VACON NX SERVICE MANUAL Appendix FR4 PDF
VACON NX SERVICE MANUAL Appendix FR4 PDF
VACON NX SERVICE MANUAL Appendix FR4 PDF
Appendix FR4
Table of content 1
Service manual
2 Version history
Service manual
1
Revision history 3
Service manual
1
4 Main circuit diagrams
Service manual
2
2
5
B-
POW
B+ / R+
R-
J1
U_HI
V_HI
W_HI
J3
DC +
L3 W / T3
X10
Service manual
INTEGRATED C
DC -
INPUT MODULE
W_LO
U_LO
V_LO
BRK
J2
TERM
A B
TERM
PE
PE
X2
MEASUREMENTS
DC +
POWER BOARD DC -
X18
X6
1 2
37
M1
GND CONTROL BOARD X1 CONTROL
+ 24 V PANEL
9
X7 X1
MAIN FAN
X2 X3 X4 X5 X6
(slot A) (slot B) (slot C) (slot D) (slot E)
NX/FR4/FC/230 AND 500 DM00001 OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD
MAIN CIRCUIT DIAGRAM
6 Main circuit diagrams
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Main circuit diagrams 7
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8 Main circuit diagrams
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Exploded view 9
3. MECHANICAL CONSTRUCTION
60PSNXPAN_A
60FR00006
60FR00070
60FR04009
60FR04002 60FR00016
60PP04000 60FR00015
60FR04003
60VB00208
60VB00308 60FR00040
60VB00210
60VB00310
60CP01304
60CP01305
60CP01306
60PP01006
60PP01000 60PP01007
60PP01001
60PP01060 60FR04000
60FR04001
60PP01042
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Exploded view 10
NOTE! CHECK THE CORRECT SPARE PARTS FROM THE SPARE PARTS LIST, WHICH IS AVAIL-
ABLE AT THE VACON SERVICE EXTRANET ADDRESS: WWW.EXTRA.VACON.COM, AND DRIVE
VERSION HISTORY TABLE IS AVAILABLE IN THE SPECIFICATIONS CHAPTER.
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Exploded view 11
• 60SA-VB00310-0012-2-ABV Power board 12A 230V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0000-5-XXV Power board FR4 3-9A 500V, not programmed, var-
nished
• 60SA-VB00210-0012-5-XXV Power board FR4 12A 500V, not programmed, var-
nished
• 60SA-VB00208-0003-5-ABV Power board 3A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0003-5-ARV Power board 3A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
• 60SA-VB00208-0004-5-ABV Power board 4A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0004-5-ARV Power board 4A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
• 60SA-VB00208-0005-5-ABV Power board 5A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0005-5-ARV Power board 5A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
• 60SA-VB00208-0007-5-ABV Power board 7A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0007-5-ARV Power board 7A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
• 60SA-VB00208-0009-5-ABV Power board 9A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00208-0009-5-ARV Power board 9A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
• 60SA-VB00410-0012-5-ABV Power board 12A 500V, air cooled, brake chopper, var-
nished
• 60SA-VB00410-0012-5-ARV Power board 12A 500V, air cooled, brake chopper,
resistor inside the unit, varnished
• 60SA-VB00710-0004-5-ABV Power board 4A 500V, air cooled, INU, brake chopper,
varnished
• 60SA-VB00710-0004-5-ARV Power board 4A 500V, air cooled, INU, brake chopper,
resistor inside the unit, varnished
• 60SA-VB00710-0009-5-ABV Power board 9A 500V, air cooled, INU, brake chopper,
varnished
• 60SA-VB00710-0009-5-ARV Power board 9A 500V, air cooled, INU, brake chopper,
resistor inside the unit, varnished
• 60SA-VB00710-0012-5-ABV Power board 12A 500V, air cooled, INU, brake chopper,
varnished
• 60SA-VB00710-0012-5-ARV Power board 12A 500V, air cooled, INU, brake chopper,
resistor inside the unit, varnished
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12 Measurement instructions
Before analyzing/checking measurements, make sure that the unit or module being
repaired is disconnected from the power supply, unless it is required to be powered
up. Make sure any dangerously high voltage remaining in circuitry is discharged and
that there is no voltage source with life threatening potential. It is imperative to
ensure that the main supply is switched off and the main terminals and DC bus bars
are de-energized.
Also, make sure that the working environment is safe and will not cause personal
injury, damage to the unit, or to the environment. If repairs are being carried out in
the field, make sure that the supply voltage cannot be switched on during service, and
the action of the service personnel will not cause unnecessary disturbance or interrup-
tion to the process.
NOTE! BUS BARS, INTERNAL COMPONENTS AND CIRCUIT BOARDS ARE ALIVE AND CARRYING
MAINS POTENTIAL WHEN ANY VACON AC DRIVE IS CONNECTED TO A POWER SUPPLY. THIS
VOLTAGE IS EXTREMELY DANGEROUS AND MAY CAUSE DEATH OR SEVERE INJURY, IF ANYONE
COMES IN CONTACT WITH EXPOSED COMPONENTS.
If the unit has a brake chopper, it is located on the underside of the back plate, in
which case, the brake chopper leads must be disconnected before removing the back
plate.
When there is a brake chopper, the disassembly entails removing the power board
before the back plate is removed. See section 5.3. Power board.
• Clean the heat sink if necessary.
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Measurement instructions 13
TABLE 2. The main circuit measurements for the FR4 (typical values).
IGBT diode forward: U/V/W to B+ 0,4 V IGBT diode reverse: B+ to U/V/W Infinite
Description:
B- = DC-
B+ = DC+
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14 Measurement instructions
N B- B+ R- U V W
L1 L2 L3
If the visual checking is satisfactory and the measurements are correct, continue with
the instructions in section 3.2.4.
Visual checking is required before proceeding with these instructions. Check that the
cover plate of the power unit has been mounted before testing.
NOTE! THE FR4 SHUNT RESISTOR CURRENT MEASUREMENT CIRCUIT CAN NOT BE MEA-
SURED WITH THE TESTER, PUT 1.
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Measurement instructions 15
NOTE! THE UC+ AND UC- VALUES ON THE POWER BOARD ARE VALID FROM VERSION
VBXXXR (NOT A TAILOR-MADE POWER BOARD), WHILE THE OLDER POWER BOARDS USE
THE VALUES: (UC+)-(UC-) => 3 V, WHICH IS VALID UP TO THE Q VERSION.
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16 Measurement instructions
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4
Measurement instructions 17
• Measure the TEMP (temperature) signal value from the contact points T+ and T-
shown in Figure 12. Skiip circuit diagram, in Section 5.5. Power module.
• Check the voltage reading against the voltage values in Table 8 Temperature vs.
Voltage values, in section 6 SPECIFICATIONS to get the equivalent temperature
value.
• If the temperature is incorrect, check and clean the contact surfaces on the power
board and on the power module.
• If after cleaning, the measurements still indicate the temperature is different to the
temperature of the unit, the power board must be changed.
Service manual
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18 Replacement instructions
5.1. Fan
5.2. AC-Choke
Checking the AC-Choke:
• Measure the coils to check that they are
intact and are not shorted to the ground.
• Also, check that they have not been burnt.
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Replacement instructions 19
• Install a new choke, taking care that the cables are positioned correctly.
• Hold the AC-choke in place and fasten the four retaining screws. See section 6.1
Torque specifications for the required torque.
• Replace the back plate.
The program can be downloaded as a zip file from Vacon's web site at
www.extra.vacon.com, Service Tools. This file is password protected and is intended
only for authorized personnel. The NCLoad or NCDrive is required before the Device
Properties Service is operational. Please ask for the password from your contact in YIT
Service Vaasa or Vacon After Market Service.
Service manual
5
20 Replacement instructions
5.4. Capacitors
Checking capacitors:
• Test each capacitor with a DC-power supply.
It is recommended that the DC power supply
current is limited to < 50mA.
• Connect the DC+ to the positive terminal and
the DC- to the negative terminal of the
capacitor. Nominal voltage is seen on the
side of capacitor and values are available on
the spare part list on www.extra.vacon.com,
Spare parts also.
• Monitor the current while testing.
• When the voltage has stabilized, the leakage
FIGURE 10. Capacitors.
current should be < 3mA.
• If the current is significantly more than 3mA,
when the voltage has stabilized, abort the
test.
• Carefully discharge each capacitor after test-
ing. Use a proper resistor that can handle the
discharging current.
Replacing capacitors:
• Replace both capacitors even if only one is
broken.
• It is essential to make sure that polarity is
correct, by checking that the small arrow on
the side of the capacitor, is aligned with the
indicator mark on the frame. The arrows on
the capacitors will then point to 10 ò clock to
align with the raise metal indicator marks on
the unit housing, as shown in Figure 10.
Capacitors.
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Replacement instructions 21
DC+ B+ DC+ T- T+
v
UH VH WH
L1 U
L2 R- V
L3 W
gB UL VL WL
control pin
T+ DC- U V W
L1 gB L L L
L1 T-
B- B-
R- DC-
R-
L2 U V W DC-
gB L L L U V W
B+ V W
DC- U U V W
H H H
L2 B+
DC+
L3 DC+ U V W +T
H H H L3 DC+ DC+
-T
FIGURE 12. Left: Skiip 20 and 22 layout. Right: Skiip 30 and 32 layout. There are
no measuring points on the skiip.
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22 Replacement instructions
power board, including the pressure plate that secures the power board to the heat
sink, which, at the same time, sandwiches the Skip power module securely between
power board and heat sink are then removed.
NOTE! THE PRESSURE PLATE SCREWS ARE TORQUE WRENCHED INTO PLACE, AND ARE
RATHER TIGHT TO LOOSEN.
• Measure the main circuit for the rectifier, brake chopper and IGBT.
• Measure the gate-emitter junction (capacitance and resistance) for the gate of the
brake chopper (gB) and for the gates of the IGBT (UL, VL, WL, UH, VH and WH).
• Use the same polarity for all gate-emitter measurements: the + lead at the gate
and the - lead at the emitter.
• If the gate-emitter measurements are correct. Measure the gate-collector junction.
They should all have the same values as the gate-emitter junction. See Table 5
MiniSkiip values in section 5.5.2. Replacement for the correct MiniSkiip values.
• Use the same polarity for all gate collector measurements: the + lead at the gate
and the - lead at the collector.
• Measure the resistance value between T+ and T-. Compare the measured value to
the value in Table 8. Temperature vs. resistance values in section 6.2. temperature
tables.
NOTE! THE CAPACITANCE VALUES SHOULD NOT DIFFER MORE THAN 20% BETWEEN THE
UPPER AND LOWER BRANCH. THE CAPACITANCE READING IS ROUGHLY HALF, IF THE POLAR-
ITY MEASUREMENT IS INCORRECT (THIS FEATURE COMES WITH FLUKE MULTIMETERS). THE
RESISTANCE VALUE FOR ALL GATE MEASUREMENTS SHOULD BE INFINITE.
NOTE! THESE ARE TYPICAL THRESHOLD VOLTAGE AND CAPACITANCE VALUES AND ARE USED
AS GUIDE LINES ONLY, AS THEY ARE NOT ABSOLUTE VALUES.
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Replacement instructions 23
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24 Replacement instructions
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Replacement instructions 25
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26 Replacement instructions
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Replacement instructions 27
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28 Replacement instructions
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Replacement instructions 29
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30 Replacement instructions
5.7.1. Tools
• A desoldering iron with an adjustable temperature control up to 350 ° C, including
twin soldering tips. The temperature increments of the desoldering iron should be
checked for accuracy.
• A magnifying glass to check the quality of the soldering joints.
• Remove the resistors quickly (~2 sec.) and efficiently by using a desoldering iron
with twin soldering tips. An example of these types of desoldering irons is the
Weller WTA50 Thermal Tweezers.
• Clean any solder from soldering joints and any solder splashes from the surround-
ing area.
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Replacement instructions 31
FIGURE 21. An example of marking the FR4 400 V/500 V VB00208 board with a
cross, “X” to show it has been modified as a 7 A board. The “VP” shown on the
board, are the initials of the person, who made the modification.
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32 Replacement instructions
D
C
B
A
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Replacement instructions 33
Removable resistors
D
C
B
A
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34 Replacement instructions
Removable resistors
D
C
B
A
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Replacement instructions 35
Removable resistors
D
C
B
A
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36 Replacement instructions
Removable resistors
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Replacement instructions 37
Removable resistors
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38 Replacement instructions
Removable resistors
D
C
B
A
3A Gate resistors
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Replacement instructions 39
Removable resistors
D
C
B
A
4A Gate resistors
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40 Replacement instructions
Removable resistors
D
C
B
A
5A Gate resistors
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Replacement instructions 41
Removable resistors
D
C
B
A
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42 Replacement instructions
Removable resistors
D
C
B
A
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Replacement instructions 43
Removable resistors
12A measurement
resistors.
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44 Replacement instructions
Removable resistors
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Replacement instructions 45
Removable resistors
9A current measurement
resistors
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46 Replacement instructions
FIGURE 36. The FR4 EMC level modification with choke v.1.0.
• Check the version of the choke. It should be v.1.0. See no. 1 in the Figure 35.
• Remove the cable cover.
• Remove both screws from the PCB of the choke. See no. 2 in Figure 35.
• Check that the hole on the right side is sealed below the PCB with thermal crease
(60MC00020).
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Replacement instructions 47
FIGURE 37. The FR4 EMC level modification with choke v.3.0
• Check the version of the choke. It should be v.3.0. See no. 1 in the Figure 36.
• Remove the cable cover.
• Remove the screw from the PCB of the choke. See no. 2 in Figure 36.
• Check that the hole on the right side is sealed below the PCB with thermal crease
(60MC00020).
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48 Specifications
6. SPECIFICATIONS
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Specifications 49
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50 Specifications
Name of
product New P/N S.No/Date Changed to previous
Frame 2 FR4 FR04015 - The new AC choke/filter cannot
be used in the new Frame 2
(FR04015 A).
AC choke/fil- PP01007 - Both the old and new AC choke/
ter package filter packages can be used in the
12A new Frame 2 FR4.
Frame 1 FR4 FR04000B - The new AC choke/filter package
cannot be used in the new Frame
1 FR4 (FR04000 A)
AC choke/fil- PP01006 - Both old and new AC choke/filter
ter package packages can be used in the new
7A Frame 1 FR4 (FR04000 B)
Mini Skiip 22 - 21.3.2003 Replaces Mini Skiip 20
NAB12T45 NAB12T45, which is compatible
with VB00208, up to version H.
The older power board does not
function with the new Mini Skiip
22.
FR4 C-level PP04051 - -
capacitor
package,
2*330nF FR4
C-level fer-
rite package.
PCB PP04052 1.6.2004 The old device does not comply
with EMC, C-level.
Power board VB00208 10.3.2003 The parts will be modified from
the same board VB00208
FR4 power VB00410 Week 53/ The type of power board has
board 2004 been changed. The old part
VB00210 has been replaced.
Mini Skiip 32 CP01308 Week 53/ The type of power module has
NAB12T49 2004 changed. It replaces CP01306,
skiip 30NAB12T49.
Power supply VB00401C 7.5.2005 The fan control has been changed
to handle pulse wide modulation
without decreasing its total life
time. There is a new layout, but
the changes are the same as the
earlier B version.
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Specifications 51
Name of
product New P/N S.No/Date Changed to previous
FR4 Mini- CP01306 30.9.2005 New pressure plate + screws.
skiip 3 gen. SKIIP 30. Pre-tightening up to 1Nm and a
1 pressure Screws final tightening to 2.2Nm. 100%
plate and MC00679 backwards compatible.
New Screws
NXS Control VB00252P 09.2.2006 A new revision of the NXS control
board
is needed for mounting larger
SRAM:s. The current 1MBit SRAM
is now obsolete. VB00252p is
compatible with VB00252o,
except that larger SRAM:s (>
1Mbit) may not be mounted on
the VB00252o boards.
NXP Control VB00561H 18.4.2006 A new version of the NXP control
is needed to support the Safe
Disable function. A NXP drive
with the Safe Disable function is
achieved with NXP control version
H (VB00561H) and OPT-AF
installed in slot B of the control.
VB00561H is HW and SW com-
patible with VB00561F.
Hardware added to support the
Safe Disable function
- AND-circuits added to gate
driver signals
- ETR trip signal is taken in to use
- over voltage protection added
to +2,6V, +3,3V and +5V
- system bus interrupt connected
to MCU MIOS module, for calcu-
lating time stamps for received
messages
- +9V raised 200mV
- connectors X10 and X11 cor-
rected in the layout
- 3rd CAN moved to DA board
connector (X9)
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52 Specifications
Name of
product New P/N S.No/Date Changed to previous
Power board VB00208AB 15.6.2006 Fan speed control needed. DeSat
diodes changed to new version
STTH112U. PCB layout changed
to avoid hot-spots.
- fan speed control added
- desat diodes changed
STTA112U => STTH112U and
schottky diodes added
- power supply snubber circuit
diodes protected with capacitors
- gate driver power supply snub-
ber circuit resistor changed 0805
= 1206
- input phase supervision cir-
cuitry modified with feed-back
capacitor / resistor
- DC-link voltage measurement
circuitry mechanical trimmer
removed.
RoHS com- VB00661 18.10.2006 Old and new version are not com-
patibility patible each other.
CAN inter- VB00363J 12.10.2006 New version: VB00363K. Brake
face AG control current drive and EMC are
increased.
Service manual
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Subject to change without prior notice
© 2008 Vacon Plc.
SM00042 E
7.2.2008
Author: J. Kukkonen