VACON NX SERVICE MANUAL Appendix FI14 PDF

VACON NX SERVICE MANUAL
Appendix FI14
3
1. SERVICE MANUAL VERSION HISTORY ................................................. 5

2. MAIN CIRCUIT DIAGRAMS .................................................................. 6
3. EXPLODED VIEW ................................................................................. 8
3.1. FI13 ....................................................................................... 8
4. MEASUREMENT INSTRUCTIONS ........................................................ 11
4.1. Power unit safety notices ........................................................ 11
4.2. FI14 500/690V ...................................................................... 11
4.3. Star coupler .......................................................................... 11
4.3.1. Description ................................................................ 11
4.3.2. Visual checking's and measurements before powering up . 17
4.3.3. Checking of power unit: .............................................. 17
4.4. FI13 unit measurements ......................................................... 17
4.4.1. How to power up FI13 unit for the measurements ........... 17
4.4.2. IGBT measurements ................................................... 23
4.5. Driver board measurements .................................................... 24
4.5.1. Gate resistance measurements .................................... 24
4.5.2. Checking of optical fiber and IGBT-control circuit ............ 25
4.5.3. Current and I2t signals measurements .......................... 28
4.5.4. Over current trip signal measurement ........................... 30
4.5.5. Temperature signal measurements ............................... 31
4.6. Fan inverter .......................................................................... 32
4.6.1. Isolation transformer .................................................. 34
4.7. Main cooling fan .................................................................... 34
4.8. DC voltage measurement ........................................................ 34
5. REPLACEMENT INSTRUCTIONS ......................................................... 35
5.1. FI13 unit assembly ................................................................. 35
5.1.1. FI13 Covers ............................................................... 35
5.1.2. FI13 ASIC assembly ................................................... 36
5.1.3. ASIC assembly ........................................................... 38
5.1.4. FI13 main cooling fans ................................................ 39
5.1.5. Cooling fan assembly .................................................. 40
5.1.6. FI13 fan inverters ...................................................... 41
5.1.7. Fan inverter assembly ................................................. 42
5.1.8. Fuse base ................................................................. 46
5.1.9. DC connective bus bars ............................................... 47
5.1.10. Block ...................................................................... 49
5.1.11. Block fastening screws .............................................. 50
5.1.12. Block assembly ........................................................ 51
5.1.13. Driver board ............................................................ 51
5.1.14. Driver board screening plate ...................................... 52
5.1.15. DC-busbars and wind channel .................................... 53
5.1.16. EMC cover ............................................................... 54
5.1.17. Power busbar ........................................................... 56
5.1.18. Balancing resistors ................................................... 57
5.1.19. Main circuit busbars .................................................. 58
5.1.20. Main circuit capacitors ............................................... 62
5.1.21. Power modules ......................................................... 63
5.2. Wiring FI13 ........................................................................... 65
5.2.1. FI10 unit balancing resistors wiring ............................... 65
5.2.2. FI13 wiring ................................................................ 67
Global 24/7 support phone: +358 (0)20 1212 575

4
5.2.3. Driver board .............................................................. 71

6. SPECIFICATIONS .............................................................................. 72
6.1. Fastening torques .................................................................. 72
6.1.1. FI13 torque table ....................................................... 72
6.2. Drive version history .............................................................. 73
6.2.1. FI14 drive version history ............................................ 73
Email: [email protected] Fax: +358 (0)204 335 091

Version history 5
1. SERVICE MANUAL VERSION HISTORY
TABLE 1. Service manual updates.

Service Manual Updated/added material
version
SM00039A First revision
SM00039B Vacon logo update
1
6 Main circuit diagram
2. MAIN CIRCUIT DIAGRAMS
FIGURE 1. NX/FI14/INU/500 and 690 power modules
2
Main circuit diagram 7
FIGURE 2. NX/FI14/INU/500 and 690 control
2
9 Exploded view
3. EXPLODED VIEW
3.1. FI14
60FI10002
60FI13305
60FI10001
60FW60050
FIGURE 4. FI13 covers and ASIC assembly, which is one module in FI14 drive.
60FI33333
BUSBAR
ASSEMBLY
60FI10003
60PP01094
FIGURE 5. FI13 side covers and connective bus bar. Used in FI14.
3
Exploded view 10
60FI10013
60PP10049
60FI13329
BUSBAR 60FI10064
ASSEMBLY
60PP13020
POWER
MODULE
60PP01005 500V
60PP01099 690V
60FI10072 60FI10071
60FI13301 60FI10015
60FI13300 60VB00493
FIGURE 6. FI13 500V block assembly. Used in FI14 drive.
3
11 Exploded view
60FI10013
60PP10049
60FI13329
BUSBAR 60FI10064
ASSEMBLY
60PP13020
POWER
MODULE
60PP01005 500V
60PP01099 690V
60FI10071
60FI10072
60FI10015
60FI13301
60FI13300 60VB00493
FIGURE 7. FI13 690V block assembly. Used in FI14 drive.
3
Exploded view 12
3
11 Measurement instructions
4. MEASUREMENT INSTRUCTIONS
4.1. Power unit safety notices
Always when you are starting analyse / checking measurements, make sure that the
unit or module at repair is not powered up, if it is not intended to be. Make sure there
are no remaining dangerous voltages in circuitry and that there is no other voltage
sources for life threatening dangerous potentials. Therefore ensure that main supply is
switched off and main terminals and DC bus bars are de-energized.
Make sure that the environment you are working at is safe and won't cause risk of
personal injury, damage to the unit, or environment. If you are repairing on the field
make sure that supply voltage can't be switched on during service and your service
actions won't cause any unnecessary disturbance or interruption to the process. Also
remember to follow local / national safety rules and regulation.
Bus bars, internal components and circuit boards are at mains potential when the
Vacon frequency converter is connected to the mains. This voltage is extremely dan-
gerous and may cause death or severe injury if you come contact with it.
4.2. FI14 500/690V
FI14 Service will be done like FI13 unit. Measurement values are same etc. Fault his-
tory contains logged data. By checking this logged data you can see which unit (PU1
or PU2) and which phase caused the fault.
4.3. Star coupler
FI14 unit is made of two FI13 units connected via Star coupler board to the control
board. Star coupler board is used instead of the normal fiber adapter board (used in
FR9-FR11 and FR13 units).
4.3.1. Description
Receivers in figure 13 there is the block diagram of the Star coupler board. It is
branching gate and measurement control signals (ADCON) and connects VaconBus1
and VaconBus2 signals to the power units. In VCA9001 ASIC there are two Vacon
Buses sending and instructions blocks and both of them are used to for communica-
tion with the power units.
CPLD circuit EPM7032 on Star coupler board is controlling ENAP signals, trip signals
and Vacon bus signals to and from the power units.
TRIP signals from the power blocks are connected to the CPLD circuit. If one power
unit trips then the ENAP signals are, turned off and both power units stop.
There is EEPROM memory on the Star coupler board. It contains information about the
Star coupler board and also about the whole inverter. The traffic through the VB1 pin
4
Measurement instructions 12
goes first to EEPROM. After uP has read with the memory (I2C bus) then uP can with
VB1EN signal change traffic to Vacon Bus 1. If VB1EN is not active then VaconBus2 is
also not active.
Output phase feedback signals (PHx) from one of the power units are coming to the
Star coupler board. They are sent forward to the control board. The actual dead time
compensation based on these signals is made on the control board.
FIGURE 7. Block diagram
4
INFO: +15V or -15V DC is missing -> AD conversion does not work.
Signals to be measured at Pin-connector to control board or at optical fiber transmit-

ters/receivers Optical fibers can be removed to check if signal is functioning or not =
visual check by pointing the fiber to a paper or other light colored surface.
FIGURE 8. Principle layout
4
Measurements for signals
1. Power up both drive´s (boards only). To read EEPROMS - supply voltage required
see previous page.
2. Measure supply voltage 24V DC to star coupler -> voltage missing problem with
that source.
3. Measure secondary voltages:

• +5V DC -> bottom of star coupler see figure 15.
• +15V DC -> pin connector to control unit (X1-37)
• -15V DC -> pin connector to control unit (X1-17)
• +24V DC -> pin connector to control unit (X1-19)
Verify that drive (control board) sends out “VB1EN” signals

• Measure signal from star coupler board X1-27, signal level is 5V DC -> if voltage
not ok, replace control board.
Verify that “AD CON”-signal is functioning.

• Measure X1-34 signal is inverted 5V -> 0V DC -> if signal does not reach 0V DC ->
replace control board.
Verify that PU1 and PU2 replies (send data)

• Remove optical fiber “7” from star coupler board / PU1
• Remove optical fiber “7” from star coupler board / PU2
Light available = data being sent, NO light = NO data -> problem in corresponding
power unit.
Verify that data from PU1 and PU2 goes from star coupler board to control
board
• Data from PU1 data bus at X1-16
• Data from PU1 data bus at X1-13
Maybe it is possible to measure frequency with a multimeter, otherwise use oscillo-

scope, if data is missing from either one -> replace starcoupler board
• Repeat measurements for optical fiber “6”, (X1-35/PU1 and X1-32/PU2)
NOTE! IF ALL ABOVE IS WORKING & NO ACTIVE FAULT PRESENT UNIT WILL REACH “READY
STATE”
4
TABLE 2. Measurement points and values

Signal measurement point Value
VB1EN pin 27 -> GND 0V -> 5V
ADcon pin 34 -> GND 5V -> 0V
VB1RX data pin 16 -> GND ~6MHz
VB2RX data pin 13 -> GND ~6MHz
+15V pin 37 -> GND +15V
-15V pin 17 -> GND -15V
TP1 see figure 15 5V
4
FIGURE 9. Star coupler measurement points
4
4.3.2. Visual checking's and measurements before powering up
Checking of cooling tunnel:
1.Remove the main fans.
2.Check the cooling tunnel and clean the heat sink and cooling tunnel if necessary.
4.3.3. Checking of power unit:
1.Remove plastic covers.
2.Check possible burn marks, broken components or foil on boards, power module
and/or rectifier module. Replace the boards, power module and/or rectifier module
without testing if they are badly burnt.
3.Test capacitors, measure AC-choke, power module and rectifier module. See specific
instructions in chapter 3.3.
4. See Vacon overview manual for troubleshooting and instructions how to power up
unit after the repairs. Overview manual is available in Vacon service web site.
4.4. FI13 unit measurements
4.4.1. How to power up FI13 unit for the measurements
How to power up boards for the measurements

1.First remove all 6A fuses from fan inverter fuse bases see figure 19. Connect DC+
and DC- from external power supply to Asic board connector X1, put jumper between
pin 1 and 2 see figure 17, connect power supply DC- to DC- busbar see figure 18.
2. Disconnect DC+ wires from driver boards and connect DC+ wires from external
power supply to each driver board see figure 16.
Do not disconnect DC- from driver boards
3. Use nominal voltage and 1A current limit. Power up quickly, if you lift power up too
slowly unit will give you fault code F_7 (Asic wakes up before driver boards) this
won´t cause any harm for the unit and you can reset the fault.
How to power up the fan inverters FI13 and NFE
FI unit
Connect DC supply to Asic board see figure 17, take of 6A fuses from fuse bases. Con-
nect DC+/- to fuse base, make sure that you connect DC wires to correct polarity and
to correct side of the fuse base see figure 19. You can power up all inverters at the
4
same time, or if your power supply is not big enough you can power up one inverter at
the time. Unit will give fault code F38_fan cooling, if just one of the inverter is running
it won’t cause any harm and you can reset the fault and power up next inverter. Use
nominal voltage and 1A current limit.
NOTE! AFTER THE MEASUREMENTS MAKE SURE THAT YOU HAVE CONNECTED ALL WIRES
BACK
FIGURE 10. Driver boards
4
1=DC+
2=DC+
3=DC-
123
FIGURE 11. ASIC board
4
FIGURE 12. DC- bus bar
FIGURE 13. Fuse base
4
FIGURE 14. Feeding points for external power supply.
4
Fan inverter
supply Fuses
Disconnect
DC wires
from fuse base and
connect DC supply
from external power
supply
NOTE! BEFORE POWERING

INVERTER CHECK THAT YOU
HAVE REMOVED THE 6A
FUSES AND CONNECTED DC
SUPPLY WIRES TO CORRECT
SIDE OF THE FUSE BASE!
MAIN COOLING FAN SUPPLY
DC- FROM FUSE BASE
FIGURE 15.
4
4.4.2. IGBT measurements

Make sure that unit or boards are not powered up.
1. Measure forward bias off free wheeling diode from, DC- to U/V/W output terminal
and reverse bias from U/V/W to DC- table 3.
2. Measure forward bias on IGBT, from U/V/W output terminal to DC+ and reverse
bias from DC+ to U/V/W table 3.
3. Measure resistance between DC busbars and motor terminal. Turn multi-meter to

resistance range and connect test leads between DC+ busbar and U-phase repeat
measurement to also to phases V and W. Repeat measurement from DC- busbar to U,
V and W motor terminals, if IGBT are short-circuited (resistance 0 Ohm.) IGBT are
broken and you have to replace power modules..
TABLE 3.
DC- to output U, V, W 0,3V
DC+ to output U, V, W 0,3V
Infinite ~0,5V
Reversed Forward
biased biased
PN-junction PN-juction
FIGURE 16.
4
DC+ DC- DC+ DC- DC+ DC-
U V W
FIGURE 17. FI13-unit main terminals
4.5. Driver board measurements
4.5.1. Gate resistance measurements

Make sure that unit or boards are not powered up
1. Start measurements at branch X10, measure gate resistance between emitter and
extinguishing, gate resistance is ~166 ohm, if boards are OK figure 24.
2. Measure resistance between emitter and output terminal. Connect multi-meter test
leads to emitter at branch X10/H and to out put terminal. Measured value should be
~0,5 ohm.
3. Measure resistance, from lower branch emitter X11/L to DC- busbar, measured
value should be ~0,5 ohm.
4. You don‘t have to do measurements to branches (X8/L and X7/H) because they are
connected parallel with (X11/L and X10/H) branch, if everything was OK proceed to
next step
4
ignition
X7/H extinguishing X10/H

1. emitter
ignition
X8/L extinguishing X11/L
emitter
FIGURE 18. Driver board
4.5.2. Checking of optical fiber and IGBT control circuit
1. Remove optical fibers from driver boards and connect the external power supply to
driver boards see instructions in chapter 4.3.1.
2. Start measurements at U-phase block and continue in order trough all blocks
3. Connect multi-meter red test lead to driver board extinguishing pin and black test
lead to same branch emitter (X11/L). Turn external power supply on use nominal volt-
age. Shine light pulses to optical receiver (H4/L), monitor that multimeter value
changes from -15V to +15V. If measured value changes driver works correctly. Con-
nect red test lead to same branch ignition pin and provide light pulses to optical
receiver. Do same measurements to next branch (X10/H) optical receiver (H2/H). You
don‘t have to do measurements to branches (X8/L and X7/H) because they are con-
nected parallel with branches (X11/L and X10/H).
4
4. Connect multi-meter black test lead to DC- busbar and red test lead to output
phase. Shine light to optical receiver (H4/L). Multi-meter should show that IGBT is
short circuit when providing light to optical receiver, if the whole circuit from optical
receiver to output is working.
5. Connect multi-meters red test lead to DC+ busbar and black test lead to output
phase. Shine light to optical receiver (H2/H). Multi-meter should show that IGBT is
short circuit when providing light to optical receiver, if the whole circuit from optical
receiver to output is working.
6. IF measurements were OK, then continue same measurement to next phase block.
7. If all measurements were OK turn external power supply off and connect all fibers
back see chapter 5.3 proceed to next step
TABLE 4.
Optical receiver Branch Measurement
H2/H X10/H emitter -> ignition
H4/L X11/L emitter -> extinguishing
4
ignition
X7/H extinguishing X10/H

1. emitter
ignition
X8/L extinguishing X11/L
emitter
H2/H H4/L
FIGURE 19. Driver board measurement points
4
4.5.3. Current and I2t signals measurements
NOTE! PAY ATTENTION AT FOLLOWING MEASUREMENT, IF YOU DO SHORT CIRCUIT BY ACCI-

DENT, IT CAN BRAKE CURRENT MEASUREMENT CIRCUIT.
1. Turn external power supply on use nominal voltage.
2. Measure voltage from I current pin at branch X12 and X9, connect multi-meter red
test lead to current pin (I current) and black to DC- figure 26, OFF SET value should
be DC 0V.
3. Measure I2t signal from branch X12 and X9, connect multi-meter test leads
between DC- and I2t pin the board is OK, if measured voltage on I2t pin is ~14.4V.
3. Check shunt resistors figure 27 and table 5, if problem was in the shunt resistors
you have to change all shunts.
I current I current
I2t I2t
DC- DC-
FIGURE 20. Current and I2t signals
4
TABLE 5.
Unit IN / A Voltage PCB Frame size
1150 400 / 500V VB00541 FR13
1300 400 / 500V VB00505 FR13
1450 400 / 500V VB00514 FR13
920 690V VB00516 FR13

1030 690V VB00547 FR13
1180 690V VB00517 FR13
FIGURE 21. Shunt resistors
4
4.5.4. Over current trip signal measurement
1. Turn on external power supply, use nominal voltage.
2. Measure voltage from over current trip signal at branch (X9 and X12). Connect
multi-meter red test lead to Itr pin and black test lead to DC-. Value in normal state is
~14.4V. Do same measurement to all phase modules.
Itr over current Itr
DC- DC-
FIGURE 22. Over current signal.
4
4.5.5. Temperature signal measurements
1. Turn on external power supply, use nominal voltage.
2. Measure temp signal (temp) from branch (X9 and X12), connect multi-meter red
test lead to temp pin and black test lead to DC- figure 29. Measured value should be
~3V at room temperature. Do same measurement to all phase modules.
Temp Temp
DC- DC-
FIGURE 23. Temperature signal
Temperature measurement, Highest value is displayed

• = U - Phase
• = V - Phase > Highest is displayed!
• = W - Phase
• = Asic board > Not displayed!
If temperature warning comes up and monitoring is showing normal values below

85°C, Asic board is too hot because:
• Fan to cool down asic board has failed.
• Environment is too warm.
Temperature limits
• warning at 85°C
• Trip at 91°C
4
4.6. Fan inverter
Power up the fan inverters see instructions in chapter 4.3.1. and check that all fan
inverters and fans are running, if all inverters and fans are working properly turn off
the power supply and proceed to next step.
1. If fan inverters don’t run check that the fan inverter supply fuses are not burnt fig-
ure Fi 19 and NFE 21.
2. If fuses are OK remove fan inverter assembly. See replacement instructions chap-
ter 5.1.7 for Fi10 and 5.2 for NFE.
3. Measure resistance from inverter board connector X2 figure 30 between pin 1 and
pin 2, if pins are in short circuit the inverter board is broken.
4. Measure resistance from field-effect transistor (fet) figure 30. Resistance should be
>2 M ohm, if resistance is smaller or legs are in short circuit the inverter board is bro-
ken.
5. Replace damaged inverter board see instructions in replacement chapter.
X2
Field-effect transistors
FIGURE 24. X2 connector and Field-effect transistors
Fan capacitor
Measure fan capacitor capacitance value with multimeter. Compare measured value to
value in capacitor. You have to change it to new, if measured value is smaller than
6.65uF.
4
TABLE 6. DIP switch settings on fan power supply VB00299 and VB00399
State S1 S2 S3 S4
running fre- S2=motor S3=motor frame size
quency voltage voltage
ON 60 Hz OFF OFF 220VAC FR8
OFF ON 230VAC
OFF 50 Hz ON OFF 240VAC FR9-FR13
ON ON 250VAC
DIP switch default settings are ON = up, OFF=down. In FR9 and bigger units unit DIP
switch setting as FR9 in TABLE 6. and FIGUTRE 33..
FIGURE 25. DIP switch settings
FIGURE 26. DIP switch in inverter board
4
4.6.1. Isolation transformer
Measure isolation transformers winding see table 7.
TABLE 7. Isolation transformer winding.

Winding Measurement point Value
(wire number)
Primary winding 2 to 1 ~6,5 ohm
Secondary winding 3 to 4,5 ~4,5 ohm
Secondary winding 6 to 4,5 ~4,7 ohm
4.7. Main cooling fan
Measure resistance from main cooling fan connector
TABLE 8. Main cooling fan connector resistances.

Wires Resistance
brown-black ~60
blue-black ~26
blue-brown ~34
4.8. DC voltage measurement
Check monitoring page at unit measuring voltages.
- If unit is not measuring anything, problem might be in:

• Asic board > Change and program Asic board.
• Opto adapter board > Replace it.
Monitoring value is too small > Check asic boards programming. If problem was not in
monitoring value, go back to Asic board programming.
4
Replacement instructions 35
5. REPLACEMENT INSTRUCTIONS
5.1. FI14 unit assembly
5.1.1. FI13 Covers

2. 2.
1. 3.
4.
5. 5.
FIGURE 27. Covers in FI14 drive are the same than in FI13 drive.
Connection and front cover, open fastening screws and lift covers off.
Side panels, first you have to remove Asic assembly and DC busbars which connect
blocks together, then you can remove panels. Open fastening screw and pull panels
out off the frame, when installing side panel make sure that panel can easily slide in
correct place.
TABLE 1. FI13 unit sizes
Current Voltage
Parts and fastening torques
1150 500
• 1. Side cover (FI10003).
1300 500
• 2. Screw M5*10, 3Nm.
1450 500
• 3. Front cover (FI10001).
• 4. Connection cover (FI10002). 920 690
• 5. Screw M5*16 (black), 3 Nm 1030 690
1180 690
5
36 Replacement instructions
5.1.2. FI13 Asic assembly
Asic cooling fan

supply wire.
Connector X1
on asic board.
FIGURE 28. In FI14 used ASIC.
Unscrew fastening screws from asic cover, unplug asic cooling fan supply wire from
asic board connector X1 and remove the cover. Unplug optical fibers, flat cables,
power supply and control box power supply from asic board. Unscrew asic plastic
frame fastening screws and remove asic assembly see figure 36.
Glolbal 24/7 support phone: +358 (0)20 1212 575
5
FIGURE 29. ASIC assembly fastening
Unscrew Asic cover fastening screws and lift cover of, when installing cover back con-
nect DC- wire to asic cover.
Parts and fastening torques:

• 1. Screw M4*8 taptite.
• 2. Asic cover
NOTE! ASIC COVER IS IN DC- POTENTIAL IF UNIT IS POWERED.
5
5.1.3. Asic assembly
1.
2.
3.
4.
6. 5.
FIGURE 30. ASIC assembly
Asic board replacement, unscrew asic board fastening screw and slide asic board out
off the asic board bracket. Unscrew fastening screws which connects asic frame and
asic metal frame. Asic insulator is fastened with four plastic rivet, be carefully when
removing the insulator.

• 1. Screw M4*8 combo, 1.35 Nm.
• 2. Asic board (VB00451).
• 3. Asic insulator.
• 4. Asic frame.
• 5. Plastic rivet.
• 6. Asic plastic frame.
5
5.1.4. FI13 main cooling fans
Main cooling fan

supply wire.
FIGURE 31. In FI14 drive used main cooling fans are the same than in FI13 used.
Unplug cooling fan supply wire, unscrew fastening screws and pull cooling fan out off
the frame.

• 1. Main cooling fan assembly.
• 2. Screw M5*10 taptite.
5
5.1.5. Cooling fan assembly
1. A
2.
B
First pull fan cable through hole in support plate (A),
after that fasten cooling fan, then install rubber bushing
and attach fan cable to fan support plate with cable tie
(B).
1.
1.
5.
3.
4.
FIGURE 32.

• 1. All fastening screws used in cooling fan assembly are M4*8 taptite, 3Nm.
• 2. Fan support (FI10070).
• 3. Intake cone (FI10054).
• 4. Cooling fan (PP01080).
• 5. Fan support (FI10046).
5
5.1.6. FI13 fan inverters

Fan inverter wire harness is attach to
frame with two cable ties.
Fan inverter wire harness con-

nectors.
FIGURE 33. Fan inverters
First you have to remove main cooling fan, the fan inverter is located behind the cool-
ing fan. Unplug and remove fan inverter connectors from holder. Push inverter wire
harness in to frame, biggest connector first figure 39. Remove fan inverter fastening
screws and remove cable ties from wire harness. Pull fan inverter out of frame, turn
inverter vertically so it can easily slide out of the frame.

• 1. Screw M5*10 taptite, 4 Nm.
• 2. Fan inverter assembly.
5
5.1.7. Fan inverter assembly

Fan capacitor,
Disconnect fan
capacitor wire
and rotate capac-
itor counterclock-
wise.
Inverter board, disconnect wires from

1. connector X8, X2, X4 and X5 remove
two fastening screw and lift inverter
board out of the frame.
2.
3.
4.
5. 6.
Isolation transformer,
disconnect wires from
fan inverter board connectors X4 and
X5, remove fastening screw and lift
transformer assembly off.
FIGURE 34.
5
Earthing
7. capacitor,
disconnect
wires,
unscrew
assembly
8. fastening
screw and
remove
capacitors.
9.
10.
FIGURE 35.

• 1. Fan capacitor (PP00011)
• 2. Inverter board
• 3. Screw M4*8 taptite
• 4. Isolation transformer (PP10051)
• 5. Spring washer M8
• 6. Screw M8*70 hexagonal
• 7. Screw M4*25
• 8. Earthing capacitor support (FR09141)
• 9. Earthing capacitor
• 10. Inverter plate (FI10047)
5
FIGURE 36. Fan inverter connections
Fan inverter connections:

• 1. Wire harness connectors X8 and X2 to inverter board connectors X8 and X2. fig-
ure 43/1.
• 2. Connect connectors figure 43/2.
• 3. Isolation transformer earth wire figure 43/3.
• 4. Isolation transformer connectors (black and blue) to inverter board (connectors
fan black and fan blue) connectors figure 43/4.
• 5. Fan capacitor figure 43/5.
• 6. Wire harness X2 connector to inverter board connector X2 figure 43/6.
5
1. 2.
3. 4.
5. 6.
FIGURE 37. Fan inverter connections
5
5.1.8. Fuse base
FIGURE 38. Fuse base assembly

• 1. Fuse holder base (FI10019).
• 2. Insulator (FI10061).
• 3. Fuse holder (PP01094).
• 4. Screw M4*8 taptite, 3Nm.
• 5. Screw M4*8 combo, 3Nm.
5
5.1.9. DC connective bus bars
FIGURE 39. Bus bars
Remove covers see chapter 5.1.1, remove ASIC assembly chapter 5.1.3 and remove
fastening screws from bus bars. See FIGURE 46.
Bus bars and insulator:

• 1. DC- bus bar (FI13001).
• 3. DC+ bus bar (FI13003).
5
FIGURE 40. Bus bars fastening screws
Busbars fastening screws

• 1. M10*20 hexagonal screw, M10 spring washer and M10 washer, 40 Nm.
• 2. M8*25 hexagonal socket-head screw, M8 spring washer and M8 washer, 25 Nm.
• 3. M6*12 combo, 4 Nm.
5
5.1.10. Block
FIGURE 41. Block fastening screws
Remove output cables from output terminals, Remove all cables and optical fibers
from driver board.
Output cables fastening

• M10*25 hexagonal screw,
• M10 spring washer
• M10 washer
• 40 Nm
5
5.1.11. Block fastening screws
FIGURE 42. Block fastening
Block fastening screws:

• 1. M8*20 hexagonal screw, M8 spring washer and M8 nut.
• 2. M8*20 hexagonal screw and M8 spring washer.
NOTE! BLOCK IS HEAVY REMOVE IT CAREFULLY!
5
5.1.12. Block assembly
5.1.13. Driver board
FIGURE 43. Driver support
Disconnect flat cables, DC supply wires, measurement wires and optical fibers from
driver board. Remove driver board support plate. Remove driver board fastening
screws and remove the board. Driver board connections see main circuit diagrams.
NOTE! IF YOU ARE INSTALLING NEW DRIVER BOARD TO UNIT, MAKE SURE THAT DRIVER
BOARD VOLTAGE MODIFICATION IS DONE PROPERLY SEE CHAPTER (5.6.2.) FOR INTRUC-
TIONS.

• 1. Screw 4*8 combo, driver board support 3 Nm, driver board 1.35 Nm.
• 2. Driver board support (Fi10055)
5
5.1.14. Driver board screening plate
1.
2.
3.
FIGURE 44. Screening plate fastening

• 1. Plastic screw M4*8.
• 2. Screening plate (FI10025).
• 3. Raising screw, 1.5 Nm.
5
5.1.15. DC-busbars and wind channel
FIGURE 45. DC bus bars fastening
DC feed busbars, first remove earth capacitor (capacitor only in V-phase block) wires
from busbars then unscrew busbars fastening screws and remove them.

• 2. Insulator holder (FI09074).
• 3. Feed busbar (FI10071).
• 4. Wind channel (FI10067).
5
5.1.16. EMC-cover
FIGURE 46. EMC cover and snubber capacitors fastening.
EMC-cover, unscrew motor cables fastening screws from power busbar, cut cable ties
from emc cover and remove motor cables. Unscrew EMC-cover fastening screw and
remove cover.
Snubber capacitors, unscrew fastening screw from IGBT-terminals and lift snubber
capacitor assemblies off.
5

• 3. EMC-plate (FI00013).
• 4. Screw M6*20 combo, 5 Nm.
• 5. Snubber capacitor assembly (PP10049).
5
5.1.17. Power busbar
Remove motor cables from bus-

bar, unscrew M8*20 screws from
IGBT-terminals. Unscrew M6*12
combo screw and remove busbar.
FIGURE 47. Power bus bar fastening.
Fastening
• 1. M8*20 hexagonal socket-head screw, 14 Nm.
• 2. M8 spring washer
• 3. M8 washer
• 4. M6*12 combo.
• 5. support insulator
5
5.1.18. Balancing resistors
FIGURE 48. Balancing resistors fastening.
FI10 unit has two balancing resistor assemblies, remove wires from main circuit bus-
bars, unscrew eight fastening screws from each assembly and lift them off. See wiring
instructions in (chapter 5.3).
NOTE! WHEN REPLACING THE BALANCING RESISTOR ASSEMBLY MAKE SURE THAT YOU HAVE
CONNECTED RESISTORS WIRES TO CORRECT PLACES.

• 1. Balancing resistor assembly.
• 3. Screw M5*12 combo, 4 Nm.
5
5.1.19. Main circuit bus bars
Main circuit
busbars,
unscrew all
fastening
screws
from bus-
bars. Lift
busbars
and insula-
tors off one
by one.
FIGURE 49. Main circuit bus bars 500V.

• 1. Busbar (FI10043).
• 3. Busbar DC+ (10040).
• 5. Busbar DC- (FI10037).
• 7. Metal plate (FI10018).
• 8.Screw M4*8 combo.
5
1.
2.
7.
3.
4. 8.
5. 7.
6. 8.
FIGURE 50. Main circuit bus bars 690V.

• 1. Busbar (FI10029).
• 2. Insulator (FI10033):
• 3. DC+ busbar (FI10026).
• 5. DC- busbar (FI10023).
• 7. Metal plate (FI10018).
• 8. Screw M4*8 combo.
5
2. 3. 2. 3. 3. 1.
3. 1. 2. 3. 3. 1.
2. 3. 2. 3. 3. 1.
3. 1. 2. 3. 3. 1.
FIGURE 51. Bus bars fastening screws in 500V unit.

• 1. (Green) Screw M6*20 combo, 4 Nm.
• 2. (Red) Screw M6*16 combo, 4 Nm.
• 3. (Blue) Screw M6*25 torx+M6 washer, 4 Nm.
5
2. 3. 3. 3. 3. 1.
2. 3. 3. 3. 3. 1.
2. 3. 3. 3. 3. 1.
2. 3. 3. 3. 3. 1.
FIGURE 52. Bus bars fastening screws in 690V unit.

• 1. (Green) Screw M6*20 combo, 4 Nm.
• 2. (Red) Screw M6*16 combo, 4 Nm.
• 3. (Blue) Screw M6*25 torx+M6 washer, 4 Nm.
5
5.1.20. Main circuit capacitors
FIGURE 53. Main circuit capacitors fastening.

• 1. Screw M4*8 taptite, 1.35 Nm.
• 2. Capacitor 500V (PP01005)
• 3. Capacitors 690V (PP09052)
5
5.1.21. Power modules
FIGURE 54. Power modules fastening.

• 2. Power module
5
TABLE 9. Fi13 power modules

Power module 500V Current Voltage
SA-FI13-1150-5-ANV 1150A 500V
SA-FI13-1300-5-ANV 1300A 500V
SA-FI13-1450-5-ANV 1450A 500V
Power module 690V Current Voltage
SA-FI13-0920-6-ANV 920A 690V
SA-FI13-1030-6-ANV 1030A 690V
SA-FI13-1180-6-ANV 1180A 690V
FIGURE 55. Example of the power module code.
5
5.2. Wiring FI13
5.2.1. FI10 unit balancing resistors wiring
FIGURE 56. 500V
5
FIGURE 57. 690V
5
5.2.2. FI13 wiring
NOTE! SEE ALSO MAIN CIRCUIT DIAGRAMS FOR WIRING INSTRUCTIONS
FIGURE 58. Power supply
5
DRIVER U DRIVER V DRIVER W

UL UH VL VH WL WH
7
6
5
WL WH VL VH UL UH 4
3
2
ASIC 1
7654321 CTRL
FIGURE 59. Optical fibers
5
FIGURE 60. Flat cables
FIGURE 61. Connections between driver board and measurement board.
5
Modification marking
Mark voltage value in the card after modification by striking out the wrong voltage
value
X17
X14
X12
X141
X142
FIGURE 62. ASIC board layout.
1. 400V and 500V units: remove jumpers X12 and X17.
2. 690V unit: remove jumpers X41, X141, X142 and X17.
5
5.2.3. Driver board
R63
R66
W1
R46
R80
FIGURE 63. Driver board (VB00493) layout.
1. 500V units: remove resistors R46 and R66.
2. 690V unit: remove resistors R63, R80 and jumper W1.
5
72 Specifications
6. SPECIFICATIONS
6.1. Fastening torques
6.1.1. FI14 torque table
TABLE 10. FI14 Torque table

Part Screw Final Note!
torque/
Nm
IGBT module M4*8 taptite 3 Nm
IGBT terminals (U, V, W) 14 Nm
Main cooling fan mounting M5*10 taptite 4 Nm
Driver board M4*8 taptite 1,35 Nm
Driver board support M4*8 taptite 3 Nm
ASIC fan M4*16 kombi 0,4 Nm
ASIC cover M4*8 kombi 1,35 Nm
ASIC assembly M4*8 kombi 3 Nm
Block mounting M8*20 hexagonal socket- 20 Nm
head+M8 spring washer
DC- bus bar 500V M6*16 kombi 4 Nm
DC+ bus bar 500V M6*20 kombi 4 Nm
DC- bus bar 690V M6*16 kombi 4 Nm
DC+ bus bar 690V M6*20 kombi 4 Nm
Power bus bar M8*20 hexagonal socket- 14 Nm
head
Fuse base plate M4*8 taptite 3 Nm
Fuse base M4*8 kombi 3 Nm
EM cover M4*8+M5*10 taptite 3 Nm /
4 Nm
Balancing resistor assem- M5*12 kombi+M4*8 taptite 4 Nm /
bly 3Nm
Main circuit capacitors M4*8 taptite 1 Nm
Inverter board M4*8 taptite 3 Nm
Inverter assembly M5*10 taptite 4 Nm
Snubber capacitors M6*20 kombi 5 Nm
Connection cover M5*16 (black) 3 Nm
Side cover M5*10 (black) 3 Nm
Protective cover M5*10 (black) 3 Nm
Main terminals (DC supply M10*25 hexagonal+M10 8 Nm
bus bar) spring washer+M10 washer
6
Specifications 73
TABLE 10. FI14 Torque table

Part Screw Final Note!
torque/
Nm
Cables to main terminals M10*25 hexagonal+M10 40 Nm
(U, V, W) spring washer+M10 washer
Connective bus bar M6*25 torx+M6 washer 4 Nm
Main circuit capacitors M4*8 taptite 1 Nm
DC bus bar fastening M10*20 hexagonal 40 Nm
M8*25 hexagonal socket- 25 Nm
head
6.2. Drive version history
6.2.1. FI14 drive revision history
TABLE 11. FI14 drive revision history

Name of New P/N S. nbr/date Change to previous
product
Isolation TM330_R776 7.6.2005 Current TE260_R577 isolation
transformer / PP10057 transformer replaced by
TM330_R776 transformer. Needs
mechanical changes
Cover, fixing FI09068D, 10.6.2005 Fan isolation transformer change
base and FI09079B TE260 -> TM330. New parts have to
inverter and be changed before the construction
plate FI10047C is compatible for isolation trans-
former TM330.
Fan inverter VB00299FB 12.7.2005 Jumper wire soldered manually
board from DC- to crystal body.
Fan capacitor PP00060 13.7.2005 Fan capacitor changed:Facon 7uF->
Arcotronics (MKP C.27/4).
Flat cable PP10041E 18.8.2005 Flat cable ground lead is extended
Measure- VB00384F 22.8.2005 Current measurement resistor
ment board accurary changed 1%->0,1%.
Measure- VB00384FB 24.8.2005 transient voltage suppressor added,
ment board compatible with old revision
Measure- VB00384G 24.8.2005 Transient voltage suppressor added,
ment board compatible with old revision
6
74 Specifications

ASIC cover FI10077, 24.8.2005 Asic-assemblies will be added asic-
MC00699 cover with the dangerous labels.
This part is manufactured by poly
carbonate sheet. It prevents and
warns unintentional touching. Other
sticeris fitting on the asic cover and
second one the metal cover for the
asic assembly.
Wire set PP13100D, 9.9.2005 /
FR13 500V, PP13106E,
Wire set PP131106A
FR13 690V
and ASIC
wire X2 Fi/
FR13
Inverter VB00299H 7.10.2005 New type of insulation, compatible
board with all older versions.
Balancing FI09063C 3.10.2005 The cooling plate is added a bending
resistors which take possible to add the wire
cooling plate to wire connector for easier assem-
bly. If the old construction would be
replaced the new construction har-
ness of wires have to replace. In
old construction wires are con-
nected to the capacitor busbars.
Balancing PP13020 3.10.2005 Balancing resistor assembly assem-
resistor (Balancing bled by Crimppi Oy. Only one resis-
assembly resistor tor sub assembly (PP13020) and 4
assembly different wire sets needed
500/690V),
PP13021
(Balancing
resistor wire
set 500V),
PP13022
(Balancing
resistor wire
set 690V)
ASIC Board VB00451K 31.10.2005 Missing resistor in the Asic board
power up circuit. The start up volt-
age varies from board to board.
6
Specifications 75

4*8 combo MC00032 02.11.2005 The washers on the old screw
screw breaks due to hydrogen brittleness
(Finnish: Vetyhauraus) caused by
the difficulties to control the manu-
facturing process, at the supplier,
for the used coating type.
There is also a need for the transi-
tion from Phillips to Torx type screw
heads for better ergonomics and
quality in Vacons factories.
Optical fiber PP13005 D 17.01.2006 Liquid cooled products needs
set Fi/CH shorter heat shrink tube of the opti-
cal fiber set.
VB00561 H, VB00561H 18.04.2006 New revision of the NXP control is
NXP Control needed for support of the Safe Dis-
with Safe able function. NXP drive with Safe
Disable Disable function is achieved with
NXP control revision H (VB00561H)
and OPT-AF installed in slot B of the
control. VB00561H is functionally
HW and SW compatible with
VB00561F.
Fan trans- PP10057 13.04.2006 Current fan transformer capacitor
former (ver. B) PHE820 availability is low. Capacitor
(ground) (FR10-13 ja support has to be updatet because
capacitor Fi9-13) capacitor case is smaller in new
change; Rifa PP09057 type.
PHE820ER72 (ver. B)
0MR (2,2 uF) (FR9)
--> Rifa PP08027
PHE840ER72 (ver. B)
0MR (2,2 uF) (FR8)
FW09163
(ver. A
6
VACON Plc.
Runsorintie 7
65380 Vaasa
Finland
Subject to change without prior notice

© 2009 Vacon Plc.
SM00039 B
21.08.2009
J.Kukkonen

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VACON NX SERVICE MANUAL

1. SERVICE MANUAL VERSION HISTORY ................................................. 5

Global 24/7 support phone: +358 (0)20 1212 575

5.2.3. Driver board .............................................................. 71

Email: [email protected] Fax: +358 (0)204 335 091

1. SERVICE MANUAL VERSION HISTORY

TABLE 1. Service manual updates.

Email: [email protected] Fax: +358 (0)204 335 091

2. MAIN CIRCUIT DIAGRAMS

FIGURE 1. NX/FI14/INU/500 and 690 power modules

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 2. NX/FI14/INU/500 and 690 control

Email: [email protected] Fax: +358 (0)204 335 091

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 6. FI13 500V block assembly. Used in FI14 drive.

Email: [email protected] Fax: +358 (0)204 335 091

FIGURE 7. FI13 690V block assembly. Used in FI14 drive.

Global 24/7 support phone: +358 (0)20 1212 575

Email: [email protected] Fax: +358 (0)204 335 091

4.1. Power unit safety notices

4.2. FI14 500/690V

4.3. Star coupler

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 7. Block diagram

Email: [email protected] Fax: +358 (0)204 335 091

INFO: +15V or -15V DC is missing -> AD conversion does not work.

Signals to be measured at Pin-connector to control board or at optical fiber transmit-

FIGURE 8. Principle layout

Global 24/7 support phone: +358 (0)20 1212 575

Measurements for signals

3. Measure secondary voltages:

Verify that drive (control board) sends out “VB1EN” signals

Verify that “AD CON”-signal is functioning.

Verify that PU1 and PU2 replies (send data)

Maybe it is possible to measure frequency with a multimeter, otherwise use oscillo-

Email: [email protected] Fax: +358 (0)204 335 091

TABLE 2. Measurement points and values

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 9. Star coupler measurement points

Email: [email protected] Fax: +358 (0)204 335 091

4.3.2. Visual checking's and measurements before powering up

Checking of cooling tunnel:

1.Remove the main fans.

4.3.3. Checking of power unit:

1.Remove plastic covers.

4.4. FI13 unit measurements

4.4.1. How to power up FI13 unit for the measurements

How to power up boards for the measurements

Do not disconnect DC- from driver boards

How to power up the fan inverters FI13 and NFE

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 10. Driver boards

Email: [email protected] Fax: +358 (0)204 335 091

FIGURE 11. ASIC board

Global 24/7 support phone: +358 (0)20 1212 575

FIGURE 12. DC- bus bar

FIGURE 13. Fuse base

Email: [email protected] Fax: +358 (0)204 335 091

FIGURE 14. Feeding points for external power supply.