1. Basic Troubleshooting FC 100/200/300

2. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 2 Main Session Topics Required Tools and Material Physical Inspection Basic Troubleshooting Logic Testing Procedures Diagnostic Information Available from the Drive

3. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 3 Touching the electrical parts of the VLT may be fatal. The largest models can require a significant amount of time to discharge it’s internal circuitry to a safe level after being disconnected from the incoming AC line power. Check Instruction Manual for further warnings. Warning

4. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 4

5. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 5 Required Reference Material Instruction Manual Service Manual Customer Connection Diagram

6. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 6 Required Tools Screwdrivers, Standard & Phillips Torx drivers T10 to T50 Metric socket set, 7 – 17 mm long extension (must be able to clear 20”) Torque wrench, 4 – 170 in./lbs. Magnet Nut starter

7. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 7 Required Equipment DVM PWM compatible voltmeter Clamp-on ammeter

8. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 8 Many Digital Meters will give erroneous readings due to PWM waveform. PWM Compatible Meter Use an Analog meter or Digital meter designed for PWM compatibility to measure output voltage.

9. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 9 Possibly Useful Tools 1000 Volt Megger Cell phone Laptop computer with Drive Software, RS-485 converter Oscilloscope

10. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 10 What Is Troubleshooting? Troubleshooting is nothing more than a logical approach to determine the answer to the question: Why is this SYSTEM not working?

11. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 11 The Logical Approach Assess The Situation Perform Physical Inspection Divide and Conquer Zero in on Malfunction

12. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 12 Physical Inspection Is the Display Lit? Warning or Alarm Message Displayed? Programmed Correctly?

13. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 13 Try a different setup Try downloading the parameters from the LCP Try downloading parameters from another drive in the same application Use MCT-10 to download the parameters Study them yourself E-mail them to the factory Is The Drive Programmed Correctly?

14. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 14 Physical Inspection Unit Installed Correctly? Are the connections tight? Environmental Conditions OK?

15. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 15 Physical Inspection Carbon Deposits Inside Drive? Burnt or Damaged Components? Blown Fuses? NOTE: Do not apply power to test the drive until Static Test has been performed!!!

16. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 16 If the Drive Blows Power Fuses Before plugging in another fuse...with power off, use the ohmmeter to check for input AND output shorts Line-to-bus and motor-to-bus, is desirable. Line-to-line if the bus connections aren’t readily available

17. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 17 Static Test Set the ohm meter on either the diode check scale or the 2K scale. Connect the + meter lead to the + DC Bus. Connect the – meter lead to L1, L2, L3 in turn. All readings should be open or capacitor charging effect.

18. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 18 Now reverse the ohm meter leads and repeat the process. The meter readings should be with in the range of 0.3 to 0.7 K ohms. Static Test

19. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 19 Repeat the process connecting the meter between the DC Bus and the output terminals. Similar reading should be obtained with these devices. Static Test

20. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 20 Drive Fault Indicators Drive fault displays and warnings Resetting alarms Sample alarms Alarm history

21. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 21 Drive fault displays and warnings What is the LCP’s display telling you? Alarms Warnings Status If you contact the factory, be sure to have the exact wording of the display!

22. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 22 Resetting Alarms TRIP (Red LED Flashing) TRIPLOCK (Red & Yellow LED’s On) Press the RESET key to restart Disconnect power to restart the drive

23. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 23 Warning / Alarm Messages ALARM 9 INVERTER TIME ALARM 10 MOTOR TIME WARNING/ALARM 12 CURRENT LIMIT Ensure drive is sized and programmed correctly Check for bad bearings Check motor parameters Check Para 1-90 Check mechanical load This is caused by motor overload conditions. Check motor parameters Check mechanical load Check Para 4-16 - 18

24. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 24 ALARM 13 OVER CURRENT ALARM 14 EARTH FAULT ALARM 16 CURR. SHORT CIRCUIT Drive has exceeded 200% current surge Check application for problems There is a short to ground in the motor or the motor wiring There is a line-to-line short circuit in the motor or the motor wiring Warning / Alarm Messages

25. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 25 Checking Current Sensors Disconnect Motor From Drive Observe Current In Display Current Should Be Zero >1 Amp Indicates Defective Current Sensor <1 Amp, Check Motor and Wiring

26. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 26 ALARM 29, 65, 66 DRIVE OVER TEMP. ALARM 30, 31, & 32 MISSING MOTOR PHASE U, V, W Is something (like an instruction manual) blocking the air flow? Check wiring between the drive and motor. This alarm doesn’t show up when the drive is starting Warning / Alarm Messages

27. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 27 ALARM 4 MAINS PHASE LOSS Measure the input voltage phase to phase while the motor is running at high speed Measure the input current in each phase Both should be balanced Warning / Alarm Messages

28. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 28 Alarm 7 DC Link Overvoltage Alarm 8 DC Link Undervoltage The DC Link Voltage is too high -Overhauling Load -High input voltage The DC Link Voltage is too low. Power outage Drive failure in the pre- charge circuit Warning / Alarm Messages

29. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 29 ALARM 2 LIVE ZERO ERROR ALARM 17 STD BUS TIMEOUT An input 4-20 mA or 2-10 V control signal is missing The connection to the serial communication port has been lost Warning / Alarm Messages

30. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 30 Warning 1 10 volt supply problem Alarm 15 Hardware Mismatch 10 Volt power supply is being over loaded. Reduce the load (min res 590ohm) Non-compatible Option Installed Warning / Alarm Messages

31. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 31 ALARM 50 - 58 AMA FAILURE ALARM 80 DRIVE INITIALIZED AMA procedure could not be carried out All parameters in the drive have been reset to their default values. Warning / Alarm Messages

32. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 32 Alarm Log Last 5 Alarms Previous 5 Available in Para. 15-3 Status Info for ea. Alarm Time, Value, Reference, Frequency, Current, Output Voltage, DC Voltage Graphic Displays

33. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 33 DIVIDE AND CONQUER 3 Phase AC Line Voltage Control Logic Motor

34. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 34 3 Phase AC Line Voltage Control Logic Motor Input Power

35. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 35 Checking Line Voltage Measure Phase to Phase AC Line Voltage L1 - L2 L1 - L3 L2 - L3 L1 L2 L3

36. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 36 Control Logic 3 Phase AC Line Voltage Control Logic Motor

37. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 37 Press “+” or “-” Keys, (or Set Parameter 0-23) to Display Digital Inputs Binary # Corresponding to Digital Inputs MSB = Term. 18 LSB = Term. 33 Digital Inputs

38. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 38 Digital Inputs If Input State is not Displayed Correctly, Measure Voltage at Terminal. Reference Meter on Terminal 20. Digital Inputs Must be 10-28VDC to be High (Logic 1)

39. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 39 Analog Inputs The Same Procedure can be Used to Check Analog Inputs

40. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 40 Analog Inputs Reference Meter (-) to Term. 55 + Lead to Term. 53 or 54 for Voltage 0-10VDC for Current 1-5VDC Observe Polarity

41. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 41 Output Circuit 3 Phase AC Line Voltage Control Logic Motor

42. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 42 Measuring Output Current

43. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 43 Drive 3 Phase AC Line Voltage Control Logic Motor

44. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 44 Measuring Output Voltage Motor

45. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 45 Drive or Motor? Voltage is Balanced But Current is not. Drive is Good Problem in Motor or Wiring Voltage is Unbalanced. Drive is Bad Not all IGBT’s Switching Correctly. Check Gate Signals

46. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 46 Before Calling the Factory, Be Able to: Describe the problem Exactly what does the LCP show? What does (or doesn’t) happen? When does the problem occur? What time of day? What is the drive doing at the time? What else is happening at the time? What have you tried?

47. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 47 Describe the problem Describe the drive Serial number MATERIAL # 178B0300 (PLUS) SERIAL # 805016H336(all of it!) Model number (FC202) Revision levels Parameter 15-43SOFTWARE VERSION Does the drive have bypass? Before Calling the Factory, Be Able to:

48. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 48 Describe the job site Call from the job site If they want a Service Station to look at the drive and the problem might be non-warranty then get a purchase order Before Calling the Factory, Be Able to:

49. | Confidential/Property of Danfoss Drives A/S | Sunday, 12 June 2016 | 49 This concludes this training module. Please proceed to the next installation module which covers applications in more detail. If you have any comments or questions, please contact: Technical Support Danfoss Drives 4401 N. Bell School Rd Loves Park, Illinois 61111 USA phone: (800) 432-6367 or (815) 639-8600