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service manual
vacon • 1
INDEX
1. VERSION HISTORY
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disassembly and power board replacement vacon • 3
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4 • vacon disassembly and power board replacement
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disassembly and power board replacement vacon • 5
5. Remove the 4 standoffs, and center module screw that secure the power board.
7. Install the new power module and thermal pad orientated as shown.
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6 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 7
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8 • vacon disassembly and power board replacement
4. Remove DB wires (1 or 2 sets model dependant) thermistor connector and fan wires
(model dependant).
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disassembly and power board replacement vacon • 9
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.
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10 • vacon disassembly and power board replacement
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disassembly and power board replacement vacon • 11
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.
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12 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 13
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14 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 15
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.
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16 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 17
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!
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18 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 19
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.
6. Remove the 8 nuts and washers that secure the top bus bar.
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20 • vacon disassembly and power board replacement
8. Remove 4 small nuts and washers and 2 larger nuts along with the 6 IGBT snubber caps.
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disassembly and power board replacement vacon • 21
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.
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22 • vacon disassembly and power board replacement
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.
3. Remove 2 screws and remove both edge brackets. Now the power board and SCR control
board are exposed.
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disassembly and power board replacement vacon • 23
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.
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24 • vacon disassembly and power board replacement
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.
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disassembly and power board replacement vacon • 25
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.
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26 • vacon disassembly and power board replacement
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.
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