Danfoss IC7 Series User manual

NOTICE

MATCHING SCR/DIODE MODULES

If all 3 SCR/diode modules installed in a frequency converter are not the same type and manufacturer, the frequency converter

can malfunction.

Check that the replacement module matches the existing modules. If not, replace all 3 SCR/diode modules.

If replacing multiple SCR/diode modules, verify that all kit numbers match.

Use these instructions with the following kits. See Table 1 for iC7 Series kits. See Table 2 and Table 3 for VLT®FC Series kits.

Table 1: Kit Numbers for iC7 Series SCR/Diode Module Kits

Kit num-

ber

Kit description

Frame/enclosure

Voltage

Current rating

176F8318

Rectifier SCR/diode 181A 1600V

FA09/FK09a/FK09c/FB09a/

FB09c

380–480/500 V AC

206A, 245A, 302A

176F8320

Rectifier SCR/diode 320A 1600V

FA09/FK09a/FK09c/FB09a/

FB09c

380–480/500 V AC

385A

176F6647

Rectifier SCR/diode 700A 1600V

FA10-FA11/FK10a/FK10c/

FB10a/FB10c/FK11/FB11

380–480/500 V AC

395A, 480A ,588A, 658A,

736A, 799A

FA12/FK12/FB12

380–480/500 V AC

893A, 1000

176F3934

Rectifier SCR 1400A 1600V

FA12/FK12/FB12

380–480/500 V AC

1120, 1260

176F4099

Rectifier Diode 1400A 1600V

FA12/FK12/FB12

380–480/500 V AC

1120, 1260

Table 2: Kit Numbers for VLT®FC Series SCR/Diode Module Kits

Kit num-

ber

Kit description

Frame/enclosure

Voltage

Power rating

176F3426

Rectifier SCR 429A 2200V

D2h/D4h/D7h/D8h

525–690 V AC

N250, N315, N400

176F3859

Rectifier SCR 320A 1600V

D1h/D3h/D5h/D6h

N160

176F3860

Rectifier SCR 586A 1600V

D1h/D3h/D5h/D6h

N200, N250

176F6647

Rectifier SCR 700A 1600V

E1h–E4h

380–480/500 V AC

All

176F6648

Rectifier SCR 650A 2200V

E1h–E4h

525–690 V AC

All

176F8318

Rectifier SCR 181A 1600V

D1h/D3h/D5h/D6h

200–240 V AC

N45K, N55K, N75K, N90K

Installation Guide

SCR/Diode Module Replacement for

Fx09-Fx12/D1h–D8h/E1h–E4h

iC7 Series Frequency Converters and VLT® FC Series Drives

1 Overview

1.1 Description

Both iC7 Series Frequency Converters and VLT®FC Series drives contain 3 SCR/diode modules. SCR/diode module replacement kits

contain the components required to replace 1 SCR/diode module. SCR/diode module conversion kits contain 3 SCR/diode modules

along with busbars and fasteners required to upgrade the drive.

1.2 Kit Numbers

Kit num-

ber

Kit description

Frame/enclosure

Voltage

Power rating

380–480/500 V AC

N90K, N110, N132, N150,

N160

176F8529

Rectifier SCR 165A 2200V

D1h/D3h/D5h/D6h

525–690 V AC

N55K, N75K, N90K, N110,

N132, N160

176F8530

Rectifier SCR 280A 2200V

D2h/D4h/D7h/D8h

525–690 V AC

N160, N200, N250

Table 3: Kit Number for VLT®FC Series SCR/Diode Module Conversion Kit

Kit num-

ber

Kit description

Frame/enclosure

Voltage

Power rating

176F3890

SCR Conversion Kit 568A

N200T5/N250T5 HO

D2h/D4h/D7h/D8h

1.3 Items Supplied

See Table 4 for the parts included in SCR/diode module replacement kits. See Table 5 for items supplied in conversion kits.

Table 4: Items Supplied in SCR/Diode Module Replacement Kits

Item description

Quantity

SCR/diode module

3 cc syringe of thermal grease

Fasteners for SCR mounting

2–4

Fasteners for busbar connection

varies

Table 5: Items Supplied in SCR/Diode Module Conversion Kits (176F3890)

Item description

Quantity

SCR/diode module

SCR input busbar

SCR-to-DC busbar

DC(-) busbar

DC(+) busbar

M6 x 24 mm Torx screw

M10 x 22 mm Torx screw

Standoff

3 cc syringe of thermal grease

Overview

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/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

D1h–D8h

20 minutes

Fx09–Fx10

20 minutes

E1h–E4h

40 minutes

Fx11–Fx12

40 minutes

Installation

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/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 SCR/Diode Modules

NOTICE

THERMAL INTERFACE

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

a poor thermal bond.

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

NOTICE

FASTENER SIZE

For some spare part kits, 2 different sizes of screws are included.

Use the screw size that fits the heat sink.

NOTICE

HEAT SINK DAMAGE

A damaged heat sink can cause a frequency converter to malfunction. A clean and undamaged mounting surface allows proper

thermal dissipation.

Take care not to scratch or damage the heat sink when cleaning and servicing the frequency converter.

Refer to the service guide for SCR/diode module disassembly. To install replacement SCR/diode modules, use the following steps.

Procedure

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

Verify that the thermal grease is not expired by checking the expiration date on the package.

If expired, order a new syringe of thermal grease (176F6769).

With the syringe, apply thermal grease to the bottom of the SCR/diode module in the pattern shown in Illustration 1.

It is not required to use the entire syringe, but excess thermal grease is not a problem.

Installation

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h

Installation Guide

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Illustration 1: SCR/Diode Module Thermal Grease Pattern

Bottom surface of SCR/diode module

Thermal grease

Place the module on the heat sink, and twist it back and forth to spread the thermal grease evenly on the SCR/diode mod-

ule and the heat sink surface.

Align the mounting holes in the SCR/diode module with the holes in the heat sink.

Insert the screws into the SCR/diode modules and hand tighten them.

Wait 1 minute.

Using a manual torque wrench to avoid over torquing the screws, follow the tightening sequence shown in Illustration 2.

Apply 0.6 Nm (5.3 in-lb) of initial torque at a maximum of 100 RPM. Then apply final torque in the same sequence using

the values listed in Table 7.

Connect the gate lead to the cable connector on the SCR/diode module.

For SCR/diode module conversion kits, continue to 2.3 Installing the SCR/Diode Module Busbars to install the rest of the

kit. Otherwise, complete the frequency converter reassembly as described in the service guide.

Installation

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h

Installation Guide

e30bh997.10

A B

Illustration 2: SCR/Diode Module Fastener Tightening Sequences

Table 7: Torque Tightening Values and Sequence

Kit number

Mounting torque [Nm (in-lb)]

Busbar connection torque [Nm (in-lb)]

Tightening order

Diagram

176F3426

6.0 (53)

12.0 (106)

1-2-3-4

176F3859

5.0 (44)

9.0 (80)

1-2-3-4

176F3860

6.0 (53)

12.0 (106)

1-2-3-4

176F3890

6.0 (53)

12.0 (106)

1-2-3-4

176F3934

5.5 (49)

11.0 (97)

1-2-3-4

176F4099

5.5 (49)

11.0 (97)

1-2-3-4

176F6647

5.5 (49)

11.0 (97)

1-2-3-4

176F6648

5.5 (49)

11.0 (97)

1-2-3-4

176F8318

2.5 (22)

5.0 (44)

1-2

176F8320

5.8 (51)

12.0 (106)

1-2-3-4

176F8529

2.5 (22)

5.0 (44)

1-2

176F8530

5.8 (51)

12.0 (106)

1-2-3-4

2.3 Installing the SCR/Diode Module Busbars

SCR/diode module conversion kits contain 3 SCRs plus new busbars. Use the following steps to install the busbars. See Illustration 3.

Procedure

Position the 3 SCR input busbars in the frequency converter, 1 on each SCR/diode module.

Fasten 3 standoffs (19 mm), 1 in each SCR/diode module connecting it to the busbar.

Fasten 3 M10 screws (T50) in the SCR-to-DC(-) busbar, connecting it to the 3 SCR/diode modules.

Fasten 3 M10 screws (T50) in the SCR-to-DC(+) busbar, connecting it to the 3 SCR/diode modules.

Position the DC(-) busbar behind the SCR-to-DC(-) busbar and fasten 1 screw connecting the busbars.

Installation

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h

Installation Guide

6. Position the DC(+) busbar behind the SCR-to-DC(+) busbar and fasten 1 standoff connecting the busbars.

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Illustration 3: SCR/Diode Module Busbar Installation

SCR/diode module

M10 screws

Standoff

SCR input busbars

Heat sink

DC(+) busbar

DC(-) busbar

M6 screw

SCR-to-DC(-) busbar

SCR-to-DC(+) busbar

Installation

SCR/Diode Module Replacement for Fx09-Fx12/D1h–D8h/E1h–E4h

Installation Guide

Danfoss A/S

Ulsnaes 1

DK-6300 Graasten

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