Danfoss VLT CDS 302 Instrucciones de funcionamiento

Compressor Drives

Troubleshooting Check List

CDS 302/CDS 303

http://cc.danfoss.com

Introduction.........................................................................................................................................4

For Your Safety.....................................................................................................................................5

Diagnostics...........................................................................................................................................6

Initial Trouble Shooting (visual inspection of the installation) .......................................................7

Input power wiring................................................................................................................................................................................... 7

Output to motor ........................................................................................................................................................................................ 7

Grounding.................................................................................................................................................................................................... 7

Control wiring............................................................................................................................................................................................. 7

Programming.............................................................................................................................................................................................. 7

Compressor Motor.................................................................................................................................................................................... 7

Cable routing .............................................................................................................................................................................................. 7

Peripheral equipment (sensors, contactors, etc)............................................................................................................................ 7

Trip on over Temperature....................................................................................................................................................................... 7

Drive interior ............................................................................................................................................................................................... 7

EMC Precautions........................................................................................................................................................................................ 7

Vibration ....................................................................................................................................................................................................... 7

Environmental conditions...................................................................................................................................................................... 7

Proper clearance ........................................................................................................................................................................................ 7

Trouble shooting ................................................................................................................................8

Fault Symptoms - Display of the drive .............................................................................................................................................. 8

No display (blank display) ...................................................................................................................................................................... 8

Intermittent display.................................................................................................................................................................................. 8

Fault Symptoms in the compressor (motor).................................................................................................................................... 9

Common drives and motor problems..............................................................................................11

Control logic problems..........................................................................................................................................................................11

Programming problems........................................................................................................................................................................11

IGBT, Motor or load problems ............................................................................................................................................................12

Procedure to conduct the dynamic test to check the IGBT .....................................................................................................12

Faults in the drive ....................................................................................................................................................................................12

EMC - Electro Magnetic Compatibility.............................................................................................................................................13

Static test procedures .......................................................................................................................14

Rectier test (static) ................................................................................................................................................................................14

IGBT static test..........................................................................................................................................................................................15

Content

3FRCC.PC.036.A2.02

Check List

Introduction

Many frequency converters that are sent back

to Danfoss every year for factory analysis

are diagnosed with No Fault Found (NFF).

Establishing whether a frequency converter is

faulty or not prior returning it to the factory can

increase the uptime of the compressor solution,

reduce the unnecessary use of resources and

limit the number of NFF.

The purpose of this check list is to facilitate

users, eld technicians, engineers and service

personnel working with Danfoss frequency

converters to identify faults and perform a

rst diagnosis on the drive before sending it to

inspection and analysis.

PERFORM THE FOLLOWING FAULT DIAGNOSIS

BEFORE RETURNING A FREQUENCY CONVERTER FOR

FACTORY INSPECTION.

CHECK ALL POSSIBILITIES.

IN CASE OF DOUBT, PLEASE SEEK DANFOSS SUPPORT.

4FRCC.PC.036.A2.02

Check List

For Your Safety

Figure 1: Drive must be

turned OFF for 20min before

repair can start

Frequency Converters (FC) contain dangerous

voltages when connected to the line voltage.

Only a competent technician should carry out

the service.

Some instructions should be compulsorily

followed to ensure safety while working with the

FC.

• Do not touch electrical parts of the FC when the

AC line is connected.

• Frequency converters contain DC-link capacitors

that can remain charged even when the

frequency converter is not powered. To avoid

electrical hazards, disconnect AC mains, any

permanent magnet type motors, and any

remote DC-link power supplies, including

battery backups, UPS and DC-link connections

to other frequency converters.

• Wait for at least 20 minutes before touching any

of the components.

• When repair or inspection is done, the AC line

must be disconnected.

• The STOP key on the control panel does not

disconnect the AC line.

• During operation and programming of the

parameters, the motor may start without

warning. So you have to activate the STOP key

when changing data.

5FRCC.PC.036.A2.02

Check List

Diagnostics

Fault detection via LCP: messages are displayed

when the frequency converter fault circuit

detects a faulty condition or an unresolved fault.

A warning light ashing display indicates

potential problems.

There are two levels of alarms; Reset Alarms and

Trip-lock Alarms.

a) In case of reset alarm: you can stop and then

start the unit.

b) In case of trip-lock alarm, you have to

disconnect the mains, wait for dark display,

then stop and start.

Figure 2: WARNINGS

and ALARM messages

are displayed when the

frequency converter fault

detects a faulty condition

WARNINGS and ALARM

Alarm Log Check the content of the alarm log.

5 latest alarms are available through the “Alarm

Log” button key on the LCP.

Check the alarm code and refer to the

troubleshooting session of the Operating

Instructions VLT® CDS 302 and CDS 303 on page

135. It contains guidance for the complete list

of alarms and warnings.

If the troubleshooting suggested does not

resolve the problem, please contact Danfoss for

support.

Do not exchange the drive before contacting

Danfoss support.

6FRCC.PC.036.A2.02

Check List

Initial Trouble Shooting (visual inspection of the installation)

This list shows a variety of conditions that

should be inspected visually as a part of initial

troubleshooting.

Display: Warnings, alarms, drive status; fault

history and many other items are available on the

local control panel of the drive.

Check for loose connections. Check for proper fusing. Check for blown fuses.

Avoid routing motor wiring. AC line wiring and

signal wiring in parallel. If parallel routing is

unavailable, try to maintain a separation of 15-

20cm between the cables or separate them with

a grounded conductive partition. Avoid routing

cables through free air.

Look for peripheral equipment such as switches

or input fuses circuit breakers that may be in the

input power side of the drive or output side of

the motor. Examine operation and condition of

these items as possible causes for operational

faults. Check function and installation of pressure

sensors or temperature sensors etc. used for

feedback to the drive.

Check the operational status of all cooling fans.

Check for blockage or constrained air passages.

Drive interior must be free of dirt, metal, chips,

moisture and corrosion. Check for burnt or

damaged power components or carbon deposits

that were the result of a disastrous component

failure. Check for cracks or breaks in the housing

of the power semiconductors or pieces of broken

components housing loose inside the unit.

Check for proper installation with regards to

electromagnetic capability. Refer to the CDS

manual, in the chapter“How to install” and then

“ Electrical Installation – EMC Protection“ for

further details.

Look for unusual amounts of vibration to which

the drive may be subject. The drive should be

mounted solidly or the use of shock mounts

employed.

Under specic conditions these units can

be operated within a maximum ambient

temperature of 50°C (24h average maximum

45 °C). Humidity level must be less than 95%

non-condensing. Check for harmful airborne

contaminates such as sulphur based compounds.

These drives require a top and bottom clearance

of 10cm to ensure proper airow for cooling.

Drives with exposed heat sinks out the back of

the drive must be mounted on a at solid surface.

Check for loose connections. Check for switching

components in the output circuit. Check for

faulty contacts in the switch gear.

The drive requires a dedicated ground wire

from its chassis to the building ground. It is also

suggested that the motor be grounded to the

drive chassis. The use of conduit or mounting

of the drive to a metal surface is not considered

a suitable ground. Check for good grounding

connections that are tight and free of oxidation.

Check for broken or damaged wires and

connections. Check the voltage source of the

signals. Though not always necessary depending

on the installation condition, the use of shield

cable or a twisted pair is recommended. Ensure

the shield is terminated correctly.

Check that the drive parameter settings are

correct according to the motor, application and

I/O conguration.

Check nameplate of the Compressor. Ensure the

compressor matches the drive. Check that drive’s

compressor par. 1-13 is set according to the

compressor e.g.:

Input power wiring

Cable routing

Peripheral equipment

(sensors, contactors, etc)

Trip on over Temperature

Drive interior

EMC Precautions

Vibration

Environmental conditions

Proper clearance

Output to motor

Grounding

Control wiring

Programming

Compressor Motor

ID Name Setup 1 Factory Setup Unit

113 Compressor Selection VZH117-R410A VZH117-R410A

7FRCC.PC.036.A2.02

Check List

Trouble shooting

Fault Symptoms - Display

of the drive

No display (blank display)

Intermittent display

A fault must have been ocurred when there is:

a) No Display in the LCP (blank)

b) Intermittent display in the LCP

There are three LED indicators lights near the

bottom of the LCP.

If the green power on LED is illuminated but the

backlit display is dark, this indicates that the LCP

itself is defective and must be replaced.

It should be certain that the display is completely

dark. An error code exists in the drive which

indicates that communications may have failed

with the control card.

This is typically seen when an option card has

been installed in the drive and is either not

connected properly or is malfunctioning.

• If neither indication is available, then the

source of the problem may be elsewhere.

Cutting out or ashing of the entire display and

power LED indicates that the power supply

(SMPS) is shutting down as a result of being

overloaded.

This may be due to improper control wiring or a

fault within the drive itself.

Figure 3: No Display in the

LCP (blank)

Figure 4: intermittent

display

8FRCC.PC.036.A2.02

Check List

Trouble shooting

Figure 5: Check control

cables

Figure 6: Disconnect all

control wiring

• The rst step is to rule out the problem in the control wiring.

• Disconnect all control wiring by unplugging the

control terminal blocks from the control card.

• If the display stays lit then the problem is in the

control wiring.

All control wiring should be checked for shorts

or incorrect connections.

• If the display continues to cut out, the fault

can be located in either the LCP itself or on

the Power card.

• First verify that the unit is properly powered up

and there is no warning or alarm .

• The most common cause of this is either

incorrect control logic or an incorrectly

programmed drive.

Such occurrences will result in one or more of the

following status messages being displayed:

The LCP stop message is displayed when the OFF

key has been pressed.

The bottom section of the display will also be

ashing when this occurs.

The stand by message is displayed when there is

no start signal at terminal 18.

Ensure that a start command is present at

terminal 18.

Fault Symptoms in the

compressor (motor):

Motor will not run

LCP Stop

Stand by (gure 8)

Figure 7: LCP stop = OFF key

pressed

9FRCC.PC.036.A2.02

Check List

Trouble shooting

Message displayed when the Terminal 27 is low

(no signal).

Ensure that terminal 27 is logic 1 (pressure

switch).

The RUN OK status display indicates that a run

command has been given to the drive but the

reference (speed command) is zero or missing.

Check the control wiring to ensure that a

proper reference signal is present at the drive

input terminals and that the unit is properly

programmed to accept the signal provided.

Improperly connected wiring or interrupted

wiring is a common service issue for a motor

not operating or the drive not responding to a

remote input.

Stop (gure 9)

Run OK: 25Hz

Quick tip:

Figure 9: Check pressure

switch

10 FRCC.PC.036.A2.02

Check List

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