NX SERVICE MANUAL

Appendix FR5
1 Table of content

1. SERVICE MANUAL VERSION HISTORY ...........................................2

2. MAIN CIRCUIT DIAGRAMS.............................................................3
3. MECHANICAL CONSTRUCTION.......................................................6
4. THE FR5 POWER UNIT (16 - 31 A) .................................................7
4.1. Safety notice ...................................................................... 7
4.2. Visual checking and measurements before powering up the unit 7
4.2.1. Checking the cooling tunnel..................................... 7
4.2.2. Checking of power board......................................... 7
4.2.3. Checking the power modules ................................... 8
4.2.4. Power unit checking, testing and measurements ........ 9
4.2.5. Testing with the power unit tester PUT 1 ................... 9
4.2.6. Checking the current measurement circuit............... 10
4.2.7. Checking the voltage measurement circuit............... 11
4.2.8. Checking the temperature measurement circuit ....... 12
4.2.9. Checking the fan.................................................. 12
4.2.10. Checking the pre-charging circuit ......................... 13
5. TEST, REMOVAL AND REPLACEMENT INSTRUCTIONS ..................14
5.1. Fan ................................................................................. 14
5.2. AC Choke......................................................................... 15
5.3. Power board..................................................................... 16
5.4. Capacitors ....................................................................... 17
5.5. Power module .................................................................. 19
5.5.1. Measurement ...................................................... 20
5.5.2. Replacement ....................................................... 20
5.6. Power board layout ........................................................... 22
5.7. The power board modifying process..................................... 25
5.7.1. Tools .................................................................. 25
5.7.2. Working process .................................................. 26
5.7.3. Check up instructions ........................................... 26
5.8. FR5 230V power board modifications ................................... 28
5.8.1. FR5 230V 17A 60VB00313 .................................... 28
5.8.2. FR5 230V 25A 60VB00313 .................................... 29
5.8.3. FR5 230V 31A 60VB00313 .................................... 30
5.9. FR5 400V/500V power board modifications........................... 31
5.9.1. FR5 400V/500V 16A 60VB00213 and 60VB00613 ..... 31
5.9.2. FR5 400V/500V 22A 60VB00213 and 60VB00613 ..... 32
5.9.3. FR5 400V/500V 31A 60VB00213 and 60VB00613 ..... 33
5.10. EMC level change ............................................................ 34
6. SPECIFICATIONS.........................................................................35
6.1. Torque specifications ......................................................... 35
6.2. Temperature tables ........................................................... 36
6.3. Drive version history ......................................................... 38
 Version History 2

1. SERVICE MANUAL VERSION HISTORY

TABLE 1. Service Manual Updates.

Service Manual Updated/Added Material
Version
SM00009A First version.
SM00009B Added EMC Level modification instructions
Links to photo gallery in exploded view
Drive version history updated.
SM00009C Drive version history.
SM00009PD Drive version history.
SM00009D Logo update.
SM00057E General update.
 3 Main Circuit Diagrams

2. MAIN CIRCUIT DIAGRAMS

FIGURE 1. NX/FR5/FC/500V, version A.

4

B-
POW
B+ / R+
R-
J1

U_HI

V_HI

W_HI
J3
DC +
X3
L1 U / T1
X4
L2 V / T2
X5
MiniSkiip
L3 W / T3
Main Circuit Diagrams

X10
INTEGRATED C
DC -

W_LO
INPUT MODULE

U_LO

V_LO
BRK
J2

TERM

FIGURE 2. NX/FR5/FC/500V, version B.

TERM
PE A B
PE
X2
MEASUREMENTS
DC +
POWER BOARD DC -
X17 X6
1 2
37
M1
+ 24 V CONTROL BOARD X1 CONTROL
GND PANEL
9
X7 X1
MAIN FAN
X2 X3 X4 X5 X6
(slot A) (slot B) (slot C) (slot D) (slot E)
NX/FR5/FC/230 AND 500
MAIN CIRCUIT DIAGRAM
OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD OPTION BOARD
DM00002
5 Main Circuit Diagrams

FIGURE 3. NX/FR5/FC/230V and 500V, version C.

 Mechanical Construction 6

3. MECHANICAL CONSTRUCTION

*NOTE! CHECK THE RIGHT SPARE PARTS FROM THE SPARE PART LIST, WHICH IS AVAILABLE
ON THE PRODUCERS EXTRANET.

60FR05003

60FR00015

60FR00016
60FR00050
60PP05052

60PP01002*

60FR05031

60FR05002
60PP05000
60FR05029

60CP01307*

60VB00313
60VB00613
60FR05052
60FR05001

60PP01043

60FR05015
60FR05009

60FR05000

60PP01061

FIGURE 4. FR5 Exploded view.

 7 Measurement Instructions

4. THE FR5 POWER UNIT (16 - 31 A)

4.1. Safety notice

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 dis-
charged 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 ser-
vice, and the action of the service personnel will not cause unnecessary distur-
bance or interruption to the process.

NOTE! BUS BARS, INTERNAL COMPONENTS AND CIRCUIT BOARDS ARE

ALIVE AND CARRYING MAINS POTENTIAL WHEN ANY AC DRIVE IS CON-
NECTED TO A POWER SUPPLY. THIS VOLTAGE IS EXTREMELY DANGEROUS
AND MAY CAUSE DEATH OR SEVERE INJURY, IF ANYONE COMES IN
CONTACT WITH EXPOSED COMPONENTS.

4.2. Visual checking and measurements before powering up the unit

4.2.1. Checking the cooling tunnel

• Remove the control unit from the power module.

• Open back plate by lifting it from its lower side up and pull back plate down-
wards.

• Clean the heat sink if necessary.

4.2.2. Checking of power board

• Remove the control unit from the power unit.

• Remove the I/O-cable cover and I/O-wires.

• Remove the control unit's fixing screws from the lower corners and from under-
neath the panel.

• Separate the control unit from the power unit.

• Remove the power unit's cover plate.

 Measurement Instructions 8

• Check for possible burn marks, broken components or foil on the power board.
Replace the board without testing if it is badly burnt.

• Test the capacitors and measure the AC choke and the power module.

4.2.3. Checking the power modules

• Remove the power terminal cover plate to access the main terminals.

• Measure diodes forward and reverse biases as shown in FIGURE 5 .

FIGURE 5. Main circuit measurements.

TABLE 2. Main circuit measurements FR5 (typical values).

Measure point Value Measure point Value

Rectifier forward: L1/L2/L3 0,45 V Rectifier reverse: B+ to Infinite
to B+ L1/L2/L3
Rectifier forward: B- to L1/ 0,45 V Rectifier reverse: Infinite
L2/L3 L1/L2/L3 to B-
Brake diode forward: R- to 0.4 V Brake diode reverse: B+ Infinite
B+ to R-
IGBT diode forward: B- to 0.4 V IGBT diode reverse: U/ Infinite
U/V/W V/W to B-
IGBT diode forward: U/V/W 0.4 V IGBT diode reverse: B+ Infinite
to B+ to U/V/W
 9 Measurement Instructions

Description:

B- = DC-, B+ = DC+

FIGURE 6. Main terminals FR5.

4.2.4. Power unit checking, testing and measurements

Visual checking is required before proceeding with these instructions. Check that
the cover plate of the power unit has been mounted before testing.

4.2.5. Testing with the power unit tester PUT 1

NOTE! THE FR5 SHUNT RESISTOR CURRENT MEASUREMENT CIRCUIT CANNOT BE MEASURED
WITH THE TESTER, PUT 1.

• Attach the power unit tester to the connector on the power unit.

• Connect a multi meter (Vdc range) to power unit tester PUT 1 for measurement.

• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Connect up the wires to B- and B+ and then apply nominal DC-volt-
age (540V).

• Check all these signals from the power unit and compare them to the values in
TABLE 3 . "Power unit values for FR4 and FR5".

• If any of these signals 24V, -15V, 15V, IU, IV or IW differ from the values in
TABLE 3 , replace the power board.

• If the TEMP signal is different from the value in the table, check the temperature
sensor from power module's contacts T+ and T-. See the instruction in section
5.5. Power module on page 19.
 Measurement Instructions 10

• Values for UC+ and UC- can be different, but the calculated value has to be
according to the value in TABLE 3 . If the value differs from the value in table,
check the capacitors. See the instructions in section 5.4. Capacitors on page 17.

TABLE 3. Power unit values FR5.

Signal name Explanation Measured value (Vdc)

24V 24V on power board +21,6 … +26,4
-15V - 15V on power board -13,5 … -16,5
+15V 15V on power board +13,5 … +16,5
UC + Value of DC+ voltage 3 (1200Vdc => 5V)
UC - Value DC- voltage 0 (at GND)
IU Current offset for U-phase 0 ± 0,1
IV Current offset for V-phase 0 ± 0,1
IW Current offset for W-phase 0 ± 0,1
TEMP Temperature signal from 2.9 (at 20° C) Values in appendix
power unit

NOTE! THE UC+ AND UC- VALUES ARE VALID FROM VERSION VBXXXR, WHILE THE
OLDER ONES USE THE FOLLOWING VALUES: (UC+)-(UC-) => 3V, WHICH IS VALID UP TO
THE Q VERSION.

4.2.6. Checking the current measurement circuit

NOTE! SHUNT RESISTORS CANNOT BE MEASURED BECAUSE RESISTORS ARE LOCATED ON

THE BOTTOM SIDE OF THE BOARD.

• Attach the power unit tester to the connector on the power unit.

• Connect a multi meter (Vdc range) to power unit tester PUT 1, for taking the
measurements.

• Supply the power unit with a DC voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.

• Measure offset values IU, IV and IW, The values are all 0V.

• Measure operating voltages, values should be -15V and +15V.

 11 Measurement Instructions

• Change the power board if the signals are different than in TABLE 3, “Power unit
values FR5.,” on page 10.

TABLE 4. Shunt resistors and measured values on the power boards VB00211,
VB00212, VB00213, VB00313, 500 V and 230 V.

Shunt
Unit Unit Shunt resistor
Power resistor Measured
current voltage from the
board until value/Ω
A V vers. R/Ω
vers. Q/Ω
60VB00211 16 500 82 422 69 140 137 -
60VB00212 23 500 56 620 51 140 - 82
60VB00213 31 500 47 182 37 140 137 82
60VB00313 17 230 165 110 66
60VB00212 23 230 56 620 51
60VB00213 31 230 47 182 37
60VB00413 32 500

TABLE 5. Shunt resistors and measured values on the power board VB00213
and VB00613, 500 V and 230 V.

Power Unit Unit

Shunt resistors/Ω Measured
board current voltage
A V value/Ω

A B C D E
60VB00613 16 500 140 137 69
60VB00613 23 500 140 82 51
60VB00613 31 500 140 137 82 37
60VB00313 18 230 165 110 66
60VB00313 25 230 165 66,5 47
60VB00313 31 230 165 110 66,5 33

4.2.7. Checking the voltage measurement circuit

• Attach the power unit tester PUT 1 to the connector on the power unit.

• Connect a multi meter (Vdc range) to the power unit tester for taking measure-
ments.

• Supply the power unit with DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use DC-voltage.
 Measurement Instructions 12

• Measure the UC+ and UC- values and compare them to the values in TABLE 3,
“Power unit values FR5.,” on page 10.

• If UC+ and UC- value differs from table's value, check the capacitors. See the
instructions in section 5.4. Capacitors on page 17.

4.2.8. Checking the temperature measurement circuit

• Attach the power unit tester to the connector on the power unit.

• Connect a multi meter (Vdc range) to the power unit tester PUT 1 for taking-
measurements.

• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.

• Measure the TEMP signal value. If TEMP-signal value is different from the values
in section 6, check temperature sensor from power module's contacts T+ and
T-. See instruction in section 5.5. Power module on page 19.

• Check and clean contact surfaces on power board and on power module.

• Change the power board if measured values from power module are in state and
contact cleaning doesn't remove temperature measurement error.

4.2.9. Checking the fan

• Attach the power unit tester to the connector on the power unit.

• Connect a multi meter (Vdc range) to the power unit tester PUT 1 for taking
measurements.

• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and
B+ = DC+. Use nominal DC-voltage.

• Measure 24V signal. Replace the power board if the signal is wrong.

• Switch on the fan with the switch on the power unit tester, PUT1. Check that the
fan rotation is correct. If the fan is not working, change it as described in sec-
tion 5.1. Fan on page 14.
 13 Measurement Instructions

4.2.10. Checking the pre-charging circuit

• Measure forward biases towards the DC+ on the rectifier from the main termi-
nals. If all measurement values are infinite, the pre-charging resistor is proba-
bly broken.

• Open the connection cover and the cover of the power unit. Check the pre-
charging resistor and the charging relay on the power board. If it is broken,
change power board according to the instructions in section 5.3. Power board on
page 16.

• Measure the DC-link capacitors, because they can be broken.

• Measure the brake chopper, because it can be shorted.

 Replacement Instructions 14

5. TEST, REMOVAL AND REPLACEMENT INSTRUCTIONS

5.1. Fan

FIGURE 7. Replacing fan.

• Look mechanical construction FR5 from section 2. Main circuit diagrams on

page 3, before starting replacement of the cooling fan.

• Remove fan from the frame by pressing plastic holders beside fan by screw-
driver and pull the fan out of the frame.

• Install the new fan just by pressing it to the frame. Check that the fan is con-
nected to the power board.

NOTE! CHECK ALL THE CONNECTIONS BEFORE STARTING THE DRIVE.

 15 Replacement Instructions

5.2. AC Choke

Checking the AC choke

• Measure that the coils are intact and not

shorted to the ground. L1,L2,L3 -->
Ground.

• Also, check that they have not been

burnt.

Replacing the AC choke

• Remove back plate fitting screw and

back plate.

FIGURE 8. AC choke. • Remove power board, see chapter 5.3.

“Power board” on page 16.

• Remove the screws from the corners of

the AC choke.

• Pull out the AC choke from underneath.

• Put a new one in from underneath and

note the location of cables.

• Hold the AC choke in place and attach

screws. See section 6.1. Torque
specifications on page 35.

• Mount back plate.

NOTE! IF ISOLATED IT-NETWORK. CHANGE

SCREW ON THE LEFT SIDE OF THE YELLOW
PRINTED CIRCUIT BOARD INTO A PLASTIC ONE.
REMOVE THE AC CHOKE TO DO THIS MODIFICA-
TION.
 Replacement Instructions
5.3. Power board
FIGURE 9. Power board.
16
Replacing the board
• Remove the main fan (see chapter 5.1.
“Fan” on page 14.), by pressing plastic
holders beside fan with a screwdriver
and pull the fan out of the frame.
• Remove power module casing before
loosening of any other screws and lift
casing upwards.
• Remove cables from the AC choke by
opening the screws and retain these
screws.
• Remove the 4 capacitor mounting screws
and 3 frame fastening screws.
• Remove the power board.
• Install new board in reversed order. See
specified torque mentioned in section
6.1. Torque specifications on page 35.
NOTE! AFTER REPLACING POWER BOARD, YOU
NEED TO PROGRAM THE POWER UNIT BY USING
A PC-PROGRAM, "DEVICE PROPERTIES SER-
VICE".
Device Properties Service tool is available
on the producer’s web site. The file is pass-
word protected and it is intended for
authorized service person only. NCLoad
and/or NCDrive have to be installed before
Device Properties Service is operational.
Please, ask the password from YIT Service
or from producer's Sales Support and Ser-
vice department.
 17 Replacement Instructions

5.4. Capacitors Checking the capacitors

• Test each capacitor with a DC power sup-

ply. It is recommended that the DC power
supply current is limited to < 50mA.

• Connect DC+ to the positive pole and DC –

to the negative pole of the capacitor. Also,
slowly increase the voltage from 0V to their
nominal levels. The nominal power supply
voltage values are available on the pro-
ducer’s extranet. For further information,
contact the producer.

• Monitor the current while testing.

• When the power voltage has stabilized, the

leakage current should be less than 3mA.
FIGURE 10. Left capacitor.
• However, if the current leakage is substan-
tially higher than the stabilized voltage
abort the test.

• Carefully discharge each capacitor after

testing. Use a proper resistor (10K,5W)
that can handle the discharging current.
Capacitors can also be discharged by using
DC power supply.

SAFETY PRECAUTION! COVER THE CAPACITOR DUR-

ING THE TEST!

Capacitor replacement

• Replace the both of the capacitors, even if

FIGURE 11. Right capacitor. just one capacitor is broken. Capacitors in
FR5 drive are:
ELKO 1000μF/420V, 16A, 23A, 60PP01002
ELKO 1500μF/420V, 31A, 60PP01003.

• Make sure that polarity is correct by check-

Caution! Risk of elec- ing that the small arrow at the side of the
tric shock! capacitor (left capacitor at 8 o’clock and
right capacitor at 2 O'clock) is pointing
towards the indicator mark in the frame
(left at 8 O’clock and right at 2 O'clock).

• See specified torque in section 6.1. Torque

specifications on page 35.
 Replacement Instructions 18

Power board insulator assembly

FIGURE 12. Power board insulator, 60FR05031, assembly.

 19 Replacement Instructions

5.5. Power module

MiniSkiip30NAB12, MiniSkiip31NAB12, MiniSkiip32NAB12. This power module cir-

cuit diagram is equivalent for all power modules in FR5.

FIGURE 13. Skiip circuit diagram, which is equivalent for all power modules in
FR5 drive.

The layout is for MiniSkiip30, MiniSkiip31 and MiniSkiip32.

L1 U V W
gB L L L
B-
DC-
R-
DC-
U V W

U V W
H H H
L2 B+

+T
L3 DC+ DC+
-T

FIGURE 14. MiniSkiip 30, MiniSkiip31, MiniSkiip 32 and MiniSkiip 36 layout.

 Replacement Instructions 20

5.5.1. Measurement

Remove the cover from the skiip by opening two screws from top of the cover. It is
contacted really tightly, so you must loosen screws from power board. After this
do the measurements shown below.

• Measure the main circuit for rectifier-, brake chopper- and IGBT.

• Measure 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. "+"-wire at gate and
"-"-wire at emitter.

• If gate emitter measurements are correct, measure gate collector junction.

They should all have the same values as gate-emitter junction. Values men-
tioned in TABLE 6, “In NX FR5 MiniSkiip haven been integrated rectifier, IGBT
and brake chopper.,” on page 21.

• Use the same polarity for all gate-collector measurements. "+"-wire at gate and
"-"-wire at collector.

• Measure resistance value between T+ and T-. Compare measured value to value
in TABLE 9, “Temperature vs. resistance.,” on page 37.

NOTE! THE CAPACITANCE VALUES SHOULD NOT DIFFER MORE THAN 20% BETWEEN UPPER
AND LOWER BRANCH. CAPACITANCE READING IS ROUGHLY HALF IF MEASUREMENT POLARITY
IS WRONG. RESISTANCE VALUE FOR ALL GATE MEASUREMENT SHOULD BE INFINITE.

5.5.2. Replacement

• Remember ESD protection.

• Clean the contact surface on power board. Clean the element surface and Skiip
ground, if needed. Used cleaner e.g. is Sinol.

• Put always thin and even layer thermal compound to the bottom of the power
module before installation.

• Put a layer of thermal paste on the module. Recommended paste is Wacker-

Chemie P21.

• See specified torques in section 6.1. Torque specifications.

NOTE! DO NOT RETIGHTEN THE SCREW TO THE NOMINAL TORQUE VALUE,

AGAIN.
 21 Replacement Instructions

NOTE! TYPICAL THRESHOLD VOLTAGE AND CAPACITANCE VALUES FOR GUID-

LINE. THEY ARE NOT ANY ABSOLUTE VALUES.

TABLE 6. In NX FR5 MiniSkiip haven been integrated rectifier, IGBT and

brake chopper.
NX 500 V
Drive current/A Module mechanics Skiip type/Semikron
16 MiniSkiip3 MiniSkiip 30NAB12
22 MiniSkiip3 MiniSkiip 31NAB12
31 MiniSkiip3 MiniSkiip 32NAB12
32 MiniSkiip3 MiniSkiip 36NAB126
NX 230 V
Drive current/A Module mechanics Skiip type/Semikron
17 MiniSkiip3 MiniSkiip 30NAB12
25 MiniSkiip3 MiniSkiip 31NAB12
31 MiniSkiip3 MiniSkiip 32NAB12

FIGURE 15. MiniSkiip installation. Check, that the bevel is on the right place.
 Replacement Instructions 22

5.6. Power board layout

FIGURE 16. FR5 power board pin order. Valid until version Q. Power boards
60VB00211, 60VB00212, 60VB00213, 60VB00313, 60VB00613, 60VB00413.
23 Replacement Instructions

FIGURE 17. FR5 power board pin order. Valid until version R. Power boards
60VB00613 and 60VB00313.
 Replacement Instructions 24

FIGURE 18. Power board installation. Clean the MiniSkiip area on the power
board. Used cleaner is e.g. Sinol.
 25 Replacement Instructions

FIGURE 19. IGBT cover installation.

5.7. The power board modifying process

5.7.1. Tools

• Soldering iron with adjustable temperature to 350 oC and with double soldering
tips. Correct temperature should be checked.

• Loop or enlargement glass to check result if that's needed.

 Replacement Instructions 26

5.7.2. Working process

NOTE! REMEMBER ESD-PROTECTION (WRIST-STRAP)

• Remove resistors by using soldering iron with double soldering tips. Example
Weller WTA50.

FIGURE 20. Removing component with soldering iron.

• Check the soldering and nearby area of removed component for splashes.

5.7.3. Check up instructions

• Confirming modification

After the modification is been competed, verify that it is correct modification.

• Labeling modification

For the sign of changes, mark the X below correct current value to card's sticker.
Person who did the changes marks initials beside of current value.
27 Replacement Instructions

FIGURE 21. Example: FR400V/500V VB00208-board modified to 7A board, VP

modified it.
 Replacement Instructions 28

5.8. FR5 230V power board modifications

5.8.1. FR5 230V 17A 60VB00313

Removable resistors

FIGURE 22. Modification to FR5 230V 17A power board 60VB00313. Removable
resistors are:
C: R25, R19, R23
F: R59, R72, R31, R79, R39, R65
I: R156
 29 Replacement Instructions

5.8.2. FR5 230V 25A 60VB00313

Removable resistors

FIGURE 23. Modification to FR5 230V 25A power board 60VB00313. Removable
resistors are:
B: R26, R20, R24
E: R173, R172, R170, R171, R158, R159
I: R156
 Replacement Instructions 30

5.8.3. FR5 230V 31A 60VB00313

Removable resistors

FIGURE 24. Modification to FR5 230V 31A power board 60VB00313. Removable
resistors are: G: R73.
 31 Replacement Instructions

5.9. FR5 400V/500V power board modifications

5.9.1. FR5 400V/500V 16A 60VB00213 and 60VB00613

Removable resistors

FIGURE 25. Modification to FR5 16A power boards 60VB00213 and 60VB00613.
Removable resistors are:
C: R25, R19, R23
F: R59, R72, R31, R79, R39, R65
I: R156
 Replacement Instructions 32

5.9.2. FR5 400V/500V 22A 60VB00213 and 60VB00613

Removable resistors

FIGURE 26. Modification to FR5 22A power boards 60VB00213 and 60VB00613.
Removable resistors are:
B: R26, R20, R24
E: R173, R172, R170, R171, R158, R159
I: R156
 33 Replacement Instructions

5.9.3. FR5 400V/500V 31A 60VB00213 and 60VB00613

Removable resistors

FIGURE 27. Modification to FR5 31A power boards 60VB00213 and 60VB00613.
Removable resistors are:G: R73.
 Replacement Instructions 34

5.10. EMC level change

EMC modification from the level H to the level T.

FIGURE 28. Remove the screw from the choke PCB board. See FIGURE 28 .
 35 Specifications

6. SPECIFICATIONS

6.1. Torque specifications

TABLE 7. Torque specifications.

Item Screw Final Panasonic Note!

torque value
Nm
IGBT M5x30 hexagonal, 1. 0,8 “5” Final
MC00679 2. 2,2 torque
after 20min
Power board M3x10 MC00453 0,3 “1” Pz1
M5x12 comb, 2,2
Torx MC00039
Capacitor M5x12 2,2
terminals
Capacitor M4x8 self-tapping 1,5 Pz2
fastening screw
Rear cover M4x8 self-tapping 2,2
screw
AC choke M4*16 self-tapping 1,5
screw
Power unit M4x10 self-tapping 2,2 Pz2
cover sunk screw
Connection M4x10 self-tapping 2,2 Pz2
cover sunk screw
Upper frame M4*16 self-tapping 2,2
screw
Choke wires M4x8 comb, Torx, 1,3 “9”
MC00039
C level M5x12 comb. 2,2
capacitor MC00039
package, M4x8, MC00031
60PP05051

Control board to M3x6, MC00401 0,5 “3” Pz1

the control box,
60VB00661,
60VB00252
Control box M4x40, MC00401 0,8 “5” Pz2
M4x8, MC00036
 Specifications 36

6.2. Temperature tables

TABLE 8. Temperature vs. voltage.

Temp Temp signal

-40 1.858
-35 1.937
-30 2.014
-25 2.097
-20 2.178
-15 2.263
-10 2.347
-5 2.434
0 2.52
5 2.608
10 2.695
15 2.785
20 2.874
25 2.966
30 3.058
35 3.149
40 3.24
45 3.334
50 3.427
55 3.52
60 3.611
65 3.706
70 3.8
75 3.894
80 3.986
85 4.08
90 4.173
95 4.267
100 4.36
105 4.454
110 4.545
115 4.639
120 4.731
37 Specifications

TABLE 9. Temperature vs. resistance.

Temperature on
monitoring page V1.9 Resistance

-40 577
-35 604.5
-30 632
-25 661.5
-20 691
-15 722.5
-10 754
-5 787
0 820
5 854.5
10 889
15 925.5
20 962
25 1000
30 1039
35 1078.5
40 1118
45 1160
50 1202
55 1245
60 1288
65 1333.5
70 1379
75 1425.5
80 1472
85 1520.5
90 1569
95 1619.5
100 1670
105 1722
110 1774
115 1828
120 1882
 Specifications 38

6.3. Drive version history

TABLE 10. Drive version history.

Name of New P/N S.Nbr/ Changed to previous

product Date
Insulator MF5 FR05029A - Layout changed dare the dif-
ferences between MF5 and
replaces old insulator
FR05010F/MF5.
L2025- PP00035 - Ferrite ring will be added to
W38030K cables between AC choke
and power board. New
version of power board
required. Replaces
PP050268.
AC choke PP05052A 18.3.2004 C filter level requires
changes to EMC board.
Capacitors added.
FR5 IP54 cover FR05017 - Gasket tape is replaced by
sealing compound.
Frame FR5 FR05000B 10043552 / Replaces older frame
1.6.04 (FR05000A). Diameter of
powerboard fixing stand
enlarged, 7mm => 8mm.
Fixing stud for back plate
extended.
FR5 Capacitor PP05051 1.6.04 C level requires AC choke
package PP00035 unit PP05052A. Old unit
C-level 2* 1μF. doesn’t fulfill required EMC
FR5 Toroid level. Toroid and capacitor
package will be added to
regular product.
AC choke/Filter FR01008 & week 25- Cable terminals added for
PP05052 31/2004 both (PP01008 & PP05052)
and 32/ constructions. AC choke
2004 package (PP05052) suites to
all FR5 drives.
Insulator plate FR05031 10.12.04 Insulator plate added to
under power board.
39 Specifications

TABLE 10. Drive version history.

Name of New P/N S.Nbr/ Changed to previous

product Date
Power supply, VB00413E 7.5.05 The fan control has been
500V, Mini II changed to handle pulse
wide modulation without
decreasing its total lifetime.
New layout, but changes are
the same as E-version
before.
FR5 intermedi- FR01616E 5.9.05 New intermediate plate
ate plate material is aluminium. New
part is 100% compatible.
SH FR5 cover FR01615D 5.9.05 New cover plate material is
aluminium. New part is
100% compatible.
FR5 Miniskiip 3 CP01306 SKIIP 30.9.05 New lid + screws. Pre-tight-
gen. 1 pres- 30, CP01307 ening up to 1Nm and Final
sure plate (lid) SKIIP 31 and tightening to 2.2Nm. 100%
and New CP01308 SKIIP backwards compatible.
Screws 32. Screws
MC00679
FR5 FR01616F 20.10.2005 Cover plate fixing hole
intermediate moved to right place
plate
Ver. A control PP01627D 18.11.2005 PP01627 Ver. A cable set
cable and A1 jumper must be removed.
Option board NOTE! A1 board X3 settings:
CMB isolated from GND and
CMA connected to GND
New holes to FR05002 08.12.2005 Schindler needs additional
FR5 power version H grounding points to cover for
cover control cable grounding.
OPTAG board OPTAG board 30.01.2006 OPTAG and OPTAH board
and OPTAH and OPTAH connector is changed to
board board connec- shorter 14mm model
connector tor 14mm
16mm
 Specifications 40

TABLE 10. Drive version history.

Name of New P/N S.Nbr/ Changed to previous

product Date
NXS Control VB00252P 09.02.2006 New version of the NXS con-
board trol is needed for supporting
bigger SRAM:s to be
mounted. The current 1MBit
SRAM used has gone to
obsolete. VB00252 P is com-
patible with VB00252 O,
except that bigger SRAM:s
(> 1Mbit) may not be
mounted in VB00252
version O.
NXP Control VB00561H 18.04.06 New version of the NXP con-
trol is needed for support of
the Safe Disable function.
NXP drive with Safe Disable
function is achieved with
NXP control version H
(VB00561H) and OPT-AF
installed in slot B of the con-
trol. VB00561H is function-
ally HW and SW compatible
with VB00561F.
Hardware added to sup-
port 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 con-
nected to MCU MIOS mod-
ule, for calculating time
stamps for received
messages.
- +9V raised 200mV.
- connectors X10 and X11
corrected in the layout.
- 3rd CAN moved to DA
board connector (X9).
41 Specifications

TABLE 10. Drive version history.

Name of New P/N S.Nbr/ Changed to previous

product Date
VB00313K VB00313L 13.09.2006 Added fan control to the
card.
VB00213 VB00631A 05.06.2006 New power board.
VB00575 25.11.2006 FR5 Input Rectifier Board
VB00575 to the production.
M00178.
- PP04053 14.05.2007 Mounting kit FR5 is not
available, anymore.
VB00213 VB00313 28.8.2007 New power board, 230 V.
C11282.
60S0000095 11.09.2007 New brake chopper retro fit
kit available. C15918.
Fan covers and 16.11.2007 Blue changed to grey.
fan connector C15918.
colour have
been changed
26.11.2007 Covers manufactured earlie
and with maximum toler-
ances can broke charging
resistor when cover is
assembled. Implemented
26.11.2007, serial no:
10991365. M00779.
 Specifications 42

TABLE 10. Drive version history.

Name of New P/N S.Nbr/ Changed to previous

product Date
Switching 24.01.2008 Switching covers are modi-
covers are fied. Groove has been added
modified to the charging resistor.
C18439.
PP05052 03.11.2008 In FR5 FC drive capacitors in
input choke module from
phases to startpoint will be
removed from units with
EMC level T.
Choke modules will be modi-
fied at factory. Modified input
choke module is to be
labeled with (T) after the PP
number.
Reason for change: Men-
tioned capacitors cause
unneccessary overvoltage
trips in distorted network
when drive is idling.
ECE00018.
 Producer
Runsorintie 7
65380 Vaasa
Finland

Subject to change without prior notice

© 2009 Producer.

SM00057E
29.10.2009
J. Kukkonen