DPD 00289 A

vacon x series
ac drives
service manual
vacon • 1
INDEX
1. Version history ..............................................................................................................2
1.1. Service manual version history....................................................................................2
1.2. Drive version history ....................................................................................................2
2. Disassembly and power board replacement .................................................................3
2.1. Frame 0 disassembly and power board replacement.................................................3
2.2. Frame 1 disassembly and power board replacement.................................................7
2.3. Frame 2 disassembly and power board replacement...............................................10
North American Tech Support Center phone: +1 (717) 261-5042

2 • vacon version history
1. VERSION HISTORY
1.1. Service manual version history
Service manual version Changed section Updated/added information

DPD00289A First version
Table 1.1: Service manual updates.
1.2. Drive version history
Name of the part New part/code Date/serial no. Change to previous
Table 1.2: Drive version history.
email: ServiceNorthAmerica@vacon.com
1
disassembly and power board replacement vacon • 3
2. DISASSEMBLY AND POWER BOARD REPLACEMENT
2.1. Frame 0 disassembly and power board replacement
1. Remove 2 screws securing the keypad in place and remove keypad.
2. Remove 4 screws securing the control board in place.
2
4 • vacon disassembly and power board replacement
3. Carefully remove the flex cable connected to the control board.
4. Disconnect DB resistor wires and thermistor connector.
2
5. Remove the 4 standoffs, and center module screw that secure the power board.
6. Remove the power board and power module.
7. Install the new power module and thermal pad orientated as shown.
2
8. Install the new power board over the power module and secure with the 4 standoffs.
Install the load spreader (orientated as shown) and tighten to 18 in. lbs.
9. Reinstall the 2 DB resistor connectors and the thermistor connector as shown in step #4.
10. Carefully install the new flex cable into the power board with the blue strip inward.
11. Reinstall the control board, secure with the 4 screws and carefully insert the flex cable.
12. Reinstall the keypad and secure with the 2 screws.
2
2
4. Remove DB wires (1 or 2 sets model dependant) thermistor connector and fan wires
(model dependant).
2
5. Remove 2 screws at top of board, 4 hex standoffs and the 2 screws that secure the power
module.
6. Apply thermal compound (Dow Chemical Type 340 or equivalent) to the bottom of the
power module installed to the new power board.
Install the power board and secure with the 4 Hex standoffs, 2 screws at the top of the
board and tighten the 2 screws for the power module and tighten to 26 in. lbs.
Reinstall the DB connections, thermistor connector and fan wires (if external fan is
installed).
Carefully install the new flex cable into the power board with the blue strip inward.
Reinstall the control board, secure with the 4 screws and carefully insert the flex cable.
Reinstall the keypad and secure with the 2 screws.
2
2
4. Remove the 2 DB wires, 4 external fan wires, 4 screws in the corner of the power board
and the 4 screws that secure the power module to the base.
2
5. Remove the power board from the base and remove the internal cooling fan. (needed for
replacement board.)
6. Install the internal cooling fan to the replacement board and attach the power wires to
the connector.
7. Apply thermal compound (Dow Chemical Type 240 or equivalent) to the power module.
8. Install the power board and secure with the 4 screws on the corners of the board and the
4 screws that secure the power module to the base and tighten to 26 in. lbs.
Reinstall the 2 DB wires, 4 external fan wires. Carefully install the new flex cable into the
power board with the blue strip inward.
Reinstall the control board, secure with the 4 screws and carefully insert the flex cable.
Reinstall the keypad and secure with the 2 screws.
2
1. Remove display ribbon connector and control board flex cable.
2. Remove 2 screws and 2 nuts that secure the fan plate.
2
3. Disconnect the internal fan wires from the connector on the power board.
4. Remove the DB wires and 7 screws securing the interconnect board and remove board.
2
5. Remove thermistor connector, external fan wires and 4 hex standoffs.
6. Remove all screws connecting the bus capacitors to the board (varies by model). Remove
the 7 nuts that secure the top of the power board.
2
7. Remove the 6 screws that secure the input and output modules to the heat sink and
remove the power board.
8. Apply thermal compound (Dow Chemical Type 240 or equivalent) to the 2 power modules.
9. Install the power board and tighten the 6 screws that secure the modules to the heat sink
to 26 in. lbs.
Install the 7 nuts that secure the top of the power board, the capacitor screws and the 4
hex stand offs.
Reconnect the thermistor connector, external fan wires and install the new flex cable
with the blue strip inward.
Install the interconnect board with the 7 screws and DB wires into the connector.
Install the fan plate and reconnect the internal fan to the connector on the power board.
Carefully insert the flex cable and display ribbon cable into the control board.
2
1. Disconnect the display and flex cables then remove the 4 screws that secure the card
tray. Set aside card tray and this will expose the power board.
2. Remove all electrical connections going to the power board. Then remove the 4 hex spac-
ers and 3 screws that secure the power board.
NOTE! If the power board is going to be replaced with a new board, ensure that the
proper switch settings are made for the voltage and horse power!
2
Switch 1 Switch 2-5

Model
Position to “ON” Position to “ON”
40600 1,3 1
40750 1,3 2
41000 1,3 3
50600 2,4 4
50750 2,4 5
51000 2,4 6
3. Remove the 4 nuts that secure the card tray enclosure and remove to expose the LIB
board.
4. Disconnect all electrical connections to the LIB board. Remove the 4 screws that secure
the board and remove the board.
2
5. Remove the 4 nuts that secure the line/load enclosure and remove.
The input, DB and IGBT modules and bus assembly are now exposed. To replace any
module the bus bar assembly needs to be disassembled. Mark or label all hardware
when disassembling so it can be reused in reassembling.
NOTE! All parts are needed and at the right location.
6. Remove the 8 nuts and washers that secure the top bus bar.
NOTE! There are 2 washers under 1 leg of each bus resistor.
2
7. Remove top bus bar and insulator.
NOTE! Notice there are two washers on the standoffs as shown.
8. Remove 4 small nuts and washers and 2 larger nuts along with the 6 IGBT snubber caps.
2
9. Remove bus bar to expose the bottom bus bar. Remove remaining hardware on the Input,
DB and IGBT modules and the 3 hex spacers.
10. The Input, DB and IGBT modules are now at a point where they can be replaced.
11. Apply heat sink compound (Dow Chemical Type 340 or equivalent) to the new module
and torque to 26 in. lb.
12. Reassemble the bus bar assembly using the instructions from the previous steps.
NOTE! Be careful to use all hardware (spacers) and make sure all connections are tight.
13. Reinstall all other hardware from the previous steps and test unit.
2
1. Remove display and flex cables and then remove the 4 screws that secure the card tray.
Lift the card tray and disconnect the internal fan from the power board.
2. Remove 8 screws and then remove the cable tray.
3. Remove 2 screws and remove both edge brackets. Now the power board and SCR control
board are exposed.
2
4. To replace the SCR control board, disconnect all electrical connections and remove the 4
screws that secure the board.
5. To replace the power board, disconnect all the electrical connections and remove the 6
screws that secure the power board.
NOTE! If a new power board is installed, set the switches to the following positions for
voltage and horse power.
Switch 1 Switch 2-4 Switch 5

Model
Position to “ON” Position to “ON” Position to “ON”
4125 1,3 2 1
4150 1,3 1 2
4200 1,3 1 3
5125 2,4 4 4
5150 2,4 3 5
5200 2,4 3 6
2
6. To replace the IGBT module, remove the 3 screws that secure the internal fan panel and
move aside. Disconnect the line/load connections and them remove the 4 screws that
secure the line/load enclosure.
7. Remove the line/load enclosure and the IGBT module will be exposed.
2
8. Remove the LEM connections and the LEM’s. Disconnect the electrical connections on
the IGBT module and the connections to the bus bar.
9. Remove the 8 hex screws the secure the IGBT to the heatsink and remove the module.
10. Apply heat sink compound (Dow Chemical Type 340 or equivalent) to the bottom of the
new module. Install the new module and the 8 hex screws.
11. Torque the screws at 12 in/lbs at first and then retorque to 45 in/lbs in the following
sequence.
12. Reconnect all of the electrical and hardware connections from the previous steps and
test.
2
13. Input and DB module replacement. Remove all hardware and electrical connections as
shown.
14. Remove defective module. Apply heat sink compound (Dow Chemical Type 340 or equiv
alent) to bottom of new module.
15. Install new module and toque to 45 in/lbs.
16. Reconnect all hardware from previous steps.
17. Functional test.

DPD 00289 A

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

DPD 00289 A

Uploaded by

Copyright:

Available Formats

vacon x series

1. Version history ..............................................................................................................2

1.1. Service manual version history....................................................................................2

1.2. Drive version history ....................................................................................................2

2. Disassembly and power board replacement .................................................................3

2.1. Frame 0 disassembly and power board replacement.................................................3

2.2. Frame 1 disassembly and power board replacement.................................................7

2.3. Frame 2 disassembly and power board replacement...............................................10

2.4. Frame 3 disassembly and power board replacement...............................................13

2.5. Frame 4 disassembly and power board replacement...............................................17

2.6. Frame 5 disassembly and power board replacement...............................................22

North American Tech Support Center phone: +1 (717) 261-5042

1.1. Service manual version history

Service manual version Changed section Updated/added information

Table 1.1: Service manual updates.

1.2. Drive version history

Name of the part New part/code Date/serial no. Change to previous

Table 1.2: Drive version history.

2. DISASSEMBLY AND POWER BOARD REPLACEMENT

2.1. Frame 0 disassembly and power board replacement

1. Remove 2 screws securing the keypad in place and remove keypad.

2. Remove 4 screws securing the control board in place.

North American Tech Support Center phone: +1 (717) 261-5042

3. Carefully remove the flex cable connected to the control board.

4. Disconnect DB resistor wires and thermistor connector.

6. Remove the power board and power module.

North American Tech Support Center phone: +1 (717) 261-5042

12. Reinstall the keypad and secure with the 2 screws.

2.2. Frame 1 disassembly and power board replacement

1. Remove 2 screws securing the keypad in place and remove keypad.

2. Remove 4 screws securing the control board in place.

North American Tech Support Center phone: +1 (717) 261-5042

3. Carefully remove the flex cable connected to the control board.

Reinstall the keypad and secure with the 2 screws.

North American Tech Support Center phone: +1 (717) 261-5042

2.3. Frame 2 disassembly and power board replacement

1. Remove 2 screws securing the keypad in place and remove keypad.

2. Remove 4 screws securing the control board in place.

3. Carefully remove the flex cable connected to the control board.

North American Tech Support Center phone: +1 (717) 261-5042

Reinstall the keypad and secure with the 2 screws.

2.4. Frame 3 disassembly and power board replacement

1. Remove display ribbon connector and control board flex cable.

2. Remove 2 screws and 2 nuts that secure the fan plate.

North American Tech Support Center phone: +1 (717) 261-5042

5. Remove thermistor connector, external fan wires and 4 hex standoffs.

North American Tech Support Center phone: +1 (717) 261-5042

2.5. Frame 4 disassembly and power board replacement

North American Tech Support Center phone: +1 (717) 261-5042

Switch 1 Switch 2-5

NOTE! All parts are needed and at the right location.

NOTE! There are 2 washers under 1 leg of each bus resistor.

North American Tech Support Center phone: +1 (717) 261-5042

7. Remove top bus bar and insulator.

NOTE! Notice there are two washers on the standoffs as shown.

North American Tech Support Center phone: +1 (717) 261-5042

2.6. Frame 5 disassembly and power board replacement

2. Remove 8 screws and then remove the cable tray.

Switch 1 Switch 2-4 Switch 5

North American Tech Support Center phone: +1 (717) 261-5042

North American Tech Support Center phone: +1 (717) 261-5042

15. Install new module and toque to 45 in/lbs.

16. Reconnect all hardware from previous steps.