Danfoss IC7 Series User manual

NOTICE

SPARE PARTS COMPATIBILITY

Danfoss recommends replacement of all IGBT modules or all brake IGBT modules when 1 or more modules fail.

For best results, replace modules with parts from the same lot number.

Table 1: Number of IGBT Modules Required by iC7 Series Frequency Converters

Frame designation

IGBT modules

Brake IGBT modules

FX09–Fx10 (no brake)

FX09–Fx10 (with brake option)

FX11–Fx12 (no brake)

FX11–Fx12 (with brake option)

Table 2: Number of IGBT Modules Required by VLT®FC Series Drives

Drive designation

IGBT modules

Brake IGBT modules

E1h–E4h (no brake)

E1h–E4h (with brake option)

1.2 Kit Numbers

Use these instructions with the following kits.

Table 3: IGBT Module Replacement Kits for iC7 Series Fx09–Fx12 Frequency Converters

Kit number

Description

176F3944

IGBT dual module 300 A 1200 V Fx09

176F3945

IGBT dual module 450 A 1200 V Fx09

176F3949

IGBT dual module 600 A 1200 V Fx09

176F3943

IGBT module 900 A 1200 V Fx10

176F4141

IGBT brake module 450 A 1700 V Fx09

176F4143

IGBT brake module 650 A 1700 V Fx10

176F3950

IGBT dual module 600 A 1200 V Fx11

176F3956

IGBT module 900 A 1200 V Fx12

Installation Guide

IGBT Module Replacement for Fx09-Fx12

and E1h–E4h

iC7 Series Frequency Converters and VLT® FC Series Drives

1 Overview

1.1 Description

This IGBT module replacement kit contains all components required to replace 1 IGBT module or 1 brake IGBT module. For the num-

ber of IGBTs installed in the frequency converter, see Table 1 and Table 2.

Kit number

Description

176F3957

IGBT module 1200 A 1200 V Fx12

176F3946

IGBT brake module 450 A 1700 V Fx11

176F4012

IGBT brake module 450 A 1700 V Fx12

Table 4: IGBT Module Replacement Kits for VLT® FC Series E1h–E4h Drives

Kit number

Description

176F6641

IGBT module 600 A T4/T5

176F6642

IGBT module 900 A T4/T5

176F6643

IGBT module 600 A 1700 V T7

176F6644

IGBT module 650 A 1700 V T7

176F6711

IGBT brake module 450 A E1, E3

176F6646

IGBT brake module 450 A E2, E4

1.3 Items Supplied

The following parts are contained in the kit.

Table 5: Items Supplied in IGBT Module Kits

Item

Quantity

IGBT module

Fasteners

varies depending on IGBT type

Syringe of thermal grease

Overview

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

2 Installation

2.1 Safety Information

NOTICE

QUALIFIED PERSONNEL

Only qualified, Danfoss authorized personnel are allowed to install the parts described in these installation instructions.

Disassembly and reassembly of the frequency converter must be done in accordance with the service guide.

Use the standard fastener torque values from the service guide, unless the torque value is specified in these instructions.

WARNING

ELECTRICAL SHOCK HAZARD

Danfoss frequency converters contain dangerous voltages when connected to mains voltage. Improper installation, and instal-

ling or servicing with power connected, can cause death, serious injury, or equipment failure.

Only use qualified electricians for the installation.

Disconnect the frequency converter from all power sources before installation or service.

Treat the frequency converter as live whenever the mains voltage is connected.

Follow the guidelines in these instructions and local electrical safety codes.

WARNING

DISCHARGE TIME

The frequency converter contains DC-link capacitors, which can remain charged even when the frequency converter is not pow-

ered. High voltage can be present even when the warning LED indicator lights are off. Failure to wait the specified time after

power has been removed before performing service or repair work can result in death or serious injury.

Stop the motor.

Disconnect AC mains and remote DC-link power supplies, including battery back-ups, UPS, and DC-link connections to other

frequency converters.

Disconnect or lock the motor.

Disconnect any brake option.

Disconnect any regen/load share option.

Wait for the capacitors to discharge fully. The minimum waiting time is listed on the frequency converter label and also in the

following discharge time table.

Before performing any service or repair work, use an appropriate voltage measuring device to make sure that the capacitors

are fully discharged.

Table 6: Discharge Time

Frame

Minimum waiting time

Fx09–Fx10

20 minutes

E1h–E4h

40 minutes

Fx11–Fx12

40 minutes

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

NOTICE

ELECTROSTATIC DISCHARGE

Electrostatic discharge can damage components.

Ensure discharge before touching internal frequency converter components, for example by touching a grounded, conduc-

tive surface or by wearing a grounded armband.

2.2 Installing the IGBT Module

For IGBT module disassembly procedures, refer to service guide. To install the replacement IGBT module or brake IGBT module, use

the following steps.

NOTICE

THERMAL INTERFACE

A proper thermal interface is required between the IGBT module and heat sink. Failure to follow these instructions results in a

poor thermal bond and causes premature IGBT failure.

Ensure that the environment is free of airborne dust and contaminants while applying the thermal grease.

Clean the heat sink using a cloth and solvent or alcohol solution to remove debris and remaining thermal grease.

With the syringe, apply a layer of thermal grease to the bottom of the IGBT module in the pattern shown in Illustration 1.

e30bh996.10

Illustration 1: IGBT Thermal Grease Pattern

Bottom of IGBT module

Thermal grease

Once the module is mounted, thermal grease seeps out to coat the area between the module and heat sink. Excess

grease is acceptable.

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

Place the IGBT module on the heat sink by aligning the mounting holes in the module to those in the heat sink. Refer to

Illustration 2.

130BF943.10

Illustration 2: Mounting the IGBT Module on the Heat Sink

IGBT module fastener

IGBT modules

Brake IGBT modules

Plastic IGBT mounting frame

Insert the mounting screws and hand tighten them.

The IGBT module requires either 4 or 10 screws to fasten it to the heat sink.

Following the fastener tightening sequence shown in Illustration 3, slowly tighten (maximum 20 RPM) all screws to 50% of

the torque values listed in Table 7 and Table 8.

Repeat the same tightening sequence and slowly tighten (maximum 5 RPM) all screws to 100% of the torque value.

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

7. Tighten the busbar connection terminals to the torque value listed in Table 7 and Table 8.

Example

1 2

e30bf941.10

Illustration 3: IGBT Fastener Tightening Sequence

Table 7: Torque Tightening Values and Sequence for iC7 Series Frequency Converters

Kit number

Mounting torque

[Nm (in-lb)]

Busbar connection

torque [Nm (in-lb)]

Diagram

Screw tightening order

176F3944

3.3 (29)

1-2-3-4

176F3945

3.3 (29)

1-2-3-4

176F3949

3.3 (29)

1-2-3-4

176F3943

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

176F4141

3.3 (29)

1-2-3-4

176F4143

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

176F3950

3.3 (29)

1-2-3-4

176F3956

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

Kit number

Mounting torque

[Nm (in-lb)]

Busbar connection

torque [Nm (in-lb)]

Diagram

Screw tightening order

176F3957

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

176F3946

3.3 (29)

1-2-3-4

176F4012

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

Table 8: Torque Tightening Values and Sequence for VLT®FC Series Drives

Kit number

Mounting torque

[Nm (in-lb)]

Busbar connection

torque [Nm (in-lb)]

Diagram

Screw tightening order

176F6641

3.3 (29)

4.0 (35)

1-2-3-4

176F6642

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

176F6643

3.3 (29)

4.0 (35)

1-2-3-4

176F6644

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

176F6711

3.3 (29)

4.0 (35)

1-2-3-4

176F6646

4.5 (40)

9.0 (80)

1-2-3-4-5-6-7-8-9-10

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

Danfoss A/S

Ulsnaes 1

DK-6300 Graasten

danfossdrives.com

Any information, including, but not limited to information on selection of product, its application or use, product design, weight, dimensions, capacity or any other tech-

nical data in product manuals, catalogues descriptions, advertisements, etc. and whether made available in writing, orally, electronically, online or via download, shall be

considered informative, and is only binding if and to the extent, explicit reference is made in a quotation or order confirmation. Danfoss cannot accept any responsibility

for possible errors in catalogues, brochures, videos and other material.

Danfoss reserves the right to alter its products without notice. This also applies to products ordered but not delivered provided that such alterations can be made without

changes to form, fit or function of the product.

*130R0770*

Installation

IGBT Module Replacement for Fx09-Fx12 and E1h–E4h

Installation Guide

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