test the capacitors and measure the AC choke and the power module.
• Remove the power terminal cover plate to access the main terminals.
Description:
B- = DC-, B+ = DC+
Visual checking is required before proceeding with these instructions. Check that
the cover plate of the power unit has been mounted before testing.
NOTE! THE FR5 SHUNT RESISTOR CURRENT MEASUREMENT CIRCUIT CANNOT BE MEASURED
WITH THE TESTER, PUT 1.
• Attach the power unit tester to the connector on the power unit.
• Connect a multi meter (Vdc range) to power unit tester PUT 1 for measurement.
• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Connect up the wires to B- and B+ and then apply nominal DC-volt-
age (540V).
• Check all these signals from the power unit and compare them to the values in
TABLE 3 . "Power unit values for FR4 and FR5".
• If any of these signals 24V, -15V, 15V, IU, IV or IW differ from the values in
TABLE 3 , replace the power board.
• If the TEMP signal is different from the value in the table, check the temperature
sensor from power module's contacts T+ and T-. See the instruction in section
5.5. Power module on page 19.
Measurement Instructions 10
• Values for UC+ and UC- can be different, but the calculated value has to be
according to the value in TABLE 3 . If the value differs from the value in table,
check the capacitors. See the instructions in section 5.4. Capacitors on page 17.
NOTE! THE UC+ AND UC- VALUES ARE VALID FROM VERSION VBXXXR, WHILE THE
OLDER ONES USE THE FOLLOWING VALUES: (UC+)-(UC-) => 3V, WHICH IS VALID UP TO
THE Q VERSION.
• Attach the power unit tester to the connector on the power unit.
• Connect a multi meter (Vdc range) to power unit tester PUT 1, for taking the
measurements.
• Supply the power unit with a DC voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.
• Measure offset values IU, IV and IW, The values are all 0V.
• Change the power board if the signals are different than in TABLE 3, “Power unit
values FR5.,” on page 10.
TABLE 4. Shunt resistors and measured values on the power boards VB00211,
VB00212, VB00213, VB00313, 500 V and 230 V.
Shunt
Unit Unit Shunt resistor
Power resistor Measured
current voltage from the
board until value/Ω
A V vers. R/Ω
vers. Q/Ω
60VB00211 16 500 82 422 69 140 137 -
60VB00212 23 500 56 620 51 140 - 82
60VB00213 31 500 47 182 37 140 137 82
60VB00313 17 230 165 110 66
60VB00212 23 230 56 620 51
60VB00213 31 230 47 182 37
60VB00413 32 500
TABLE 5. Shunt resistors and measured values on the power board VB00213
and VB00613, 500 V and 230 V.
A B C D E
60VB00613 16 500 140 137 69
60VB00613 23 500 140 82 51
60VB00613 31 500 140 137 82 37
60VB00313 18 230 165 110 66
60VB00313 25 230 165 66,5 47
60VB00313 31 230 165 110 66,5 33
• Attach the power unit tester PUT 1 to the connector on the power unit.
• Connect a multi meter (Vdc range) to the power unit tester for taking measure-
ments.
• Supply the power unit with DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use DC-voltage.
Measurement Instructions 12
• Measure the UC+ and UC- values and compare them to the values in TABLE 3,
“Power unit values FR5.,” on page 10.
• If UC+ and UC- value differs from table's value, check the capacitors. See the
instructions in section 5.4. Capacitors on page 17.
• Attach the power unit tester to the connector on the power unit.
• Connect a multi meter (Vdc range) to the power unit tester PUT 1 for taking-
measurements.
• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.
• Measure the TEMP signal value. If TEMP-signal value is different from the values
in section 6, check temperature sensor from power module's contacts T+ and
T-. See instruction in section 5.5. Power module on page 19.
• Check and clean contact surfaces on power board and on power module.
• Change the power board if measured values from power module are in state and
contact cleaning doesn't remove temperature measurement error.
• Attach the power unit tester to the connector on the power unit.
• Connect a multi meter (Vdc range) to the power unit tester PUT 1 for taking
measurements.
• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.
• Measure 24V signal. Replace the power board if the signal is wrong.
• Switch on the fan with the switch on the power unit tester, PUT1. Check that the
fan rotation is correct. If the fan is not working, change it as described in sec-
tion 5.1. Fan on page 14.
13 Measurement Instructions
• Measure forward biases towards the DC+ on the rectifier from the main termi-
nals. If all measurement values are infinite, the pre-charging resistor is proba-
bly broken.
• Open the connection cover and the cover of the power unit. Check the pre-
charging resistor and the charging relay on the power board. If it is broken,
change power board according to the instructions in section 5.3. Power board on
page 16.
5.1. Fan
• Remove fan from the frame by pressing plastic holders beside fan by screw-
driver and pull the fan out of the frame.
• Install the new fan just by pressing it to the frame. Check that the fan is con-
nected to the power board.
5.2. AC Choke
Capacitor replacement
FIGURE 13. Skiip circuit diagram, which is equivalent for all power modules in
FR5 drive.
L1 U V W
gB L L L
B-
DC-
R-
DC-
U V W
U V W
H H H
L2 B+
+T
L3 DC+ DC+
-T
5.5.1. Measurement
Remove the cover from the skiip by opening two screws from top of the cover. It is
contacted really tightly, so you must loosen screws from power board. After this
do the measurements shown below.
• Measure the main circuit for rectifier-, brake chopper- and IGBT.
• Measure gate emitter junction (capacitance and resistance) for the gate of the
brake chopper (gB) and for the gates of the IGBT (UL, VL, WL, UH, VH and WH).
• Use the same polarity for all gate emitter measurements. "+"-wire at gate and
"-"-wire at emitter.
• Use the same polarity for all gate-collector measurements. "+"-wire at gate and
"-"-wire at collector.
• Measure resistance value between T+ and T-. Compare measured value to value
in TABLE 9, “Temperature vs. resistance.,” on page 37.
NOTE! THE CAPACITANCE VALUES SHOULD NOT DIFFER MORE THAN 20% BETWEEN UPPER
AND LOWER BRANCH. CAPACITANCE READING IS ROUGHLY HALF IF MEASUREMENT POLARITY
IS WRONG. RESISTANCE VALUE FOR ALL GATE MEASUREMENT SHOULD BE INFINITE.
5.5.2. Replacement
• Clean the contact surface on power board. Clean the element surface and Skiip
ground, if needed. Used cleaner e.g. is Sinol.
• Put always thin and even layer thermal compound to the bottom of the power
module before installation.
FIGURE 15. MiniSkiip installation. Check, that the bevel is on the right place.
Replacement Instructions 22
FIGURE 16. FR5 power board pin order. Valid until version Q. Power boards
60VB00211, 60VB00212, 60VB00213, 60VB00313, 60VB00613, 60VB00413.
23 Replacement Instructions
FIGURE 17. FR5 power board pin order. Valid until version R. Power boards
60VB00613 and 60VB00313.
Replacement Instructions 24
FIGURE 18. Power board installation. Clean the MiniSkiip area on the power
board. Used cleaner is e.g. Sinol.
25 Replacement Instructions
5.7.1. Tools
• Soldering iron with adjustable temperature to 350 oC and with double soldering
tips. Correct temperature should be checked.
• Remove resistors by using soldering iron with double soldering tips. Example
Weller WTA50.
• Check the soldering and nearby area of removed component for splashes.
• Confirming modification
• Labeling modification
For the sign of changes, mark the X below correct current value to card's sticker.
Person who did the changes marks initials beside of current value.
27 Replacement Instructions
Removable resistors
FIGURE 22. Modification to FR5 230V 17A power board 60VB00313. Removable
resistors are:
C: R25, R19, R23
F: R59, R72, R31, R79, R39, R65
I: R156
29 Replacement Instructions
Removable resistors
FIGURE 23. Modification to FR5 230V 25A power board 60VB00313. Removable
resistors are:
B: R26, R20, R24
E: R173, R172, R170, R171, R158, R159
I: R156
Replacement Instructions 30
Removable resistors
FIGURE 24. Modification to FR5 230V 31A power board 60VB00313. Removable
resistors are: G: R73.
31 Replacement Instructions
Removable resistors
FIGURE 25. Modification to FR5 16A power boards 60VB00213 and 60VB00613.
Removable resistors are:
C: R25, R19, R23
F: R59, R72, R31, R79, R39, R65
I: R156
Replacement Instructions 32
FIGURE 26. Modification to FR5 22A power boards 60VB00213 and 60VB00613.
Removable resistors are:
B: R26, R20, R24
E: R173, R172, R170, R171, R158, R159
I: R156
33 Replacement Instructions
Removable resistors
FIGURE 27. Modification to FR5 31A power boards 60VB00213 and 60VB00613.
Removable resistors are:G: R73.
Replacement Instructions 34
FIGURE 28. Remove the screw from the choke PCB board. See FIGURE 28 .
35 Specifications
6. SPECIFICATIONS
Temperature on
monitoring page V1.9 Resistance
-40 577
-35 604.5
-30 632
-25 661.5
-20 691
-15 722.5
-10 754
-5 787
0 820
5 854.5
10 889
15 925.5
20 962
25 1000
30 1039
35 1078.5
40 1118
45 1160
50 1202
55 1245
60 1288
65 1333.5
70 1379
75 1425.5
80 1472
85 1520.5
90 1569
95 1619.5
100 1670
105 1722
110 1774
115 1828
120 1882
Specifications 38
SM00057E
29.10.2009
J. Kukkonen