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Vacon CX Service Manual
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PC
BOARDS
Service Manual M4 - M10
22.10.2001
Page
87
Power Board Wiring (CB00042)
NTC
res
ist
or
Tem
perature r
esist
or in
heat sink
Rectifier terminals
3 =
> U
5 =
> V
7 =
> W
1 =
(DC+
)
Pin 1 to co
ntacto
r coil (A2
)
Pin 2
to tra
nsfor
mer 23
0 V
Braking
IGBT
IGBT Ph
ase W
IGBT Ph
ase V
IGBT Ph
ase U
Adap
ter board term
inal X7
Co
ntr
ol
boa
rd
t
er
mi
nal X
5
A1
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
C13
C14
C15
C16
C17
C18
C19
C20
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
C31
C32
C33
C34
C35
C36
C37
C38
C39
C40
C41
C42
C43
C44
C45
C47
C48
C50
C52
C53
C55
C56
C57
C58
C59
C60
C61
C62
C63
C64
C65
C66
C67
C68
C69
C70
C71
C72
C73
C74
C75
C76
C77
C78
C79
C80
C81
C82
C83
C84
C85
C86
C87
C88
C89
C90
C91
C92
C93
C94
C95
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
D1
1
D12
D13
D14
D15
D16
D17
D18
D19
D20
D21
D22
D23
D24
D25
D26
D27
D28
D29
D30
D31
D32
D33
D34
D35
D36
D37
D38
D39
D40
D41
D42
D43
D44
D45
D46
D47
D48
D49
D50
D51
H1
H2
H3
H4
H5
H6
H7
H10
H11
H12
H15
H19
H20
H21
K1
K2
K3
Q1
Q2
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R13
R14
R15
R16
R17
R18
R19
R20
R21
R22
R23
R24
R25
R26
R27
R28
R29
R30
R31
R32
R33
R34
R35
R36
R37
R38
R3
9
R40
R41
R42
R43
R44
R45
R46
R47
R48
R49
R50
R51
R52
R53
R54
R55
R56
R57
R58
R59
R60
R61
R62
R63
R64
R65
R66
R67
R68
R69
R70
R71
R72
R73
R74
R75
R76
R77
R78
R79
R80
R81
R82
R83
R84
R85
R86
R87
R88
R89
R90
R91
R92
R93
R94
R95
R96
R101
R103
R10
8
R10
9
R110
R111
R11
3
R114
R115
R116
R117
R118
R11
9
R121
R12
2
R123
R124
R125
R126
R127
R128
R129
R13
0
R131
R132
R133
R13
4
R135
R136
R137
R138
R139
R140
R141
R142
R143
R144
R145
R146
R147
R148
R149
R150
R151
R152
R153
R154
R155
R156
R157
R158
R159
R160
R161
R162
R163
R164
R165
R16
6
R167
R168
R169
R17
0
R171
R172
R17
3
R174
R175
R176
R177
R178
R179
R180
R181
R182
R183
R184
R185
R186
R18
7
R188
R18
9
S1
T1
T2
V1
V2
V3
V4
V5
V6
V7
V8
V9
V10
V11
V12
V13
V14
V15
V16
V17
V18
V19
V21
V22
V23
V24
V25
V26
V27
V28
V29
V30
V31
V32
V33
V34
V35
V36
V37
V38
V39
V40
V41
V42
V43
V44
V45
V46
V47
V48
V49
V50
V51
V52
V59
V60
V61
V62
V63
V64
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10
X11
X12
X13
X14
X15
X16
X17
X18
X19
X20
X21
X22
86
88
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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4
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Vacon CX Specifications
General
Brand
Vacon
Model
CX
Category
Media Converter
Language
English
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