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Appendix FR9
0
1
3 Main circuit diagrams
2
2
4
B-
B+ / R+
R-
* ) EMC-H only
A
X2
L3 W / T3
2 *)
commo n
X3
2 mode filter
X8 DC -
2
2 2 4 4 4
X6 X5
X10
*) X41
W_LO
X11 X13
W_HI
U_LO
V_LO
U_HI
V_HI
BR K
BR K
TERM
TERM U
I_U
TERM V
I_V
TERM W
I_W
DC-
DC+
B D X4
MAINS VOLTAGE
5 4
SUPE RVISION
relay
Charge
X13 X9 POWER BOARD
RECTIFIER BOARD I_U
VB00458 VB00323
I_V
ready
Charge
+ 24 V
PE MEASU REMENTS
DC+
X50
IFS
I_W
PE
X7 X5 X8 X15 H74 0...H746 J4
X1 X6
1 3 2 3 1 2
+ 24 V 2 7 OPTIC FIBRES
J2 H1...H7 Ext
J1
J1 + 24 V
2 2
OPTO ADAPTER
37
blue BOARD
black CONTROL BOARD X1 CONTROL
4 2 VB00252, VB00661 or VB0076 1 PANEL
brown 9
M2 M3 X7 X1
FAN BOARD
X2 X3 X4 X5 X6
X5 X4 X8 X3
INVERTER FAN (slot A) (slot B) (slot C) (slot D) (slot E)
FAN X6 FAN
MAIN FAN FREQUENCY
CONVERTER X7
X2
M4 OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD
DIVIDER
DC +
DC -
FAN
5 Main circuit diagrams
2
2
6
B-
B+ / R+
R-
* ) 500 V, EMC-H only
A
X2
L3 W / T3
2 *)
commo n
X3
2 mode filter
X8 DC -
2
2 2 4 4 4
X6 X5
X10
*) X41
W_LO
X11 X13
W_HI
U_LO
V_LO
U_HI
V_HI
BR K
BR K
TERM
TERM U
I_U
TERM V
I_V
TERM W
I_W
DC-
DC+
B D X4
MAINS VOLTAGE
5 4
SUPE RVISION
relay
Charge
X13 X9 POWER BOARD
RECTIFIER BOARD I_U
500 / VB00459 500 / VB00225
I_V
ready
Charge
+ 24 V
PE 690 / VB00460 690 / VB00425 MEASU REMENTS
DC+
X50
IFS
I_W
PE
X7 X5 X8 X15 H74 0...H746 J4
X1 X6
1 3 2 3 1 2
+ 24 V 2 7 OPTIC FIBRES
*** ) 690 V only J2 H1...H7 Ext
*** )
Ending 2 2
OPTO ADAPTER
J1
J1
+ 24 V
Terminal 37
blue BOARD
black CONTROL BOARD X1 CONTROL
4 2 VB00252, VB00661 or VB0076 1 PANEL
brown 9
M2 M3 X7 X1
FAN BOARD
X2 X3 X4 X5 X6
X5 X4 X8 X3
INVERTER FAN (slot A) (slot B) (slot C) (slot D) (slot E)
FAN X6 FAN
MAIN FAN FREQUENCY
CONVERTER X7
X2
M4 OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD
DIVIDER
DC +
DC -
FAN
7 Exploded view
3. EXPLODED VIEW
60MC00079
60FR08059
60FR08058
60FR09012
60FR00031
60FR09013
FIGURE 5. Covers
3
Exploded view 8
60S00528
60FR09092
60FR09093
60FR09020
60PP01068
60FR09132
60FR09133
60PP01080 60PP09041
60VB00399 (500V)
60VB00299 (690V)
60VB00899 (230V)
60PP10057 (500V/690V)
60PP09056 (230V)
FIGURE 6. FR9 fan, inverter, control
3
9 Exploded view
60FR08018
60PP01039 500V
60FR09059 60PP01046 690V
60FR09010
Main terminal
assembly
60FR09039
60PP09012
3
Exploded view 10
60S00335 (500V/230V)
60PP01041 (690V)
3
11 Exploded view
60PP01082
60PP01083
Main terminal
support plate
60VB00333
EMC cover
3
Measurement instructions 12
4. MEASUREMENT INSTRUCTIONS
Always before starting analysis/checking measures, make sure that the unit or module
under repair is not powered up, if it is not intended to be. Make sure there are no
remaining dangerous voltages in the circuit and there are no other voltage sources
with dangerous life threatening potentials. Therefore, ensure that the main supply is
switched off and main terminals and DC busbars are de-energized.
Make sure that the environment you are working in is safe and won't cause risk of per-
sonal injury, damage to the unit or environment. If you are repairing on the field,
make sure that the supply voltage can't be switched on during the service and your
service actions won't cause any unnecessary disturbance or interruption to the pro-
cess. Also remember to follow local/national safety rules and regulations.
NOTE! REMEMBER TO FILL ALL RESULTS OF THE ANALYSES TO THE FAULT REPORT WITH
DETAILED INFORMATION OF UNIT / MODULE TYPE. THE NX_ FAULT REPORT IS AVAILABLE
BY REQUEST FROM VACON PLC OR IT CAN BE DOWNLOADED FROM VACON SERVICE WWW-
PAGES.
4
13 Measurement instructions
NOTE! MAKE SURE THAT THE UNIT OR BOARDS ARE NOT POWERED UP.
IBGT measurements
• Measure the forward bias of the free wheeling diode from B- (DC-) to U/V/W output
terminal and reverse bias from U/V/W to B- (DC-).
• Measure the forward bias on the IGBT, from U/V/W output terminal to B+/R+
(DC+) and reverse bias from B+/R+ (DC+) to U/V/W.
Rectifiers measurements
• Measure the rectifier forward bias from L1/L2/L3 to B+/R+ (DC+) terminal and
reverse bias from B+/R+ (DC+) to L1/L2/L3.
• Measure the rectifier forward bias from B- (DC-) to L1/L2/L3 terminal and reverse
bias from L1/L2/L3 to B- (DC-).
Infinite ~0,5V
Reversed Forward
biased biased
PN-junction PN-junction
4
Measurement instructions 14
B+/R+
B- R-
L1 L2 L3 L1 L2 L3 U V W U V W
4
15 Measurement instructions
Rectifier board VB00459 500V has two diodes in parallel connection and VB00460
690V unit has diodes connected to series.
• Disconnect connectors X13, X12, X11 and X10 from the rectifier board.
• Test the relays by attaching the +24V DC-power supply DC+ to rectifying board
connector X13-PIN5 and the DC- to connector X13-PIN3 and X13-PIN1 (Figure 15).
• Measure the diode forward bias from J3, J7 and J11 to X9 (Figure 15).
4
Measurement instructions 16
• Measure the diodes forward bias from J3 to X10/1, J7 to X11/1 and J11 to X12/1.
• Compare the measurement results to the values in Table 3.
• If the measurement results are not the same as the values in Table 3, replace the
rectifying board (see the instructions in Chapter 5)
4
17 Measurement instructions
X13
DC-/pin 1
DC-/pin 3
DC+/pin 5
J3
X10
X10/1
X11
X11/1 J7
X12
X12/1 J11
X9
FIGURE 15. Rectifier board measurement points.
4
Measurement instructions 18
• Remove the rectifier board and measure the rectifier freewheeling diodes.
Measurement points
1.
2.
3.
4
19 Measurement instructions
4
Measurement instructions 20
R-
B-
Gate wires
B+ / R+
FIGURE 18. Brake chopper measurement points
4
21 Measurement instructions
Measurement points
From To Voltage
R- B+/R+ ~0,4V
B+/R+ R- infinity
B- R- ~0,4V
R- B- infinity
Measurement points
Capacitance
From To (variance 20%)
X11 red X11 black 50nF
X13 red X13 black 50nF
4
Measurement instructions 22
Connection wires
Resistance (variance
From To +/-20%)
black brown ~62
brown blue ~36
blue black ~27
4
23 Measurement instructions
NOTE! THIS TABLE IS FOR FAN POWER SUPPLY 60VB00299, Make sure that the fan
inverter is running when checking the indicator lights.
4
Measurement instructions 24
4.7. Terminals
• Check that cables L1 and L3 do not touch the ferrite ring (Figure 20).
4
25 Measurement instructions
MAKE SURE THAT THE DC-WIRES ARE CONNECTED TO CORRECT POLARITY ON THE CAPACI-
TORS BEFORE TURNING ON THE POWER SUPPLY.
DISCHARGE EACH CAPACITOR AFTER TESTING. USE A PROPER RESISTOR THAT CAN HANDLE
THE DISCHARGING CURRENT.
• If a broken capacitor needs to be replaced, all the capacitors in the same block have
to be replaced. Also check the busbars and insulators and replace them if they are
damaged.
4
Measurement instructions 26
4.9. AC-choke
• Measure that the coils are intact and not shorted to ground. Check that the coils are
not burned.
4
27 Replacement instructions
5. REPLACEMENT INSTRUCTIONS
5
Replacement instructions 28
5
29 Replacement instructions
5
Replacement instructions 30
L1
L1 L2
L2 L3
L3 L1 L2 L3
L3 U/T1 V/T2
V/T2 W/T3
W/T3 U/T1
U/T1 V/T2
V/T2 W/T3
W/T3
PE
B- B+/R+ R-
5
31 Replacement instructions
5
Replacement instructions 32
5
33 Replacement instructions
5
Replacement instructions 34
5
35 Replacement instructions
5
Replacement instructions 36
Optical fibers
5
37 Replacement instructions
Parts
• 1. Screw M4x8 taptite
(60MC00031), bit Pz2, torque
4Nm.
• 2. Clamp for ferrite ring
(60FR09039).
5
Replacement instructions 38
5.9. EMC-cover
3.
Fan connection
5
39 Replacement instructions
Terminal replacement:
• Open the terminal assembly fastening screws. Unscrew and remove the cables from
the IGBT and rectifier terminals. Lift the terminal assembly off the frame.
• Be careful when removing/installing the terminal assembly. Sharp edges in the unit
could damage the isolation transformer.
5
Replacement instructions 40
Fastening:
• 1. R-: M8x16 hexagonal socket-
head (60MC00392) + M8 spring
washer (60MC00145) + cable
terminal (X11) + M8 spring
washer (60MC00058) + M8
washer (60MC00104). Bit Hop6,
torque 9Nm.
• 2. DC+/-: M8x16 hexagonal
socket head (60MC00392) + M8
spring washer (60MC00058) +
M8 washer (60MC00104) +
cable terminal. Bit Hop6, torque
9Nm.
• 3. DC busbars: cable terminal +
M8 spring washer (60MC00058)
+ M8 washer (60MC00104) +
M8 nut (60MC00057). Bit
13mm, torque 20Nm.
5
41 Replacement instructions
L1
L2
L3
5
Replacement instructions 42
5.13. Wiring
Wiring:
• 1. Optical wire harness, from Vacon opto adapter to power board.
• 2. Rectifier board power supply, from power board connector X9 to rectifier board
connector X13.
• 3. DC+/- cables, from DC+/- busbars to DC terminal.
• 4. Brake cable, from brake busbar to brake terminal.
5
43 Replacement instructions
X8
X11/13
Wiring:
• 1. Power supply cable, from power board connectors X7, X5 and X10.
• 2. Power supply 24VDC, from power board X15 to Vacon opto adapter.
• 3. Internal fan, from power board X8 to internal fan (see Figure 35).
• 4. Brake control wires to connectors X11 and X13 on the power board.
5
Replacement instructions 44
5
45 Replacement instructions
5
Replacement instructions 46
5
47 Replacement instructions
5.14. DC terminal
5
Replacement instructions 48
5
49 Replacement instructions
1. 5.
3.
2.
4.
6.
Rectifier sub-assembly:
• Clean the heat sink carefully with a spirituous cleaning agent (do not use an oily
cleaning agent). Spread thermal paste smoothly to the bottom of the rectifier.
• Install the rectifiers, pre-tighten, wait 15 minutes and then tighten to final torque.
See specified torques in Chapter 6.
5
Replacement instructions 50
7.
5. 1. 2. 3.
4.
1.
2. 6.
3.
8.
5
51 Replacement instructions
1. 2. 3.
4.
Gate wires:
• Install rectifier gate wires through insulator and busbar holes (yellow arrows in
Figure 49).
5
Replacement instructions 52
2.
3. 9.
4. 7.
8.
1.
6.
10.
5.
X11
X13
6.
FIGURE 50. How to mount the wires and board on rectifier sub-assembly
Parts in Figure :
• 1. Cables, choke to rectifier (L1: 60PP09020, L2: 60PP09021 and L3: 60PP09022).
• 2. Screw M8x16 hexagonal (60MC00392), bit Hop6, torque 9Nm.
• 3. Spring washer M8 (60MC00058).
• 4. Washer M8 (60MC00104).
• 5. Busbar rectifier (60FR09082).
• 6. Brake control wires (60PP09062, 60PP09063).
• 7. Screw 4x8 combi (60MC00032, red in figure), bit Tx20, torque 1.35Nm.
• 8. Screw M4x16 combi (60MC00038, black in figure), bit Tx20, torque 1.35Nm.
• 9. EMC-level H only: Screw M4x8 (60MC00036, yellow in figure) + M4 spring
washer (MC00477) + M4 washer (MC00060), bit Pz2, torque 1.35Nm.
• 10. Rectifier board (60VB00459 500V, 60VB00460 690V, 60VB00458 230V).
5
53 Replacement instructions
By installing these parts, the rectifier board is raised 3mm to avoid contact between
the fastening screws and insulator. The parts must all the installed at the same time
and are not available separately.
5
Replacement instructions 54
5
55 Replacement instructions
5
Replacement instructions 56
500V
690V
5
57 Replacement instructions
2 2 2 2
3 3 3 3
3 3 3 3
3 3 3 1
FIGURE 57. Main circuit busbar fastening screws 500V, 690V and 230V units
5
Replacement instructions 58
1. 1.
2. 2.
5
59 Replacement instructions
1. 2. 3. 4.
5. 6. 7.
FIGURE 59. Busbars in DC-link
5
Replacement instructions 60
4.
1.
3.
2.
FIGURE 60. Mounting of main cooling fan and fan cable routing
NOTE! AFTER INSTALLATION, CHECK THAT THE COOLING FAN CAN ROTATE EASILY.
5
61 Replacement instructions
5
Replacement instructions 62
5
63 Replacement instructions
5
Replacement instructions 64
5
65 Replacement instructions
1.
4.
2.
5.
3.
6.
7.
5
Replacement instructions 66
1.
2.
3.
5
67 Replacement instructions
NOTE! AFTER INSTALLING THE 50MM FAN, CHECK THAT THE FAN CAN ROTATE EASILY AND
IS INSTALLED IN THE CORRECT DIRECTION SEE (FIGURE 67)
NOTE! FAN CAPACITOR PP00089 REPLACED OLD CAPACITOR 60PP00060. FOR MORE
INFORMATION, SEE SERVICE BULLETIN SBU00136.
5
Replacement instructions 68
All the necessary SAF parts are found in the spare part 60FR09969.
5
69 Replacement instructions
500V 690V
4
4 5
5 6
6
0V
bit Pz1, torque
40
5V
4
52
0.56Nm.
V
90
5
6
6
• Connect the SAF trans-
former wires to con-
nectors 4-6 as shown
on the right.
• Connect the SAF trans-
former wires to the BLU
E
capacitor wires: blue BRO
WN
to blue and brown to
brown.
• Connect the SAF trans-
former 0-wire on the
fuse base as shown
below.
5
Replacement instructions 70
L1 and L2. L1
5
71 Replacement instructions
FR9 230V
• Fan inverter (60VB00899).
• Isolation transformer (60PP09056).
• Rectifier board (60VB00458).
• Power board (VB00323).
FR9 500V
• Fan inverter (60VB00399).
• Isolation transformer (60PP10057)
• Rectifier board (60VB00459).
• Power board (VB00225).
5
Replacement instructions 72
5.27. EMC-variations
EMC-level H
• Capacitors in AC-choke terminals (Figure 72).
• Screw in rectifier board X41 (Figure 50 and Figure 73).
• Terminal assembly two ferrite rings (Figure 74).
• EMC-board 60VB00333 (Figure 61 and Figure 75).
• Capacitors to input terminals (Figure 76).
5
73 Replacement instructions
FIGURE 76. Terminals with EMC capacitors. Notice the EMC-wires (red arrows).
5
Replacement instructions 74
5
75 Specifications
6. SPECIFICATIONS
6
Specifications 76
6
77 Specifications
6
Specifications 78
6
79 Specifications
6
Specifications 80
6
81 Specifications
6
Specifications 82
6
83 Specifications
6
Specifications 84
6
85 Specifications
6
Specifications 86
6
87 Specifications
6
Specifications 88
6
89 Specifications
6
Specifications 90
6
91 Specifications
6
Specifications 92
This table shows if a drive is compatible with a fan inverter uppgrade kit.
690V
6
93 Specifications
6
Vacon Plc.
Runsorintie 7
65380 Vaasa
Finland
SM00014 E
02.04.2012
Documentation@vacon.com
Document ID:
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