mv7000_user_manual_section5_protection_4mkg0015_rev_c[1].pdf

Customer :MV7000 MEDIUM VOLTAGE DRIVE RANGE

Ref : 4MKG0015

Project : USER MANUAL

Version Ind-Work : C

Document :SECTION 5: PROTECTION AND DIAGNOSTICS

Date : 01 Sept 07

File :MV7000 User Manual Section 5_Protection_4MKG0015_rev C

Page : 5-1/44 2007 CONVERTEAM For Support and comments contact [email protected]

This document is the exclusive property of CONVERTEAM and cannot be reproduced, transmitted or disclosed without prior authorisation.

MV7000 MEDIUM VOLTAGE DRIVE RANGE

USER MANUAL

SECTION 5: PROTECTION AND DIAGNOSTICS

AUTHORISED FOR ISSUE BY : Samir Soua

C 01 Sept 07 EA THUFAIL System Updation

B 07 Dec 06 EA THUFAIL Updated after users feedback

A 10/02/2006 EA THUFAIL Initial issue Version Date Author Reason for new issue (see last pages for modification record)


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CONTENTS

FOREWORD .................................................................................................................................. 3

SECURITY WARNING ................................................................................................................... 3

5. PROTECTION AND DIAGNOSTICS....................................................................................... 3

5.1 INTRODUCTION.............................................................................................................. 4 5.2 PROTECTION.................................................................................................................. 5 5.3 DIAGNOSTICS................................................................................................................. 7 5.3.1 Drive Status Indicators ............................................................................................... 7 5.3.2 Keypad Menu 3 - Fault Menu ..................................................................................... 8 5.3.3 Keypad Menu 4 - Alarm Menu.................................................................................. 21 5.3.4 Important fault causes based on standard functionalities of MV7000 ....................... 25 5.3.5 PIB100 Controller board Indicators .......................................................................... 28 5.3.6 Gate Driver Indicators .............................................................................................. 29 5.3.7 Fault Finding Guide.................................................................................................. 33

LIMITATION OF LIABILITY ......................................................................................................... 43

MODIFICATION RECORD ........................................................................................................... 44

TABLE OF ILLUSTRATIONS

Figure 5- 1 MV 7000 (STDA) Protection Single Line Diagram................................................................................5 Figure 5- 2 Gate Driver Board ...............................................................................................................................29 Figure 5- 3 LED Indicators for Gate Driver/IGBT Failure Diagnostic ....................................................................29 Figure 5- 4 Gate Driver Fault Reset ......................................................................................................................32

Table 5- 1 MV 7000 Protection features with ANSI code ........................................................................................6 Table 5- 2 Standard Fault list ..................................................................................................................................9 Table 5- 3 Standard Alarm List..............................................................................................................................21


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FOREWORD

The following signs will require reader attention in this manual.

SECURITY WARNING

Users shall read safety instructions available in Section 1 of User manual.

5. PROTECTION AND DIAGNOSTICS

This document is the Section 5 of MV7000 User manual, which is made of 6 Sections.

Note:

Notes separate important information from the text and give

additional information.

Important!

Important means that the relevant instruction must be

followed exactly to avoid loss of data or damage.

Warning!

Warning means that the operator may be injured if the

instructions are not followed.

SECTION 2: Technical Data

SECTION 3:

Installation

SECTION 4: Operating Instructions

SECTION 5: Protection & Diagnostic

SECTION 6: Maintenance & Safety

SECTION 1: Introduction


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5.1 INTRODUCTION

The Section 5 comprises the details concerning Protection and Diagnostics. This includes

MV 7000 Drive system Protection

Diagnostics with Drive Indicators, Keypad - Fault Menu & Alarm Menu, PIB Controller board indicators and Gate driver Indicators and the fault finding guide

In general MV 7000 Drive systems with all its auxiliaries are available in three different configurations in terms of protection and diagnosis categorization.

Standalone (STDA)

STDA is the configuration with Diode Bridge for DC link voltage generation from the supply network and controlled IGBT Inverter block for generation of motor output from DC link. The Diode Bridge and the Inverter units are dedicated to each other with a single sequential task involving both units. A PEC controller controls this common task as well as regulation of the Inverter block. Hence the system works as a standalone drive.

For the selected STDA, the standard and generic features of protection and diagnostics are either common features of all MV7000 architecture or features specific to STDA standards, handled by the generic section of the control.

For specific applications, Standalone inverter can be consisted of two parallel inverter stacks with common DC link controlled with single controller based on Master-Slave arrangement.

Active Front End (AFE)

AFE is the configuration with controlled IGBT inverters for DC link voltage generation from the supply network. AFE has unique controls for regulation and separate start/stop sub sequence tasks apart from the common main sequence in the PEC controller.

For high power applications, 2 AFE inverters are used in parallel outputs connected to a common DC bus and common neutral for the DC link. This configuration is termed as Parallel AFE Configuration.

Machine Bridge (MB)

MB is the Configuration with controlled IGBT inverters for motor output voltage generation from a connected DC link voltage input. MB has unique controls for its regulation as Inverter for the machine model and also separate start/stop sequence tasks apart from the common main sequence in the PEC controller.

For specific applications, two 2 MB inverters can be in parallel configuration.

Parallel inverters

As mentioned in the above paragraphs, each of the above configurations has parallel configurations that will have specific protection and diagnostic features.

The specific features, faults and Alarms corresponding to one configuration are shown in the menu tables indicating the configuration for which it is used. Note that the 3 configurations described above can also be in customized form to suit to specific applications with add-on features.


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5.2 PROTECTION

A general layout of single line diagram for the protection scheme of an example for MV 7000 Standalone configuration is shown in Figure 5- 1. The protection features shown in this single line diagram are represented as ANSI standard codes listed in Table 5- 1.

Figure 5- 1 MV 7000 (STDA) Protection Single Line Diagram

V

V

A

27

99F 50G 59

60 50

48

50

48 52F

3

Gate Driver

34F

59

50

27

27X

M

80W

26W

21W

63W

Emergency Stop

External Fault

86E

PEC

CONTROLLER

Cooling Unit

34F

V


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Table 5- 1 MV 7000 Protection features with ANSI code

Protection feature ANSI Code

Circuit Breaker / Contactor interlocking 3 Water conductivity 21W Water temperature 26W Under voltage 27 Auxiliary Under voltage 27X Programming Device Fault 34F Incomplete Sequence 48 Over current 50 Ground Fault 50G CB Fault 52F Over voltage 59 Voltage unbalance 60 Water pressure 63W Water flow 80W Emergency Stop 86E IGBT/Gate Driver Fault 99F

The features listed above are the common protection features for MV 7000 Drives. Additional features are incorporated, depending on the configuration or application or process requirement. Please refer to the project specific documents for details and additional features.


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5.3 DIAGNOSTICS

5.3.1 Drive Status Indicators

The four LED indicators on the Drive Data ManagerTM Keypad give a first indication of drive status.

The DDMTM Keypad indicators are shown in Section 4.

Turning ON the ALARM or FAULT indicator and Turning OFF the READY and RUNNING indicators indicate a Fault condition.

5.3.1.1 Alarm

If the ALARM indicator LED is ON, indicates a fault/Warning has occurred which may not be a serious condition to trip the drive. For important safeties, alarms often come as precondition to faults from lower threshold detection lesser than the fault limit. The parameterization allows No presence of alarms as a precondition to start the drive for the first start up.

Note 1 Alarms are latched (memorized). To clear an alarm, the drive RESET function is to be used. A RESET can be achieved while the drive is running by either toggling the status of

parameter P0.06 (RESET) from the DDMTM keypad, or pressing alternatively & keys, or

using remote RESET (refer to specific project documentation for remote RESET details). The RESET will be effective only when the Alarm/Fault condition does not persists at the time of Resetting.

Note 2 The drive will be prevented from starting until all Alarms have been cleared using the RESET function (optional parameterization)

Note 3 Some of the alarms are also categorized with automatic reset upon the loss of alarm condition, which is a prerequisite for some functions.

5.3.1.2 Fault

If the FAULT indicator LED is ON, indicates a fault has occurred which causes the drive to shut down. The first Fault or Alarm time is stored and displayed on the 3

rd line of Menus 3 & 4.

Note: Faults are latched (memorized) and must be cleared before the drive can be operated again. Carrying out a RESET as described in Note 1 above will clear faults. The RESET will be effective only when the Fault condition does not persists at the time of Resetting.


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5.3.2 Keypad Menu 3 - Fault Menu

Refer to User manual section 4 for Menu 3 navigation details. For each ANSI function number, probable causes of the fault and action to be carried out are given in the Fault Finding Guide (section 5.3.7).

The representation of the cells with different types of characters is shown below indicating the type of action on occurrence of the corresponding fault.

Fault parameter of type TRIP (default and not modifiable for

any Drive System)

Fault parameter of type STOP (Normal Stop) condition

(default and not modifiable for any Drive System)

Parameter of OPTIONAL Usage (used if the corresponding

function is available for the drive system)

Fault Parameter of type TRIP, which is OPTIONAL

depending on the Drive system used/application

Fault Parameter of type STOP, which is OPTIONAL


Fault Parameter of type TRIP by default, which can also

be configured as type STOP or an ALARM Parameter

Fault Parameter of type STOP by default, which can also

be configured as type TRIP or an ALARM Parameter

If a parameter has any of the two conditions true then, the parameter will be shown splitting the cell corresponding to the parameter in to two.

Example: P3.011 is shown for STDA and AFE as

This means that Parameter 3.011 is Optional, by default the fault action is Stop (Normal) and it can be changed to different action like Trip or different menu like Alarm whichever is Project specific.

T

S

O

T (O)

S (O)

T (S/A)

S (T/A)

O

S (T/A)


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Parameter NOT USED

The three basic drive system configurations for MV 7000 are columned to show how one Parameter influences each of these configurations and the type of fault action for each configuration.

The three basic configurations are STDA Standalone configuration.

MB Machine Bridge Configuration

AFE Active Front End

5.3.2.1 Fault List for MV7000 standard functionalities

Table 5- 2 Standard Fault list

FAULT ACTION TYPE Parameter Keypad Display

STDA AFE MB Comments

ANSI

CODE

P3.001 CB Trip Inten FT T T -- Main CB trip Intention 52F

P3.002 Ext Emergency

Stop T T T

External Emergency fault either hardware wiring or remote CS.

86E/ RE

P3.003 Main CB Flt T T T Main CB position not in accordance with the command

48

P3.004 Ground switch Flt T T T

Ground switch not in accordance with main CB and Pre-charge

command.

57F

P3.005 PreChrg Cont 1 FT T T --

Pre-charge contactor 1 error, not in

accordance with command

48

P3.006 PreChrg Cont 2 FT T T --

Pre-charge contactor 2 error, not in

accordance with command

48

P3.007 Insulation FT T T T Insulation/Earth fault

in the drive 50G

P3.008 DC Link too low FT T T T DC link Under voltage 27

P3.009 DC Link over volt

FT T T T DC link Over voltage 59

P3.010 DC Link Unbalance

FT T T T

DC Link voltage unbalance

60

O O P3.011

Chopper Temp FT

S (T/A)

--

S (T/A)

Breaking chopper Over Temperature

73F

--


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ANSI

CODE

P3.012 Keypad Link Flt T T T Keypad Link Fault 34F

P3.013 Quick Dis Relay FT O O O High discharge rate limit exceeded

57

P3.014 Inverter Thermal

FT O O O Inverter Thermal fault 73F

P3.015 Speed Sensor Flt T(O) -- T(O) Encoder Fault 34F

P3.015 to

P3.018 Reserve Reserve

P3.019 PWM Pattern FT T(O) T(O) T(O)

Fault for Synchronous PWM discordance for high speed application

34F

P3.020 to


P3.025 Ground Switch #2 FT T T T

Ground switch not in accordance with main CB and Pre-charge

command.

57F

P3.026 DCvolt#1-2 DiscordFT T T T

DC bus measurement discordance between the parallel inverters

57F

P3.027 Current#1-2 Unbal FT T T T

Current measurement discordance between the parallel inverters

52F

P3.028 DClink#2 Unbalanc FT T T T

DC volt: unbalance in the 2

nd inverter of

parallel configuration

52F

P3.033 IGBT 1 U2+ FAULT T T T IGBT 1 U2+ FAULT 90F

P3.034 IGBT 1 U1+ FAULT T T T IGBT 1 U1+ FAULT 90F

P3.035 IGBT 1 U2- FAULT T T T IGBT 1 U2- FAULT 90F

P3.036 IGBT 1 U1- FAULT T T T IGBT 1 U1- FAULT 90F

P3.037 IGBT 1 V2+ FAULT T T T IGBT 1 V2+ FAULT 90F

P3.038 IGBT 1 V1+ FAULT T T T IGBT 1 V1+ FAULT 90F

P3.039 IGBT 1 V2- FAULT T T T IGBT 1 V2- FAULT 90F

P3.040 IGBT 1 V1- FAULT T T T IGBT 1 V1- FAULT 90F

P3.041 IGBT 1W2+ FAULT T T T IGBT 1W2+ FAULT 90F

P3.042 IGBT 1W1+ FAULT T T T IGBT 1W1+ FAULT 90F

P3.043 IGBT 1W2- FAULT T T T IGBT 1W2- FAULT 90F

P3.044 IGBT 1W1- FAULT T T T IGBT 1W1- FAULT 90F

P3.045 IGBT 1H+ FAULT T T T` IGBT 1H+ FAULT 90F


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ANSI

CODE

P3.046 IGBT 1H- FAULT T T T IGBT 1H- FAULT 90F

P3.047 To

P3.048 Reserve

Reserve

P3.049 IGBT 2 U2+ FAULT T (O) T (O) T (O) IGBT 2 U2+ FAULT 90F

P3.050 IGBT 2 U1+ FAULT T (O) T (O) T (O) IGBT 2 U1+ FAULT 90F

P3.051 IGBT 2 U2- FAULT T (O) T (O) T (O) IGBT 2 U2- FAULT 90F

P3.052 IGBT 2 U1- FAULT T (O) T (O) T (O) IGBT 2 U1- FAULT 90F

P3.053 IGBT 2 V2+ FAULT T (O) T (O) T (O) IGBT 2 V2+ FAULT 90F

P3.054 IGBT 2 V1+ FAULT T (O) T (O) T (O) IGBT 2 V1+ FAULT 90F

P3.055 IGBT 2 V2- FAULT T (O) T (O) T (O) IGBT 2 V2- FAULT 90F

P3.056 IGBT 2 V1- FAULT T (O) T (O) T (O) IGBT 2 V1- FAULT 90F

P3.057 IGBT 2W2+ FAULT T (O) T (O) T (O) IGBT 2W2+ FAULT 90F

P3.058 IGBT 2W1+ FAULT T (O) T (O) T (O) IGBT 2W1+ FAULT 90F

P3.059 IGBT 2W2- FAULT T (O) T (O) T (O) IGBT 2W2- FAULT 90F

P3.060 IGBT 2W1- FAULT T (O) T (O) T (O) IGBT 2W1- FAULT 90F

P3.061 IGBT 2H + FAULT T (O) T (O) T (O) IGBT 2H+ FAULT 90F

P3.062 IGBT 2H - FAULT T (O) T (O) T (O) IGBT 2H- FAULT 90F

P3.063 To

P3.064 Reserve

Reserve

P3.065 DFE I+ Flt high T -- -- DFE I+ high Fault direct analog

76

P3.066 DFE I- Flt high T -- -- DFE I- high Fault direct analog

76

P3.067 DC Volt + Flt high T T T DC voltage between U+ and 0V is high

Fault direct analog

59

P3.068 DC Volt- Flt high T T T DC voltage between U- and 0V is high

Fault direct analog

59

P3.069 Inv Cur U Flt high T T T Inverter Current U ph: high Fault direct

analog

50

P3.070 Inv Cur V Flt high T T T Inverter Current V ph: high Fault direct

analog

50

P3.071 Inv Cur W Flt high T T T Inverter Current W

ph: high Fault direct analog

59

P3.072 Zero Seq Volt Flt high

T T T Zero Sequence Voltage High

59

P3.073 Network volt U high -- T -- Network Voltage higher Fault

59

P3.074 Network volt V high -- T -- Network Voltage 59


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ANSI

CODE

higher Fault

P3.075 Network volt W high

-- T -- Network Voltage higher Fault

59

P3.076 Ftr Volt UV high T (O) T (O) -- Filter line voltage UV high direct analog

59CF

P3.077 Ftr Volt VW high T (O) T (O) -- Filter line voltage VW high direct analog

59CF

P3.078 Ftr Cur U high T (O) T (O) -- Filter current phase U high direct analog

50CF

P3.079 Ftr Cur W high T (O) T (O) -- Filter current phase W high direct analog

50CF

P3.080 Reserved Reserved

P3.081 DFE I+ Flt high

high T -- -- DFE I+ Flt high

calculated 76

P3.082 DFE I- Flt high high T -- -- DFE I- Flt high calculated

76

P3.083 DC Volt+ Flt high

high T T T DC volt + Flt high

calculated 59

P3.084 DC Volt- Flt high

high T T T DC volt - Flt high

calculated 59

P3.085 Inverter Cur U Flt

high high T T T Inverter Current U

Fault high calculated 50

P3.086 Inverter Cur V Flt

high high T T T Inverter Cur V Flt

high calculated 50

P3.087 Inverter Cur W Flt

high high T T T Inverter Cur W Flt

high calculated 50

P3.088 Zero Seq Volt Flt

high high T T T

P3.089 Network volt U high high

-- T -- Network Over Voltage calculated

59

P3.090 Network volt V high high


59

P3.091 Network volt W high high


59

P3.092 Filter Volt UV high high

T (O) T (O) -- Filter line-voltage UV high calculated

59CF

P3.093 Filter Volt VW high high

T (O) T (O) -- Filter line-voltage VW high calculated

59CF

P3.094 Filter cur U high high

T (O) T (O) -- Filter current U high calculated

50CF

P3.095 Filter cur W high high

T (O) T (O) -- Filter current W high calculated

50CF


P3.097 PIB ACFAIL Flt T T T PIB AC Failure Fault 34F

P3.098 PIB LINK Flt T T T PIB LINK Fault 34F

P3.099 PIB SOFT FAIL Flt T T T PIB Software FAIL Fault

34F/90F

P3.100 PIB GENERAL Flt T T T PIB Board GENERAL Fault

34F


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ANSI

CODE

P3.101 PIB USER Flt T T T PIB USER Fault 34F

P3.102 TOGGLE PIB/CPU Flt

T -- -- TOGGLE PIB/CPU Fault

34F

P3.103 TOGGLE CPU/PIB Flt

T T T TOGGLE CPU/PIB Fault

34F

P3.104 PIB Init Flt T T T PIB initialization Fault 34F

P3.105 CPU Software Wdog Flt

T T T CPU Software Watch dog Fault

34F

P3.106 I/O Rack Hrd Flt T T T I/O Rack Hardware Fault

98F

P3.107 I/O Rack Link Flt T T T I/O Rack Link Fault 98F

P3.108 PIB504 Flt -- T T PIB504 Fault 98F

P3.109 PIB504 Chan. A Optical Link Flt

-- T T PIB504 Chan. A Optical Link Flt

34F

P3.110 PIB504 Chan. B Optical Link Flt

-- T T PIB504 Chan. B Optical Link Flt

34F

P3.111 PIB504 Chan. C Optical Link Flt

-- T T PIB504 Chan. C Optical Link Flt

34F

P3.112 PIB504 Chan. D Optical Link Flt

-- T T PIB504 Chan. D Optical Link Flt

34F

P3.113 Speed Meas. Board Flt

T (O) -- T (O) Encoder Interface Card Fault (If used)

34F

P3.114 Controller Watch Dog Relay Fault

T T T 34F


P3.116 Chopper PIB ACFAIL Flt

T (O) T (O) -- Acknowledgement fail from Chopper PIB

34F

P3.117 Chopper PIB LINK Flt

T (O) T (O) -- Failure in Chopper PIB Link Fault

34F

P3.118 Chopper PIB SOFT FAIL Flt

T (O) T (O) -- Software failure Chopper PIB

34F

P3.119 Chopper PIB GENERAL Flt

T (O) T (O) -- General Fault - Chopper PIB

34F

P3.120 Chopper PIB USER Flt

T (O) T (O) -- User Fault Chopper PIB

34F

P3.121 Chopper TOGGLE PIB/CPU Flt

T (O) T (O) -- Toggle PIB/CPU card fault for Chopper control

34F

P3.122 Chopper TOGGLE CPU/PIB Flt

T (O) T (O) -- Toggle CPU/PIB card fault for Chopper control

34F

P3.123 Chopper PIB init Flt

T (O) T (O) -- Chopper PIB Initialization Fault

34F

P3.124 to


P3.129 DC Link Dischrg Flt T T T DC Link Discharge Fault

48

P3.130 PreChrg TOut Flt T T -- Pre-charge Timeout Fault

48


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Date : 01 Sept 07






ANSI

CODE

P3.131 Flycatch TOut Flt S (T/A) -- S (T/A) Fly catching Timeout Fault

90F/48

P3.132 Start Up TOut Flt S (T/A) S (T/A) S (T/A) Start Up Timeout Fault

48

P3.133 Drv Stpng TOut Flt T T T Drive Stopping Timeout Fault

48

P3.134 Test Pulse Flt T T T Test pulse while not grounded Fault

48/90F

P3.135 Aux Stopped Flt T T T Auxiliaries stopped while DC link not discharged - Fault

48/88F

P3.136 Motor Magnet TOut Ft

T -- T Motor magnetizing Timeout Fault

90F

P3.137 to


P3.161 Aux Supply OFF Flt T (S/A) T (S/A) T (S/A) Aux. supply OFF Fault

48/88F

P3.162 220V Supply OFF Flt

T (S/A) T (S/A) T (S/A) 220V supply OFF Fault

48/88F

P3.163 400V Supply OFF Flt

T (S/A) T (S/A) T (S/A) 400V supply OFF Fault

48/88F

P3.164 Fan Supply OFF Flt T (S/A) T (S/A) T (S/A) Fan supply OFF Fault 48/88F

P3.165 PreChrg Sply OFF Flt

T (S/A) T (S/A) T (S/A) Pre-charge supply OFF Fault

48

P3.166 Pump1 Sply OFF Flt

T (S/A) T (S/A) T (S/A) Cooling unit pump 1 supply OFF Fault

48/88F

P3.167 Fuse Flt T (S/A) T (S/A) T (S/A) Fuse Fault 48/88F

P3.168 Fan Flow Flt T (S/A) T (S/A) T (S/A) Fan Flow Fault 48/88F

P3.169 Cooling unit Flt T T T Cooling unit Fault 48/88F

P3.170 Cool unit Flow Flt T T T Cooling unit flow Fault

48/88F

P3.171 Pump1 cont Flt T T T Cooling unit pump 1 contactor Fault

48/88F

P3.172 Pump 1&2 cont Flt T (O) T (O) T (O) Cooling unit pumps 1 and 2 Fault

48/88F

P3.173 to


P3.177 2nd Conv. Aux. supply OFF Flt

T (O) T (O) T (O) 88F

P3.178 2nd Conv. 220V supply OFF Flt

T (O) T (O) T (O) 88F

P3.179 2nd Conv. 400V supply OFF Flt

T (O) T (O) T (O) 88F

P3.180 2nd Conv. Fan supply OFF Flt

T (O) T (O) T (O) 88F

P3.182 2nd Conv. Cooling unit pump 1 supply OFF Flt

T (O) T (O) T (O)

Optional for the slave inverter of parallel configuration with 2 inverters controlled by two PIB boards with a common VMIC CPU. The comments are identical to the corresponding faults in the master converter

88F


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ANSI

CODE

P3.183 2nd Conv. Fuse Flt T (O) T (O) T (O) 88F

P3.184 2nd Conv. Fan Flow Flt

T (O) T (O) T (O) 88F

P3.185 2nd Conv. Cooling unit Flt

T (O) T (O) T (O) 88F

P3.186 2nd Conv. Cooling unit flow Flt

T (O) T (O) T (O) 88F

P3.187 2nd Conv. Cooling unit pump 1 contactor Flt

T (O) T (O) T (O) 88F

P3.188 2nd Conv. Cooling unit pumps 1 & 2 contactor alarm

T (O) T (O) T (O)

converter

88F

P3.189 to


P3.196 Watch dog from MB_Ch: A Flt

-- -- T Watch Dog Fault from MB Channel A

34F

P3.197 Wdog from MB_ChB Flt

-- -- T Watch Dog Fault from MB Channel B

34F

P3.198 Wdog from MB_ChC Flt

-- -- T Watch Dog Fault from MB Channel C

34F

P3.199 Wdog frm AFE_ChA Flt

-- T -- Watch Dog Fault from AFE channel A

34F

P3.200 MB ChA not Ready Flt

-- T -- Machine Bridge Ch: A not ready while AFE running

34F

P3.201 MB ChB not Ready Flt

-- T -- Machine Bridge Ch: B not ready while AFE running

34F

P3.202 MB ChC not Ready Flt

-- T -- Machine Bridge Ch: C not ready while AFE running

34F

P3.203 ChA Wrong MB ID Flt

-- -- T Ch: A wrong Machine Bridge ID Fault

34F

P3.204 ChB Wrong MB ID Flt

-- -- T Ch: B wrong Machine Bridge ID Fault

34F

P3.205 ChC Wrong MB ID Flt

-- -- T Ch: C wrong Machine Bridge ID Fault

34F

P3.206 MB ChA DC Discor Flt

-- -- T Machine Bridge Ch: A DC Voltage measure Discordance Fault

34F

P3.207 MB ChB DC Discor Flt

-- -- T Machine Bridge Ch: B DC Voltage measure Discordance Fault

34F

P3.208 MB ChC DC Discor Flt

-- -- T

Machine Bridge Ch: C DC Voltage measure Discordance Fault

34F

P3.209 AFE DC Discor Flt -- T -- AFE Ch. A DC Voltage measure Discordance Fault

34F


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Date : 01 Sept 07






ANSI

CODE

P3.209 to P3.212 Reserve Reserve

P3.213 2nd Conv. PIB ACFAIL Flt

T (O) T (O) T (O)

P3.214 2nd Conv. PIB LINK Flt

T (O) T (O) T (O) 34F

P3.215 2nd Conv. PIB SOFT FAIL Flt

T (O) T (O) T (O) 34F

P3.216 2nd Conv. PIB GENERAL Flt

T (O) T (O) T (O) 34F

P3.217 2nd Conv. PIB USER Flt

T (O) T (O) T (O) 34F

P3.218

Reserve

P3.219 2nd Conv. TOGGLE CPU/PIB Flt

T (O) T (O) T (O) 34F

P3.220 2nd Conv. PIB init Flt

T (O) T (O) T (O)

Optional in case of configuration with 2 converters controlled by two PIB boards

with a common VMIC CPU.

34F

P3.221 2nd Conv. I/O Rack Hrd Flt

T (O) T (O) T (O) 34F

P3.222 2nd Conv. I/O Rack Link Flt

T (O) T (O) T (O) 34F

P3.223 2nd Conv. Watch Dog Relay Flt

T (O) T (O) T (O) 34F

P3.225 Filter U Temp. High High Flt

T (O) T (O) T (O) Filter line high temp

fault

P3.226 Filter V Temp. High High Flt


fault

P3.227 Filter W Temp. High High Flt


fault

P3.228 Filter Discharge Flt T (O) T (O) T (O) Filter Discharge Fault

P3.229 to


P3.257 Mains voltage too high Flt

-- T -- Mains voltage too high Fault

59

P3.258 Mains Volt. too Low Flt

-- T -- Mains voltage too low Fault

27

P3.259 Start while Filter not discharged Flt

-- T -- Start while filter not discharged Fault

48

P3.260 DFE+filter Flt -- T -- Diode Front End mode with filter enabled Fault

59CF

P3.261 MB ChA Ground Sw Flt

-- T (O) -- Machine Bridge Ch: A Ground Switch Fault

57F

P3.262 MB ChB Ground Sw Flt

-- T (O) -- Machine Bridge Ch: B Ground Switch Fault

57F

P3.263 MB ChC Ground Sw Flt

-- T (O) -- Machine Bridge Ch: 57F


Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE

Sw Flt C Ground Switch Fault

P3.264 to


P3.321 2nd Conv. IGBT 1 U2+ FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 U2+ FAULT

90F



90F

P3.323 2nd Conv. IGBT 1 U2- FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 U2- FAULT

90F



90F

P3.325 2nd Conv. IGBT 1 V2+ FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 V2+ FAULT

90F



90F

P3.327 2nd Conv. IGBT 1 V2- FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 V2- FAULT

90F



90F

P3.329 2nd Conv. IGBT 1 W2+ FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 W2+ FAULT

90F



90F

P3.331 2nd Conv. IGBT 1 W2- FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 W2- FAULT

90F



90F

P3.333 2nd Conv. IGBT 1 H+ FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 H+ FAULT

90F

P3.334 2nd Conv. IGBT 1 H- FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 1 H- FAULT

90F





90F



90F



90F



90F



90F



90F



90F



90F

P3.345 2nd Conv. IGBT 2 T (O) T (O) T (O) 2nd Conv. IGBT 2

90F


Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE

W2+ FAULT W2+ FAULT



90F



90F



90F

P3.349 2nd Conv. IGBT 2 H+ FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 2 H+ FAULT

90F

P3.350 2nd Conv. IGBT 2 H- FAULT

T (O) T (O) T (O) 2nd Conv. IGBT 2 H- FAULT

90F



P3.353 2nd Conv. DFE I+ Flt high

T (O) T (O) T (O) 2nd Conv. DFE I+ Flt high

76

P3.354 2nd Conv. DFE I- Flt high

T (O) T (O) T (O) 2nd Conv. DFE I- Flt high

76

P3.355 2nd Conv. DC volt + Flt high

T (O) T (O) T (O) 2nd Conv. DC volt + Flt high

59

P3.356 2nd Conv. DC volt - Flt high

T (O) T (O) T (O) 2nd Conv. DC volt - Flt high

59

P3.357 2nd Conv. Inverter Cur U Flt high

T (O) T (O) T (O) 2nd Conv. Inverter Cur U Flt high

50

P3.358 2nd Conv. Inverter Cur V Flt high

T (O) T (O) T (O) 2nd Conv. Inverter Cur V Flt high

50

P3.359 2nd Conv. Inverter Cur W Flt high

T (O) T (O) T (O) 2nd Conv. Inverter Cur W Flt high

59

P3.360 2nd Conv. Zero Seq Volt Flt high

T (O) T (O) T (O) 2nd Conv. Zero Seq Volt Flt high

P3.361 2nd Conv. Network volt U high

T (O) T (O) T (O) 2nd Conv. Network volt U high

59

P3.362 2nd Conv. Network volt V high

T (O) T (O) T (O) 2nd Conv. Network volt V high

59

P3.363 2nd Conv. Network volt W high

T (O) T (O) T (O) 2nd Conv. Network volt W high

59

P3.364 2nd Conv. Filter volt UV high

T (O) T (O) T (O) 2nd Conv. Filter volt UV high

59CF

P3.365 2nd Conv. Filter volt VW high

T (O) T (O) T (O) 2nd Conv. Filter volt VW high

59CF

P3.366 2nd Conv. Filter cur U high

T (O) T (O) T (O) 2nd Conv. Filter cur U high

50CF

P3.367 2nd Conv. Filter cur W high

T (O) T (O) T (O) 2nd Conv. Filter cur W high

50CF

P3.368 2nd Conv. reserved AI 8high PIB102 -2

T (O) T (O) T (O) 2nd Conv. reserved AI 8high PIB102 -2

P3.369 2nd Conv. DFE I+ Flt high high

T (O) T (O) T (O) 2nd Conv. DFE I+ Flt high high

76

P3.370 2nd Conv. DFE I- Flt high high

T (O) T (O) T (O) 2nd Conv. DFE I- Flt high high

76

P3.371 2nd Conv. DC volt + Flt high high

T (O) T (O) T (O) 2nd Conv. DC volt + Flt high high

59


Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE

P3.372 2nd Conv. DC volt - Flt high high

T (O) T (O) T (O) 2nd Conv. DC volt - Flt high high

59

P3.373 2nd Conv. Inverter Cur U Flt high high

T (O) T (O) T (O) 2nd Conv. Inverter Cur U Flt high high

50

P3.374 2nd Conv. Inverter Cur V Flt high high

T (O) T (O) T (O) 2nd Conv. Inverter Cur V Flt high high

50

P3.375 2nd Conv. Inverter Cur W Flt high high

T (O) T (O) T (O) 2nd Conv. Inverter Cur W Flt high high

50

P3.376 2nd Conv. Zero Seq Volt Flt high high

T (O) T (O) T (O) 2nd Conv. Zero Seq Volt Flt high high

59

P3.377 2nd Conv. Network volt U high high

T (O) T (O) -- 2nd Conv. Network volt U high high

59

P3.378 2nd Conv. Network volt V high high

T (O) T (O) -- 2nd Conv. Network volt V high high

59

P3.379 2nd Conv. Network volt W high high

T (O) T (O) -- 2nd Conv. Network volt W high high

59

P3.380 2nd Conv. Filter volt UV high high

T (O) T (O) T (O) 2nd Conv. Filter volt UV high high

59CF

P3.381 2nd Conv. Filter volt VW high high

T (O) T (O) T (O) 2nd Conv. Filter volt VW high high

59CF

P3.382 2nd Conv. Filter cur U high high

T (O) T (O) T (O) 2nd Conv. Filter cur U high high

50CF

P3.383 2nd Conv. Filter cur W high high

T (O) T (O) T (O) 2nd Conv. Filter cur W high high

50CF

P3.385 to



Ref : 4MKG0015




Date : 01 Sept 07




5.3.2.2 Process or External Faults

Apart from the standards faults listed above, MV7000 drives can be adapted with project or process specific faults. These faults are custom oriented depending on the type of application in which MV7000 drives are used.

Some general categorizations of process faults are as follows.

1) Medium voltage Supply distribution faults:

The important faults concerned to main transformers for the drive input supply are accepted from the external resource or through external hardwired terminals. These faults include Transformer temperature, Transformer Pressure, Transformer oil level threshold, Buchholz relay status etc. The status of MV breaker failure is also added. The fault list varies depending on the distribution system employed for the corresponding application.

1) Emergency conditions and watch dog signals based on process and application, which need direct affectation as trip in the MV7000 drives. The number and types of emergency contacts depend upon application.

2) Motor related fault conditions. Based on application and motor characteristics concerned to a particular application, different motor protection status are accepted through hardwired external terminals or as field bus status words concerning the motor operation. Some typical faults are Motor over speed detection, Motor stalling etc.

3) Other miscellaneous faults exclusive to a particular project and application.

Note1 Please refer to the project specific documents for process or external faults concerned to the specific project.

Note2 Similarly, there are also Alarms concerned to process or application specific functionalities. Also refer to the project specific documentation to know the list of Alarms concerning the project.


Ref : 4MKG0015




Date : 01 Sept 07




5.3.3 Keypad Menu 4 - Alarm Menu

For Menu 4 navigation details please refer to the User manual section 4. For each ANSI function code, probable causes of the fault and action to be carried out are given the Fault Finding Guide (section 5.3.7).

Parameter of type ALARM (Fixed and not modifiable for

any Drive System)

Parameter of type ALARM, which is OPTIONAL


Parameter of type ALARM by default, which can also

be configured as type FAULT with Trip or Stop

depending on the drive configuration used/application

Parameter NOT USED

5.3.3.1 Alarm list for MV7000 standard functionalities

Table 5- 3 Standard Alarm List

ALARM TYPE Parameter Keypad Display


ANSI

CODE

P4.001 LocalMode Active Alm

A A A Stand Alone mode active

83A

P4.002 CPU Card Temp Alm

A A A CPU Card Temperature Alarm

34A

P4.003 Main CB Pos Alm A A -- Main CB Position Alarm

52A

P4.004 Grnd Sw Pos Alm A A A Ground Switch Position Alarm

57A

P4.005 Reserve -- -- -- Reserve

P4.006 Keypad Link Fail Alm

A -- A Keypad Link Failure Alarm

98F

P4.007 Speed Sensor Alm A A A Speed sensor Alarm 77SA

P4.008 DC Link Low Alm A A A DC Link Low voltage Alarm

27A

P4.009 DC Link Too Low Alm

Reserve 27A

P4.010 Chop Temp Hi Alm A (O) --

A (O) Chopper High Temperature Alarm

73A

A (O) A (O) P4.011

Chop Temp TooHi Alm A (F)

--

A (F)

Chopper Too High Temperature Alarm

73A

P4.012 DC Link

Overvoltage Alm A A A DC Link Overvoltage

Alarm 59A

P4.014 to

P4.015

Reserve Reserve

A

A (O)

A (F)

--


Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE

P4.015

P4.016 Kinetic Support On A (O) -- -- Kinetic Support On

P4.017 Kinetic Support Not available at Zero

Spd A (O) -- --

Kinetic Support Not available at Zero

Speed

P4.025 GND Switch#2 Pos

AL A A A

Second inverter Ground Switch Position Alarm

P4.026 DCvolt#1-2 DiscordAL A

A A Measured voltage

discordance between 2 parellel inverters

P4.027 Current#1-2 Unbal

AL A A A

Measured current unbalance between 2 parellel inverters

P4.129 Precharge Thermal

Alm A A --

Precharge Thermal Alarm

P4.130 Dischrg Res Cool

AL A A A

Discharge Resistor Cooling Alarm

P4.131 to


P4.161 Aux Supply OFF Alm

A (F) A (F) A (F) Auxiliary supply OFF Alarm

88A

P4.162 220V Supply OFF Alm

A (F) A (F) A (F) 220V supply OFF Alarm

88A

P4.163 400V Supply OFF Alm

A (F) A (F) A (F) 400V supply OFF Alarm

88A

P4.164 Fan Supply OFF Alm

A (F) A (F) A (F) Cooling Unit Fan supply OFF Alarm

88A

P4.165 PreChrg Sply OFF Alm

A (F) A (F) -- Precharge supply OFF Alarm

48

P4.166 Pump1 Sply OFF Alm

A (F) A (F) A (F) Cooling unit pump 1 supply OFF Alarm

88A

P4.167 Fuse Alm A (F) A (F) A (F) Auxiliary DC supply Fuse Alarm

88A

P4.168 Fan Flow Alm A (F) A (F) A (F) Fan Flow Alarm 88A

P4.169 Cooling Unit Alarm A A A Cooling Unit Alarm 88A

P4.170 Cooling unit flow

alarm A A A

Cooling Unit flow Alarm

88A

P4.171 Pump1 Cont Alm A (O) A (O) A (O) Cooling unit pump 1 contactor Alarm

88A

P4.172 Pump2 Cont Alm A (O) A (O) A (O) Cooling unit pump 2 contactor Alarm

88A

P4.173 Pump2 Sply OFF

Alm A (O) A (O) A (O) Cooling unit pump 2 supply OFF Alarm

88A



Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE



P4.177 2nd Conv. Aux. supply OFF Alm

A (O) A (O) A (O) 2nd Conv. Aux. supply OFF Alm

88A

P4.178 2nd Conv. 220V supply OFF Alm

A (O) A (O) A (O) 2nd Conv. 220V supply OFF Alm

88A

P4.179 2nd Conv. 400V supply OFF Alm

A (O) A (O) A (O) 2nd Conv. 400V supply OFF Alm

88A

P4.180 2nd Conv. Fan supply OFF Alm

A (O) A (O) A (O) 2nd Conv. Fan supply OFF Alm

88A

P4.181 Reserve

Reserve

P4.182

2nd Conv. Cooling unit pump 1 supply OFF Alm

A (O) A (O) A (O)

2nd Conv. Cooling unit pump 1 supply OFF Alm

88A

P4.183 2nd Conv. Fuse Alm

A (O) A (O) 2nd Conv. Fuse Alm

88A

P4.184 2nd Conv. Fan Flow Alm

A (O) A (O) A (O) 2nd Conv. Fan Flow Alm

88A

P4.185 2nd Conv. Cooling unit alarm

A (O) A (O) A (O) 2nd Conv. Cooling unit alarm

88A

P4.186 2nd Conv. Cooling unit flow alarm

A (O) A (O) A (O) 2nd Conv. Cooling unit flow alarm

88A

P4.187 2nd Conv. Cooling unit pump 1 contactor alarm

A (O) A (O) A (O) 2nd Conv. Cooling unit pump 1 contactor alarm

88A

P4.188 2nd Conv. Cooling unit pump 2 contactor alarm

A (O) A (O) A (O) 2nd Conv. Cooling unit pump 2 contactor alarm

88A

P4.189 2nd Conv. Cooling unit pump 2 supply OFF Alm

A (O) A (O) A (O) 2nd Conv. Cooling unit pump 2 supply OFF Alm

88A




P4.193 MB ChA Trip Alm -- A -- Trip request from MB Ch: A Alarm

34A

P4.194 MB ChB Trip Alm -- A -- Trip request from MB Ch: B Alarm

34A

P4.195 MB ChC Trip Alm -- A -- Trip request from MB Ch: C Alarm

34A

P4.196 AFE Trip Alm -- -- A Trip request from AFE Alarm

34A

P4.197 to

P4.205 Reserve Reserve 34A

P4.206 MB ChA Vdc Discor

AL -- A --

MB Ch: A DC Volt measure Discordance

Alarm

34A


Ref : 4MKG0015




Date : 01 Sept 07






ANSI

CODE

P4.207 MB ChB Vdc Discor

AL -- A --

MB Chan. B DC Volt measure Discordance

Alarm

34A

P4.208 MB ChC Vdc Discor AL

-- A -- MB Chan. C DC Volt measure Discordance

Alarm

34A

P4.209 AFE Vdc Discor

Alm -- -- A

AFE Chan. A DC Volt measure Discordance

Alarm

34A

P4.210 to


P4.225

Filter U Temp. High Alm

A (O) A (O) A (O) Filter U Temp. High Alm

P4.226 Filter U Temp. Sensor Alm

A (O) A (O) A (O) Filter U Temp. Sensor Alm

P4.227 Filter V Temp. High Alm

A (O) A (O) A (O) Filter V Temp. High Alm

P4.228 Filter V Temp. Sensor Alm

A (O) A (O) A (O) Filter V Temp. Sensor Alm

P4.229 Filter W Temp. High Alm

A (O) A (O) A (O) Filter W Temp. High Alm

P4.230 Filter W Temp. Sensor Alm

A (O) A (O) A (O) Filter W Temp. Sensor Alm

P4.231 to


P4.257 Mains Volt. High Alm

-- A -- Mains voltage high

Alarm 59A

P4.258 Mains Volt. Low Alm

-- A -- Mains voltage low

Alarm 27A

P4.259 Wait for filter discharge before start Alm

-- A -- Wait for filter

discharge before start Alarm

27A

P4.260 to

P4.409

Reserve

Reserve


Ref : 4MKG0015




Date : 01 Sept 07




5.3.4 Important fault causes based on standard functionalities of MV7000

5.3.4.1 Pre-charging

The drive monitors the DC voltage level while pre-charging and in normal condition the DC voltage level has to be achieved to the set point with specified time characteristic. Any deviation to this will trigger a pre-charge time out fault.

Therefore, in case if the pre-charge supply is lower than the design conditions can cause a pre-charge time out fault.

An important possible cause of appearance of the pre-charge timeout fault is the existence of short circuit on the DC bus while pre-charging.

It is strongly advised to maintain the pre-charging power supply to the operating point characteristics.

For the thermal safety of pre-charge contactors and DC link, MV7000 has a software limitation to avoid too frequent operation of Pre-charge contactors.

Pre-charge limitation - Only 3 pre-charging attempts in 10-minute period and the period between two subsequent pre-charge attempts should not be less than 30 seconds. Any deviation to either of the above conditions will lead to a Pre-charge thermal limitation. If this happens, then the operator has to wait for 10 minutes to reset the limitation to attempt for the next pre-charge.

5.3.4.2 DC link Discharging

During the time drive is turned OFF, if the DC link is not discharged through discharge circuit to at least 2% in 5 minute, will trigger a discharge fault. Also if the initial discharge does reach less than 70% in 1 minute, trigger a discharge fault.

If the auxiliaries are stopped while the DC link is not fully discharged, will trigger a fault. Make sure that the auxiliaries are running till the end of full discharge. Running of auxiliaries till the complete discharge is essential for safety operation of the drive.

If drive has option Discharge relay fault will occur in case of failure of Discharge relays OR a detection of discharge feedback while the IGBT are working OR detection of Discharge open while the IGBT are OFF.

Enabling of IGBT gate driver pulses will be carried only if the discharge-relay open feedback is true.

Attention - Care should be taken in handling a recovery once discharge fault is noticed. The software disables the drive to restart if the DC link is not fully discharged. In case of consistent presence of Discharge fault, do not engage in any physical contact with equipment and wait for the service of Converteam personnel. DO NOT CLOSE the Grounding switch if the DC link is not fully discharged


Ref : 4MKG0015




Date : 01 Sept 07




5.3.4.3 Contactors / Supply faults

All power supply status contactors of MV7000 from Main CB to Auxiliary supplies are continuously monitored for feedback failure. Therefore, detection of a supply loss or contactor failure causes a supply off or contactor failure fault.

In case of contactor or supply loss detection, check whether all supplies are turned ON or identify in case any contactors are faulty based on the fault identification and replace the same.

5.3.4.4 Cooling Unit faults

The cooling unit pressure, temperature, flow and conductivity are continuously measured and controlled by a dedicated cooling unit control. Reaching the threshold limits of any of these parameters will cause a cooling unit fault.

For the Cooling unit pumps, if there is no redundancy option of pumps, the drive will have an immediate trip effect upon the pump failure.

In case of redundant option, the pump will switch to the second pump and vice versa. A fault will be triggered only if both pumps are failed.

The details of the cooling unit are displayed in the cooling unit chamber.

5.3.4.5 Time out faults

The drive monitors the occurrence of time critical stages of drive starting like fly catch, starting time, pre-charge time and other critical sequential stepsany deviation to the allotted time will cause a time out fault with or without the presence of other correlated faults.

5.3.4.6 Temperature faults

Temperature fault from Sinus filter Reactor.

MV7000 system monitors the temperature feedback from 3 sensors for each phase legs of the sinus filter. Any deviation to thresholds will lead to alarms at lower threshold and fault at higher threshold.

If the temperature is in the alarm level, the customer is advised to stop the drive in normal process stop before the higher temperature threshold is reached.

5.3.4.7 DC voltage

The control monitors the DC voltage level throughout the operation of the drive.

Any deviation of a DC measurement lesser than 80% (can be different in some application based on special transformer design to accommodate higher de-rating limits) will trigger a low DC voltage fault.

There is an over voltage alarm if the DC link voltage exceeds around 115% of the DC voltage.

In normal case, de-rating of +10 to 10 can be well accommodated within the trip limits for DC voltage

MV7000 performs effective DC voltage balancing regulation that helps to avoid high ripples in DC bus voltage as well as regulating the DC voltage to the operating set points. Any deviation from an effective balancing offset will lead to a DC bus voltage unbalance fault. The cause of this unbalance can be due to many fault reasons either from the load motor side or from the network side, please revert to converteam support in case any unexpected occurrence of DC voltage unbalance.


Ref : 4MKG0015




Date : 01 Sept 07




DC voltage discordance for AFE

The AFE inverters of MV7000 drive series, monitors the measured DC voltage from the AFE and compare with the measured DC voltage send from each channels of Machine Bridges connected through TIB communication and any discordance between the values will lead to a fault effect.

For the parallel configuration with 2 inverters in parallel, the controller monitors the total DC voltage of both inverters and compared for any discordance. Any discordance to this will cause a DC voltage unbalance fault.

5.3.4.8 Controller boards and Communication

MV7000 drive system monitors the performance of the controller through the task period scanning to maintain watchdog status. It monitors the hardware status of the controller and associated cards in the PEC rack for MV7000 system control as well as the discordance of measurement and scaling of analogue values of the I/O cards etc.

If the drive system comprises multi channel architecture like AFE - MB or parallel AFE, then the optical communication though the TIB card is continuously monitored. Faults concerned to TIB card, communication failure, PIB card will cause trip effect.

Please refer to the fault and alarm tables for the faults concerned to the controller performance.

Process / External fault conditions:

Based on application, the critical faults concerned to the external power supply panels; motors and process part are hardwired to MV7000 external inputs or send through field bus communication. These faults are project specific and application dependent. Please refer to the project specific documents for details.


Ref : 4MKG0015




Date : 01 Sept 07




5.3.5 PIB100 Controller board Indicators

Within the controller rack, power interface board PIB100G has a 7-segment-display on the front that indicates the status of the board. During booting, the board has to run through several steps until normal operation starts. If the board remains in an unusual status for a prolonged time, an error is indicated.

0 : RAM test [replace board].

1 : 1st step of booting [DPR fault - replace board].

2 : 2nd step of booting. The PIB100E is waiting for the initial software parameters from the CPU. This takes 1 min approx.

3 : 3rd step of booting, waiting for normal data from CPU.

4 : 4th step of booting. (only if slave PIB100E is waiting for the IRQ3 on the VME bus).

: Normal working conditions.

: Gating.

d : Drive fault detected. See User Manual Section 5.3.2.

o or t : Internal fault of the board software detected. Overflow task or wrong address. To reboot, toggle the power switch of the rack supply.

b : Bad configuration parameters check task time, PWM time, bridge types, etc.

r : Hardware reset in progress.

Dot flashing : background task is running (ok).

No display : Programming mode or system failure.

Note: If the display alternates between 2 and 3, the PIB100E and the CPU do not agree on hardware configuration and/or software versions.


Ref : 4MKG0015




Date : 01 Sept 07




5.3.6 Gate Driver Indicators

Gate driver board comprises several LED indicators, as shown on Figure 5- 2.

Figure 5- 2 Gate Driver Board

5.3.6.1 Normal operation

Green LED Turn ON: IGBT is OFF. Yellow LED Turn OFF: IGBT is ON. Red diagnostic LED indicators must be off. During normal drive operation, each IGBT is pulsing with a high frequency, so that the individual on/off flashing is invisible. Both LED indicators appears to be ON.

5.3.6.2 Abnormal condition

When both Green & Yellow LED indicators are dark, shows the gate driver supply voltage is missing.

In case of IGBT failure or Gate Driver board failure, diagnostic is indicated with either red LED are ON. The combination of these red LEDs, which are ON, indicates the type of failure as shown on Figure 5- 3.

Figure 5- 3 LED Indicators for Gate Driver/IGBT Failure Diagnostic

FO output: IGBT status feedback

FO input: pulse command

IGBT ON LED (Yellow)

IGBT OFF LED (Green)

Failure diagnostic LED indicators (red)

IGBT ON LED

IGBT OFF LED

Failure diagnostic LEDs

IGBT pulse command is too short

Gate driver power supply is too low

IGBT over current

IGBT Vce over voltage

IGBT short circuit


Ref : 4MKG0015




Date : 01 Sept 07




The Gate Driver communicates with PEC controller through fiber optic status feedback. In case of the failure diagnostic, PEC controller trips the drive and blocks all IGBT pulses.

Note: Only first fault is displayed on diagnostic LED indicators. If gate driver has not been cleared after previous gate drive fault, red LED indicators still corresponds to previous diagnostic. Refer to Section 5.3.6.3 for gate driver reset procedure.

IGBT/Gate Driver Diagnostic LED Fault details

There are 5 different combinations of fault conditions diagnosed by the three fault LEDs of Gate driver. These fault conditions are as the following.

1) IGBT pulse command is too short

Description

Pulse commands sent by PEC controller to gate drivers are individually calibrated with a minimum duration in order to avoid any IGBT damage.

If gate driver detects a pulse command on fiber optic input, which is shorter than the minimum pulse duration, a fault status is sent back to controller.

Probable causes

a) Failure of PIB310 firing board in PEC controller rack

b) The characteristics of the fiber optic connected to the gate driver might be altered.

c) Failure of optical receiver of gate driver

d) No connection/Improper connection of fiber optic.

Operations to be carried out

a) Check the optic fiber connections and verify whether connected properly.

b) Replace the board or component, which is suspected to be in malfunction.

IGBT ON request

IGBT OFF request

minimum pulse duration

IGBT ON request

IGBT OFF request

minimum pulse duration


Ref : 4MKG0015




Date : 01 Sept 07




2) Gate driver power supply is too low

Description

The Gate Driver monitors DC supply. When DC supply voltage falls under a fixed level, a fault status is sent back to controller.

Probable causes

a) Failure of DC power supply to Individual gate driver.

b) Failure of 24V common supply (if several gate drivers are faulty).

c) Failure of Gate driver.

d) The DC Power supply is not connected/not properly connected.

e) IGBT failure (short-circuit between gate and emitter)


a) Check 24Vdc bus voltage

b) Check gate driver supply voltage (17.4 DC Voltage)

c) Check and verify whether gate driver supply connections are proper.

d) Check IGBT impedance (gate/emitter and collector/emitter impedance mustn't be short-circuited). Take care of polarity when measuring collector/emitter impedance: (+) on collector and (-) on emitter (otherwise you will measure the impedance of a diode in direct sense).

e) Replace the board or component that is suspected to be in malfunction.

3) IGBT Over current

Description

The Gate Driver monitors Vce voltage when IGBT is ON (Vce saturation voltage). When Vce saturation voltage is too high, this means IGBT current is excessive and a fault status is sent back to controller.

Probable causes

a) Short-circuit on inverter output (cables, dV/dt filter, motor)


a) Check the insulation of each equipment connected to inverter output.

4) IGBT Over voltage

Description

The Gate Driver monitors Vce voltage when IGBT is OFF. When Vce voltage is too high, a fault status is sent back to controller.

Probable causes

a) DC link over voltage.

b) Clamp capacitor failure.

c) Gate driver failure (no dV/dt limitation during IGBT turn off).

d) An excessive current has been switched off.


Ref : 4MKG0015




Date : 01 Sept 07





a) Check clamp capacitors and connection between capacitors and IGBT stacks.

b) Replace the board or component, which is suspected to be in malfunction.

5) IGBT Short-Circuit

Description

Gate Driver monitors Vce voltage when IGBT is turning on. If Vce voltage stays above a predefined level, this means that another IGBT is faulty and short-circuited. A fault status is sent back to controller.

Probable causes

a) Another IGBT connected to the firing board might be damaged (short-circuit)


a) Check IGBT impedance (gate/emitter and collector/emitter impedance mustn't be short-circuited) for each IGBT in the stack. Take care of polarity when measuring collector/emitter impedance: (+) on collector and (-) on emitter (otherwise you will measure diode forward impedance).

b) If one IGBT is damaged, look for failure cause among the following non-exhaustive list

Bad IGBT command / gate driver or controller malfunction

Bad IGBT cooling (low clamp pressure, high water temperature, low water flow)

Repetitive Vce over voltage (problem with clamp capacitor)

5.3.6.3 Fault Reset:

When the gate driver detects a fault, the corresponding diagnostic is memorized and displayed on diagnostic LED indicators. At the same time, optic fiber status feedback is kept off for 20 ms as shown on Figure 5- 4. The PEC controller then memorizes IGBT fault.

After 20 ms, optic fiber status feedback returns to healthy, but the fault diagnostic is still memorized and displayed on gate driver. At this time, if a new IGBT fault occurs, optic fiber status feedback will be switched off for 20 ms, but the diagnostic will not be updated and it will correspond to the previous fault.

In order to clear diagnostic LED indicators, gate driver power supply must be switched off and then switched on.

Figure 5- 4 Gate Driver Fault Reset

Failure diagnostic

LEDs

Optic fiber status feedback

Gate Driver power supply

20 ms

healthy fault

diagnostic LED lit

fault

detected

power supply

switched off

power supply

switched on


Ref : 4MKG0015




Date : 01 Sept 07




5.3.7 Fault Finding Guide

For each section based on a specific ANSI function code, the following details will be found regarding a fault

Probable causes of the fault

Actions and checking which are recommended to be performed in order to identify the origin of the fault

5.3.7.1 ANSI Code - 13F [Pulse Generator (Speed Encoder) Fault]

Fault Description

Faulty detection or no detection of pulses from Speed Encoder by PIB 201 or DIZ 232A interfaces boards.

Probable causes

a) Pulse generator (optional) failure.

b) Faulty/Improper wiring between Pulse Generator and Controller interface board (PIB 201/DIZ 232).

c) Controller interface board (PIB201 or DIZ 232) failure.


a) Check the Pulse generator/Encoder is proper and the Encoder wirings to Interface board.

b) Check controller interface board (PIB201 or DIZ 232) and replace if faulty.

5.3.7.2 ANSI Code - 21F / 21W [De-ionized Water Conductivity]

Refer to the cooling unit documentation and MV7000 User manual section 6 for details.

5.3.7.3 ANSI Code - 26F / 26W [De-ionized Water Temperature]

Refer to the cooling unit documentation and MV7000 User manual section 6 for details.

WARNING

Hazardous Medium Voltages are present within this equipment. These voltages may exist even after isolation of the main and auxiliary supply sources.

Wait at least 10 minutes after Grounding for isolation and lockout of all external supply sources and opening doors of Medium Voltage compartments.

CONFIRM that the stored energy in ALL capacitor circuits is DISCHARGED and the drive system GROUNDED before working on the equipment. (Refer to Section 6 of this manual for the Grounding Procedure.)


Ref : 4MKG0015




Date : 01 Sept 07




5.3.7.4 ANSI Code 27 AC [Incomer Mains AC Under Voltage]

Fault Description

The mains network voltage is below the predefined low voltage limit.

Probable causes

a) There is a Low network voltage.

b) There can be a failure on the main Transformer.

c) There can be a failure of Controller Analog Input board (PIB 102) for measurement and PIB 70x unit.

e) Network capacitors might be damaged.


a) Check the main transformer secondary is energized and in good working condition

b) Check whether Network capacitors are damaged or not.

c) Check whether PIB 102 and PIB 70x are connected properly.

5.3.7.5 ANSI Code - 27 / 27A [DC Link Under voltage]

Fault Description

The DC link voltage is below the predefined low voltage limit.

Probable causes

a) There is a Low network voltage.

b) Failure in DC link Voltage measurement (either of the two PIB 70x units is faulty).

c) There can be a failure of Controller Analog Input board (PIB 102) for measurement.

d) There can be a failure on Main transformer.

e) The DC link under voltage can also be a consequence of other drive faults (e.g. IGBT, Diode Bridge or motor short-circuit).


a) Check whether the two PIB 70x units connected to the DC link for DC Voltage measurements are not faulty and Controller Analog Input board (PIB102) are in working condition.

b) Check the connection between PIB 70x unit and the corresponding PIB 102 Analog Input.

c) Check whether the 24 V supply to the PIB 70x unit is proper or not.

d) Check the main transformer output voltage for fault voltage.

d) If another fault is active, refer to the corresponding ANSI number; otherwise check Diode Bridge, IGBT Bridge and motor impedance.


Ref : 4MKG0015




Date : 01 Sept 07




5.3.7.6 ANSI Code - 34A [Controller CPU Over temperature Alarm]

Probable causes

a) There is no proper cooling of Control Processing Unit board.

b) The CPU board failure.


a) Check whether control cabinet cooling is working in proper way.

b) Check controller rack fans, air inlet and filters for proper working condition.

c) Check whether a failure occurred on the CPU and replace the CPU board if necessary.

5.3.7.7 ANSI Code - 34F / 34A [Controller Fault]

Probable causes

a) One of the controller boards is faulty.

b) The control power supply is faulty.


a) Check the Control Processing Units and replace the faulty one.

b) Check the control power supplies and to verify not faulty.

c) Read the PIB100E status on 7-segment-display and refer to User manual section 5.3.5.

5.3.7.8 ANSI Code 48 [Incomplete Sequence]

Fault Type 1 - No response to Circuit Breaker or Contactor command

Probable causes

a) Contactor or circuit breaker is either not ready or in incorrect operation/ damaged.

b) The OPEN or CLOSE command from Digital Output is not received by Contactor or Circuit Breaker due to either bad wiring, controller digital output failure or Contactor relay damaged.


a) Check whether the Contactor or Circuit Breaker receives the OPEN or CLOSE command correctly from the Digital Output of the controller.

b) Check whether the Contactor or Circuit Breaker is functioning properly.


Ref : 4MKG0015




Date : 01 Sept 07




Fault Type 2 - Sequence too long

There are three types of faults that can be occurred under this Fault category. They are defined as follows.

Fault (2.1) - Pre-charge Time-out Fault

Probable causes

a) There is no supply voltage for pre-charge transformer.

b) The Fuses of pre-charge transformer output are blown out/burned.

c) The DC voltage measurement sensor failure or controller analog input board failure.

d) The DC link capacitor damaged.


a) Check the voltage on pre-charge transformer primary input terminals for the supply voltage.

b) Check whether the Fuses of the pre-charge transformer output are blown out.

c) Check the DC voltage measurement sensor and controller analog input board (PIB102).

Fault (2.2) - Fly catching / Start-Up Time-out Fault

Probable causes

a) The firing of IGBT is Incorrect.

b) There is a failure of Motor current measurement.

c) The Motor winding is damaged.

d) There is no proper connection between Inverter and Motor.


a) Check the motor Current measurement units for each phase on the inverter output and controller analog input board (PIB102) for correct operation.

b) Check the resistors R5, R6 and R7 (10V conversion) across the three Analog Input slots for motor current measurement in PIB 102.

b) Check the motor current waveform on PIB102 analog test points (refer to datasheet for board description). Current magnitudes must be identical and currents must be 120 shifted.

c) Check the IGBT pulses with pulse test mode (refer to User manual section 4).

d) Check the motor windings and the connections between Inverter and Motor.


Ref : 4MKG0015




Date : 01 Sept 07




Fault (2.3) - Power Off Time-out Fault

Probable causes

a) The DC link voltage is not being discharged within predetermined time after drive stop command.

b) The DC link balancing-resistor (resistor connected in parallel with DC link capacitor) is damaged (open circuit) or disconnected.

c) The failure of DC voltage measurement unit (PIB 70x) or controller analog input board failure.

d) Either the main Transformer Circuit Breaker or pre-charge contactor is not opened properly, or an external AC supply is connected to Diode Bridge.


After the drive has been safely grounded, the following procedures can be carried out.

a) Check the DC link balancing resistors and connections.

b) Check DC voltage measurement units (PIB 70x) and controller analog input measurement board (PIB102).

c) Check the 24V supply to the PIB 70x units for any supply loss.

5.3.7.9 ANSI Code - 50 / 50A [Over Curren

mv7000_user_manual_section5_protection_4mkg0015_rev_c[1].pdf

Documents

mv7000 user manual section

c document

diagnostics date

user manual version

fault menu

4mkg0015 project

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