Service Manual FCD 300

Service Manual for FCD300

Release 01/2003 1
Revise 08/01/2003 by DD Service Manager, Steffen Sundbæk
 Service Manual FCD 300

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 from the 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 from the installation.
2. The [STOP/RESET] key on the optional control panel does not disconnect the equipment from mains 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.

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 Service Manual FCD 300

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

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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:
Drives_Hotline@danfoss.com, 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.

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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

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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)

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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

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Service tool = Ordering no. 175N2404

LCP2 = Ordering no. 175N0131

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LCP2 cable = Ordering no. 175N0162

LCP2 remote mounting kit = Ordering no. 175N0160

LCP2 plug kit = Ordering no. 175N2118

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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

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 Service Manual FCD 300

8. Place, tightening torque and sequence for screws

Screw Torque Place / Tightening sequence

type
Inverter part TX20 3,0 Nm
M5x34
screws 6 4

1 2

3 5

Service M3x16 1,3 Nm

Switch screws

Earth- TX20 3,0 Nm

ground M4x12
connections screws

Plug and TX10 1,5 Nm

installations
print in
installations
box
LCP2 M16x1,5 3,0 Nm
connector

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 Service Manual FCD 300

FCD TX20 5,0 Nm

mounting on M5x16
motor. screws

Plast cover TX10 1,5 Nm

inverter part

Control card TX10 1,5 Nm

inside the
plastic cover

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9. Function diagram

Ext. Brake
Resistor

L1 U
R
L2
F V

L3
I W

temp.

Mech.
Brake Main
Control Power Basic Motor Control
Supply

Aux.
Ext.
24V
Power
Supply

Control Card
: functional w. ext. 24V power
LCP2
: safety isolation (PELV)
Std./Field Analog I/O Relay
RS 485 Digital inputs
: functional isolation Bus Digital output

FCD Functional Diagram

Ver. 1.02
M.Sachmann, B Pawlowski 001002

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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 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”, wrong alarm massage. This fault is
corrected in SW version 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.

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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 • Shorted IGBT
Rectifier module) • Shorted DC Bus
• Shorted brake IGBT
• Mis-wired Dynamic Brake option
Motor operation unstable (Speed • Start compensation set too high
Fluctuating) • Slip Compensation set too high
• Improper current feedback
• PID Regulator or Auxiliary Reference mis-adjusted
• Control signal noise
Motors draws high current but • Start voltage too high
cannot start. • Open winding in motor
(May appear to rock back and • Open connection to motor
forth) • One inverter phase missing. (Test output phase
balance.)
Motor runs unloaded but stalls • Current Limit set too low
when loaded. • One half of one inverter phase missing. (Test output
(Motor may run rough and VLT phase balance.)
may trip).
Unbalanced input phase currents • Input line voltage
NB: • Faulty connection on input wiring
Slight variations in phase • Fault in plant power transformer
currents are normal. • Input Rectifier module faulty (open diode).
Variations greater than 5%
require investigation

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Unbalanced motor phase currents. • Open motor winding

• Faulty motor connection
NB: • Fault in inverter section (see Symptom No.6.)
Slight variations in phase
currents are normal.
Variations greater than 5%
require investigation

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

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).

-UDC
(hole)
96 Terminal
97
98
81
82 +UDC

Terminal
122
123
91
92
93

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.

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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 Measure from –UDC terminal (hole) and +UDC terminal (82)
separation to ground in turn.
(Multimeter in ohm Each resistance must be above 1 (one) Meg Ohm.
position)
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 Connect the positive (+) meter lead to –UDC terminal (hole).
(Multimeter in check Connect the negative (-) meter lead to L1 (91), L2 (92) and L3
diodes position) (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.

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Static Test, IGBT circuit Connect the positive (+) meter lead to –UDC terminal (hole).
(Multimeter in check Connect the negative (-) meter lead to W (98), V (97) and U
diodes position) (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 Connect the positive (+) meter lead to R- terminal (82).
-- If availably -- Connect the negative (-) meter lead to R+ terminal (81).
(Multimeter in check The reading should show a diode drop.
diodes position)
*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.

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13.2. Dynamic test

WARNING: These measurement are done with main supply connected to the unit,
and therefore don’t touch anything without the right protection.

This test is possibly to do with the service tool (175N2404) connected between the
installations box and the electronic part.
Measurement Method Point Value
DC output 24 V RMS volt meter Between terminal 12 to 24 V DC
GND terminal 55
DC output 10 V RMS volt meter Between terminal 50 to 10 V DC
GND terminal 55
DC output 5V RMS volt meter Between terminal 67 to 5 V DC
(to BUS option) GND terminal 70
DC output 5 V RMS volt meter Between terminal V to 5 V DC
(to LCP option) GND terminal G
Motor current Current clamp and Cable from Terminal 96, Depend on the load, but
min. 25 % load 97 and 98. imbalance should be
within 2 %
Motor voltage Analog volt meter Between Terminal 96, 97 Depend on the load, but
and min. 25 % load and 98. imbalance should be
within 2 %
Supply current Current clamp and Cable from Terminal 91, Depend on the load, but
min. 25 % load 92 and 93. imbalance should be
within 5 %
Supply voltage RMS volt meter and Between Terminal 91, 92 380 to 480 V ± 10 % and
min. 25 % load and 93. max. imbalance 2%
UDC voltage and RMS volt meter and Between Hole in plastic 450 to 765 V and ripple
ripple Scope and min. 25 % (-UDC) and terminal 82 300 Hz and under 1%
load (+UDC)
Analog and RMS meter Terminal 12 to 50. Depend how the I/O is
digital I/O set-up by the parameter
Relay option RMS meter (volt or Terminal 01, 02 and 03. OFF (inactive): terminal
ohm) 01 and 03 are shorted.
ON (Active): terminal 01
and 02 are shorted
Break control RMS volt meter Terminal 81 and 82. UDC bus voltage when
signals output - active. Normal about 770
dynamics V on first switch on
Break control RMS volt meter Terminal 122 and 123. 0,45 * supply voltage
signals output - when active else 0 V.
mechanist WARRING:
DIRECT
CONNECTION
TO SUPPLY LINES
DC input 24 V RMS volt meter Between terminal 36(+) 24 V DC
from ext. supply to terminal 35 (-)
(if connected)
NB: See terminal function in chapter “Control inputs / outputs”

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14. LED indications

No. Name Colour OK status Alternatives Function
1 Status Yellow Off Off Status is OK of the FCD
On Corresponding to parameter setting. For further
information see design guide - parameter number 26 and
DeviceNet manual for specific DeviceNet signalling.
2 Bus Green On On OK status for the field bus used
(If bus (not relevant for non field bus device)
option is Slow flashing Local operation or local stop
present, else
Off) 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)
Off Not OK status for the field bus used
(not relevant for non field bus device)
3 Alarm Red Off Off No alarm is present
Flashing Flashing while trip/trip lock is present
4 Warning Yellow Off Off No warring is present
Flashing Flashing while warning situation is present
5 On Green On On The unit is powered from either line in or 24V DC
Off Power to the unit is missing from either line in or 24V
DC

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15. Power up test / Control card test

The diagnosis of the Drive consists of two tests:

Power up test
Extended CC test

The Power up test is carried out every time the Drive is powered up and consists of:
Checksum validation of calibration data stored in EEPROM
Checksum validation of hardware and motor dependent parameters in EEPROM

The extended power card test can be activated via the parameter 620 and consist of:
Checksum 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 Internal LED LED Fault source

fault fault appearance appearance
number number 75% of the 25% of the
time time
37 0 □□□□■ ■■■■■ No fault after Extended CC test or
Communication fault between CC and BMC2
38 1 □□□■■ ■■■□■ FLASH fault
39 2 □□■□■ ■■□■■ RAM fault
40 3 □□■■■ ■■□□■ Calibration constants area of CC EEPROM fault
41 4 □■□□■ ■□■■■ Information constants area of CC EEPROM fault
42 5 □■□■■ ■□■□■ Motor control area of CC EEPROM fault
43 6 □■■□■ ■□□■■ Entire area of BMC2 EEPROM fault
44 7 □■■■■ ■□□□■ Minimum SW version fault
45 8 ■□□□■ □■■■■ Input /output test failed

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16. Replacement of control card

NB
Remember to use ESD protection when changing the Control card

1 Remove flat band cables from control card

2 Dismount control card cover (5 screws pos 1, TX 10, torque 1,5 Nm)
3 Mount board stacker (included) into 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

1 2 1

2 2 3
4 4

2 2 4

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, the card initialises it self to the
right motor power. This doesn’t happen if using a Control card that have been used.

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17. Control Connections

Note: 31A is internally connected to terminal 50 (+10V)

Note: G is internally connected to terminal 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 For motor connection with 6 wires

97 V out of the motor (U1, V1, W1,
98 W U2, V2, W2) see design guide
81 Rb- Brake resistor
82 Rb+ Brake resistor

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19. Useful Data (supplement to the design guide)

Main electrical data.

Model Input Full load # Input Output Full load Power Power
voltage input Phase frequency voltage output
current current
[V AC] [A] * [Hz] [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 voltage, except FCD335 that is at 460V line.
**) Perhaps a new drive size. Approximate power at 400V line.

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 Service Manual FCD 300

19.1. Thermal conditions / derating

Motor mount, top 380V, 4,5

kHz.
Motor mount, top 480V,
4,5 kHz. 0,37 - 0,55kW
1,5kW 0,37 - 0,75 kW
Output current, % of nom.

Output current, % of nom.

1,1kW
1,5kW 1,1kW 0,75kW
100% 100%

80%

60%
50% 50%
40%

40 45 50 36 40 45 50

Amb. temp. Deg. C. Amb. temp. Deg. C.

Wall mount, 380V, 4,5kHz.

Wall mount, 480V, 4,5 kHz.

0,37 - 1,1kW 0,37 - 0,75 kW

Output current, % of nom.
Output current, % of nom.

1,5kW 1,5kW
1,1kW

100% 100%

60%
50%

45 50 40 45 50

Amb. temp. Deg. C. Amb. temp. Deg. C.

Data for FCD types not showed in diagram .

• 2,2 kW equals with 1,1 kW

• 3,0 kW at 3 kHz equals with 1,5 kW at 4,5 kHz

• 3,3 kW 2 deg C lower than 3.0 kW

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 Service Manual FCD 300

19.2. AC mains Voltage Compatibility

The units are designed to operate under applicable NEC standards (Star and Delta
connections), also on IT, TT, TN-S, TN-C-S, and TN-C ACe mains (the different AC mains
are described in VDE 0100).

The units are designed to observe UL 508C by recommending using fuses similar to
Bussmann KTS-R.
NB: Test with “Branch Circuit Fuses” has been performed on FCD 330, with 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

92 122

123

Gatedrive
and
protection

91

Output voltage: 45% of the line voltage (single rectified mains supply).
Max. continuous output current: 0,8 A.
Overload protection level: approx. 1,4 A.
Max. switching frequency: depending on brake size, see below.

WARNING: the circuit is only protected against overload or short circuit between
the terminals. It is NOT protected against overload or short circuit from any of the
terminals to earth.

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 Service Manual FCD 300

19.4. Digital outputs

Digital output have PNP open collector output static signal, totem pole for pulse signals.
Digital output current is max. 25 mA continuous and 50 mA for short time, 13 ms.
The output is short circuit protected and protected against voltage transients caused by
inductive loads.
If the digital output is overloaded, it will be turned off after 13 ms and once a second the
output will be activated again.

19.5. LCP cable length

Max. distance between LCP2 and FCD300: 3 m.

20. Voltage level overview

Voltage level description (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
Time in under voltage before trip 2,5 sec

21. Current levels

Current level description

Short circuit (and earth short circuit fault) 260% Inom
Time in short circuit before trip (inverter disable) 5 – 8 µs

Over current (hardware) 210% Inom

Time in over current before trip 2 – 4 sec

Earth fault 4 –5 A
Time in earth fault before trip (inverter disable) 5 – 8 µs

Software current limit 160% Inom

Time in software current limit before trip 60 sec

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 Service Manual FCD 300

22. Help and support contact

To help to solve problems or information to find a cause for the problem, the followed
places could be used:

• Local Hotline at the local Danfoss company in your country

• Danfoss Drive FAQ database – could be found on the Danfoss Drives intranet
• DD Global Hotline – Hotline Request From can be found on the Danfoss Drives
intranet, for emergency cases phone +45 7488 6100 or Drives_Hotline@danfoss.com
can be used.

23. Failure reporting and complaint/analyse report

23.1. 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 additional information about the fault reason on the
drive or if a analyse about reason for fault if the reason is unknown.

The FCD should be send to Danfoss Graasten “complain and analyse department” for
analyse together with the Customer Complaint Report.

If a possibly product fault has been observed please contact the DD Global Hotline or
“complain and analyse department” as soon as possibly.

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 Service Manual FCD 300

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.

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