Danfoss VLT Decentral FCD 300 User manual

Service Manual FCD 300
Release 01/2003 1
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
Service Manual for FCD300

Service Manual FCD 300
Release 01/2003 2
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
General warning and your safety
General warning
The voltage of the frequency converter is dangerous whenever the converter is connected to mains. Incorrect
fitting of the motor or frequency converter may cause damage to the equipment, serious injury or death.
Consequently, it is essential to comply with the instructions in this manual as well as local and national rules
and safety regulations.
These rules concern your safety
1. The frequency converter must be disconnected fromthe mains if repair work is to be carried out. Check
that the mains supply has been disconnected and that the prescribed time has passed before removing the
inverter part fromthe installation.
2. The [STOP/RESET] key on the optional control panel does not disconnect the equipment frommains and
is thus not to be used as a safety switch.
3. The unit must be properly connected to the earth, the user must be protected against the supply voltage
and the motor must be protected against overloading pursuant to prevailing national and local regulations.
4. The earth leakage currents are higher than 3.5 mA.
5. Protection against motor overload is not included in the factory setting. If this function is required, set
parameter 128 Motor thermal protection to data value ETR trip or data value ETR warning. For the North
American market: The ETR functions provide overload protection of the motor, class 20, in accordance
with NEC.
Warning against unintended start
1. The motor can be brought to a stop by means of digital commands, bus commands, references or a local
stop, while the frequency converter is connected to mains. If personal safety considerations make it
necessary to ensure that no unintended start occurs, these stop functions are not sufficient.
2. While parameters are being changed, the motor may start. Consequently, the stop key [STOP/RESET] on
the optional control panel must always be activated; following which data can be modified.
3. A motor that has been stopped may start if faults occur in the electronics of the frequency converter, or if a
temporary overload or a fault in the supply mains or the motor connection ceases.
Warning:
It can be extremely dangerous to touch the electrical parts even
when the AC line supply has been disconnected.
For FCD 300: wait at least 4 minutes.

Service Manual FCD 300
Release 01/2003 3
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
Content
1. Scope and field of service manual...............................................................................................4
2. Service Policy for FCD 300.........................................................................................................4
2.1. In General.............................................................................................................................4
2.2. Field Service........................................................................................................................4
3. Installation, programming and basic fault tracing.......................................................................4
4. Replacement.................................................................................................................................4
5. Spare parts....................................................................................................................................5
5.1. Complete electronic parts.....................................................................................................5
5.2. Control cards........................................................................................................................5
5.3. Various parts........................................................................................................................5
5.4. Picture of Control cards.......................................................................................................6
5.5. Picture of Various parts.......................................................................................................7
6. Product Notes.............................................................................................................................10
7. Tools needed..............................................................................................................................10
8. Place, tightening torque and sequence for screws......................................................................11
9. Function diagram.......................................................................................................................13
10. Special conditions, which might cause problems..................................................................14
11. Symptom / Causes chart.........................................................................................................15
12. Application or FCD fault.......................................................................................................17
13. Test (measurement) on the FCD............................................................................................18
13.1. Static test........................................................................................................................19
13.2. Dynamic test..................................................................................................................21
14. LED indications.....................................................................................................................23
15. Power up test / Control card test............................................................................................24
16. Replacement of control card..................................................................................................25
17. Control Connections..............................................................................................................26
18. Power Connections................................................................................................................26
19. Useful Data (supplement to the design guide).......................................................................27
19.1. Thermal conditions / derating........................................................................................28
19.2. AC mains Voltage Compatibility...................................................................................29
19.3. Mechanical brake control and supply............................................................................29
19.4. Digital outputs................................................................................................................30
19.5. LCP cable length............................................................................................................30
20. Voltage level overview..........................................................................................................30
21. Current levels.........................................................................................................................30
22. Help and support contact........................................................................................................31
23. Failure reporting and complaint/analyse report.....................................................................31
23.1. Failure reporting.............................................................................................................31
23.2. Complaint/analyse report...............................................................................................31

Service Manual FCD 300
Release 01/2003 4
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
1. Scope and field of service manual
This Service manual is made with the purpose to help when doing technical service on the
FCD300 in the field.
The service manual will be updated continuous to be able to improved the service and
always be up-to-date.
Comment and proposal to this service manual, please send an e-mail to DD global hotline:
[email protected], with your comment.
2. Service Policy for FCD 300
2.1. In General
The FCD 300 is a non-repairable product.
Depending on economical or practical service situation repairs can be proceeded by
exchange of complete units or exchange the control card.
2.2. Field Service
- Repair in the field Exchange the drive (only the electronic part, not the installation parts)
to new or exchange the control card.
- Factory repair No factory repair.
NB: The complete service policy can be found on the Global Service Page.
3. Installation, programming and basic fault tracing
For installation, programming and basic fault tracing use the Design Guide MG.04.A3.xx
4. Replacement
Only repair option is by replacing the control card, complete electronic part or exchange
damage parts in the installation box. If the installation box, it self, is damage, then a new
have to be ordered through commercial department.
Replacing the control card could repair the electronic part.
NB
Always use ESD protection when change the control card or remove the plastic part
from the electronic part.

Service Manual FCD 300
Release 01/2003 5
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
5. Spare parts
5.1. Complete electronic parts
These part can be downsized / downgraded 1 (one) size
FCD303 P T4 C66 EB R1 D0 F12 T00 C0 = Ordering no.178B1484
FCD307 P T4 C66 EB R1 D0 F12 T00 C0 = Ordering no.178B1485
FCD315 P T4 C66 EB R1 D0 F12 T00 C0 = Ordering no.178B1486
FCD330 P T4 C66 EB R1 D0 F12 T00 C0 = Ordering no.178B2301
NB
All unit are complete spare unit with ProfiBus 12MB and extended brake.
These parts can be ordered from Euro Stock Hotel
5.2. Control cards
ProfiBus 12 MB control card = Ordering no. 175N2338
AS(i) control card = Ordering no. 175N2324
DeviceNet control card = Ordering no. 175N2325
(Picture of parts can be seen on the follow pages)
NB
These parts can be ordered from Euro Stock Hotel
5.3. Various parts
Service kit (All parts used in the installation box) = Ordering no. 175N2121
Converting kit to new control plug system = Ordering no. 175N2409
Converting kit to new control plug system = Ordering no. 175N2409
Service tool (cable length 0,7 m) = Ordering no. 175N2404
LCP2 = Ordering no. 175N0131
LCP2 cable (cable length 3 m)= Ordering no. 175N0162
LCP2 remote mounting kit (cable length 3 m) = Ordering no. 175N0160
LCP2 plug kit = Ordering no. 175N2118
(Picture of parts can be seen on the follow pages)
NB
These parts can only be ordered through commercial, NOT from Euro Stock Hotel

Service Manual FCD 300
Release 01/2003 6
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
5.4. Picture of Control cards
ProfiBus 12 MB control card = Ordering no. 175N2338 – PCBID: 175N1300
(Also used for non-Bus and ProfiBus 3MB)
AS(i) control card = Ordering no. 175N2324 – PCBID: 175N1635
(also used to converting the electronic spare part to AS(i))
DeviceNet control card = Ordering no. 175N2325 – PCBID: 175N2158
(also used to converting of electronic spare part to DeviceNet)

Service Manual FCD 300
Release 01/2003 7
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
5.5. Picture of Various parts
Service kit (All parts used in the installation box) = Ordering no. 175N2121
Converting kit to new control plug system = Ordering no. 175N2409

Service Manual FCD 300
Release 01/2003 8
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
Service tool = Ordering no. 175N2404
LCP2 = Ordering no. 175N0131

Service Manual FCD 300
Release 01/2003 9
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
LCP2 cable = Ordering no. 175N0162
LCP2 remote mounting kit = Ordering no. 175N0160
LCP2 plug kit = Ordering no. 175N2118

Service Manual FCD 300
Release 01/2003 10
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
6. Product Notes
For software updates see product note no 6
For description of modifications of the control plug see product note no 7
For description of the modification on the earth spring see product note no 8
NB
Products notes can be found on Danfoss Drives intranet.
7. Tools needed
• Torx screw driver TX20 for joining /splitting electronic part and installation part.
• Torx screw driver TX10 for internal screws for fixing control card cassette and
printed circuit boards.
• Torque wrench (0-5 Nm) with bits TX10 and TX20
• LCP2 Control unit (175N0131)
• LCP2 plug kit (175N2118)
• LCP2 cable (175N0162)
• Service tool kit (175N2404, new tool under construction) gives access to all
electrical terminals during operation.
• ESD protection kit - wristband and Portable Bench mat.
• True RMS Digital Multimeter
• True RMS Current Clamp
• Analog voltmeter

Service Manual FCD 300
Release 01/2003 11
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
8. Place, tightening torque and sequence for screws
Screw
type Torque
Place / Tightening sequence
Inverter part TX20
M5x34
screws
3,0 Nm
1
2
3
4
5
6
Service
Switch M3x16 screws 1,3 Nm
Earth-
ground
connections
TX20
M4x12
screws
3,0 Nm
Plug and
installations
print in
installations
box
TX10 1,5 Nm
LCP2
connector M16x1,5
3,0 Nm

Service Manual FCD 300
Release 01/2003 12
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
FCD
mounting on
motor.
TX20
M5x16
screws
5,0 Nm
Plast cover
inverter part TX10 1,5 Nm
Control card
inside the
plastic cover
TX10 1,5 Nm

Service Manual FCD 300
Release 01/2003 13
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
9. Function diagram
L2
L3
L1
W
V
U
F
I
R
Basic Motor Control
Main
Power
Supply
Ext.
24V
Ext. Brake
Resistor
FCD Functional Diagram
Ver. 1.02
M.Sachmann, B Pawlowski 001002
: functional w. ext. 24V power
: safety isolation (PELV)
: functional isolation
temp.
Aux.
Power
Supply
LCP2
Relay
RS 485 Digital inputs Analog I/O
Digital output
Std./Field
Bus
Control Card
Mech.
Brake
Control

Service Manual FCD 300
Release 01/2003 14
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
10. Special conditions, which might cause problems
• The earth connection must be good especially in PROFIBUS installations.
It is important to fit a heavy connection from the frame of the controller having the
PROFIBUS master (PLC) and all bus nodes.
• Check all screws and pins securing the internal earth connection.
• Screws fixing the printed circuit boards
• Screws fixing the control card cassette
• Pins in the edge(s) of the electronic box
• Screws fixing the spring(s) in the installation part
• Earth connection done by the customer
(See location of screws in chapter “Place, tightening torque and sequence for
screws”)
• Cables must be carefully placed in the installation box to avoid mechanical damage
when the plugs between the electronic part and the installation part are joint.
• If 24 V back up supply is used (EB versions) the 400 V power should not be switched on
approx 3 seconds later than the 24 V. Switch it on simultaneously (before 2 seconds) or
after 4 seconds. Else fault 37 will trip the unit (see product note no 6).
• If the SWversion is 1.32 or older, the FCD could trip with alarm “high temp.” when the
drive is switch on out in an “under voltage”, wrong alarm massage. This fault is
corrected in SWversion 1.40. To correct this fault, if occur update the SW to 1.42 or
newer.
• Connector problem. Pins in the 36-pole multi connector plug could be damage doing
placing the electronic part on the installations box after a repair or service. (see product
note no. 7)
This problem could normal seen as a bus communication future, since the pin that is
most exposed are the bus connection to the control card. If the problems occur then
check the plug directly on the control card for damage. If the control card is damage
change the control card and the pin extension else only change the pin extension.

Service Manual FCD 300
Release 01/2003 15
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
11. Symptom / Causes chart
Symptom/Cause chart is generally directed towards the more experienced technician. The
intent of this chart is to provide a range of possible causes for a specific symptom. In doing
so, this chart provide a direction, but with limited instructions.
Symptom Possible Causes
LED “ON” is not light • Missing power line in
• Missing 24 V ext. supply
LED “Bus” is flashing • Bus communication error
• Bus address conflict – e.g. dual address
• Local operation or Local stop
LED “Status” is light • Corresponding to parameter setting. For further
information see design guide - parameter number 26
and DeviceNet manual for specific DeviceNet
signalling.
No LED light
• Incorrect or missing input voltage
• Incorrect or missing DC Bus voltage
• Remote control wiring loading the power supply
• Control card not connected right – check plugs
• Defective Control Card
• Defective Interface /ILD Card
• Defective Relay Card
Blown input line fuses (Shorted
Rectifier module) • Shorted IGBT
• Shorted DC Bus
• Shorted brake IGBT
• Mis-wired Dynamic Brake option
Motor operation unstable (Speed
Fluctuating) • Start compensation set too high
• Slip Compensation set too high
• Improper current feedback
• PID Regulator or Auxiliary Reference mis-adjusted
• Control signal noise
Motors draws high current but
cannot start.
(May appear to rock back and
forth)
• Start voltage too high
• Open winding in motor
• Open connection to motor
• One inverter phase missing. (Test output phase
balance.)
Motor runs unloaded but stalls
when loaded.
(Motor may run rough and VLT
may trip).
• Current Limit set too low
• One half of one inverter phase missing. (Test output
phase balance.)
Unbalanced input phase currents
NB:
Slight variations in phase
currents are normal.
Variations greater than 5%
require investigation
• Input line voltage
• Faulty connection on input wiring
• Fault in plant power transformer
• Input Rectifier module faulty (open diode).

Service Manual FCD 300
Release 01/2003 16
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
Unbalanced motor phase currents.
NB:
Slight variations in phase
currents are normal.
Variations greater than 5%
require investigation
• Open motor winding
• Faulty motor connection
• Fault in inverter section (see Symptom No.6.)

Service Manual FCD 300
Release 01/2003 17
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
12. Application or FCD fault
Measurement Possible fault Action
Supply voltage imbalance Missing a phase from the
supply or the supply could
have the imbalance or the
drives rectifier could be
defect.
Disconnect the drive and
measure the supply
imbalance again on the
supply lines (terminal 91, 92
and 93).
Supply voltage imbalance
without the FCD installed The supply causes the imbalance Check the supply system for imbalance, maybe from a
other drive
Supply voltage imbalance
with FCD installed The drives rectifier is obvious defect. No repair possibly. Change the electronic part.
Motor current imbalance,
but no motor voltage
imbalance
Normal not a drive fault, the
fault is obvious in the
cabling to the motor or in the
motor.
Check the motor cabling and
connections, and check the
motor for fault.
UDC ripple has not 300 Hz
(330Hz at 60 Hz power) The ripple is about 200 Hz then a input phase is possibly
missing
Check the supply for a
missing phase.
DC output voltage low
(5 V, 10 V and 24 V) Current limit reach or the drives SMSP is defect. Disconnect all connection to DC outputs.
If DC output then ok, find the
connection that getting the
drive to reach the current
limit.
If DC output still low with a
small current load, then
change the electronic part.
NB
This list is not fulfilled but gives some ideas to decide if the fault is cause by the
application or the drive.

Service Manual FCD 300
Release 01/2003 18
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
13. Test (measurement) on the FCD
NB
The terminals below reference to the pin on the electronic part that connect to the
terminal number on the installations part, when connected.
The DC bus is availably on Terminal 82 (+UDC) and through the left hole in the plastic (-
UDC).
NB
Static test should be done with a True RMS multimeter measurement. All
measurement is on the electronic part.
NB
When an open reading is shown, the multimeter may indicate a capacitor charging
effect.
NB
Diode drop (200-500 ohms or 0.3-0.7 Volts, depending on the type of measurement
being used).
WARNING: Before any measurement is done on the electronic part check the DC
bus voltage, to be sure that the DC bus is discharge.
Terminal
96 97 98
81
82
Terminal
91 92 93
122
123
-UDC
(hole)
+UDC

Service Manual FCD 300
Release 01/2003 19
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
13.1. Static test
Checking DC bus charge
(Multimeter in voltage
position)
Check the DC bus for remaining charge by measuring the
voltage on the DC terminals.
Measure between –UDC (hole) and +UDC (82).
The voltage must be less than 10 Volt.
Wait about 4 min. A resistor (200 ohm 50 W) could also be
connected to the –UDC and +UDC terminals, to decrease the
discharge time.
Static Test, Ground
separation
(Multimeter in ohm
position)
Measure from –UDC terminal (hole) and +UDC terminal (82)
to ground in turn.
Each resistance must be above 1 (one) Meg Ohm.
Measure L1 (91), L2 (92) and L3 (93) terminals to the ground
in turn.
Each resistance must be above 1 (one) Meg Ohm.
Measure W(98), V (97) and U (96) terminals to the ground in
turn.
Each resistance must be above 1 (one) Meg Ohm.
Measure between R+ (82) and –UDC terminal (hole) to the R-
(81) in turn.
Each resistance must be above 1 (one) Meg Ohm.
Static Test, Rectifiers
(Multimeter in check
diodes position)
Connect the positive (+) meter lead to –UDC terminal (hole).
Connect the negative (-) meter lead to L1 (91), L2 (92) and L3
(93) terminals in turn.
Each reading should show a diode drop.
*Reverse the meter leads
Connect the negative (-) meter lead to –UDC terminal (hole)
Connect the positive (+) meter lead to L1 (91), L2 (92) and L3
(93) terminals in turn.
Each reading should show open.
Connect the positive (+) meter lead to +UDC terminal (82).
Connect the negative (-) meter lead to L1 (91), L2 (92) and L3
(93) terminals in turn.
Each reading should show open.
*Reverse the meter leads
Connect the negative (-) meter lead to +UDC terminal (82)
Connect the positive (+) meter lead to L1 (91), L2 (92) and L3
(93) terminals in turn.
Each reading should show a diode drop.

Service Manual FCD 300
Release 01/2003 20
Revise 0
8
/
01
/200
3
by DD Service Manager, Stef
fen Sundbæk
Static Test, IGBT circuit
(Multimeter in check
diodes position)
Connect the positive (+) meter lead to –UDC terminal (hole).
Connect the negative (-) meter lead to W(98), V (97) and U
(96) terminals in turn.
Each reading should show a diode drop.
*Reverse the meter leads
Connect the negative (-) meter lead to –UDC terminal (hole).
Connect the positive (+) meter lead to W(98), V (97) and U
(96) terminals in turn.
Each reading should show open.
Connect the positive (+) meter lead to +UDC terminal (82).
Connect the negative (-) meter lead to W(98), V (97) and U
(96) terminals in turn.
Each reading should show open.
*Reverse the meter leads
Connect the negative (-) meter lead to +UDC terminal (82).
Connect the positive (+) meter lead to W(98), V (97) and U
(96) terminals in turn.
Each reading should show a diode drop.
Static Test, Brake IGBT
-- If availably --
(Multimeter in check
diodes position)
Connect the positive (+) meter lead to R- terminal (82).
Connect the negative (-) meter lead to R+ terminal (81).
The reading should show a diode drop.
*Reverse the meter leads
Connect the negative (-) meter lead to R- terminal (82).
Connect the positive (+) meter lead to R+ terminal (81).
The reading should show open.