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CX
Vacon CX Service Manual
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PRECAUTIONS/SAFETY
NOTICES
Service Manual M4 - M10
29.12.1999
Page 3
To maintain safe construction, des
igned isolation, clearances, creepage
distances and especially correct operatio
n of the complete drive, use only
spare parts delivered by Producer.
All rights reserved by Producer.
2
4
Table of Contents
1. PRECAUTIONS / SAFETY NOTICES
2
2. FOREWORD
4
3. INDEX
5
4. WARRANTY
8
4.1 Service policy
8
4.2 Materials
9
4.2.1 Stock of spare units
9
4.2.2 Stock of spare parts
9
5. FUNDAMENTALS
10
5.1 General description
10
5.2 Technical data
12
5.2.1 Power ratings
12
5.2.2 Technical specifications
12
5.3 Recommendations
15
5.3.1 Safety precautions
15
5.3.2 ESD precautions
16
5.4 Tools
17
5.4.1 General
17
5.4.2 Basic tool requirements
17
5.5 Spare parts
18
6. MAINTENANCE
19
6.1 Recommended maintenance actions
19
6.2 Re-forming of DC bus electrolytic capacitors
20
6.2.1 Precautions and safety notices
20
6.2.2 Capacitors
21
6.2.3 Re-forming after long storage period
21
7. TROUBLESHOOTING
23
7.1 General
23
7.2 Fault codes on panel
23
7.2.1 Fault codes, possible reasons and checking to be done
23
7.3 Troubleshooting for a defective unit
50
7.3.1 Warnings
50
7.3.2 Checking instructions
50
8. MAIN CIRCUIT
61
8.1 General
61
8.2 AC- to DC converter
61
8.2.1 Description
61
8.2.2 Operation
61
8.2.3 Troubleshooting
62
8.2.4 Assembly instructions
65
8.2.5 Tightening order and torque
65
8.2.6 Wiring table
66
8.2.7 Spare Parts
67
8.3 DC bus and precharging circuit
67
8.3.1 Description
67
8.3.2 Operation
68
8.3.3 Troubleshooting
69
8.3.4 Spare parts
70
8.4 DC- to AC-converter (inverter)
70
8.4.1 Description
70
8.4.2 Operation
70
8.4.3 Troubleshooting
70
8.4.4 Assembly instructions of IGBTs
70
8.4.5 Tightening order and torque
71
8.4.6 Spare parts
72
8.5 Balancing thick foil resistors
72
8.5.1 Description
72
8.5.2 Operation
72
8.5.3 Troubleshooting
72
8.5.4 Assembly instructions
72
8.5.5 wiring table
72
8.5.6 Spare parts
72
8.6 Mechanics
73
8.6.1 Bus bars
73
8.6.2 Input Terminals
76
8.7 Connectors
77
8.8 NTC resistor
77
8.9 Main circuit diagrams
77
9. PC BOARDS
78
9.1 General
78
9.2 Power board
78
9.2.1 Description
78
9.2.2 Warnings
79
9.2.3 Layouts, connectors and signals
79
9.2.4 Schematic diagrams
88
9.2.5 Troubleshooting
88
9.2.6 Gate circuitry
88
9.2.7 Replacement of the Power Boards
90
9.2.8 Spare parts
91
9.3 Control board
91
9.3.1 Description
91
9.3.2 Warnings
92
9.3.3 Layout, connectors and wirings
92
9.3.4 Schematic diagrams
95
9.3.5 Troubleshooting
95
9.3.6 Replacement of Control Board
95
9.3.7 Spare parts
97
9.4 Adapter board
98
9.4.1 Description
98
9.4.2 Warnings
98
9.4.3 Layout, connectors and wirings
98
9.4.4 Schematic diagrams
105
9.4.5 Troubleshooting
105
9.4.6 Scaling resistors
105
9.4.7 Settings on board
105
9.4.8 Spare parts
105
9.5 Branching board
105
9.5.1 Description
105
9.5.2 Warnings
106
9.5.3 Layout, connectors and wiring
106
9.5.4 Schematic diagrams
108
9.5.5 Troubleshooting
108
9.5.6 Spare parts
108
9. 6 Extender (Expander) board
108
9.6.1 Description
108
9.6.2 Warnings
109
9.6.3 Layout, connectors and wirings
109
9.6.4 Schematic diagram
120
9.6.5 Troubleshooting
120
9.6.6 Setting of current measurement circuitry
120
9.6.7 Setting of position jumper
121
9.6.8 Replacement of Extender board
121
9.6.9 Spare parts
122
9.7 VDR board
123
9.7.1 Description
123
9.7.2 Layout, connectors and wirings
123
10. OPTIONAL BOARDS
124
11. COOLING FANS
126
11.1 General
126
11.2 Main fans
126
11.3 Warnings
126
11.5 Replacement instructions
127
12. FCDRIVE AND FCLOAD SOFTWARE TOOLS
133
13. APPENDIXES
134
13.1 NTC.XLS
134
13.2 Torque specifications
136
13.2.1 Construction M4
136
13.2.2 Construction M5
137
13.2.3 Construction M6
137
13.2.4 Construction M7
139
13.2.5 Construction M8 - M10
139
13.3 Adapter board resistors for M4 - M10 CX/CXL drives
140
13.4 Gate resistors
142
13.5 Cross reference list for Extender boards
146
14. SPARE PART LIST
147
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Vacon CX Specifications
General
Brand
Vacon
Model
CX
Category
Media Converter
Language
English
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