Danfoss VLT Decentral FCD 300, Service Manual

Page 1: ...Service Manual FCD 300 Release 01 2003 1 Revise 08 01 2003 by DD Service Manager Steffen Sundbæk Service Manual for FCD300 ...

Page 2: ... 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 accor...

Page 3: ...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 condit...

Page 4: ...change 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 t...

Page 5: ...l 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 ...

Page 6: ...iBus 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 ...

Page 7: ...e 01 2003 7 Revise 08 01 2003 by DD Service Manager Steffen 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 ...

Page 8: ...Service Manual FCD 300 Release 01 2003 8 Revise 08 01 2003 by DD Service Manager Steffen Sundbæk Service tool Ordering no 175N2404 LCP2 Ordering no 175N0131 ...

Page 9: ...ice Manual FCD 300 Release 01 2003 9 Revise 08 01 2003 by DD Service Manager Steffen Sundbæk LCP2 cable Ordering no 175N0162 LCP2 remote mounting kit Ordering no 175N0160 LCP2 plug kit Ordering no 175N2118 ...

Page 10: ...s 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...

Page 11: ...htening 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 ...

Page 12: ...FCD 300 Release 01 2003 12 Revise 08 01 2003 by DD Service Manager Steffen 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 ...

Page 13: ...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 ...

Page 14: ... 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 SW version is 1 32 or older the FCD could trip with alarm high temp when the drive is switch on out in an under voltage wro...

Page 15: ...ontrol 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 Auxiliar...

Page 16: ...003 by DD Service Manager Steffen 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 ...

Page 17: ... 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 mi...

Page 18: ...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...

Page 19: ...7 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...

Page 20: ...pen 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 di...

Page 21: ... Depend on the load but imbalance should be within 2 Supply current Current clamp and min 25 load Cable from Terminal 91 92 and 93 Depend on the load but imbalance should be within 5 Supply voltage RMS volt meter and min 25 load Between Terminal 91 92 and 93 380 to 480 V 10 and max imbalance 2 UDC voltage and ripple RMS volt meter and Scope and min 25 load Between Hole in plastic UDC and terminal ...

Page 22: ...Service Manual FCD 300 Release 01 2003 22 Revise 08 01 2003 by DD Service Manager Steffen Sundbæk ...

Page 23: ...low flashing Local operation or local stop Fast flashing Interface working but no communication with master see also field bus manual for more specific info not relevant for non field bus device 2 Bus Green On If bus option is present else Off Off Not OK status for the field bus used not relevant for non field bus device Off No alarm is present 3 Alarm Red Off Flashing Flashing while trip trip loc...

Page 24: ...cksum validation of calibration data stored in EEPROM Checksum validation of hardware and motor dependent parameters in EEPROM Flash check I O test If the extended test power up test fails the Drive will display one of the following error messages LCP2 fault number Internal fault number LED appearance 75 of the time LED appearance 25 of the time Fault source 37 0 No fault after Extended CC test or...

Page 25: ... female plug 36 pole 4 Dismount old control card and replace with new 3 screws TX 10 torque 1 5 Nm 5 Remount control card cover and flat band cables NB ProfiBus Control card When install a 12 MB ProfiBus Control card that should run 3 MB remember to change parameter 678 to 3 MB Else the GSD file in the PLC doesn t work NB Initialising of Control card When replacing the Control card with a new card...

Page 26: ...minal 55 24 V and 10 V ground Note 35 and 36 are galvanic isolated from control ground only functional not PELV 18 Power Connections Terminal Function Comment 91 L1 Main supply 92 L2 Main supply 93 L3 Main supply 122 Mbr Switched output negative 123 Mbr Positive output 96 U 97 V 98 W For motor connection with 6 wires out of the motor U1 V1 W1 U2 V2 W2 see design guide 81 Rb Brake resistor 82 Rb Br...

Page 27: ...z V A HP kW 303 3x380 480 1 2 3Ø 50 60 0 480 1 4 0 5 0 37 305 3x380 480 1 6 3Ø 50 60 0 480 1 8 0 75 0 50 307 3x380 480 1 9 3Ø 50 60 0 480 2 2 1 0 0 75 311 3x380 480 2 6 3Ø 50 60 0 480 3 0 1 5 1 1 315 3x380 480 3 2 3Ø 50 60 0 480 3 7 2 0 1 5 322 3x380 480 4 7 3Ø 50 60 0 480 5 2 3 0 2 2 330 3x380 480 6 1 3Ø 50 60 0 480 7 0 4 0 3 0 335 3x380 480 6 8 3Ø 50 60 0 480 7 6 5 0 3 3 Based on 380V line volta...

Page 28: ...urrent of nom Amb temp Deg C 100 50 40 Motor mount top 480V 4 5 kHz 0 37 0 55kW 40 36 1 1kW 0 75kW 50 80 45 1 5kW Output current of nom Amb temp Deg C 100 50 45 Wall mount 380V 4 5kHz 0 37 1 1kW 60 1 5kW Output current of nom Amb temp Deg C 100 50 40 Wall mount 480V 4 5 kHz 1 1kW 0 37 0 75 kW 50 45 1 5kW Data for FCD types not showed in diagram 2 2 kW equals with 1 1 kW 3 0 kW at 3 kHz equals with...

Page 29: ...ith satisfactory result This means that it is allowed to sell the units without any demands regarding specific type of pre fuse Regarding UL Circuit Breaker CTI25MB from Danfoss or similar should be used to full fill UL 19 3 Mechanical brake control and supply Gatedrive and protection 92 91 122 123 Output voltage 45 of the line voltage single rectified mains supply Max continuous output current 0 ...

Page 30: ...ription DC link voltage Inverter Over voltage Disable 820 V Inverter Over voltage Enable 805 V Voltage High Warning with Brake 800 V Brake Start 770 V Voltage High Warning Without Brake 765 V Inverter Under voltage Enable Inrush Enable 450 V Voltage Low Warning 440 V Inverter Under voltage Disable Inrush Disable 410 V Voltage trip times Time in over voltage before trip 5 or 15 times within 10ms Ti...

Page 31: ... Failure reporting All failures have to be reported to Danfoss Drives via Fault Registration Form or the WIIS fault registration system preferred Drives or parts exchanged within warranty must be stocked for 2 months and returned if further investigations on request from DD The WIIS is availably on the Danfoss Drives intranet 23 2 Complaint analyse report Use a Customer Complaint Report if additio...

Page 32: ...lease 01 2003 32 Revise 08 01 2003 by DD Service Manager Steffen Sundbæk 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 ...