VACON NX SERVICE MANUAL Appendix FR4 PDF

NX SERVICE MANUAL
Appendix FR4
Table of content 1
1. SERVICE MANUAL VERSION HISTORY....................................................2

2. MAIN CIRCUIT DIAGRAMS .....................................................................4
3. MECHANICAL CONSTRUCTION ...............................................................9
3.1. Spare part sets for the FR4 unit .................................................. 10
3.2. Control boards in the FR4 unit .................................................... 10
3.3. Power boards in the FR4 unit ...................................................... 10
4. THE FR4 POWER UNIT (3-12 A) ...........................................................12
4.1. Safety notice ............................................................................ 12
4.2. Visual checkings and measurements before powering up the unit .... 12
4.2.1. Checking the cooling tunnel .......................................... 12
4.2.2. Checking the power board ............................................ 12
4.2.3. Checking the power module .......................................... 13
4.2.4. Power unit checking, testing and measurements .............. 14
4.2.5. Testing with the power unit tester PUT 1......................... 14
4.2.6. Checking the current measurement circuit ...................... 15
4.2.7. Checking the voltage measurement circuit ...................... 16
4.2.8. Checking the temperature measurement circuit ............... 16
4.2.9. Checking the fan ......................................................... 17
4.2.10. Testing the pre-charging circuit ................................... 17
5. TEST, REMOVAL AND REPLACEMENT INSTRUCTIONS ...........................18
5.1. Fan ......................................................................................... 18
5.2. AC-Choke ................................................................................ 18
5.3. Power board............................................................................. 19
5.4. Capacitors ............................................................................... 20
5.5. Power module .......................................................................... 21
5.5.1. Skiip power module measurements ................................ 21
5.5.2. Replacing the skiip power module .................................. 22
5.6. Power board............................................................................. 26
5.7. The process of modifying a board................................................ 30
5.7.1. Tools ......................................................................... 30
5.7.2. Working process.......................................................... 30
5.7.3. Checkup instructions.................................................... 30
5.7.4. The tailored power boards ............................................ 32
5.8. EMC level modification from H to T .............................................. 46
6. SPECIFICATIONS .................................................................................48
6.1. Torque specifications ................................................................. 48
6.2. Temperature tables ................................................................... 48
6.3. Drive version history ................................................................. 50
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2 Version history
1.SERVICE MANUAL VERSION HISTORY
TABLE 1. Service manual updates.

Service Manual Updated/added material
version
SM00042E First version
Service manual
1
Revision history 3
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1
4 Main circuit diagrams
2. MAIN CIRCUIT DIAGRAMS
FIGURE 1. NX/FR4/FC/230 V and 500 V FC, version A.
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2
5
B-
POW
B+ / R+
R-
J1
U_HI
V_HI
W_HI
J3
DC +
FIGURE 2. NX/FR4/FC/230 V and 500 V FC, version B.

X3
L1 U / T1
X4
L2 V / T2
MiniSkiip
X5
Main circuit diagrams
L3 W / T3
X10
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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
FIGURE 3. NX/FR4/230 V and 500 V FC, version C.
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Main circuit diagrams 7
FIGURE 4. NX/FR4/230 V and 500 V INU, version B.
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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
FIGURE 5. Exploded view.
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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.
3.1. Spare part sets for the FR4 unit
60FR00040 Assembly kit FR4 includes the parts:

• FR00016 Earthing lamella
• FR04004 Bushing plate FR4
• MC00044 M4x16-DIN7500CE-Thread Forming-Zn-Pz
• MC00051 Bushing rubber GD21
• MC00354 Label Drive modified
• PP00001 Screw Sheet Cover PTK41
60FR00079 Mounting kit FR4 includes the parts:

• FR00016 Earthing lamella
• MC00051 Bushing rubber GD21
• MC00354 Label Drive modified
• PP00001 Screw Sheet Cover PTK41
3.2. Control boards in the FR4 unit

• 60VB00561 Control board NXP
• 60VB00252 Control board NXS
3.3. Power boards in the FR4 unit

• 60SA-VB00308-0000-2-XXV Power board FR4 3-8A 230V, not programmed, var-
nished
nished
• 60SA-VB00308-0003-2-ABV Power board 3A 230V, air cooled, brake chopper, var-
nished
nished
nished
nished
nished
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Exploded view 11
nished
nished
• 60SA-VB00210-0012-5-XXV Power board FR4 12A 500V, not programmed, var-
nished
nished
• 60SA-VB00208-0003-5-ARV Power board 3A 500V, air cooled, brake chopper, resis-
tor inside the unit, varnished
nished
nished
nished
nished
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,
varnished
varnished
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12 Measurement instructions
4. THE FR4 POWER UNIT (3-12 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 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.
4.2. Visual checkings and measurements before powering up the unit
4.2.1. Checking the cooling tunnel

• Remove the control unit from the power module to avoid damaging it.
• Open the back plate by lifting it upwards along its lower edge and then slide the
plate downwards to disengage it from the edge retainer.
NOTE! A BRAKE RESISTOR IS AVAILABLE AS AN INTERNAL AND AS AN EXTERNAL OPTION

FOR FRAME FR4 IN THE VOLTAGE CLASSES NX_2 AND NX_5.
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.
4.2.2. Checking the power board

• Remove the control unit from the power unit.
• Remove the I/O-cable cover and the I/O-wires.
• Remove the control unit's fixing screws from the lower corners and from under-
neath the panel.
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Measurement instructions 13
• Separate the control unit from the power unit.

• Remove the power unit's cover plate.
• 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 module

• Remove the power terminal cover plate to access the main terminals.
• Measure the diodes' forward and reverse bias as shown in the diagram below:
TABLE 2. The main circuit measurements for the FR4 (typical values).
Measurement point Value Measurement point Value
Rectifier forward: L1/L2/L3 to B+ 0,45 V Rectifier reverse: B+ to L1/L2/L3 Infinite
Rectifier forward: B- to L1/L2/L3 0,45 V Rectifier reverse: L1/L2/L3 to B- Infinite

Brake diode forward: R- to B+ 0,4 V Brake diode reverse: B+ to R- Infinite
IGBT diode forward: B- to U/V/W 0,4 V IGBT diode reverse: U/V/W to B- Infinite
IGBT diode forward: U/V/W to B+ 0,4 V IGBT diode reverse: B+ to U/V/W Infinite
NOTE! SHORT-CIRCUITS CAN BE MEASURED FROM THE IGBT BRAKE TERMINALS.
Description:
B- = DC-
B+ = DC+
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N B- B+ R- U V W
L1 L2 L3
FIGURE 6. Main terminals FR4.
If the visual checking is satisfactory and the measurements are correct, continue with
the instructions in section 3.2.4.
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 FR4 SHUNT RESISTOR CURRENT MEASUREMENT CIRCUIT CAN NOT BE MEA-
SURED WITH THE TESTER, PUT 1.
• Attach the power unit-tester to the connector on the power unit.

• Connect a multimeter (selecting the VDC range) to the power unit tester PUT 1 to
take the measurements.
• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and B+
= DC+. Connect the power supply leads to B- or B+ and then apply a nominal volt-
age.
• Check all signals from the power unit and compare them to the values in Table 3
Power Unit Values for FR4.
• If any of these signals 24V, -15V, 15V, IU, IV or IW are different from the value in
Table 3, the power board must be replaced.
• If the TEMP-signal is different from the value in the table, check the temperature
sensor from the power module's contacts T+ and T-. See the instructions in section
5.5. Power module.
• The values for UC+ and UC- can be different, but the calculated value has to be
according to the value in table 2. If the value differs from the value in the table,
check the capacitors. See the instructions in section 5.4. Capacitors.
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TABLE 3. Power unit values for FR4
Signal name Description Measurement value/VDC

24V 24V on the power board +21,6 … +26,4
-15V -15 V on the power board -13,5 … -16,5
+15V 15 V on the power board +13,5 … +16,5
UC + Value of DC+ voltage 3 (1200VDC => 5V)
UC - Value of 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 The temperature signal from the power 2.9 (at 20° C) Values are in the
unit appendix
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.
4.2.6. Checking the current measurement circuit

• Measure the shunt resistors against the GND (i.e. terminal X2). The measurement
points are indicated on FIGURE 9, see number 4 on Power Board, in section 5.3.
Power Board.
• Measure the U-phase, on the right side of R19/R20.
• Measure the V-phase, on the bottom side of R24.
• Measure the W-phase, on the top side of R25/R26.
• Compare the measured values to values in TABLE 4.
• Supply the power unit with a DC-voltage from a DC power supply. B-=DC- and
B+=DC+. Connect the power supply leads to B- or B+ and then apply a nominal
voltage.
• Measure the offset values IU, IV and IW. The values are all 0 V.
• Measure the operating voltages. The values are -15 V and +15 V.
• Change the power board, if any signal is different to those in TABLE 3 and in TABLE
4.
• If the measurements above are correct, check the control unit with the control unit
tester as mentioned in the NX Service manual overview.
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TABLE 4. Shunt resistors for units 230 V and 500 V.
Unit current Shunt Shunt Shunt Shunt Measurement Voltage/

Power board
value A A/Ω B/Ω C/Ω D/Ω value/Ω V
VB00205/FC 3 680 1210 435 500
VB00206/FC 4 392 4020 357 500
VB00207/FC 5 392 953 278 500
VB00208/FC 3 715 560 475 332 453 500
VB00208/FC 4 715 560 475 332 321 500
VB00208/FC 5 715 560 475 332 251 500
VB00208/FC 7 715 560 475 332 186 500
VB00208/FC 9 715 560 475 332 143 500
VB00209/FC 9 200 560 147 500
VB00210/FC 12 120 1800 330 111 500
VB00210/FC 16 120 1800 330 83 500
VB00210/INU 4 510 255 332 321 500
VB00210/INU 9 510 255 332 142 500
VB00210/INU 12 510 255 332 111 500
VB00410/FC 12 120 1800 330 111 500
VB00410/FC 13 120 1800 330 111 500
VB00710/INU 4 510 255 332 321 500
VB00710/INU 9 510 255 332 142 500
VB00308/FC 3 920 820 422 154 416 230
VB00308/FC 4 920 820 422 154 271 230
VB00308/FC 7 920 820 422 154 209 230
VB00308/FC 8 920 820 422 154 152 230
VB00310/FC 11 154 820 226 128 230
VB00310/FC 12 154 820 226 91 230
NOTE! CHECK THE POWER BOARD MODIFICATION INSTRUCTIONS.
4.2.7. Checking the voltage measurement circuit

• Attach the power unit-tester PUT 1 to the connector on the power unit.
• Supply the power unit with DC-voltage from a DC power supply. B- = DC- and B+ =
DC+. Connect the power supply leads to B- or B+ and then apply a nominal volt-
age.
• Measure the UC+ and UC- values and compare them to the values in Table 3 Power
unit values of FR4, in section 4.2.5. Testing the power unit tester PUT1.
• If the UC+ and UC - values differ from the values in Table 3, check the capacitors.
See the instructions in section 5.4. Capacitors.
4.2.8. Checking the temperature measurement circuit

• Remove the Power Board as show in section 5.3. Power board.
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• 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.
4.2.9. Checking the fan

• Supply the power unit with a DC-voltage from a DC power supply. B- = DC- and B+
= DC+. Connect the power supply leads to B- or B+ and then apply a nominal volt-
age.
• Measure the 24 V signal. Replace the power board, if the signal is incorrect.
• Switch on the fan with the switch on the power unit tester, PUT1. Check the rotation
of the fan. If the fan is not working, change it. See section 5.1. Fan for replacement
instructions.
4.2.10. Testing the pre-charging circuit

• Measure the forward bias towards the DC+ on the rectifier from the main terminals.
If all measurement values are infinite, the pre-charging resistor is probably 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 the
power board according to the instructions in section 5.3. Power board.
• Measure the DC-link capacitors, because they can be broken.
• Measure the brake chopper, because it can be shorted.
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18 Replacement instructions
5. TEST, REMOVAL AND REPLACEMENT INSTRUCTIONS
5.1. Fan
• Before replacing the cooling fan, refer to Fig-

ure 5. Exploded view in section 3. Mechanical
Construction, and to the main circuit dia-
grams in section 2. Main Circuit Diagrams.
• Using a screwdriver, depress the plastic
retainer clips on the sides of the fan (shown
pointed out with red arrows in the adjacent
photo, Figure 7. Cooling fan cover) and with-
draw the fan from the frame.
• Install the new fan by simply pressing it into
the frame.
• Check the fan wire connections carefully.
FIGURE 7. Cooling fan cover.
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.
Replacing the AC-Choke:

• Remove the back plate retaining screw and
remove the back plate.
NOTE! A BRAKE RESISTOR IS AVAILABLE AS AN

INTERNAL OPTION FOR FRAME FR4 IN THE VOLT-
AGE CLASSES NX_2 AND NX_5.
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.
THIS ALSO ENTAILS REMOVING THE POWER
BOARD. SEE SECTION 5.3. POWER BOARD.
• Remove the power board. See the instruc-

tions in section 5.3. Power board.
• Remove the screws from the corners of the
FIGURE 8. AC choke wires. AC choke located on the front of the unit.
• Note the location of the cables and pull out
the AC-Choke from the back of the unit.
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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.
5.3. Power board
Replacing the board:

• Using a screwdriver, depress the plastic
retainer clips on the sides of the fan and with-
draw the fan from the frame. See no. 1 in Fig-
ure 9.
• Remove the pressure plate before loosening
any other screws. Lift the pressure plate away
from the unit. See no. 2 in Figure 9.
• Remove the cables from the AC choke care-
fully using either a pair of pliers or by depress-
ing the connector clips with a screwdriver,
depending on the model. See no. 3 in Figure
9.
• Remove the four capacitor screws. See no. 4
in Figure 9. Measure the shunt resistors
against the GND, terminal X2.
• Remove the power board.
• To install a new power board follow the first
four instructions in reversed order.
The screw torques, required for fastening the
power board, are shown in section 6.1. Torque
FIGURE 9. Power board. specifications, Table 6. Torque specifications.
NOTE! AFTER REPLACING THE POWER BOARD, THE

POWER UNIT MUST BE PROGRAMMED WITH THE
‘DEVICE PROPERTIES SERVICE’ PC PROGRAMME.
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.
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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.
NOTE! THE METAL CUP ON THE BRIM OF A CAPACI-

TOR IS IN THE MINUS POTENTIAL. WATCH IT
WHEN THE CONNECTORS ARE USED.
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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5.5. Power module
MiniSkiip20NAB12T45, MiniSkiip22NAB12T45, MiniSkiip30NAB12T49 and

MiniSkiip32NAB12T49. This power module circuit diagram is the equivalent for all
power modules in FR4.
DC+ B+ DC+ T- T+
v
UH VH WH
L1 U
L2 R- V
L3 W
gB UL VL WL
DC- B- DC- pow er connector
control pin
FIGURE 11. Skiip circuit diagram
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.
5.5.1. Skiip power module measurements

To access the Skiip power module the power board must first be removed.
All of the power board fastening screws must be removed as shown section 5.3. The
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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.
5.5.2. Replacing the skiip power module

• Remember to use ESD protection at all times, when working with the electronic
components of any AC drive.
• Clean the contact surfaces on the power board.
• Always put a thin and even layer of thermal compound on the bottom of the Skiip
power module before installing it on the heat sink.
• It is recommended that 'Wacker-Chemie P12' thermal paste is used.
• Torque the the pressure plate in place, using the torque values specified in section 6
Torque specifications, Table 6. Torque specifications.
The pressure of the torque has been calculated to accommodated the properties of
the thermal paste. Therefore, the screws should not be tightened more after they
have been finally torqued down, as this will affect the density and thickness of the
layer of thermal paste, and detrimentally affect the pastes thermal qualities.
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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TABLE 5. MiniSkiip measurement values.
Miniskiip 20 Miniskiip 22 Miniskiip 30

Diodes (IGBT,
rec tifier and brake ~0.4V ~0.4V ~0.4V
diode)
R- to B- ~1.6V ~2.2V ~1.3V
IGBT gate ~3nF ~4nF ~7nF
Brake gate ~1.5nF ~1.5nF ~1.5nF
Note! The bevelled corner.
FIGURE 13. Mini Skiip installation.
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FIGURE 14. Power board installation.
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FIGURE 15. IGBT cover installation.
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5.6. Power board
FIGURE 16. Power board 3-9A valid up to version D.
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FIGURE 17. Power board 3-9A from version F.
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FIGURE 18. Power board 12A up to version D.
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FIGURE 19. Power board 12A from version F.
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5.7. The process of modifying a board
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.
5.7.2. Working process
NOTE! REMEMBER TO USE ESD-PROTECTION (WRIST-STRAP).
• 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.
FIGURE 20. Removing a component with a twin tip desoldering iron.
• Clean any solder from soldering joints and any solder splashes from the surround-
ing area.
5.7.3. Checkup instructions

• Confirming the modification.
After the modification has been completed, verify that it is the intended correct
modification.
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• Labeling the modification. See Figure 21.

To indicate what change has been made, mark an X below the correct current value
on the label provided on the board. The person responsible for the changes, initials
the current value marked on the board.
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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5.7.4. The tailored power boards
5. 7. 4. 1. Modification of 230 V power boards

Removable resistors
Current measurement resistors

3A
D
C
B
A
FIGURE 22. FR4 FC power board 60VB00308, 3 A, 230 V.
Service manual
5
Removable resistors

4A
D
C
B
A
Service manual
5
Removable resistors

7A
D
C
B
A
Service manual
5
Removable resistors

8A
D
C
B
A
Service manual
5
Removable resistors

11A
Service manual
5
Removable resistors

12A
Service manual
5
5. 7. 4. 2. Modification of 400 V/500 V power boards
Removable resistors
3A Current measurement resistors
D
C
B
A
3A Gate resistors
FIGURE 28. FR4 FC power board 60VB00208, 3 A, 400 V/500 V.
Service manual
5
Removable resistors
D
C
B
A
4A Gate resistors
Service manual
5
Removable resistors
D
C
B
A
5A Gate resistors
Service manual
5
Removable resistors
D
C
B
A
Service manual
5
Removable resistors
D
C
B
A
Service manual
5
Removable resistors
12A measurement
resistors.
Service manual
5
5. 7. 4. 3. Modification of 400 V/500 V INU power boards
Removable resistors

4A
FIGURE 34. FR4 INU power board 60VB00710, 4 A, 400 V/500 V.
Service manual
5
Removable resistors
9A current measurement
resistors
FIGURE 35. FR4 INU power board 60VB00710, 9 A, 400 V/500 V.
Service manual
5
5.8. EMC level modification from H to T
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).
Service manual
5
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).
Service manual
5
48 Specifications
6. SPECIFICATIONS
6.1. Torque specifications
TABLE 6. Torque specifications.
Frame Item Screw Final torque

FR4 IGBT M5*35 2 Nm
FR4 Capac itor teminals M5*12 2 Nm
FR4 Capac itor fast ening M4*8 self- t apping 1,5 Nm
FR4 PC board M4*8 self- t apping 2 Nm
FR4 Rear c over M4*8 self- t apping 2 Nm
6.2. Temperature tables
TABLE 7. Temperature vs. voltage values.
Temperature: Temp. signal: Temperature: Temp. signal:

-40 1,86 45 3,33
-35 1,94 50 3,43
-30 2,01 55 3,52
-25 2,1 60 3,61
-20 2,19 65 3,71
-15 2,26 70 3,8
-10 2,35 75 3,89
-5 2,43 80 3,98
0 2,52 85 4,08
5 2,61 90 4,17
10 2,7 95 4,27
15 2,79 100 4,36
20 2,87 105 4,45
25 2,97 110 4,54
30 3,06 115 4,64
35 3,15 120 4,73
40 3,24
Service manual
6
Specifications 49
TABLE 8. Temperature vs. resistance values.
Monitoring page V1.9 Resistance Monitoring page V1.9 Resistance

- 40 577 45 1160
- 35 604,5 50 1202
- 30 632 55 1245
- 25 661,5 60 1288
- 20 691 65 1355,5
- 15 722,5 70 1379
- 10 754 75 1425,5
-5 787 80 1472
0 820 85 1520,5
5 854,5 90 1569
10 889 95 1619,5
15 925,5 100 1670
20 962 105 1722
25 1000 110 1774
30 1039 115 1828
35 1078,5 120 1882
40 1118
Service manual
6
50 Specifications
6.3. Drive version history
TABLE 9. Drive version history
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.
Service manual
6
Specifications 51
Name of
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)
Service manual
6
52 Specifications
Name of
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
6
Subject to change without prior notice
© 2008 Vacon Plc.
SM00042 E
7.2.2008
Author: J. Kukkonen

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NX SERVICE MANUAL

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

1.SERVICE MANUAL VERSION HISTORY

TABLE 1. Service manual updates.

2. MAIN CIRCUIT DIAGRAMS

FIGURE 1. NX/FR4/FC/230 V and 500 V FC, version A.

FIGURE 2. NX/FR4/FC/230 V and 500 V FC, version B.

FIGURE 3. NX/FR4/230 V and 500 V FC, version C.

FIGURE 4. NX/FR4/230 V and 500 V INU, version B.

FIGURE 5. Exploded view.

3.1. Spare part sets for the FR4 unit

60FR00040 Assembly kit FR4 includes the parts:

60FR00079 Mounting kit FR4 includes the parts:

3.2. Control boards in the FR4 unit

3.3. Power boards in the FR4 unit

4. THE FR4 POWER UNIT (3-12 A)

4.1. Safety notice

4.2. Visual checkings and measurements before powering up the unit

4.2.1. Checking the cooling tunnel

NOTE! A BRAKE RESISTOR IS AVAILABLE AS AN INTERNAL AND AS AN EXTERNAL OPTION

4.2.2. Checking the power board

• Separate the control unit from the power unit.

4.2.3. Checking the power module

Measurement point Value Measurement point Value

Rectifier forward: L1/L2/L3 to B+ 0,45 V Rectifier reverse: B+ to L1/L2/L3 Infinite

Rectifier forward: B- to L1/L2/L3 0,45 V Rectifier reverse: L1/L2/L3 to B- Infinite

NOTE! SHORT-CIRCUITS CAN BE MEASURED FROM THE IGBT BRAKE TERMINALS.

FIGURE 6. Main terminals FR4.

4.2.4. Power unit checking, testing and measurements

4.2.5. Testing with the power unit tester PUT 1

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

TABLE 3. Power unit values for FR4

Signal name Description Measurement value/VDC

4.2.6. Checking the current measurement circuit

TABLE 4. Shunt resistors for units 230 V and 500 V.

Unit current Shunt Shunt Shunt Shunt Measurement Voltage/

NOTE! CHECK THE POWER BOARD MODIFICATION INSTRUCTIONS.

4.2.7. Checking the voltage measurement circuit

4.2.8. Checking the temperature measurement circuit

4.2.9. Checking the fan

4.2.10. Testing the pre-charging circuit

5. TEST, REMOVAL AND REPLACEMENT INSTRUCTIONS

• Before replacing the cooling fan, refer to Fig-

FIGURE 7. Cooling fan cover.

Replacing the AC-Choke:

NOTE! A BRAKE RESISTOR IS AVAILABLE AS AN

• Remove the power board. See the instruc-

5.3. Power board

Replacing the board:

NOTE! AFTER REPLACING THE POWER BOARD, THE

NOTE! THE METAL CUP ON THE BRIM OF A CAPACI-

5.5. Power module

MiniSkiip20NAB12T45, MiniSkiip22NAB12T45, MiniSkiip30NAB12T49 and

DC- B- DC- pow er connector

FIGURE 11. Skiip circuit diagram

5.5.1. Skiip power module measurements

5.5.2. Replacing the skiip power module

TABLE 5. MiniSkiip measurement values.

Miniskiip 20 Miniskiip 22 Miniskiip 30

Note! The bevelled corner.

FIGURE 13. Mini Skiip installation.

FIGURE 14. Power board installation.

FIGURE 15. IGBT cover installation.