Altivar 1000
Use and maintenance manual
Retain for future use
IGBT voltage source inverter
3300 V
1300 - 14400 kVA
Contents
1.
2.
Scope ...................................................................................................................................................................................................................................1
Product Identification and Safety Rules ...............................................................................................................................................................................2
2.1.
2.2.
2.3.
2.5.
3.
Product Identification........................................................................................................................................................................ 2
Incorporation Rules .......................................................................................................................................................................... 2
Cautionary Plates on Cabinet Front Doors ....................................................................................................................................... 3
Safety and Warning Symbols ........................................................................................................................................................... 5
Equipment Parts...................................................................................................................................................................................................................6
3.1. General ............................................................................................................................................................................................ 6
3.2. Converter ......................................................................................................................................................................................... 6
3.3. Inverter Power Modules ................................................................................................................................................................. 15
3.4. Rectifier Power Modules ................................................................................................................................................................ 18
3.5. Control Modules and Control Cards ............................................................................................................................................... 21
3.6. Inverter Current and DC Voltage Transducers ............................................................................................................................... 60
3.7. Inverter Firing Card and Isolated Supply ........................................................................................................................................ 60
3.8. Rectifier Bridge Firing Card ............................................................................................................................................................ 66
3.9. Insulated Transmitter Interface Card .............................................................................................................................................. 67
3.10. Rectifier Bridge Precharge Diode Card .......................................................................................................................................... 70
3.11. Precharge Circuit (AFE configuration only) .................................................................................................................................... 71
3.12. Encoder requirements and connections ......................................................................................................................................... 74
3.13. Ground Fault Detector.................................................................................................................................................................... 77
4.
Converter Start Up .............................................................................................................................................................................................................80
4.1. User Interface (Keypad and PC Tool)............................................................................................................................................. 80
4.2. Drive Status Summary ................................................................................................................................................................... 84
4.3. Inverter Protections Summary ........................................................................................................................................................ 84
4.4. Parameters Reset .......................................................................................................................................................................... 85
4.5. Programming Levels ...................................................................................................................................................................... 85
4.6. Control Modes................................................................................................................................................................................ 85
4.7. Motor Rated Power EU/NEMA Selection........................................................................................................................................ 86
4.8. Quick Motor Start-Up...................................................................................................................................................................... 86
4.9. Encoder test (if present) ................................................................................................................................................................. 89
4.10. Protections Description .................................................................................................................................................................. 90
4.11. Start Up Procedure......................................................................................................................................................................... 98
5.
Maintenance, Checks and Troubleshooting.....................................................................................................................................................................101
5.4. Electrical Check of an Inverter Power Module ...............................................................................................................................107
5.5. Measuring and Displaying Inverter Output Currents and D.C. Voltages ........................................................................................108
6.
Parts Replacement...........................................................................................................................................................................................................110
6.2. Main Fans (Air cooled units only) ..................................................................................................................................................114
6.3. Water Pumps (Water cooled units only) ........................................................................................................................................114
6.4. Control Cards ................................................................................................................................................................................114
7.
Spare Parts ......................................................................................................................................................................................................................117
7.1. POWER MODULES ......................................................................................................................................................................117
7.4. Firing Cards AND Thermo Switch Interfaces .................................................................................................................................121
7.5. Precharge CIRCUIT (only for afe configuration) ............................................................................................................................121
7.6. Control parts..................................................................................................................................................................................121
7.7. PLC PARTS ..................................................................................................................................................................................122
7.9. FANS (Air Cooling Unit Only) ........................................................................................................................................................122
7.10. PUMPS (Water Cooling Unit Only) ................................................................................................................................................122
1. Scope
Scope of this manual is to provide use and maintenance instructions, troubleshooting information and spare parts list for Altivar 1000
Medium Voltage Variable Speed Electrical Drives.
This manual, together with the other manuals and drawings here listed, is part of the equipment and is to be stored in a safe and easilyretrievable place for the whole lifetime of Altivar 1000. These documents are to be available to technicians servicing the equipment since
contain safety, access and service rules, and complete maintenance and programming instructions.
Altivar 1000 is a configurable equipment built on job specifics needs by assembling standard basic cabinets. Manuals are the same and
apply to all models and types, electrical schematic diagrams and mechanical drawings are specific for each installation and job.
Only actions described in these manuals shall be performed on equipment. Neither other action, measurement or change of any type shall
be carried out.
Standard set of documents for ATV 3300V equipments consists of:
•
Altivar 1000
Safety and Installation Manual
•
Altivar 1000
Maintenance Manual
•
Electric and Electronic Equipment (Boards)
General Operation and Maintenance Manual
•
Altivar 1000
Programming Manual
•
Altivar 1000
Active Front End Programming Manual
•
Altivar 1000
Cooling System Use and Maintenance Manual (this manual)
•
Altivar 1000
Electric schematic diagrams, job-specific (code different from job to job)
1
2. Product Identification and Safety Rules
2.1.
Product Identification
This manual provides instructions about the IGBT Medium Voltage Variable Speed Electrical Drives designed and manufactured by
Schneider Toshiba Inverter Europe and identified by the product family name Altivar 1000 with power range from 1300 to 14400 kVA.
Related European and International Product Standard is CEI EN 61800-xx group. According to this group of Standards, Altivar 1000 is
defined as a subsystem of an Adjustable Speed Electrical Power Drive System [PDS] and, more precisely, the part of PDS defined as
Complete Drive Module [CDM].
2.2.
Incorporation Rules
According to EU Machinery Directive 98/37/EC and 2006/42/EC, or outside EU applicable laws, this equipment is not a complete machine
and it shall be incorporated into a system before to be operated.
The Altivar 1000 is part of an installation consisting of other different equipments and machines grouped to form a system. All the
functional safety relating functions needed by the system shall be guaranteed by the System Integrator.
The Altivar 1000 shall be installed according to this manual and cannot be operated until the system (machinery), in which is incorporated,
has been declared complying with the “Machinery Directive 98/37/EC and 2006/42/EC” or other local applicable laws.
It has been noted that Altivar 1000 alone shall not be CE marked since it is a part of an installation consisting of other different
equipments and machines.
2
2. Product Identification and Safety Rules
2.3. Cautionary Plates on Cabinet Front Doors
CAUTION DANGER !
RISK OF DEATH OR ELECTRIC SHOCK
MAINTENANCE SHALL BE PERFORMED EXCLUSIVELY BY AUTHORIZED SKILLED
PERSONNEL
MORE THAN ONE POWER SUPPLY IS CONNECTED TO THE EQUIPMENT
LETHAL VOLTAGES CAN EXIST EVEN IF ALL SUPPLIES ARE DISCONNECTED.
WAIT 10 MINUTES BEFORE STARTING THE EARTHING SAFETY PROCEDURE
MAINTENANCE ON THIS CABINET SHALL BE PERFORMED STRICTLY FOLLOWING
THE INSTRUCTIONS SPECIFIED IN THE USER MANUALS
Standard cautionary plate on cabinet doors
3
2. Product Identification and Safety Rules
2.4.
Safety and Cautionary Mandatory Rules
CAUTION! DANGER!
RISK OF DEATH, ELECTRIC SHOCK, HEAVY INJURIES TO PERSONNEL
RISK OF FIRE AND/OR DAMAGES TO EQUIPMENT AND/OR TO THE SYSTEM
It is mandatory to fully understand and strictly apply all Safety and Cautionary Rules listed in the ATV1000 - Safety and Installation
Manual;
see in particular Chapter 2 about :
- Functional Safety Hazard
- Operator Mandatory Skill
- Hazard on Accessing ATV 1000 Cabinets
- Risk to Inappropriate Use and Connection
- Minimal Safety Integration Requirements.
It is mandatory to fully understand and strictly apply all Safety Rules according to local laws and all safety site regulations.
4
2. Product Identification and Safety Rules
2.5.
Safety and Warning Symbols
This manual contains different cautionary statements:
DANGER !
Warns against actions that can lead to hazardous scenarios, risk of death or electrical shock. Highlights
some hazardous situations that can arise during maintenance operations.
WARNING!
Procedures that must be strictly followed or operating modes that shall not be applied: highlights the risk
of damaging the parts of the equipment.
NOTE
Relates to a clarification about instructions, repair operation or any other subject.
Dangerous scenarios are highlighted using the following symbols:
Risk of death, fire or heavy injuries
The job requires the personnel is skilled for the purpose, well aware of safety rules, regulations and
standards while operating on Medium Voltage Equipments. Full knowledge of installation power supply
system and ATV 1000 diagrams is needed.
Risk of death, electric shock or heavy injuries
The job requires the personnel is skilled for the purpose, well aware of safety rules, regulations and
standards while operating on Medium Voltage Equipments. Full knowledge of installation power supply
system and ATV 1000 diagrams is needed.
5
3. Equipment Parts
3.1.
General
For following aspects:
•
•
•
•
Product outline
Simplified electrical diagrams
Technical data
Overall dimensions
Refer to Chapter 3 of “Altivar 1000 Safety and Installation Manual”.
3.2.
Converter
Altivar 1000 Converter consists of a NPC type, Voltage Source, IGBT inverter with both Diode Front End and Active Front End
configuration.
The converter is based on a modular structure, which main parts are the Inverter Power Modules and the Rectifier Power Modules; both
air cooling and water cooling version are available.
The Converter contains all other essential auxiliary circuits and devices: current and voltage transducers, power supplies, precharge
circuit, firing boards, ground fault detector, output reactors, safety ground switch.
6
3. Equipment Parts
3.2.1. Diode Front End (12 and 24 Pulse)
1300 to 2600 kVA - Air Cooling / 1600 to 3600 kVA - Water Cooling
Air cooling sizes:
ATV 1K3 A33 12P / ATV 1K3 A33 24P / ATV 1K8 A33 12P / ATV 1K8 A33 24P / ATV 2K6 A33 12P /
ATV 2K6 A33 24P
Water cooling sizes:
ATV 1K6 W33 12P / ATV 1K6 W33 24P / ATV 2K4 W33 12P / ATV 2K4 W33 24P /
ATV 3K6 W33 12P / ATV 3K6 W33 24P
Diode Front End 12 Pulse - Simplified Schematic Diagram
M
3
Converter
Diode Front End 24 Pulse - Simplified Schematic Diagram
M
3
Converter
7
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Air Cooling
Main Fan
Rectifier
Bridge
Inverter
Phase
Current
Transducer
Link Bus
Bar
Output
Phase Bar
Ground
Switch
Insulation
Controller
Sensor
Output
Reactor
TITOIA
Boards
8
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Water Cooling
Rectifier
Bridge
Inverter
Phase
Link Bus
Bar
Output
Phase Bar
TRAL80
Transformers
Insulation
Controller
Sensor
Output
Reactor
Water cooling
Pipes
9
3. Equipment Parts
3.2.2. Diode Front End (12 and 24 Pulse)
3600 to 5200 kVA – Air Cooling / 4800 to 7200 kVA – Water Cooling
Air cooling sizes:
ATV 3K6 A33 12P / ATV 3K6 A33 24P / ATV 5K2 A33 12P / ATV 5K2 A33 24P
Water cooling sizes:
ATV 4K8 W33 12P / ATV 4K8 W33 24P / ATV 7K2 W33 12P / ATV 7K2 W33 24P
Diode Front End 12 Pulse - Simplified Schematic Diagram
M
3
Converter
Diode Front End 24 Pulse - Simplified Schematic Diagram
M
3
Converter
10
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Air Cooling
Main
Fan
Rectifier
Bridge
Link Bus
Bar
Inverter
Phase
Output
Reactor
11
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Water Cooling
Rectifier
Output
Phase Bar
Bridge
Current
Transducer
TRAL80
Transformers
TITOIA
Inverter
Boards
Phase
Insulation
Controller
Output
Reactor
Sensor
Ground
Switch
12
Water cooling
Pipes
3. Equipment Parts
3.2.3. Active Front End 1600 to 3600 kVA – Water Cooling
ATV 1K6 W33 AFE / ATV 2K4 W33 AFE / ATV 3K6 W33 AFE
AFE Simplified Schematic Diagram
M
3
Converter Cubicle Drawing
Line Side
Output Reactor
Line side
Phase
Motor Side
Output Reactor
Line side
Phase
Line side
Phase
Motor side
Phase
Motor side
Phase
Motor side
Phase
Water
cooling
pipes
13
3. Equipment Parts
3.2.4. Active Front End 4800 to 7200 kVA – AFE – Water Cooling
ATV 4K8 W33 AFE / ATV 7K2 W33 AFE
AFE Simplified Schematic Diagram
M
3
Converter Cubicle Drawing
Line Side Output
reactor
DC Fuses
Line side
Phase
Precharge
Board
Precharge
transformer
Motor side
Phase
Water
cooling
pipes
14
3. Equipment Parts
3.3.
Inverter Power Modules
The Inverter Power Module is an assembly with different standard sizes that includes IGBTs and FWD, Clamping Diodes, capacitors,
heatsink, Firing cards and Bus bar.
The heatsink is cooled by air or deionised water and is electrically connected to M, central point of the DC link circuit.
Inverter Power Module simplified schematic diagram:
+
PP
DP
P
M
~
N
DN
NN
PP:
external positive IGBT and FWD
P:
internal positive IGBT and FWD
N:
internal negative IGBT and FWD
NN:
external negative IGBT and FWD
DP:
positive CLAMPING DIODE
DN:
negative CLAMPING DIODE
FWD = Free Wheeling Diode
−
15
3. Equipment Parts
3.3.1. Air Cooled Inverter Power Modules
MOD ATV 1K3 A33
This Inverter Power Module is used in the following equipment sizes:
ATV 1K3 A33 12P / ATV 1K3 A33 24P
MOD ATV 1K8 A33
This Inverter Power Module is used in the following equipment sizes:
ATV 1K8 A33 12P / ATV 1K8 A33 24P
ATV 3K6 A33 12P / ATV 3K6 A33 24P
MOD ATV 2K6 A33
This Inverter Power Module is used in the following equipment sizes:
ATV 2K6 A33 12P / ATV 2K6 A33 24P
ATV 5K2 A33 12P / ATV 5K2 A33 24P
For Inverter Power Module part number see chapter 7.
16
3. Equipment Parts
3.3.2. Water Cooled Inverter Power Modules
MOD ATV 1K6 W33
This Inverter Power Module is used in the following equipment sizes:
ATV 1K6 W33 12P / ATV 1K6 W33 24P /
ATV 1K6 W33 AFE
MOD ATV 2K4 W33
This Inverter Power Module is used in the following equipment sizes:
ATV 2K4 W33 12P / ATV 2K4 W33 24P /
ATV 2K4 W33 AFE
ATV 4K8 W33 12P / ATV 4K8 W33 24P /
ATV 4K8 W33 AFE
MOD ATV 3K6 W33
This Inverter Power Module is used in the following equipment sizes:
ATV 3K6 W33 12P / ATV 3K6 W33 24P /
ATV 3K6 W33 AFE
ATV 7K2 W33 12P / ATV 7K2 W33 24P /
ATV 7K2 W33 AFE
For Inverter Power Module part number see chapter 7.
17
3. Equipment Parts
3.4.
Rectifier Power Modules
The Rectifier Power Module is an assembly with different standard sizes that includes Thyristors, Diodes, Heatsink, Firing card and
Precharge devices.
The heatsink is cooled by air or deionised water and is electrically connected to the intermediate point of the Rectifier Power Module.
This is the principle electric diagram of rectifier bridge module for 12 pulses configuration:
Precharge
Devices
+
L1
L2
L1:
L2:
L3:
+:
-:
Input line phase 1
Input line phase 2
Input line phase 3
Output +
Output -
L1-1:
L2-1:
L3-1:
L1-2:
L2-2:
L3-2:
+:
-:
Input line phase 1-1
Input line phase 2-1
Input line phase 3-1
Input line phase 1-2
Input line phase 2-2
Input line phase 3-2
Output +
Output -
L3
This is the principle electric diagram of rectifier bridge module for 24 pulses configuration:
Precharge
Devices
+
L1-1
L2-1
L3-1
-
L1-2
L2-2
L3-2
18
3. Equipment Parts
3.4.1. Air Cooled Rectifier Power Modules
RAD ATV 550 A33 12P
This Rectifier Power Module is used in the following equipment sizes:
ATV 1K3 A33 12P / ATV 1K8 A33 12P /
ATV 2K6 A33 12P
RAD ATV 550 A33 24P
This Rectifier Power Module is used in the following equipment sizes:
ATV 1K3 A33 24P / ATV 1K8 A33 24P /
ATV 2K6 A33 24P
RAD ATV 1K1 A33 12P
This Rectifier Power Module is used in the following equipment sizes:
ATV 3K6 A33 12P / ATV 5K2 A33 12P
For Rectifier Power Module part number see chapter 7.
19
3. Equipment Parts
3.4.2. Water Cooled Rectifier Power Modules
RAD ATV 750 W33 12P
This Rectifier Power Module is used in the following equipment sizes:
ATV 1K6 W33 12P / ATV 2K4 W33 12P /
ATV 3K6 W33 12P
RAD ATV 750 W33 24P
This Rectifier Power Module is used in the following equipment sizes:
ATV 1K6 W33 24P / ATV 2K4 W33 24P /
ATV 3K6 W33 24P
RAD ATV 2K2 W33 12P
This Rectifier Power Module is used in the following equipment sizes:
ATV 4K8 W33 12P / ATV 7K2 W33 12P
20
3. Equipment Parts
3.5.
Control Modules and Control Cards
3.5.1. General
The present paragraph includes:
−
−
−
−
−
connection diagrams of the Control Modules for both Motor Side Inverter and Line Side Converter;
description of control signals ( Control Module of the Motor Side Inverter – Control Module of the Line Side Converter);
connections of voltage and current transducers;
optical fiber connections;
encoder requirements and encoder connection diagram.
The Control Module includes a main CPU Board (SCADA PLUS control card) and several firing and interface cards. The control card
performs all regulation, logic and diagnostics functions. All cards and related power supplies are placed in an assembly (Control Module);
The number of interface and firing cards depends on the inverter size: Table 1 (Line Side Control Module) and Table 2 (Motor Side
Control Module) list the cards used for each equipment size.
The cards and power supplies included in the Control Module are:
GA1, GA2:
Stabilised Power Supply Units providing ±24V power supply to INTVECM interface card/s,
MODVEC and FOVECM cards, INTSYNCB cards (used in Line Side Control Module only) and
INT4TA cards (used only in Line Side Control Module of configurations consisting of several
inverter bridges in parallel), as well as the DCPT and ACCT LEM transducers.
ALIM:
the card providing power supplies for the control card (SCADA PLUS).
SCADA PLUS:
the control card based on a DSP (Digital Signal Processor) dedicated to control algorithms and
a 16-bit microprocessor. The card includes: two phone sockets (one of which is used for
connection to the user's terminal), 2 connectors for serial RS232 and Profibus links,
respectively, and the XM1 terminal board for signal exchange with outside equipment.
INTVECM:
interface card that includes DCPT and CT burden resistors, as well as overcurrent,
overvoltage and current differential hardware protection circuits. Equipment consisting of a
single or 2 inverter bridges in parallel require one INTVEC card only.
MODVEC-S:
modulator card that, driven by the CPU card, generates the waveshapes of IGBT gating
signals. Besides, this card receives the IGBT monitoring signals and implements a range of
diagnostic functions (information is given to the operator by DISP1, on board 7 segment
display).
FOVECM:
expansion card for the 2 parallel inverter bridge. It is equipped to transmit, by fiber-optic link,
the IGBT gating signals and receive, by fiber-optic link, IGBT monitoring signals (information is
given by DISP1, on board 7 segment display).
INTPREA:
interface card that send by optic fiber the “Precharge OK” signal from INTVECM card to
TCPSA card mounted on brige rectifier (used only in DFE configuration).
INTSYNCB:
interface card between synchronism transformers and SCADA PLUS control card
nd
21
3. Equipment Parts
CONTROL CARDS of MOTOR SIDE CONTROL MODULE DFE
EQUIPMENT SIZE
ALIM
SCADA PLUS
INTVECM
MODVEC
FOVECM
ATV 1K3 A33 / ATV 1K8 A33
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33
1
1
1
1
-
1
1
1
1
1
1
ATV 1K6 W33 / ATV 2K4 W33
ATV 3K6 W33
1
1
1
1
-
1
ATV 4K8 W33 / ATV 7K2 W33
1
1
1
1
1
1
EQUIPMENT SIZE
INTPREA
1
CONTROL CARDS of MOTOR SIDE CONTROL MODULE AFE
ALIM
SCADA PLUS
INTVECM
MODVEC
FOVECM
ATV 1K3 A33 / ATV 1K8 A33
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33
1
1
1
1
-
1
1
1
1
1
ATV 1K6 W33 / ATV 2K4 W33
ATV 3K6 W33
ATV 4K8 W33 / ATV 7K2 W33
1
1
1
1
-
1
1
1
1
1
CONTROL CARDS of LINE SIDE CONTROL MODULE
EQUIPMENT SIZE
ALIM
SCADA PLUS
INTVECM
MODVEC
FOVECM
ATV 1K3 A33 / ATV 1K8 A33
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33
1
1
1
1
-
1
1
1
1
1
1
ATV 1K6 W33 / ATV 2K4 W33
ATV 3K6 W33
1
1
1
1
-
1
ATV 4K8 W33 / ATV 7K2 W33
1
1
1
1
1
1
22
INTSYNC
1
3. Equipment Parts
3.5.2. Control Module Electrical Diagrams
Single Inverter Sizes – DFE Configuration - Motor Side Control Module Electrical Diagram
23
3. Equipment Parts
24
3. Equipment Parts
25
3. Equipment Parts
2 Inverter in Parallel Sizes - DFE configuration - Motor Side Control Module Electrical Diagram
26
3. Equipment Parts
27
3. Equipment Parts
28
3. Equipment Parts
Single Inverter Sizes – AFE Configuration - Motor Side Control Module Electrical Diagram
29
3. Equipment Parts
30
3. Equipment Parts
31
3. Equipment Parts
2 Inverter in Parallel Sizes - AFE configuration - Motor Side Control Module Electrical Diagram
32
3. Equipment Parts
33
3. Equipment Parts
34
3. Equipment Parts
Single Inverter Sizes – AFE Configuration - Line Side Control Module Electrical Diagram
35
3. Equipment Parts
36
3. Equipment Parts
37
3. Equipment Parts
2 Inverter in parallel Sizes – AFE Configuration - Line Side Control Module Electrical Diagram
38
3. Equipment Parts
39
3. Equipment Parts
40
3. Equipment Parts
3.5.3. Control Cards
SCADA PLUS Main CPU Card
Layout of SCADA PLUS Card
SCADA PLUS Control Card
Card description:
U1: microprocessor
U36: FLASH memory
U7: EEProm
U56: coprocessor
XM1: control terminal board
X5: Synchronous interface (Fieldbus)
RL1, RL2, RL3: Relays
K3: RS232 / 485HD serial connectors
K4/K5: expansion board connectors
KUA1, KUB1: UCS interface connectors (opt.)
X3: Basic/Advanced Features Keypads
X7: Digital I/O expansion card (SIOVA)
41
3. Equipment Parts
Microprocessor Plus Control Terminal Block
42
3. Equipment Parts
SCADA PLUS Card jumpers and switches
Name
JP1
JP2
Default
ON
OFF
3 2 1
JP3
1-2
3 2 1
JP4
2-3
3 2 1
JP5
1-2
3 2 1
JP6
3 2 1
JP7
3 2 1
JP8
JP13
JP14
JP15
2-3
1-2
1-2
1-2
3 2 1
3 2 1
JP18
JP19
2-3
OFF for all SVTL sides
1-2
ON for all SVTL sides
2-3
Open for all SVTL sides
1-2
Analog output PWM0
2-3
Analog output VA
1-2
Analog output ±10V or 0÷10V
2-3
Analog output 4-20mA
1-2
Analog output PWM1
1-2
EEprom
/
/
Analog
outputs
Analog
outputs
Analog
outputs
2-3
Analog output VB
1-2
Analog output ±10V or 0÷10V
2-3
Analog output 4-20mA
Analog
outputs
1-2
Reserved sw download
Reserved
Reserved
Connects TX232 to X3 for Keypad Advanced
/
/
/
Serial link
OFF
OFF
ON
3 2 1
JP16
JP17
Function
ON
EErom write protection
1-2
OFF for all SVTL sides
2-3
Connects I2C – clock to X3, only for future development
1-2
Connects RX232 to X3 for Keypad Advanced
2-3
Connects I2C – data to X3, ,only for future development
1-2
RX - RS232
2-3
RX - RS485
Serial link
Serial link
Serial link
/
ON
OFF
RS485 line ended on 221ohm
Reserved
JP22
ON
Reserved
Serial link
JP23
OFF
Reserved
/
SW1 - 1
OFF
ON
At XM1-5 terminal, the supply (+5V) is available for encoder
Encoder
SW1 - 2
ON
OFF
ON
External power supply 12-24V
Load resistance (121Ω) connected to channel A (LINE-DRIVER encoder)
Encoder
Load resistance (121Ω) connected to channel B (LINE-DRIVER encoder)
Encoder
ON
OFF
Load resistance (121Ω) connected to channel Z (LINE-DRIVER encoder)
Encoder
ON
Current input on XM1-28/29 (R=475Ω)
OFF
Voltage input on XM1-28/29
Analog
inputs
ON
Current input on XM1-26/27 (R=475Ω)
OFF
ON
Voltage input on XM1-26/27
Pull-up to 10V on XM1-26/27
SW1 – 3
OFF
ON
ON
OFF
SW1 - 4
ON
SW3 - 1
OFF
SW3 - 2
OFF
SW3 – 3
OFF
OFF
Analog
inputs
Analog
inputs
Pull-down to 0V on XM1-26/27
Analog
inputs
OFF
PC In terface: ON for RS485 , OFF for RS232
/
OFF
PC In terface: ON for RS485 , OFF for RS232
/
DP1 - 3
OFF
PC In terface: OFF for RS485 , OFF for RS232
/
DP1 - 4
OFF
PC In terface: OFF for RS485 , OFF for RS232
/
SW3 - 4
OFF
DP1 - 1
DP1 - 2
ON
OFF
43
3. Equipment Parts
Table - SCADA PLUS control terminal block
Warnings: Do not connect voltage signals greater than 24 VDC to input connections
Function
Description
XM1 Label
Relay
3
NO
Fault Output Relay
5A – 250VAC
RO1 Fault NO
4
COM
RO1 Fault Com
44
NC
5A – 250VAC
RO1 Fault NC
1
NO Configurable Output Relay
5A – 250VAC
RO2 Prog NO
2
COM
RO2 Prog Com
43
NC
5A – 250VAC
RO2 Prog NC
45
COM
RO3 Prog NO
46
NO Configurable Output Relay
5A – 250VAC
RO3 Prog Com
Encoder Power
5
5V-150mA-Isolated Encoder Supply-must be switched off
Encoder +5V
Supply
(SW1_A :OFF) to connect external 12-24V supply
6
Isolated encoder 0V
Encoder gnd
Encoder Interface 7
Channel B
5-12-24V (1024 PPR). With line driver encoder 5V connect set SW1_B to
8
Channel /B
ON positon (121Ω load resistance connected to encoder output signals )
9
Channel A
5-12-24V (1024 PPR). With line driver encoder 5V connect set SW1_C to
10
Channel /A
ON positon (121Ω load resistance connected to encoder output signals )
11
Channel Z
(If necessary) 5-12-24V. With line driver encoder 5V connect set SW1_D to
12
Channel /Z
ON positon (121Ω load resistance connected to encoder output signals)
Digital Inputs
13
DI 1 Start/Stop
The application of +24 VDC will cause the drive to start and ramp up in speed
The removal of +24 VDC will cause the drive to ramp down in speed and to
stop.
14
15
16
17
18
19
20
24V Isolated Input – Hi = Ramp speed in the reverse direction – Low = Ramp down
24V Isolated Input 8mA - Programmable
24V Isolated Input 8mA - Programmable
24V Isolated Input 8mA - Programmable
24V Isolated Input 8mA - Programmable
24V Isolated Input 8mA - Programmable
21
DI 2 Prog
DI 3 Prog
DI 4 Prog
DI 5 Prog
DI 6 Prog
DI 7 Prog
DI 8 Drive
enable
DO 4/DI 9(***)
22
DO 5/DI 10(***)
Digital Output
23
D0 6 (***)
Digital Power
Supply
24
DI supply+24V
25
26
DI /DO ground
AI 1+
27
AI 1-
28
AI 2+
Isolated Programmable Differential Inputs. Inputs can be:
a)Through 5-10KΩ potentiometer.(Nom 5KΩ)
b) External Voltage Signal ±10V. Input Impedance 40 KΩ
c) External Current Signal 0/4-20mA. Input Impedance 475Ω
29
34
35
36
37
38
39
40
41
42
AI 2AO 1
AO 2
AI/AO ground
AO 3
AO 4
AI/AO ground
+10Vdc
AI/AO ground
-10Vdc
Isolated Programm.-PWM, 0/4-20mA,0-10VDC or ±10VDC-5mA
Isolated Programm.-PWM, 0/4-20mA,0-10VDC or ±10VDC-5mA
0V Isolated Analog Supply
Isolated Programmable-0-10VDC or ±10VDC-5mA
Isolated Programmable-0-10VDC or ±10VDC-5mA
0V Isolated Analog Supply
+10VDC – 5mA potentiometer power supply
0V Isolated Analog Supply
-10VDC – 5mA potentiometer power supply
Digital
Inputs/Outputs
Analog Inputs
Analog Outputs
Analog Reference
44
24V Isolated Input – Drive Enable – Hi = Drive Enabled – Low = Drive Disabled
24V-10mA Isolated Output /
Input 8mA – Progammable.
24V-10mA Isolated Output /
Input 8mA – Progammable.
24V-10mA Isolated Output – Programmable
Protected with autorestoring fuse
100 mA -24V Isolated Digital Supply
Protected with autorestoring fuse
0V Isolated Digital Supply
3. Equipment Parts
MODVEC-S Modulator Card
Layout of MODVEC-S Card
45
3. Equipment Parts
X1:
X2:
X3:
X4:
X5:
X7:
X8:
HL1:
HL2:
HL15:
HL16:
HL18:
HL19:
HL20:
HL22:
HL3:
HL23:
HL4:
HL29:
HL5:
HL24:
HL6:
HL30:
HL7:
HL25:
HL8:
HL31:
HL9:
HL26:
HL10:
HL32:
HL11:
HL27:
HL12:
HL33:
HL13:
HL28:
HL14:
HL34:
Connector for signal exchange with SCADA PLUS card
Not used for Silcovert ATV equipment
Connector for serial link connection with SCADA PLUS card
Not used for Silcovert ATV equipment
connector for P24V/N24V power supply
Logic inputs (Main Circuit Breaker closing command)
Connector tor commands sent to the first FOVECM card (config. with 2 parallel bridges)
red led: ON means trip of the WDOG protection
red led: ON/OFF means proper equipment operation
green led: ON means that P6,5V power supply is available
green led: ON means that P5SMIN power supply ( from P6,5V ) is available
green led: ON means that P5MIN power supply is available.
green led: ON means that P5MAX power supply is available
green led: ON means that P24MIN power supply is available
green led: ON means that P5V power supply (obtained from P24 V ) is available
red led: ON means that gating pulses of PP, positive arm of U phase are released
green led: OFF means gating anomaly of PP, positive arm of U phase
red led: ON means that gating pulses of P, positive arm of U phase are released
green led: OFF means gating anomaly of P, positive arm of U phase
red led: ON means that gating pulses of N, negative arm of U phase are released
green led: OFF means gating anomaly of N, negative arm of U phase
red led: ON means that gating pulses of NN, negative arm of U phase, are released
green led: OFF means gating anomaly of NN, negative arm of U phase
red led: ON means that gating pulses of PP, positive arm of V phase, are released
green led: OFF means gating anomaly of PP, positive arm of V phase
red led: ON means that gating pulses of P, positive arm of V phase, are released
green led: OFF means gating anomaly of P, positive arm of V phase
red led: ON means that gating pulses of N, negative arm of V phase, are released
green led: OFF means gating anomaly of N, negative arm of V phase
red led: ON means that gating pulses of NN, negative arm of V phase, are released
green led: OFF means gating anomaly of NN, negative arm of V phase
red led: ON means that gating pulses of PP, positive arm of W phase, are released
green led: OFF means gating anomaly of PP, positive arm of W phase
red led: ON means that gating pulses of P, positive arm of W phase, are released
green led: OFF means gating anomaly of P, positive arm of W phase
red led: ON means that gating pulses of N, negative arm of W phase, are released
green led: OFF means gating anomaly of N, negative arm of W phase
red led: ON means that gating pulses of NN, negative arm of W phase, are released
green led: OFF means gating anomaly of NN, negative arm of W phase
D9 to D24:
D50 to D61:
DISP1 :
transmitters of gating signals to the firing cards of phases U, V and W
receivers of monitoring signals from gating cards of positive and negative arms of phases U, V and W
displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been detected.
In the case of protection trip, the meaning of the coded information displayed on DISP1 can be found in paragraph 6.6.
46
3. Equipment Parts
MODVEC-S Card jumpers setting
CAUTION
The MODVEC card before being installed in any ATV Equipment, must be customized
(by setting jumpers and switches) for the actual application, as a function of equipment
size.
ATV 1K3 A33 / ATV 1K8 A33 / ATV 2K6 A33
ATV 1K6 W33 / ATV 2K4 W33 / ATV 3K6 W33
XJ1
XJ2
XJ3
XJ4
XJ5
XJ6
XJ7
1–2
2–3
2–3
2–3
2–3
Open
1–2
XJ1
XJ2
XJ3
XJ4
XJ5
XJ6
XJ7
1–2
2–3
2–3
2–3
1–2
Open
1–2
SW1-SW2
SW4-SW15
SW1-SW2
SW4-SW15
ATV 3K6 A33 / ATV 5K2 A33
ATV 4K8 W33 / ATV 7K2 W33
The switch SW3 is used to select the switching frequency value of the inverter at 780 Hz or 1000 Hz :
Fsw
[Hz]
SW3
1000
780
47
3. Equipment Parts
INTVECM Analog Interface Card
Layout of INTVECM Card
48
3. Equipment Parts
X1:
X2A:
X2B:
X3A:
X3B:
X4:
X5A:
X5B:
X6:
X7:
X8:
HL1:
HL2:
HL3:
HL4:
HL5:
DISP1:
P24V / N24V power supply terminal board
Terminal board for VDC1 transducer signals and PREC_OK logic output signal
Terminal board for VDC2 transducer signal and PREC_OK logic output signal
Terminal board for current transducer signals of inverter bridge no 1
Terminal board for current transducer signals of inverter bridge no 2
Connector for connection to SCADA PLUS card
Not used
Not used
Connector for connection with ALIM power supply card
Logic inputs
Not used
green led: ON means that P15V power supply is available
green led: ON means that N15V power supply is available
green led: ON means that P24V power supply is available
green led: ON means that N24V power supply is available
green led: ON means that the precharge phase has successfully ended
displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been detected. In the case of
protection trip, the meaning of the coded information displayed by DISP 1 can be found in paragraph 6.6.
The following table shows the labels of the solder terminals of burden and gain-setting resistors of the following signals:
IDC current and phase currents in the case of single inverter bridge or two bridges in parallel (IR1/2, IS1/2, IT1/2)
DC voltages VDC1 and VDC2
Gain of signals related to phase currents IR, IS, IT
SIGNAL
TERMINAL BOARD
IR1
X3A – 01
IS1
X3A – 04
IT1
X3A – 07
VDC1
X2A – 04
VDC2
X2B – 01
IR2
X3B – 01
IS2
X3B – 04
IT2
X3B – 07
IR Current gain
------------
IS Current gain
------------
IT Current gain
------------
SOLDER TAG
T17 (signal) – T19 (ground)
T18 (signal) – T2O (ground)
T21 (signal) – T23 (ground)
T22 (signal) – T24 (ground)
T25 (signal) – T27 (ground)
T26 (signal) – T28 (ground)
T33 (signal) – T35 (ground)
T34 (signal) – T36 (ground)
T13 (signal) – T15 (ground)
T14 (signal) – T16 (ground)
TO1 (signal) – TO3 (ground)
TO2 (signal) – TO4 (ground)
TO5 (signal) – TO7 (ground)
TO6 (signal) – TO8 (ground)
TO9 (signal) – T11 (ground)
T1O (signal) – T12 (ground)
T45 – T46 ( R 204 )
T47 – T48 ( R 202 )
T41 – T42 ( R 199 )
T43 – T44 ( R 197 )
T37 – T38 ( R 194 )
T39 – T40 ( R 192 )
49
3. Equipment Parts
Customizing INTVECM Card
All resistors for customization of signals generated by voltage and current transducers must have tolerance ±1% and rated power 0,5 W
@ 70°C
Full scale values:
Currents on a.c. side:
Voltages on d.c. side :
5 V @ IACMAX
5 V @ VDCMAX
For customization of INTVECM cards, refer to the tables of this paragraph that indicate how to perform this operation taking into account
the equipment size and the type of Control Module (on Motor side or Line side).
ATV 1K3 A33 / ATV 1K6 W33
SIGNALS AND
POSITION
IR1 (T17-T19)
IR1 (T18-T20)
IS1 (T21-T23)
IS1 (T22-T24)
IT1 (T25-T27)
IT1 (T26-T28)
IR2 (T01-T03)
IR2 (T02-T04)
IS2 (T05-T07)
IS2 (T06-T08)
IT2 (T09-T11)
IT2 (T10-T12)
VDC1 (T33-T35)
VDC1 (T34-T36)
VDC2 (T13-T15)
VDC2 (T14-T16)
IDC (T29-T31)
IDC(T30-T32)
VALUE OF
BURDEN RESISTORS
100 // 100 // 475
6810 // 6810
100 // 100 // 475
6810 // 6810
100 // 100 // 475
6810 // 6810
Open
Jumper
Open
Jumper
Open
Jumper
100
Open
100
Open
Open
Open
ATV 1K8 A33 / ATV 2K4 W33
SIGNALS AND
VALUE OF
POSITION
BURDEN RESISTORS
IR1 (T17-T19)
82,5 // 82,5 // 121
IR1 (T18-T20)
1K // 22K1 // 33K2
IS1 (T21-T23)
82,5 // 82,5 // 121
IS1 (T22-T24)
1K // 22K1 // 33K2
IT1 (T25-T27)
82,5 // 82,5 // 121
IT1 (T26-T28)
1K // 22K1 // 33K2
IR2 (T01-T03)
Open
IR2 (T02-T04)
Jumper
IS2 (T05-T07)
Open
IS2 (T06-T08)
Jumper
IT2 (T09-T11)
Open
IT2 (T10-T12)
Jumper
VDC1 (T33-T35)
100
VDC1 (T34-T36)
Open
VDC2 (T13-T15)
100
VDC2 (T14-T16)
Open
IDC (T29-T31)
Open
IDC(T30-T32)
Open
ATV 2K6 A33 / ATV 3K6 W33
SIGNALS AND
POSITION
IR1 (T17-T19)
IR1 (T18-T20)
IS1 (T21-T23)
IS1 (T22-T24)
IT1 (T25-T27)
IT1 (T26-T28)
IR2 (T01-T03)
IR2 (T02-T04)
IS2 (T05-T07)
50
VALUE OF
BURDEN RESISTORS
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
Open
Jumper
Open
3. Equipment Parts
IS2 (T06-T08)
IT2 (T09-T11)
IT2 (T10-T12)
VDC1 (T33-T35)
VDC1 (T34-T36)
VDC2 (T13-T15)
VDC2 (T14-T16)
IDC (T29-T31)
IDC(T30-T32)
Jumper
Open
Jumper
100
Open
100
Open
Open
Open
ATV 3K6 A33 / ATV 4K8 W33
SIGNALS AND
POSITION
IR1 (T17-T19)
IR1 (T18-T20)
IS1 (T21-T23)
IS1 (T22-T24)
IT1 (T25-T27)
IT1 (T26-T28)
IR2 (T01-T03)
IR2 (T02-T04)
IS2 (T05-T07)
IS2 (T06-T08)
IT2 (T09-T11)
IT2 (T10-T12)
VDC1 (T33-T35)
VDC1 (T34-T36)
VDC2 (T13-T15)
VDC2 (T14-T16)
IDC (T29-T31)
IDC(T30-T32)
R194, R199, R204
VALUE OF
BURDEN RESISTORS
82,5 // 82,5 // 121
1K // 22K1 // 33K2
82,5 // 82,5 // 121
1K // 22K1 // 33K2
82,5 // 82,5 // 121
1K // 22K1 // 33K2
82,5 // 82,5 // 121
1K // 22K1 // 33K2
82,5 // 82,5 // 121
1K // 22K1 // 33K2
82,5 // 82,5 // 121
1K // 22K1 // 33K2
100
Open
100
Open
Open
Open
15K
51
3. Equipment Parts
ATV 5K2 A33 / ATV 7K2 W33
SIGNALS AND
POSITION
IR1 (T17-T19)
IR1 (T18-T20)
IS1 (T21-T23)
IS1 (T22-T24)
IT1 (T25-T27)
IT1 (T26-T28)
IR2 (T01-T03)
IR2 (T02-T04)
IS2 (T05-T07)
IS2 (T06-T08)
IT2 (T09-T11)
IT2 (T10-T12)
VDC1 (T33-T35)
VDC1 (T34-T36)
VDC2 (T13-T15)
VDC2 (T14-T16)
IDC (T29-T31)
IDC(T30-T32)
R194, R199, R204
VALUE OF
BURDEN RESISTORS
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
82,5 // 82,5 // 82,5
82,5 // 1820 // 1820
100
Open
100
Open
Open
Open
15K
INTVECM Card jumpers setting
ATV 1K3 A33 / ATV 1K8 A33 / ATV 2K6 A33
ATV 1K6 W33 / ATV 2K4 W33 / ATV 3K6 W33
XJ0
XJ1
XJ5
XJ6
XJ7
XJ8
XJ9
XJ10
XJ11
XJ12
XP20
2-3
1–2
2-3
Close
Close
Open
2-3
1-2
1-2
Open
2–3
ATV 3K6 A33 / ATV 5K2 A33
ATV 4K8 W33 / ATV 7K2 W33
52
XJ0
XJ1
XJ5
XJ6
XJ7
XJ8
XJ9
XJ10
XJ11
XJ12
XP20
2-3
1 -2
2-3
Close
Close
Open
2-3
2-3
1-2
Close
2–3
3. Equipment Parts
FOVECM Optic Fibres Expansion Card
Layout of FOVECM Card
X1:
X2:
X3:
P24V power supply connector
Connector for connection with: MODVEC card (X8 connector), when the FOVECM card under consideration is associated with
the 2nd parallel bridge a former FOVECM card (X3 connector), when the FOVECM card under consideration is associated with
the 3rd or 4th parallel bridge.
Connector for connection of the FOVECM card under consideration with a latter FOVECM card (X2 connector) associated with
the 3rd or 4th parallel bridge. A termination plug (order code ELP22586908) shall be inserted in the X3 socket of the card
associated with the last parallel.
53
3. Equipment Parts
The following signals pass through X2 and X3 connectors:
•
12 IGBT gating commands;
•
12 monitor signals that check gating of positive and negative arms of the phase module;
•
the summarized protection signal: 0ANGU_ESPFO;
•
the reset signal: RIPRISTINO_MOD.
HL9:
HL10:
HL20:
HL23:
HL26:
HL29:
HL21:
HL24:
HL27:
HL30:
HL22:
HL25:
HL28:
HL31:
DISP1:
green led: ON means that the P24P power supply is available.
green led: ON means that the P5_ESPFO power supply is available
green led: OFF means gating anomaly of PP, positive arm of U phase
green led: OFF means gating anomaly of P, positive arm of U phase
green led: OFF means gating anomaly of N, negative arm of U phase
green led: OFF means gating anomaly of NN, negative arm of U phase
green led: OFF means gating anomaly of PP, positive arm of V phase
green led: OFF means gating anomaly of P, positive arm of V phase
green led: OFF means gating anomaly of N, negative arm of V phase
green led: OFF means gating anomaly of NN, negative arm of V phase
green led: OFF means gating anomaly of PP, positive arm of W phase
green led: OFF means gating anomaly of P, positive arm of W phase
green led: OFF means gating anomaly of N, negative arm of W phase
green led: OFF means gating anomaly of NN, negative arm of W phase
displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been; detected. In the case of
protection trip, the meaning of the coded information displayed by DISP1 can be found in paragraph 6.6.
FOVECM Card jumpers setting
The FOVECM card is used in the ATV Control Modules in the case of equipment configurations with 2 bridges in parallel ( it is not
included in the case of single inverter bridge )
This paragraph gives the tables for setting the jumpers ( XJ0, XJ1, XJ2 and XJ3 ) located on the card.
ATV 3K6 A33 / ATV 5K2 A33
ATV 4K8 W33 / ATV 7K2 W33
54
XJ0
XJ1
XJ2
XJ3
Close
Close
1-2
1-2
3. Equipment Parts
INTPREA Diode Front End Precharge Interface Card
Layout of INTPREA Card
This card is used only in motor side – DFE configuration control module.
XAL:
XIN:
XP:
DL1:
DL2:
DL3:
DL4:
RC1:
TR1:
RC2:
TR2:
Power supply terminal board.
Terminal board for input “Precharge OK” from INTVECM card
Terminal board for output signals to MODVEC-S card.
Green led: ON means that the power supply is available.
Green led: ON means that the precharge is OK
Red led: ON means protection Thyristor command error on bridge rectifier n° 1
Red led: ON means protection Thyristor command error on bridge rectifier n° 2
fiber-optic link receiver of protection “thyristors command error” from TCPSA card on bridge rectifier n° 1
fiber-optic link transmitter of “Precharge OK” signal to TCPSA card on bridge rectifier n° 1
fiber-optic link receiver of protection “thyristors command error” from TCPSA card on bridge rectifier n° 2
fiber-optic link transmitter of “Precharge OK” signal to TCPSA card on bridge rectifier n° 2
55
3. Equipment Parts
INTSYNCB Active Front End Line Voltage Interface Card
Layout of INTSYNCB Card
This card is used only in line side control module.
X1:
X2:
X3:
HL1:
HL2:
P24V/N24V power supply terminal board.
Terminal board for input synchronization signals
Terminal board for output signals to SCADA PLUs card.
Green led: ON means that the P15V power supply is available.
Green led: ON means that the N15V power supply is available.
Customizing INTSYNCB Card
Component
T01 –T02 (R19)
T03 –T04 (R20)
T05 –T06 (R21)
T07 –T08 (R22)
T09 –T10 (R23)
T11 –T12 (R24)
56
Values of burden
resistors
6810
2 x 267K //
301K // 3,3 M
jumpers
Setting
JP1 – JP2 – JP3 – JP4
Open
3. Equipment Parts
3.5.4. Connections of Current Transducers, Voltage Transducers and Optic Fibres
This paragraph includes the tables that list the connections of current transducers (on the a.c. side of Inverter Bridges) to the INTVECM
card, of optic fibers from MODVEC and FOVECM cards to the TGUNTNB card and of voltage transducers (on d.c. side of Inverter
Bridges) to the INTVECM card.
The connections of the Line Side Control Module are identical to those of Motor Side Control Module.
CURRENT TRANSDUCERS (INTVECM)
INTVECM 1st and 2nd
Function
inverter bridge
Name
Terminals
IR1 M
X3A-1
IR1 +
IR1 IS1 M
IS1 +
IS1 IT1 M
IT1 +
IT1 IR2 M
IR2 +
IR2 IS2 M
IS2 +
IS2 IT2 M
IT2 +
IT2 -
Terminals
—
—
X3A-2
—
X3A-3
—
X3A-4
—
X3A-5
—
X3A-6
—
X3A-7
—
X3A-8
—
X3A-9
Current measure of U1 phase
TADC power supply, U1 phase, positive
TADC power supply, U1 phase, negative
Current measure of V1 phase
TADC power supply, V1 phase, positive
TADC power supply, V1 phase, negative
Current measure of W1 phase
TADC power supply, W1 phase, positive
TADC power supply W1 phase, negative
—
X3B-1
Current measure of U2 phase
—
X3B-2
TADC power supply, U2 phase, positive
—
X3B-3
TADC power supply, U2 phase, negative
—
X3B-4
Current measure of V2 phase
—
X3B-5
TADC power supply, V2 phase, positive
—
X3B-6
TADC power supply, V2 phase, negative
—
X3B-7
Current measure of W2 phase
—
X3B-8
TADC power supply, W2 phase, positive
—
X3B-9
TADC power supply W2 phase, negative
In all ATV configurations, the voltage transducers are always connected to the INTVECM card according to the following table.
VOLTAGE TRANSDUCER CONNECTIONS
Label
Terminals
Function
VDC1 M
X2A-4
DC1 bus, voltage measure
VDC1 +
X2A-5
VDC1 power supply, positive
VDC1 -
X2A-6
TVDC1 power supply, negative
VDC2 M
X2B-1
DC2 bus, voltage measure
VDC2 +
X2B-2
VDC2 power supply, positive
VDC2 -
X2B-3
TVDC2 power supply, negative
57
3. Equipment Parts
OPTIC FIBERS CONNECTIONS
CARDS
MODVEC
st
1 bridge
Name
A1HU1
A1HU1M
A1HU2
A1HU2M
A1HU3
A1HU3M
A1HU4
A1HU4M
terminal
D9
D50
D10
D53
D11
D56
D12
D59
A1HV1
A1HV1M
A1HV2
A1HV2M
A1HV3
A1HV3M
A1HV4
A1HV4M
D15
D51
D16
D54
D17
D57
D18
D60
A1HW1
A1HW1M
A1HW2
A1HW2M
A1HW3
A1HW3M
A1HW4
A1HW4M
D21
D52
D22
D55
D23
D58
D24
D61
A1HU21
A1HU21M
A1HU22
A1HU22M
A1HU23
A1HU23M
A1HU24
A1HU24M
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
A1HV21
A1HV21M
A1HV22
A1HV22M
A1HV23
A1HV23M
A1HV24
A1HV24M
A1HW21
A1HW21M
A1HW22
A1HW22M
A1HW23
A1HW23M
A1HW24
A1HW24M
58
FOVECM
TGUNTNB
TGUNTNB
card
card
terminal
label
component
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
APP 1
APP 1
AP 1
AP 1
AN 1
AN 1
ANN 1
ANN 1
APP 1
APP 1
AP 1
AP 1
AN 1
AN 1
ANN 1
ANN 1
APP 1
APP 1
AP 1
AP 1
AN 1
AN 1
ANN 1
ANN 1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
D1
D20
D2
D21
D3
D22
D4
D23
APP 2
APP 2
AP 2
AP 2
AN 2
AN 2
ANN2
ANN 2
APP 2
APP 2
AP 2
AP 2
AN 2
AN 2
ANN 2
ANN 2
APP 2
APP 2
AP 2
AP 2
AN 2
AN 2
ANN 2
ANN 2
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
RC1
TR1
nd
2
bridge
D5
D24
D6
D25
D7
D26
D8
D27
D9
D28
D10
D29
D11
D30
D12
D31
Function
U11PP firing
U11PP Monitoring
U21P Firing
U21P Monitoring
U31N Firing
U31N Monitoring
U41NN Firing
U41NN Monitoring
V11PP Firing
V11PP Monitoring
V21P Firing
V21P Monitoring
V31N Firing
V31N Monitoring
V41NN Firing
V41NN Monitoring
W11PP Firing
W11PP Monitoring
W21P Firing
W21P Monitoring
W31N Firing
W31N Monitoring
W41NN Firing
W41NN Monitoring
U21PP Firing
U21PP Monitoring
U22P Firing
U22P Monitoring
U23N Firing
U23N Monitoring
U24NN Firing
U24NN Monitoring
V21PP Firing
V21PP Monitoring
V22P Firing
V22P Monitoring
V23N Firing
V23N Monitoring
V24NN Firing
V24NN Monitoring
W21PP Firing
W21PP Monitoring
W22P Firing
W22P Monitoring
W23N Firing
W23N Monitoring
W24NN Firing
W24NN Monitoring
3. Equipment Parts
OPTIC FIBERS CONNECTIONS
Name
HVTHR11
HVTHR11M
HVTHR21
HVTHR21M
INTPREA card
TCPSA card
TCPSA card
terminal
label
component
A1
RC1
A1
TR1
A1
RC1
A1
TR1
TR1
RC1
TR2
RC2
Function
“Precharge OK” signal for rectifier bridge 1
Rectifier bridge 1 monitoring
“Precharge OK” signal for rectifier bridge 2
Rectifier bridge 2 monitoring
59
3. Equipment Parts
3.6.
Inverter Current and DC Voltage Transducers
The following tables give information about voltage and current transducers used in different configurations and sizes.
EQUIPMENT SIZE
TA LEM CURRENT
TRANSDUCER
ATV 1K3 A33 12P/24P
ATV 1K8 A33 12P/24P
2
2
3
3
ATV 2K6 A33 12P/24P
ATV 3K6 A33 12P/24P
ATV 5K2 A33 12P/24P
2
2
2
3
6
6
ATV 1K6 W33 12P/24P
ATV 2K4 W33 12P/24P
ATV 3K6 W33 12P/24P
ATV 4K8 W33 12P/24P
2
2
2
2
3
3
3
6
ATV 7K2 W33 12P/24P
2
6
EQUIPMENT SIZE
3.7.
TVDC LEM VOLTAGE
TRANSDUCER
TVDC LEM VOLTAGE
TRANSDUCER
TA LEM CURRENT
TRANSDUCER
ATV 1K6 W33 AFE
ATV 2K4 W33 AFE
2+2
2+2
3+3
3+3
ATV 3K6 W33 AFE
ATV 4K8 W33 AFE
ATV 7K2 W33 AFE
2+2
2+2
2+2
3+3
6+6
6+6
Inverter Firing Card and Isolated Supply
Altivar Equipments include Medium Voltage IGBT Inverter Phase Modules. Each IGBT needs a gate drive card TGUNTNB that
commands IGBT turn-on and turn-off by application of proper voltage signals to its gate terminals. Insulated, turn-on and turn off logic
signals from the Control Modules reach the gate drive cards by optic fiber link.
Each Inverter Phase Module includes 4 IGBT's, of which two are indicated as "EXTERNAL" and the other two as "INTERNAL", depending
on their function.
By consequence, as for the relevant IGBTs, the gate drive cards are indicated as "INTERNAL" (TGUNTNB-INT ) or "EXTERNAL" (
TGUNTNB-EXT ). These two card types are different from each other only because of some tuning components.
The power supply of TGUNTNB cards consists of a 28V - 80 kHz square wave voltage delivered by the TALIMB card (that converts 220V50Hz into 200V-80kHz voltage) through a step-down transformer (TRAL80) that lowers the output voltage delivered by the TALIMB card
from 200 to 28 V (at 80 kHz).
The following drawing shows the connection diagram of the power supply of the gate drive cards located inside the Inverter Phase
Modules.
60
3. Equipment Parts
Inside the TALIMB card, located inside the Control Cubicle, three LEDs are clearly visible that monitor the operating modes of the card,
more precisely: if the green LEDs are on, the card is operating properly while the red LED, if on, means malfunction.
In the case that all LEDs are off, check the fuses inside the card, once switched off the power supply and verified that no voltage is
available at input terminals J1-1 and J1-2.
WARNING
•
Inside the TALIMB card the voltage reaches 200V a.c. at a frequency of
80 kHz: getting in touch with such voltage is very dangerous for
operators' safety.
•
Inside the power supply card, TALIMB, no isulation exists between the
220V - 50/60 Hz input and the 200V - 80 KHz output. An insulation
transformer is therefore always interposed on the input side. For
safety reason, the output terminal J2-2 must always be grounded;
therefore no grounding connection is allowed on the input side of the
TALIMB card.
61
3. Equipment Parts
The following table lists the IGBT firing cards and related power supply, as used by different configurations and sizes.
62
EQUPMENT SIZE
TALIMB
FIRING CARD
POWER SUPPLY
TRAL80
POWER SUPPLY
TRANSFORMER
TGUNTNB - EXT
FIRING CARD
TGUNTNB - INT
FIRING CARD
ATV 1K3 A33 12P/24P
ATV 1K8 A33 12P/24P
ATV 2K6 A33 12P/24P
ATV 3K6 A33 12P/24P
1
1
1
1
2
2
2
3
6
6
6
12
6
6
6
12
ATV 5K2 A33 12P/24P
1
3
12
12
ATV 1K6 W33 12P/24P
ATV 2K4 W33 12P/24P
1
1
2
2
6
6
6
6
ATV 3K6 W33 12P/24P
ATV 4K8 W33 12P/24P
ATV 7K2 W33 12P/24P
1
1
1
2
3
3
6
12
12
6
12
12
EQUPMENT SIZE
TALIMB
FIRING CARD
POWER SUPPLY
TRAL80
POWER SUPPLY
TRANSFORMER
TGUNTNB - EXT
FIRING CARD
TGUNTNB - INT
FIRING CARD
ATV 1K6 W33 AFE
ATV 2K4 W33 AFE
1
1
6+6
6+6
6+6
6+6
ATV 3K6 W33 AFE
ATV 4K8 W33 AFE
ATV 7K2 W33 AFE
1
2
2
6+6
12 + 12
12 + 12
6+6
12 + 12
12 + 12
6
3. Equipment Parts
3.7.1. Layout of TALIMB 80 kHz Power Supply
J1:
Input power supply (50 / 60 Hz) terminal board
J2:
Output (80 kHz) terminal board
FU1:
4A – 250V fuse
FU2:
4A – 250V fuse
DL16:
green led: ON means that power supply of inside power circuits is available
DL16A:
green led: ON means that power supply of inside control circuits is available
DL17:
red led: ON means trip of hardware internal overcurrent protection (output overload or short-circuit)
63
3. Equipment Parts
3.7.2. Layout of TGUNTNB IGBT Firing Card
XAL:
DL1:
DL2:
DL3:
RC1:
TR1:
power supply terminal board (connected to TALPTNA card)
green led: ON means power supply available
red led: ON means power supply failure
red led: ON means protection trip due to a fault detected by the Gate Unit
fiber-optic link receiver of firing command
fiber-optic link transmitter of Gate Unit monitoring signal (no light means fault)
CAUTION
The INTERNAL and EXTERNAL TGUNTNB cards are different because
some components have different values; therefore they cannot be exchanged between
each other and have different order codes
As far as the jumper JP1 is concerned, the customization logic is:
64
TGUNTNB
Jumper JP1
INTERNAL
EXTERNAL
1–2
3–2
3. Equipment Parts
Locations of the 4 TGUNTNB cards, 2 of EXT ( external ) and 2 of INT ( internal ) type, inside the inverter phase module:
External TGUNTNB
card (APP)
Internal TGUNTNB card
(AP)
Internal TGUNTNB card
(AN)
External TGUNTNB
card (ANN)
TALPTNA card
3.7.3. Layout of TALPTNA Supply Card
XM1:
XM2:
80 kHz power supply terminal board
output terminal board (connected to TGUNTNB card)
65
3. Equipment Parts
3.8.
Rectifier Bridge Firing Card
3.8.1. Layout of TCPSA Thyristor Firing Card
This card is used only in DFE configuration.
XM1:
XM2:
DL1:
RC1:
TR1:
RC2:
TR2:
66
80 kHz power supply terminal board
thyristors firing command terminal board
green led: ON means power supply available
fiber-optic link receiver of “Precharge OK” signal
fiber-optic link transmitter of protection “thyristors command error” to INTPREA card
fiber-optic link receiver of protection “thyristors command error” from another TCPSA card
fiber-optic link transmitter of “Precharge OK” signal to another TCPSA card
3. Equipment Parts
3.9.
Insulated Transmitter Interface Card
Temperature detectors (thermal switches), suited to protect the inverter in the case of malfunction of the cooling circuit, are placed on the
heatsink of each power module (inverter phase module and rectifier module).
The contacts of the thermal switches placed on the heatsinks of the phase modules of each inverter bridge, are connected to a card
(TITOIA) that receives such signals and transmits, by optic fiber link, a summarized information about contact status to a relay output
receiver card (XITOIA).
By use of these cards, insulation is implemented between the power section and the Control Module for all Inverter Equipment
configurations (from single inverter bridge to 2 parallel bridges); what is necessary because the thermal switches are installed on the
heatsinks of power modules, that are working at high voltage; thanks to the optic fiber link the relay logic results electrically insulated from
the thermal switches.
In normal operating conditions (no trip of thermal switches) all the contacts are closed, and the optic fibers transmit an uninterrupted light
flow. Tripping of any thermal switch results in tripping of the Inverter Equipment protection: “ IGBT OVERTEMPERATURE “.
Useful information, to find out the thermal switch that has tripped, is given by LEDs E2 ÷ E9 of the XITOIA card/s and E1 ÷ E2 of the
TITOIA cards.
Each phase module includes a thermal switch (ST).
The three contacts of the thermal switches of each three phase Inverter bridge (both on motor side and line side) are connected in series and sent to a
single input of the TITOIA card; each card has two inputs and drives two optic fiber trasmitters.
The outputs of the TITOIA cards are sent, by optic fiber link, to the XITOIA card, that has 8 optic fiber inputs and drives 8 relay
outputs, each related to an input.
The following table gives information about the optical link insulated interface cards of thermal switches and micro switch of fuses used in
different configurations and size.
EQUIPMENT SIZE
TITOIA CARD
XITOIA CARD
ATV 1K3 A33 12P/24P
ATV 1K8 A33 12P/24P
4
4
1
1
ATV 2K6 A33 12P/24P
ATV 3K6 A33 12P/24P
ATV 5K2 A33 12P/24P
4
4
4
1
1
1
ATV 1K6 W33 12P/24P
ATV 2K4 W33 12P/24P
ATV 3K6 W33 12P/24P
ATV 4K8 W33 12P/24P
4
4
4
4
1
1
1
1
ATV 7K2 W33 12P/24P
4
1
EQUIPMENT SIZE
TITOIA CARD
XITOIA CARD
ATV 1K6 W33 AFE
ATV 2K4 W33 AFE
ATV 3K6 W33 AFE
ATV 4K8 W33 AFE
ATV 7K2 W33 AFE
4
4
4
8
8
1
1
1
2
2
67
3. Equipment Parts
3.9.1. Layout of TITOIA insulated transmitter interface card
XM2:
XM1:
E3:
E1:
E2:
TF1:
TF2:
68
80 kHz power supply terminal board
Logic inputs: terminal board
XM1 – 1/2: logic input no. 1
XM1 – 3/4: logic input no. 2
green led: ON means that power supply is available.
red led: ON means that logic input no.1 is connected to a closed contact.
red led: ON means that logic input no.2 is connected to a closed contact.
transmitter (to the XITOIA card) of the logic signal of input no.1
transmitter (to the XITOIA card) of the logic signal of input no.2
3. Equipment Parts
3.9.2. Layout of XITOIA insulated receiver interface card
XM1:
XM2:
E1:
E2/E9:
RF1/RF8:
K1/K8:
+24V DC power supply terminal board.
terminal board of output contacts
green led: ON means that power supply is available.
red led: ON means a continuously lit optical signal on RF1 / RF8
receivers of optical signals from TITOIA card/s
output relay contacts
69
3. Equipment Parts
3.10. Rectifier Bridge Precharge Diode Card
3.10.1. Layout of TDIPRA precharge card
This card is used only in DFE configuration.
KK:
KA:
70
Chatode terminal connected to precharge resistors
Anode terminal connected to input line terminal
3. Equipment Parts
3.11. Precharge Circuit (AFE configuration only)
The purpose of the precharge circuit is to charge the capacitor banks of the inverter equipment above a preset minimum voltage value, by
a limited current amplitude, before closing the Main Circuit Breaker.
The precharge sequence must be enabled only if the cooling unit is operating properly and neither protections nor interlocks are in the
disable condition.
•
A wrong, or untimely closure of the Contactor Precharge (CP) when
the auxiliary a.c. supply is on, will charge the capacitors of the DC
busses to high voltage, even when the main power supply is
switched off.
•
Do not tamper the micro-switches of the doors of power cubicles,
because this could result in phase modules being supplied at high
voltage while doors are open.
•
Not to damage components of the precharge circuit, do not carry
out more than three consecutive precharges in 10 minutes.
WARNING
Simplified schematic diagram of Precharge circuit:
TRAPREC
Board
Precharge
transformer
The following table give information about the precharge circuit components used in different size
ATV 1K6 W33 AFE
ATV 2K4 W33 AFE
ATV 3K6 W33 AFE
PRECHARGE
TRANSFORMER
2
2
2
PRECHARGE RECTIFIER
(TRAPREC)
2
2
2
ATV 4K8 W33 AFE
ATV 7K2 W33 AFE
4
4
4
4
EQUIPMENT SIZE
FUSES
3
3
3
6
6
71
3. Equipment Parts
3.11.1. Layout of TRAPREC Precharge Rectifier Card
This card is used only in AFE configuration.
X1/X2:
X3/X4:
72
Input of bridge rectifier
Output of bridge rectifier
3. Equipment Parts
3.11.2. Precharge Logic
The logic sequence for converter start requires interlocks to the control card SCADA PLUS, as shown in the following time diagrams:
where:
MConD L.M., MConD L.R. =
programmable delay of the logic signal "Precharge OK" (respectively for the Motor Side and
Network Side Control Module), since the instant at which the DC voltages of the intermediate
circuits have reached the value Vdcpr (set by Net Parameter menu);
MConT = timeout for Main Circuit Breaker closing, since the instant at which the "Precharge OK" signal has switched on; within such
time interval, lack of the "Circuit Breaker closed" feedback signal trips the protection PHC. This parameter sets a time
delay between the Circuit Breaker closing command and the command to switch the Control Module into the
"Synchronisation Search" mode.
Example:
Active Front End ATV Equipment
UL = 3000 V
Motor side Inverter Control Module
Vinp = 3000 V
Threshold of PRECHARGE OK = 0,8 * 1,35 * 3000 = 3240 Vdc
MConD = 5 s
Line side Inverter Control Module
Threshold of PRECHARGE OK = Vdcpr = 3240 Vdc
MConD = 10 s
MConT = 2 s
(The value of the parameter MConD of the Motor side Control Module must be set lower than the setting of the same parameter in Line
side Control Module)
On closing CP, the precharge contactor, the phase of precharging capacitor banks starts: Vdc, that measures the DC Bus voltage, starts
to increase; the Control Module is informed of the start of the precharge phase by the logic input DRIVE ENABLE (terminals XM1-20 of
the card CONVEC1D); the Control Module monitors the voltage Vdc: on reaching the preset threshold value (for more details see the
"Programming Manual"), with a delay time set by the relevant parameter MConD, the signal “PRECHARGE COMPLETED” (logic output of
the "PRECHARGE OK" relay; terminals X2A 9-10 of the INTVECM A31 C card inside the Control Module) switches on; at this point it is
possible to close the Main Circuit Breaker of the Converter Equipment.
In the case that, within the preset timeout, the voltage Vdc does not reach the preset threshold value, the protection "Prec Fail" trips.
73
3. Equipment Parts
3.12. Encoder requirements and connections
3.12.1. Encoder type and connection
The default configuration for the encoder interface circuits (on SCADA PLUS card) is:
Supply voltage
Output stage
Encoder pulse number
Output signals
: 24 V
: Line Driver - signals at 5V (EIA 485)
: 1024
: bi-directional with zero pulse
The encoder pulse number is defined through [02.13] “Encoder Pulse” parameter
The encoder 24V - 500 mA supply is insulated towards all the other control supplies.
Maximum input frequency of the control card: FMAX=100KHz
The maximum speed in rpm of the encoder (motor) can be calculated using the following formula:
Re v MAX =
FMAX * 60
N ° pulses / revolution
The duration of the zero impulse mast be included
O
0
between electrical 90 and 360 .
Termination resistor for encoder line-driver: 120Ω
As regards the choice of the encoder, ASIRobicon recommend to use encoder equipped with the following:
•
•
trip against short-circuit on the output;
trip against polarity reversing on the supplies.
Depending from the encoder used, it is necessary to configure the SW1 switch, present on the SCADA PLUS card, as follows:
sw1 - 1 
sw1 - 2 

sw1 - 3 
sw1 - 4 
74
ON
for LINE DRIVER encoder - see diagram I
3. Equipment Parts
sw1 - 1 
sw1 - 2 

sw1 - 3 
sw1 - 4 
OFF for other Encoder (PUSH PULL) – see diagram II
Connections diagram for LINE DRIVER encoder (24V for alimentation and 5V for signals) and for PUSH PULL encoder (24V for
alimentation and signals); for both the encoder types the 24V alimentation is internal at the control.
Diagram I – Line Driver Encoder
75
3. Equipment Parts
Diagram II – Push Pull Encoder
76
3. Equipment Parts
3.13. Ground Fault Detector
Altivar converter equipment, both in DFE and AFE configuration, is always supplied by a dedicated converter transformer and in normal operation no point of
the circuit is directly connected to ground. It behaves therefore as an insulated system in witch the first earth fault can not produce any earth fault current, so
that the ground fault can not be detected by any converter protection, except a dedicated ground protection, which is purposely included.
The ground protection function is performed by a dedicated module connected to the DC Bus and including a Hall Effect Voltage Transducer (TV LEM),
together with suitable resistance and an electronic card (XPTERA), driven by the output of such TV LEM, with the function of the detecting the flow of earth
current.
Part number: 1000088782
1000088782
DFE configuration Ground Fault Detector
77
3. Equipment Parts
1000088782
AFE configuration Ground Fault Detector
3.13.1. XPTERA electronic Card
Description
The XPTERA electronic card is supplied at ± 24 V. Check the connection between the terminal 10 of the XPTERA electronic card and
terminal E of the TV LEM voltage transducer. Terminals 22 and 23 of the XPTERA electronic card must be short-circuited.
Relays K1 and K2 release on ground fault.
XPTERA card part number: ELP26403901
ELP26403901
78
3. Equipment Parts
Customizing
COMPONENT
R1
R2
R3
R4
R5
R6
R7
R8
R9
R10
R11
R12
R23
R14
R15
RP
1
XPTERA CARD
TORRETTE
X1 – X2
X3 – X4
X5 – X6
X7 – X8
X9 – X10
X10 – X12
X13 – X14
X15 – X16
X17 – X18
X19 – X20
X21 – X22
X23 – X24
X25 – X26
X27 – X28
X29 – X30
VALUE
Jumper
Jumper
Jumper
Jumper
Jumper
Jumper
Jumper
Jumper
Jumper
150Ω // 100 Ω
150Ω // 100 Ω
150Ω // 100 Ω
150Ω // 100 Ω
150Ω // 100 Ω
150Ω // 100 Ω
TEST POINT
M 17
VOLT
2 ÷ 5,5 V tipici
Tuning procedure
When the ATV equipment is fed by the network, having checked that no leakage current to ground exists, the peak value of the signal
existing between terminals 15 and 16 (earth) of the PTERA electronic card must be measured by an oscilloscope; typical values range
from 0.5 to 4 V.
The voltage between terminals 17 and 4 (earth) of the XPTERA electronic card must be measured by a digital multimeter while the
trimmer RP1 must be adjusted so that:
Vterminal 17 to 4 = Vpeak terminal 15 to 16 + 1.5 V
Example:
Vpeak terminal 15 to 16 = 4 V
Vterminal 17 to 4 = 4 + 1.5 = 5.5 V
In the case that the ground fault protection is required to trip on a given value of the ground resistance, the procedure is as follows:
connect a resistance of the required value (e. g. 25 kΩ) between one phase and ground
adjust the trimmer RP1 of the PTERA electronic card until the protection trips (releasing relay K1)
♦
79
4. Converter Start Up
4.1.
User Interface (Keypad and PC Tool)
There are two methods of user interface to the drive - programming and monitoring interface. Three keypads are available, as identified
below, as well as the PC Tool, which is discussed in Section 6.2.1.2
4.1.1. Keypad description
Main characteristics:
•
•
•
•
80
Graphic Display (5 lines X 24 characters)
20 keys: 5 function keys: Stop, Auto, Man, Reset, Canc/Enter, 4
arrow keys, Shift, Canc/Enter, 10 numerical keys for easier access
and changing parameters
Text message visualization
Memory capability for storing parameters; downloading to other VFD
4. Converter Start Up
Key Functions
Combinations of keys
Advanced keypad
Motor Stop in MAN (manual) operation
Selects MAN operation. Starts drive when MAN is hit again
Selects AUTO operation
Fault Reset. Tests fault LED
Display parameter value. Enter new value
Navigates through the levels of the system menu
Changes active digit in the programming mode
or
or
Navigation throughout the menu.
Modification of the value of a parameter
Speed setting in MAN operation
Return to main screen / display
then
then
then
then
Access to the programming levels
Activates the Numeric Parameter Access
When in a menu returns to the top of menu structure
When in a menu returns to the bottom of menu structure
then
Numeric data insertion
then
then
Shortcut to Motor menu
(different keys select different Menus)
Shortcut to online help
then
81
4. Converter Start Up
4.1.2. PC Tool Description
9 pin male
9 pin female
To SCADA PLUS Control
Board connector K3
To PC serial port
•
Connect the to the serial port RS232
•
Insert the PC tool disk, that was provided with the drive, into the PC
•
Execute the file setup.exe; an icon is created on the desktop is used to launch the program
•
To open program, double click
•
Click on for communication with the drive
•
Click on to create configuration file
•
•
WzPlus25.lnk
Click on to take away the parameters from inverter
Click on Auto Menu
Click on 49.00 Quick Start – a window opens containing all parameters for commissioning
Box to modify
parameters
Menu
Keypad
Monitor
82
4. Converter Start Up
4.1.3. Programming using Keypad
Programming example (Programming level 1)
Set the motor rated current parameter [02.06] Mot Full Load Curr
Function
Press
Step
.
Using
Press
or
Use
or
Using
or
OR Numeric Keys
Press
then
Keypad Intermediate
Keypad Advanced
1
EU-NEMA Select is displayed
2
Search for “Mot Full Load Curr”
3
Goes into access parameter/programming mode and displays actual value
4
Highlights digit to be modified.
Can navigate through active digits
5
Select new value of active digit
Can change value of active digit using numeric keys
6
Confirms and saves new value. Returns to list of parameters.
7
Returns to monitor display
4.1.4. Programming using PC Tool
As a guide for a complete use of the pctool program, it is possible to activate an help on line selecting the icon
on the control bar;
the page visualized from the help is shown below:
83
4. Converter Start Up
4.2.
Drive Status Summary
Idle
Precharge
Ready
Protection
Run
Jog
Stopping
Fast stop
Fluxing
Fly Restart
Bus Drop
DC Braking
Self Commissioning
Lock Ramp Current
Lock Ramp Voltage
Tune Speed
Tune Flux
Tune Isd
Tune Speed
4.3.
No trips are present: the drive is ready to be precharged
Precharge in progress
Inverter ready to be started
Protection occurred
Inverter running
Inverter in Jog operation
Stop in progress
Fast Stop in progress
Motor magnetization
Fly Restart
Main supply loss management
Braking in DC mode
Self Commissioning motor parameters
Current Rollback
Vdc Rollback
Speed regulator tuning
Flux regulator tuning
Current regulator tuning
Speed regulator tunning
Inverter Protections Summary
Hardware Protections
Over Curr
Over Volt
Extrn Trp
Desaturat
Mod Supply
DPRAM Err
Wdog Ext
INTVEC Pr
Over Temp
ThyrComErr
Mod Conf
84
Overcurrent (IAC max total)
DC Overvoltage (VDC max)
External protection
Desaturation
Loss of power supply of MODVECS card
RAM dual port damage
Watch dog protection
INTVECM protection
IGBT overtermperature
Thyristor command error
Configuration error MODVECS board
4. Converter Start Up
Software Protections
Prec Fail
Over Spd
Confg Err
DSP Fail
Net Fail
Stall
Fast Stop
UnderVolt
DrivSzErr
Gnd Flt
Therm Prt
Speed Dev
Curr Offs
SWF Error
UnderLoad
SpdRfLss
OutPhasOut
AI User Fl
SWF CfgErr
Cks MODErrWrong
4.4.
Precharge fault
Overspeed trip
Configuration parameters error
DSP program not responding
Network Communication loss
Motor Stalled
Emergency stop
Undervoltage protection
Inverter size not selected
Ground fault
Motor/inverter overload
Speed deviation trip
Offset on current transducer
Switching Frequency selected not permitted
Under load fault
Loss speed reference
Loss of output phase
NTC o PTC protection from analogical input
Switching Frequency selection Error between SCADA Plus and MODVEC–S cards
Communication loss between SCADA Plus and MODVEC–S cards
Parameters Reset
To reset the parameters to their default values, use function Reset All [01.03] in the Main Setting family. When this function is invoked all
parameters except those pertaining to motor and drive data will be reset to their default values.
4.5.
Programming Levels
There are three (3) programming levels:
•
Level 1 is the quick start level
•
•
•
•
•
•
•
Access code is 0001
Minimal number of selected parameters within one menu – up to 14 parameters
Quick start of the motor with the drive
Level 2 is a higher level for defining process parameters to control the process and application
Access code is 0002
The parameters are organized in menus and families - more than 100 parameters
This allows user-enabled macros and the setting up of the Dl/DO and AI/AO
•
•
•
4.6.
Level 3 is an advanced level and the detailed description of this level is given in Inverter Programming Manual PMP CA ATV E 2523.
Access code is 0003
Approximately 400 parameters are available
Control Modes
There are three (3) motor control algorithms available. Select the mode that is correct for the application.
•
Scalar (V/Hz, V) mode – used for multiple motor applications
•
•
Sensorless Vector Mode (SLS, S), control without an encoder feedback
Field-oriented Control (FOC, F) – used for applications requiring tight torque/speed control
85
4. Converter Start Up
4.7.
Motor Rated Power EU/NEMA Selection
Select the standard that is applicable based upon location. The standard will be utilized when programming the motor parameters.
•
•
EU – European Standard
NEMA – United States Standard
4.8.
Quick Motor Start-Up
The control is supplied with parameters set to the default values. Some of them are:
V/Hz control algorithm with linear characteristic (Programming level 1)
Parameter input line rated voltage (AC Input Voltage) to 3600V.
Speed reference from PROFIBUS.
Acceleration / deceleration ramps: 60 sec.
Current oscillation compensation: DISABLED
The motor quick start-up utilizes a minimum number of parameters. (See the following table)
Parameter Address/Name
Serial
Advanced Keypad and
Address PC Tool
01.01
EU-NEMA Select
EU Standard
01.02
Motor Control Mode
02.01
EU - Motor Power
EU – Selects parameters 02.01 and 02.17
NEMA – Selects parameters 0202 and 0218
V/Hz Ctrl – Scalar Control
SLS Ctrl - Sensorless Vector – Vector control without
Encoder feedback
FOC Ctrl – FieldOriented Control – Encoder feedback
EU - Rated motor nameplate power in Kw
02.02
NEMA - Motor Power
NEMA - Rated motor nameplate power in HP
02.05
02.06
Motor Voltage
Mot Full Load Curr
Motor nameplate voltage
Motor nameplate current
02.08
02.09
Motor Frequency
Mot Full Load Speed
02.10
02.11
02.17
02.18
06.03
11.10
Motor Max Oper Freq
Motor Power Factor
Motor Efficiency
AC input voltage
Rated motor frequency
Rated motor speed – actual RPM from motor
nameplate
Minimum process operating frequency
Maximum process operating frequency
EU Standard - Rated motor power factor
NEMA - Rated motor efficiency
Actual main input supply voltage.
Motor Min Oper Freq
Autotuning Select
22.12
Accel Time 1
22.13
Decel Time 1
SETUP
Description
Used for tuning the motor for drive operation
Tune Off - Disabled
Self Comm - Enables Self Commissioning
Mot prm C – calculates internal parameter for
enhanced drive performance
Stand Self - Pulses are enabled but the shaft does not
move
Acceleration ramp time #1
Typical settings
•
Pump application – 30 seconds
•
Fan application – 60 seconds
Deceleration ramp time #1
Typical settings
•
Pump application – 30 seconds
•
Fan application – 60 seconds
Ctrl
Mode
EU
NEMA
Standard
NEMA
V, S, F
V/Hz
V/Hz
V, S, F
Motor Kw
value
3300V
Motor FLC
value
50 Hz
1500 RPM
0 Hz
60 Hz
0.85
V, S, F
Motor HP
value
3300V
Motor FLC
value
60 Hz
1800 RPM
0 Hz
70 Hz
S, F
V, S, F
V, S, F
V, S, F
S, F
3600V
Tune Off
.95
3600V
Tune Off
V, S, F
V, S, F
S, F
S, F
V, S, F
S, F
60 s
60 s
V, S, F
60 s
60 s
V, S, F
Now that the parameters have been selected, the drive is ready to be started and the motor checked for correct phasing orientation.
NOTE
86
The motor should be uncoupled and the control modes must be V/Hz.
4. Converter Start Up
Local Operation
The steps to accomplish the start are as follows:
1.
Precharge Drive;
2.
Press [Man/Start] to select the local operation (from keypad)
•
3.
4.
5.
Advanced keypads. The message “Manual Press enter to confirm” appears. Press [Enter/Canc] to confirm. The keypad
goes back to the display of the status and the LED “On” flashes to indicate the operation is in manual mode.
Press [Man/Start] button to start motor. The drive should now be running and the RUN LED lit. A speed command is required.
Use the UP and DOWN arrow keys to control the speed
Check motor’s orientation. If incorrect, change any two phases at the motor terminal’s U,V,W or modify the parameter [06.05]
Motor Phase Seq Sel from UVW to UWV and re-verify.
NOTE
For V/Hz mode go to step 7. For SLS and FOC go to step 6.
Autotuning
6.
For SLS and FOC control mode, Autotuning is required using parameter [11.10]:
To identify motor parameters three commissioning procedures are available:
•
•
•
Self commissioning with motor at no load = Self comm: Use this procedure when the motor is not connected to the load.
Motor Parameter calculation = Mot prm C: Calculates internal parameter for enhanced drive performance. You need to
specify the no load current entering in programming level #3.
Self commissioning with motor at stand still = Stand Self: Pulses are enabled but the motor shaft does not move. Use when
motor is already coupled with load.
•
•
•
Self Commissioning (with motor at no load)
With Drive Enable command OFF (IDLE status), set in Manual mode.
Then set Drive Enable command ON: the led ON lights on.
•
•
•
•
•
•
•
•
With motor at no load, set the parameter [11.10] to “Self comm”.
Confirm YES when the dialog box appears. The drive will be automatically reset.
When the drive returns to READY status, give the MAN/START command.
Inverter starts the motor up to 90 % of “Motor Frequency” in order to perform the Autotuning procedure
Drive status shown is “TUNING”.
When Self Commissioning is completed the inverter stops the motor.
The Motor Parameter Calculation is completed through the automatic execution of the “Mot prm C” procedure.
The drive will be automatically reset.
Self commissioning procedure is completed and is possible to start the motor in automatic or manual mode.
NOTE
•
•
•
•
•
It is strongly recommended to use [22.12] and [22.13] at values greater or equal to default
values (60 sec.).
If no run command is given within 200 seconds after the set of [11.10] to picklist variable
“Self Comm”, the drive return to the original condition.
If the ATV is not in READY status, setting [11.10] to “Self Comm” is ignored.
During the “TUNING” status, STOP command can be given. If the motor is accelerating,
the drive returns to the READY status waiting for a run command in order to complete the
self commissioning procedure. If the drive is performing measurements (motor speed
constant), the motor is stopped and a protection for “self commissioning failed” occurs. If
the motor is decelerating the STOP command has not effects on the procedure.
During the “TUNING” status, if Drive Enable is set to off, a protection for “self
commissioning failed” occurs.
87
4. Converter Start Up
Motor Parameter Calculation
Calculates internal parameter for enhanced drive performance. By setting manually Mot prm C in the parameter Autotunning Select
[11.10] internal parameter calculation is executed automatically. It’s necessary to specify, at programming level #3, the following motor
data. The operation will calculate the parameter identified as output.
Motor Parameter calculation [11.10] = Mot prm C
Necessary Input
Output
Parametri
[02.01]
[02.03]
[02.05]
[02.06]
[02.07]
[02.08]
[02.09]
[02.17]
Parametri
Nome
[03.01]
ROTOR RESISTANCE
Motor Power NEMA**
Motor Voltage
Mot Full Load Current
Motor NoLoad Current
Motor Frequency
Mot Full Load Speed
[03.02]
[03.03]
[03.04]
[03.05]
[03.19]
Stator Resistance
Rotor Leakage induct
Stat Leakage Induct
Magnetizing Induct
Fluxing Time
Motor Power Factor (cosϕ)*
Motor Efficiency**
[02.18]
*
**
Nome
Motor Power EU*
related with EU setup
related with NEMA setup
Self Commissioning with motor at stand still
In Manual mode and “IDLE” status, set Drive Enable command ON : the led ON lights on.
•
Set [11.10] to picklist variable “Self Stand”.
•
Confirm YES when the dialog box appears The drive will be automatically reset.
•
When drive returns to READY status, give the “run” command
•
Drive will pass from “READY” status to “TUNING” status for ten times
•
Drive will be reset.
•
If no error messages appear, and the drive returns to “IDLE” status, the drive is ready to run.
NOTE
During the Self Commissioning with motor at stand still, the motor will not move. To erase the
procedure, press “CANCEL” on the dialog box.
Coupling the motor
7. Couple the motor to the load.
Running the drive to full speed with the load
8. Run the drive up to full speed. If problems exist refer to the Troubleshooting Chapter in the Inverter Programming Manual.
88
4. Converter Start Up
Run in Automatic Operation
The steps to accomplish the start are as follows:
1.
Close Drive Enable command:
•
This is a customer input command (SCADA Plus terminal XM1-20 to XM1-24).
2.
Press [AUTO] to select the operation in automatic mode and press [Enter/Canc] to confirm
3.
Close Start/Stop command:
•
This is a customer input command.
4.
Typical speed command will come into Analog Input 1, PROFIBUS or motopotenziometer.
•
This input can be a 0 -20mA, 4-20mA or 0-10V
4.9.
Encoder test (if present)
1.
Make sure that the connections for the encoder power supply and signals are correct.
2.
Enable Speed feedback from encoder, “Speed Fdbck Select [04.04]” = Encoder.
3.
Enable local control with the Keypad.
4.
Precharge the inverter
5.
Give a start command and speed reference other than zero, from the Keypad
6.
Verify coherence between motor rotation direction, speed feedback sign and speed reference sign.
Example: reference positive – motor RST correct, clockwise rotation – encoder feedback positive
89
4. Converter Start Up
4.10. Protections Description
The present paragraph describes all the hardware and software trips implemented in the control SCADA PLUS of the
Altivar 3300V.
Each protection causes the shut-off of the inverter and the relay “R01 Fault” is denergized. Use protection code to recognize converter
damages or malfunctions.
MAXIMUM OUTPUT CURRENT TRIP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
OverCurr
002 TRIP: ATV HW TRIP - MAXIMUM CURRENT
This protection it is based on the current signal coming from the INTVECM card; the trip occurs whenever the current peak value
overcomes the IAC max - tot threshold. This value is indicated in the following table:
EQUIPMENT SIZE
NUMBER OF INVERTER IN
PARALLEL
IAC max-tot
INTERVENTION THRESHOLD MAX TOTAL CURRENT
ATV 1K3 A 33
1
560 Apk
ATV 1K8 A 33
1
840 Apk
ATV 2K6 A 33
1
1240 Apk
ATV 3K6 A 33
2
1680 Apk (2 x 840 Apk)
ATV 5K2 A 33
2
2480 Apk (2 x 1240 Apk)
ATV 1K6 W 33
1
560 Apk
ATV 2K4 W 33
1
840 Apk
ATV 3K6 W 33
1
1240 Apk
ATV 4K8 W 33
2
1680 Apk (2 x 840 Apk)
ATV 7K2 W 33
2
2480 Apk (2 x 1240 Apk)
MAXIMUM D.C. VOLTAGE TRIP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
OverVolt
003 TRIP: ATV HW TRIP - MAXIMUM DC BUS VOLTAGE
it is based on the DC-link voltage, acquired through a Hall effect transducer (TV LEM); it occurs whenever the voltage overcomes the
established max value (6000V); this value is set via hardware. The voltage scaling on the burden resistors is 5V @ VDCMAX.
EXTERNAL TRIP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
ExtrnTrp
004 TRIP: ATV HW TRIP - EXTERNAL TRIP FROM CONFIGURABLE DIGITAL INPUT
Protection occurrs when dedicate digital input reaches zero level.
DESATURATION:
90
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Desaturat
005 TRIP: ATV HW TRIP - INVERTER PHASES TRIP
4. Converter Start Up
It is based on the monitoring signals coming from the IGBT firing card, transmitted via fibre optics, (TGUNTNB firing card connected
through the O.F. to MODVEC and FOVECM control cards).
When this protection occurs, it is possible to determine which firing card has failed by checking the status of the LEDs on MODVECS or
FOVECM cards or it is possible to read 7 elements display “Disp1” on MODVECS card. In the following table are shown the codes
displayed on “Disp1”.
Anomaly
“Disp1” MODVEC or FOVECM
Gate Unit Anomaly Positive external IGBT fase U
Gate Unit Anomaly Positive internal IGBT fase U
Gate Unit Anomaly Negative internal IGBT fase U
Gate Unit Anomaly Negative external IGBT fase U
0
1
2
3
Gate Unit Anomaly Positive external IGBT fase V
Gate Unit Anomaly Positive internal IGBT fase V
Gate Unit Anomaly Negative internal IGBT fase V
Gate Unit Anomaly Negative external IGBT fase V
4
5
6
7
Gate Unit Anomaly Positive external IGBT fase W
Gate Unit Anomaly Positive internal IGBT fase W
Gate Unit Anomaly Negative internal IGBT fase W
Gate Unit Anomaly Negative external IGBT fase W
8
9
a
b
In the following table are shown the codes displayed on “Disp1” of MODVEC card with inverter in parallel
Anomaly
“Disp 1” MODVEC
“Disp 1” FOVECM 1
Angu inverter 1
Angu inverter 2
0 to b
d
0 to b
LOSS OF POWER SUPPLY OF MODVECS BOARD:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Mod Supply
006 TRIP: ATV HW TRIP - MODVEC BOARD POWER SUPPLY
It annunciates the 24V supply loss on MODVEC card.
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
ResetFault
007 TRIP: ATV HW TRIP - ANOMALY WITH RESET COMMAND: DRIVE
RUNNING WITHOUT PULSES
RAM DUAL PORT DAMAGE:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
DPRAM Err
009 TRIP: ATV HW TRIP - DPRAM TEST FAULT
It annunciates the anomaly of RAM Dual Port component.
WATCH DOG PROTECTION:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Wdog Ext
010 TRIP: ATV HW TRIP - WATCH DOG
INTVECM PROTECTION:
Error code displayed on PC
Tool or Keypad
INTVEC Pr
Message displayed on HMI
012 TRIP: ATV HW TRIP - INTVEC M BOARD PROTECTION
91
4. Converter Start Up
This trip can be due to two possible causes:
•
•
maximum current
maximum differential current
In both cases, the current level is monitored through the motor current signals acquired by means of three Hall effect transducers
(TA LEM) mounted on the inverter phases.
The detection of which trip has occurred (maximum current or maximum differential current or maximum DC voltage) is performed
by means of a code on 7 elements display on interface cards (NTVECM1 for single inverter and 2 inverters in parallel).
MAXIMUM CURRENT
The maximum current trip occurs whenever the trip threshold is overcome (hardware guards); the following table shows the trip threshold value
depending on the drive class and drive size:
EQUIPMENT SIZE
NUMBER OF INVERTER IN
PARALLEL
MAX CURRENT
TRIP THRESHOLD
ATV 1K3 A 33
1
560 Apk
ATV 1K8 A 33
1
840 Apk
ATV 2K6 A 33
1
1240 Apk
ATV 3K6 A 33
2
840 Apk per inverter
ATV 5K2 A 33
2
1240 Apk per inverter
ATV 1K6 W 33
1
560 Apk
ATV 2K4 W 33
1
840 Apk
ATV 3K6 W 33
1
1240 Apk
ATV 4K8 W 33
2
840 Apk per inverter
ATV 7K2 W 33
2
1240 Apk per inverter
The voltage scaling on the TA LEM burden resistors is 5V@ IACMAX.
DIFFERENTIAL CURRENT (only parallel configuration)
The differential current trip occurs whenever the current unbalance of each phase exceeds 50% of the rated current (for class 1 service)
of the single inverter.
In the following table are shown the codes displayed on “Disp1” Related with Converter configuration.
Single inverter
Anomaly
Code on“Disp1” displayed on
INTVECM board
Inverter max current
Max voltage BUS DC 1
Max voltage BUS DC 2
contemporary protections
1
4
7
8
Two inverters in parallel
Anomaly
Inverter 1 max current
Inverter 2 max current
Differential current
Max voltage BUS DC 1
Max voltage BUS DC 2
contemporary protections
92
Code on“Disp1” displayed on
INTVECM board
1
2
3
4
7
8
4. Converter Start Up
IGBT OVERTEMPERATURE:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Over Temp
013 TRIP: ATV HW TRIP - PHASES OVERTEMPERATURE
It annunciates that one or more temperature switches (mounted on inverters, braking chopper and three-phase reactors) have
opened.
THYRISTOR COMMAND ERROR:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
ThyrComErr
Once the “Precharge OK” command from the control has been given, the drive trips after a certain time if the feedback signal
(stating that the thyristor bridge is on) is not received by the control. This protection is activated on inverter DFE configuration.
CONFIGURATION ERROR MODVECS BOARD:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Mod Conf
015 TRIP: ATV HW TRIP - MODVEC BOARD CONFIGURATION ERROR
PRECHARGE FAULT:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Prec Fail
018 TRIP: ATV SW TRIP - INVERTER PRECHARGE FAIL
Once the precharge command (DRIVE ENABLE) has been given, this drive trips after 10s if the DC-link voltage is still below 85% of the
rated value, calculated as 1,35∗ AC input voltage [06.03]
OVERSPEED TRIP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Over Spd
019 TRIP: ATV SW TRIP - OVERSPEED
The control detected a speed exceeding the threshold set by the Ovrspd flt setpoint [67.06] parameter. Only for FOC or SLS.
CONFIGURATION PARAMETERS ERROR:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Confg Err
020 TRIP: ATV SW TRIP - PARAMETER CONFIGURATION ERROR
This protection occurs for different reasons, which can be identified analysing the Config Error [78.05] parameter value.
93
4. Converter Start Up
DSP PROGRAM NOT RESPONDING:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
DSP Fail
021 TRIP: ATV SW TRIP - DSP PROGRAM LOCKED
An error occurred during a program start up in the DSP.
NETWORK COMUNICATION LOSS:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Net Fail
022 TRIP: ATV SW TRIP - PROFIBUS CONNECTION LOST
The Network communication is lost.
MOTOR STALL:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Stall
024 TRIP: ATV SW TRIP - MOTOR STALL PROTECTION TRIP
The STALL protection can be enabled only when F.O.C. control is selected; it can occur in two different situations:
•
•
after giving the Start command, with speed reference other than zero, the speed feedback remains at zero for a period longer than
the selected time-out;
with motor running, the difference between speed reference and feedback exceeds a settable maximum value for a period longer
than the selected time-out.
EMERGENCY STOP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Fast Stop
025 TRIP: ATV SW TRIP - FAST STOP
This protection is automatically enabled after precharge ok.
UNDERVOLTAGE PROTECTION:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Under Volt
026 TRIP: ATV SW TRIP - MINIMUM DC BUS VOLTAGE SW PROTECTION
It monitors the D.C. voltage on the DC-link; this protection is automatically enabled after the precharge of the D.C. filter capacitors is
accomplished.
The set-point value is represented by the parameter UV-VdcHS Prot Thrsed [69.01] which is a percentage of the rated voltage set by the
AC input voltage [06.03].
VDC read < UV-VdcHS Prot Thrsed
EXAMPLE:
94
threshold
AC input voltage = 3600 V Vdcnom = 3600 · 1,35 = 4860 V
UV-VdcHS Prot Thrsed = 75% = 4860 * 0,75 = 3645 V
VDC lread < 3645 V Minimum Voltage Protection
4. Converter Start Up
DRIVE SIZE ERROR:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
DrivSzErr
027 TRIP: ATV SW TRIP - WRONG INVERTER SIZE SETTING
This protection occurs when no inverter sizes are selected or a wrong value is set.
GROUND FAULT:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Gnd Flt
028 TRIP: ATV SW TRIP - GROUND FAULT PROTECTION
The protection occurs whenever the sum of the inverter output currents is different than zero and higher than 14% of the IAC maxtot trip value.
EXAMPLE:
ATV 1K8 A 33
IACmax = 840 Apk
IGND = Iu + Iv + Iw
IGND > 0,14 *840 A
IGND > 117,6 A
Intervention of the GROUND FAULT protection
MOTOR/INVERTER OVERLOAD:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Therm Prt
030 TRIP: ATV SW TRIP - MOTOR OVERTEMPERATURE
It occurs when the allowable motor overload conditions have been exceeded.
The parameters related to this function are:
Overload [66.02] : sets the maximum allowable overload as a percentage of the rated current
Overload timeout [66.03] : sets the maximum allowable duration of such overload current.
To be enabled, this protection requires that the preset value of ImTOV be larger than 105%.
The protection trips when the following inequality occurs:
∫
(Is2
− In2 ) dt
  Im TOV  2

2
≥ 
 − In  ⋅ Im TDl
  100 



Is= actual motor current
In = rated motor current
EXAMPLE
In = 400 A
Iov = 620 A
Tsc = 60 s
rated motor current
overload current
maximum time duration of the preset overload current
Using this data, the values to be assigned to the parameters are:
ImTov = (620/400) * 100 = 155%
ImTDl = 60s
95
4. Converter Start Up
If the value of the overload motor current is exactly 620A, the overload protection trips after 60 s.
If, on the contrary, the overload motor current is lower, or larger, than 620A, the trip time shall be, respectively, longer or shorter than 60s.
The exact value of the trip time can be calculated by the following equation:
2
t int
 Im TOV 

 −1
100 

=
⋅ Im TDl
2
 Is 
  − 1
 In 
In the following image is shown the inverse time protection curve.
900
800
700
Time [sec]
600
500
400
300
200
100
0
400
500
600
700
800
Current [A]
SPEED DEVIATION TRIP:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Speed Dev
031 TRIP: ATV SW TRIP - SPEED DEVIATION
When a speed (transducer analogic or from encoder: Speed Fdbck Select parameter) is present (with VHz, SLS and FOC control), this
trip occurs if, with function enabled (Motor stall enable [67.01]) with the speed reference set at the maximum value (Motor Max Open
Freq [02.11]), speed feedback differs from the reference more than ±5%, for a period longer than a parameter Mtr stall delay time
[67.03].
If the speed reference is less-than the maximum value and speed feedback differs from the reference more than ±5%, for a period longer
than a parameter Mtr stall delay time [67.03] occurs an alarm.
OFFSET ON CURRENT TRANSDUCER:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Curr Offs
034 TRIP: ATV SW TRIP - TA OVERCORRECTION PROTECTION
This protection occurs when there is an offset on TA analogical input.
96
4. Converter Start Up
SWITCHING FREQUENCY SELECTED NOT PERMITTED:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
SWF Error
036 TRIP: ATV SW TRIP - SWITCHING FREQUENCY NOT ALLOWED
This protection occurs with switching frequency selected not permitted.
UNDER LOAD FAULT:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
UnderLoad
037 TRIP: ATV SW TRIP - MINIMUM MOTOR LOAD
LOSS SPEED REFERENCE:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
SpdRfLs
038 TRIP: ATV SW TRIP - SPEED REFERENCE LOST
Loss of speed reference
LOSS OF OUTPUT PHASE:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
OutPhasOut
039 TRIP: ATV SW TRIP - OUTPUT PHASE LOST
This protection occurs when one motor phase isn’t connected.
ANALOGICAL INPUT NTC OR PTC PROTECTION:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
AI User FI
047 TRIP: ATV SW TRIP - PTC OR NTC TRIP
SWITCHING FREQUENCY SELECTION ERROR BETWEEN SCADA AND MODVECS:
Error code displayed on PC
Tool or Keypad
SWF CfgErr
Message displayed on HMI
048 TRIP: ATV SW TRIP - SWITCHING FREQUENCY CONFIGURATION ERROR
This protection occurs when switching frequency selection on MODVECS card (through dedicated switches) is different with
SCADA PLUS software settings.
SERIAL COMMUNICATION LOSS BETWEEN SCADA AND MODVECS:
Error code displayed on PC
Tool or Keypad
Message displayed on HMI
Cks MODErr
049 TRIP: ATV SW TRIP - MODVEC BOARD CHECKSUM ERROR
Loss communication between SCADA PLUS card and MODVECS card.
97
4. Converter Start Up
4.11. Start Up Procedure
4.11.1. Preliminary Checks
Installation
•
•
•
Environmental conditions check: the rooms in which the equipments are installed should be clean and without dust
Check all the cubicle section, which must be clean inside as well
Umidity and other materials shouldn’t be present inside the equipments
Ground Connection
This check is to be completed before startup; the connection, according to the project documents, should be checked.
Following equipment is to be checked:
•
•
•
transformer
cubicle
motor
Cubicle Connection
The ground bar must be electrically continous in each cubicle section. All the connections used to join the cubicle sections are to be
checked. These are:
•
•
•
•
•
power electronics
logic
signals
optical fibres
hydraulic circuit
Cooling System.
•
•
•
visual check of all the connections and lockings
fill the circuit following the detailed procedure
all the circuit must be hermetic, in particular joints, connections
Connections Check.
•
•
•
•
Check the cabling of the transformer, cubicle and motor
Check the connection:
•
between main switch and transformer
•
between transformer and cubicle
•
between cubicle and motor
The connections of all the terminal blocks and auxiliary circuits
Lockings
Voltage Measurement.
•
Before power up, check if all the supply have a value according to the specified data on the electrical drawings.
4.11.2.
Auxiliary Circuits Checks
These conditions must be fullfilled in order to check the auxiliary circuits:
•
•
The precharge circuit must be open removing the precharge fuses, in order to avoid the charge of the d.c bus after an unespected
closing of the precharge contactor.
Remove the medium voltage switch and set it in “test” position (so it’s possible to move it without voltage)
Auxiliary Power On
•
•
•
•
•
•
Supply the auxiliary circuit following the distribution as shown in the draft
Check that the applied voltage are correct and that all the equipment are correctly supplied
Check the pumps rotating sense
Start the cooling system control unit
Check the water level until the air output is completed
Check the fans rotating sense
Drive Parameters Configuration
Setup the correct inverter parameters, in particular:
•
•
•
98
The motor rated data
Inverter rated data
The operating logic detailed in the drafts
4. Converter Start Up
Logics
•
•
•
•
check the operating status of the cubicle logics.
check the protection intervention, in particular the interfacing with the medium voltage switch (opening command after a protection)
Remove the connection carrying the VDC1 and VDC2 signals. Simulate the two voltages with a supply unit on the ballast
resistances and start precharging phase without the fuses checking the correct sequence operation
Start inverter running (without voltage) in VHz TN control mode and check the output voltage waveform
4.11.3. Startup
Warning: the closing of the “voltage present” switch will happen only after the precharge of the inverter and with the presence of the signal
“precharge OK”.
Precharge
•
•
•
•
•
•
•
•
reconnect the precharging circuit as before the test (insert fuses, remove voltage simulation on ballast resistances, insert
connectors). Leave the main switch removed
reach the status of “no protection” and close the cubicle doors
Start the cooling unit
Start precharging checking the behaviour of the d.c. voltages (VDC1 and 2)
As the level of 40% of the nominal value is reached remove the command
Start again the precharge and wait for the sequence to be completed. The two voltages VDC1 and 2 must have the same value (2%
difference allowed)
As the main switch is still removed, this will be closed but the undervoltage protection will be activated
Insert the main switch and repeat the sequence
After the precharging phase, the inverter is in the “ready” status and it’s possible to proceed with the running.
99
4. Converter Start Up
Running
VHz Control
•
Start the inverter in local mode, with no load on the motor, VHz TN control mode, speed feedback from the encoder (if available).
Set a speed reference of 100 RPM
•
Check the motor rotating sense and the speed feedback (if available), which must be positive if the motor runs in the “forward”
direction
•
Proceed with the current compensation tuning if necessary
•
Reach the maximum motor speed, checking all the variables involved in the rotation of the motor:
•
frequency
•
voltage
•
current
FOC/SLS Control
•
Insert the FOC TN control mode and start the inverter
•
Check the motor rotating sense and the speed feedback, which must be positive if the motor runs in the “forward” direction
•
Reach the maximum motor speed, checking all the variables involved in the rotation of the motor:
•
speed
•
frequency
•
voltage
•
current
Remote Test (if applicable)
•
System test in remote mode
•
References and feeback signals regulations
Process tests
100
5. Maintenance, Checks and Troubleshooting
5.1. Safety Prescriptions
Risk of death, fire or heavy injuries
The job requires the personnel is skilled for the purpose, well aware of safety rules,
regulations and standards while operating on Medium Voltage Equipments. Full knowledge
of installation power supply system and ATV 3300V diagrams is needed.
Risk of death, electric shock or heavy injuries
The job requires the personnel is skilled for the purpose, well aware of safety rules,
regulations and standards while operating on Medium Voltage Equipments. Full knowledge
of installation power supply system and ATV 3300V diagrams is needed.
5.2. Periodical Maintenance and Checks
The ATV 3300V is a static converter equipment using power semiconductor as power control device.
Even thought power semiconductor don’t need maintenance over component life, many auxiliary components need to be periodically
checked, and/or tested and/or cleaned. Again, some vital auxiliary paths (like air filter and water deionizing resins) shall de cleared and
substituted on a regular time schedule.
The suggested maintenance operations are reported hereunder:
1)
Check the conditions of the air filters, if any.
2)
Check screw terminals of power connections.
3)
Check screw terminals of auxiliary connections.
5.3. Protections Troubleshooting
In normal operation, the converter control carries out checks to detect any possible anomaly, basing its analysis both on hardware and
software checks.
In the case of detected anomaly, the operator is informed by:
•
•
a message (fault type) on the user's terminal display;
messages on the display and lighting of the relevant leds of the INTVECM interface cards, the MODVEC modulator card and the
FOVECM pulse duplication cards.
To cancel such anomaly indications, it is first necessary to eliminate their causes, if still active, and then reset any active protection that is
stored inside the memory of the control module. This is done by applying the proper command, through a "reset" pushbutton (the Reset
function is connected to the digital input 9); or by the user's terminal, through the RS key.
The following table lists all protection signals, their possible causes and the actions to be carried out, if any, in order to eliminate the
anomaly.
101
5. Maintenance, Checks and Troubleshooting
5.3.1. Hardware Protections
USER's TERMINAL
DISPLAY
DESCRIPTION
CAUSE/ACTION
Over Curr
Protection trip:
maximum instantaneous
overcurrent at drive output
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits
and after a waiting time (10 minutes at least) to allow for discharge of
capacitor banks
These precautions are necessary for the safety of operators.
- check that neither short circuit between motor phases or phase fault to
ground exists;
- check the wiring and for correct operation of the encoder and its mechanical
coupling (FOC only );
- check that the acceleration ramp time is not too short;
- check the torque reference upper limits and torque current.
Over Volt
Protection trip:
maximum DC bus
overvoltage; instantaneous
value of DC voltage has
exceeded the protection trip
threshold.
A motor stop was initiated with too short deceleration time.
Extrn Trp
External protection.
The dedicated digital input reached level zero.
Check the state of the contacts (to be found on the Equipment Elementary
Diagram) that are connected to the terminal board to implement such logic
input, and/or other possible external protections, active through the
NETWORK.
Desaturat
Protection trip:
Gate unit anomaly (faulty
operation detected by the
Gate unit; one of the IGBT
firing boards).
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits
and after a waiting time (10 minutes at least) to allow for discharge of
capacitor banks.
These precautions are necessary for the safety of operators.
Protection trip causes:
IGBT desaturation;
Loss of power supply to firing circuits;
Suggested checks:
Check IGBTs.
Check power supply to firing circuits;
NOTE: Sometimes this protection may cut-in in case of an overcurrent event.
In such a case follow the instructions given at Over Curr.
Mod Supply
Protection trip:
minimum modulator supply
The instantaneous value of the rectified voltage that supplies the modulator
board has fallen below the safety threshold value.
This rectified voltage is obtained from G1 power supply.
DPRAM Err
Dual Port error
Check microprocessor board
Protection trip:
minimum DC bus voltage
detected by hardware.
The instantaneous value of the DC bus voltage has fallen below the threshold
value. This protection is not necessary for ATV inverter and must be disabled
opening the JP19 jumper on the SCADA control board.
OVER CURRENT
The instantaneous value of
the output current of one drive
phase module has exceeded
the protection trip threshold.
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits
and after a waiting time (10 minutes at least) to allow for discharge of
capacitor banks.
These precautions are necessary for the safety of operators.
OVER CURRENT:
- check that neither short circuit between motor phases nor phase fault to
ground exists;
- check the wiring and the correct operation of the encoder and its mechanical
coupling (FOC only).
- check that the acceleration ramp times are not too short;
- check the upper limits of torque reference and torque current.
Vdc Min
INTVEC Pr
OVER VOLTAGE
The instantaneous value of
DC voltage has exceeded the
protection trip threshold
CURRENT UNBALANCE
Protection trip occurs
whenever an unbalance is
detected among the phase
currents of ATV bridges in
102
OVER VOLTAGE
A motor stop was initiated with too short deceleration time.
5. Maintenance, Checks and Troubleshooting
USER's TERMINAL
DISPLAY
Overt Temp
DESCRIPTION
CAUSE/ACTION
parallel.
CURRENT UNBALANCE:
- check the wiring and the correct operation of the phase modules of all drive
bridges, their IGBT firing cards and the
phase current transducers
(TA LEM);
- check security of the bolts of the drive output bars
The temperature of one or
more heat sinks has
exceeded the preset limit
causing the related thermal
switch to trip.
Check the cooling system for correct operation.
All signals from such thermal
switches are combined as
normally closed, with contacts
series connected, and
monitored by the diagnostics
of the control module as a
single switch.
ThyrComErr
Internal pre-charge system
failure (only DFE equipment
configuration).
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power
circuits and after a waiting time (10 minutes at least) to allow for
discharge of capacitor banks.
Check if the green LED D2 on the INTPREA board (control panel position) is
on.
Check the fiber optics between the INTPREA board and the TCPSA/B boards
on the rectifier bridges.
Mod Conf
Modulator start-up error.
Problem on the modulator board sw bootstrap (MODVEC board, control panel
position).
Change the modulator board.
103
5. Maintenance, Checks and Troubleshooting
5.3.2. Software Protections
USER's TERMINAL
DISPLAY
Prec Fail
DESCRIPTION
Pre-charge fault
CAUSE/ACTION
ALL CHECKS ABOUT EQUIPMENT WIRING AND FUSE CONDITIONS
MUST BE CARRIED OUT WITH THE PRECHARGE KNIFE SWITCH (its
symbol can be found on the Equipment Elementary Diagram) OPEN AND
AFTER A WAITING TIME (OF 10 MINUTES AT LEAST) TO ALLOW FOR
DISCHARGE OF CAPACITOR BANKS;
THESE PRECAUTIONS ARE NECESSARY FOR THE SAFETY OF
OPERATORS.
Loss of power supply of the precharge circuit.
Check the availability of auxiliary power supply (220 - 440 V).
Besides, check that, once the precharge command has been sent, the value of
the DC bus voltage, shown as "VDC" parameter on the user's terminal display
in its Monitor mode, is not null.
Also check, by the user's terminal, that the "VInp" parameter, included in the
"Drive Parms" section, has been set at a proper value.
Check, having switched off both the Main and Auxiliary Power Supplies, the
soundness and proper operation of all components of the precharge circuit
(see on paragraph 5.4): fuses on the a.c. power supply, knife switch and
contactor, 2000 VA insulation transformer, single pole automatic breakers,
step-up transfor-mers, diode rectifiers, fuses on the D.C. side.
Over Spd
This protection is active in
FOC and SLS operation
modes only.
The motor has exceeded the preset speed limit threshold.
Check the value of the preset speed limit threshold.
The speed regulator is not correctly adjusted.
Confg Err
Incorrect parameter
configuration.
Check the monitor parameter [78.05] Config error to understand what
configuration error has occurred.
DSP Fail
Error at start of DSP program
Replace the microprocessor board.
Net Fail
Loss of communication
network.
Check the status of the net Master: it must be active.
Check that the Microprocessor Board is correctly connected to the Profibus
expansion board (Network Board or PLC Interface Board). Also check the
connection cable between the ATV and the net master for damage.
Check consistency between the profibus node setting, parameter [06.13]
Profibus ID (for PROFIBUS network) or parameter [06.14] Modbus ID (for
MODBUS network) and the drive Network address sent by the net master.
Set speed not reached.
The difference (in %) between
the speed reference and
actual motor speed exceeded
the value set at parameter
[67.08] Motor stall max err for
more seconds than set by use
of parameter [67.09] Motor
stall max time.
Check the parameters related to the function for consistency.
Check the setting of torque and torque current limits.
Check the encoder for correct operation.
Load too high.
Fast Stop
Emergency stop.
If the protection trip is wrong:
Check the setting of parameter [65.02] Fast/coast trip enbl (family [65.00] FastCoast config on the Protect Menu).
Check the digital input on the terminal block
UnderVolt
Minimum DC bus voltage sw
checked.
The instantaneous value of the DC bus voltage has fallen below the threshold
value set by 70% of:
[06.03] AC input voltage * 1.35.
Check the value of the DC bus voltages measured by the voltage transducers
by checking the VDC parameters on the user's display (in Monitor mode).
DrivSzErr
Drive size not selected.
Drive size not selected.
Select the actual drive size.
Ground fault.
The instantaneous value of
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits and
Stall
Gnd Flt
104
5. Maintenance, Checks and Troubleshooting
USER's TERMINAL
DISPLAY
DESCRIPTION
CAUSE/ACTION
the sum of the drive output
currents has exceeded the
protection trip threshold.
after a waiting time (10 minutes at least) to allow for discharge of capacitor
banks.
These precautions are necessary for the safety of operators.
An insulation loss occurred, either in the connection cables to the motor, or
inside the motor windings.
This protection may trip only in case one output phase is connected to ground.
Protection against inverter
overload.
The inverter operated in overload conditions for a time longer than the related
preset value fixed by the inverter overload class (parameter [06.08] Ovl Class
Selection).
The motor speed is under a
preset value for a time
greather than a preset time.
The motor is overloaded.
Check the acceleration ramp.
Check the parameters [67.10] Undspd flt setpoint (minimum speed fault
setpoint) and [67.11] Undspd timeout (maximum time under the minimum
speed fault setpoint).
Mot ThPrt
Protection against motor
overload.
The motor operated in overload conditions for a time longer than the related
preset value (parameters [66.02] Overload and [66.03] Overload timeout)
Speed Dev
Motor speed different from
the speed demand.
This protection trips if the motor steady state speed is different from the set
reference. The motor is overloaded.
DSP initialization error.
Check microprocessor board.
Current offset.
Check current transducers.
RAM Error
RAM DSP error.
Check microprocessor board.
SWF Error
Switching frequency not
allowed.
Change the switching frequency parameter value (parameter [06.12] Switching
Frequency, family [06.00] Drive data, Drive Menu).
UnderLoad
Loss of load.
Check if Underload settings are correct for load motor shaft
Loss of speed reference.
Check external analog signal connections at microprocessor board terminals
(e.g. disconnected wire), and analog input configuration.
Loss of one phase on motor.
All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits and
after a waiting time (10 minutes at least) to allow for discharge of capacitor
banks.
These precautions are necessary for the safety of operators.
Check connection at drive and motor terminals and the motor cable.
Floating Point Error.
Check microprocessor board.
Open Brake
Crane control: open brake
fault.
The brake status, (Digital Input) selected by [30.06] DI - Brake Status and
[30.07] Brake open status, remains closed during the open procedure. Check
parameter [30.09] Brake opening time in order to be sure to verify that
mechanical times needed for the brake opening are set correctly.
Close Brk
Crane control: close brake
fault.
The brake status , (Digital Input), selected by [30.06] DI - Brake Status and
[30.07] Brake open status, remains opened during the close procedure. Check
parameter [30.15] Brake closing time in order to be sure to verify that
mechanical times needed for the brake closing are set correctly.
Trq Prove
Crane control: Toque proving
fail
Torque proving failed because the motor torque is not greater than the
threshold set by [30.01] Torque proving thres. It is possible to delay the torque
proving test using the parameter [30.04] Trq prov fail time.
Inv ThPrt
UnderSpd Er
DSPFormErr
Curr Offs
SpdRfLs
OutPhasOut
FP Error
TrqTh High
Crane control: Torque proving The torque threshold is too high, causing motor rotation during torque proving.
There is a motor rotation when the brake is closed.
threshold greater than brake
torque capability
105
5. Maintenance, Checks and Troubleshooting
USER's TERMINAL
DISPLAY
106
DESCRIPTION
CAUSE/ACTION
Brk & Run
Crane control: Unwanted
brake close condition
The brake status (Digital Input) selected by [30.06] DI - Brake Status and
[30.07] Brake open status, indicates that the brake is closing when the motor is
running.
It appears only if the parameter [30.12] Unwanted closed mode is set to “Fault”.
AI User Fl
Analog Input NTC/PTC
management
Check the temperature of thermistor connected to analog input
SWF CfgErr
Switching frequency
configuration error
The switching frequency selected through the parameter [06.12] Switching
Frequency is incompatible with the MODVEC board switch setting.
Change the parameter setting or the MODVEC SW3 switch setting.
Cks MODErr
Corrupted message from
modulator to control board.
Check the connection between the modulator board (MODVEC board) and the
control board (SCADA board).
5. Maintenance, Checks and Troubleshooting
5.4.
Electrical Check of an Inverter Power Module
The foIlowing paragraph gives the procedure to be followed to perform a first check of the integrity of an inverter phase module.
This test must be performed in full compliance with safety rules as shown in the “Safety and Installation Manual” PMP CA ATV E 2521.
+
∼
M
Disconnect the module under test by removing the bolts that connect the power terminals to the DC bars (front bar assembly) and to the
output AC bar.
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
Make available an analog multimeter (the multimeter type based on a pointer) arranged for resistance measurement (on the range Ω x 1).
Check the conditions shown in the following table:
POINTS to be TESTED
WARNING
VALUE
+ Terminal
- Terminal
+
M
Open
M
+
about 20 Ω
-
M
about 20 Ω
M
-
Open
M
~
Open
~
M
Open
+
~
Open
~
+
about 20 Ω
-
~
about 20 Ω
~
-
Open
+
-
Open
-
+
about 80 Ω
Only analog multimeters (those endowed with a pointer) are suitable for this resistance
measurement (on the range Ω x 1)
Do not use digital multimeters.
107
5. Maintenance, Checks and Troubleshooting
5.5.
Measuring and Displaying Inverter Output Currents and D.C. Voltages
ATV 3300V Inverter Equipments are endowed with current and voltage Hall effect transducers (TA LEM and TV LEM on equipment
elementary diagrams); this makes available, inside the control module, across the load resistances of such LEM transducers, electrically
insulated signals that measure inverter d.c. voltages and output currents.
The load resistances, soldered to appropriate pins, are placed inside the card INTVECM.
The scale factors of signals is:
Equipment Size
Output current scale
DC bus voltage scale
ATV 1K3 A33
ATV 1K8 A33
ATV 2K6 A33
ATV 3K6 A33
ATV 5K2 A33
ATV 1K6 W33
ATV 2K4 W33
ATV 3K6 W33
ATV 4K8 W33
ATV 7K2 W33
5 V @ 560 A
5 V @ 840 A
5 V @ 1240 A
5 V @ 840 A
5 V @ 1240 A
5 V @ 560 A
5 V @ 840 A
5 V @ 1240 A
5 V @ 840 A
5 V @ 1240 A
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
5 V @ 3000 V
Inverter output currents may be measured as voltages across load resistances of TA LEM transducers by a “ true RMS ” multimeter;
voltages on DC side may be measured across load resistances of TV LEM transducers by a DC multimeter. Both waveshapes of inverter
output currents and DC voltages may be displayed by an oscilloscope.
EXAMPLE:
Equipment size: ATV 7K2 W33
Measurements on the card INTVECM by a true RMS multimeter:
108
SIGNALS
PINS
MEASURED VALUE
IR1
T17-T19
1,52 VRMS
IS1
T21-T23
1,48 VRMS
IT1
T25-T27
1,51 VRMS
IR2
TO1-TO3
1,50 VRMS
IS2
TO5-TO7
1,47 VRMS
IT2
TO9-T11
1,53 VRMS
VDC1
T33-T35
3,99 VDC
VDC2
T13-T15
3,97 VDC
VOLTAGE / CURRENT
1240
= 377 ARMS
5
1240
1,48 ⋅
= 367 ARMS
5
1240
1,51 ⋅
= 374 ARMS
5
1240
1,50 ⋅
= 372 ARMS
5
1240
1,47 ⋅
= 365 ARMS
5
1240
1,53 ⋅
= 379 ARMS
5
3000
3,99 ⋅
= 2394V DC
5
3000
3,97 ⋅
= 2382V DC
5
1,52 ⋅
5. Maintenance, Checks and Troubleshooting
The total output current can be so calculated:
I R = I R1 + I R 2 = 377 + 372 = 749 ARMS
I S = I S 1 + I S 2 = 367 + 365 = 732 ARMS
I T = I T 1 + I T 2 = 374 + 379 = 753 ARMS
V DC _ TOT = V DC1 + V DC 2 = 2394 + 2382 = 4776V DC
Waveform shown on the oscilloscope
IR1 (T17-T19)
2,15 Vpk
I R1 _ pk = 2,15 ⋅
I R1 _ RMS ≅
1240
= 533 Apk
5
533
2
= 377 ARMS
109
6. Parts Replacement
6.1. Power Modules
This action must be performed in full compliance with the Safety precautions that can be found in paragraph 5.1, Safety prescriptions,
of this manual.
Be sure that the inverter power supply of gate firing cards is off (switch off the power supply of the TALIMB card).
6.1.1. Air cooled inverter power modules
The air cooled inverter power module must be removed according to the following procedure:
I. Disconnect the power bus bars
Remove the bolts that connect the power terminals of the inverter module both to the DC bars and to the output AC bar.
II.
Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
On all gate firing cards, unplug the optic fibers from the relevant sockets (RC and TR on the board).
III.
Remove the inverter module
Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.
The new air cooled inverter power module must be installed according to the following procedure:
I.
Insert the inverter phase module
Slide the module along the metal rails on the support board up to the right position and fix the module by using
the bolts removed earlier.
II.
Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the gate firing cards with AC voltage to the terminal block X02.
On all gate firing cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to
match fiber plugs with socket labels, in accordance with the inverter equipment Elementary Diagram.
III. Connect the power bus bars
Use the original bolts to connect the power terminals of the inverter module both to the DC bars and to the output AC bar.
110
6. Parts Replacement
6.1.2. Air cooled rectifier power modules
The air cooled rectifier power module must be removed according to the following procedure:
I. Disconnect the power bus bars
Remove the bolts that connect the power terminals of the rectifier module to the DC bars.
II. Disconnect the power cables
Remove the bolts that connect the power terminals of the rectifier module to the AC input line cables.
III.
Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect the twisted cable that supplies the cards with AC 80 kHz voltage.
Unplug the optic fibers from the relevant sockets (RC and TR on the board).
IV.
Remove the rectifier module
Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.
The new air cooled inverter power module must be installed according to the following procedure:
I.
Insert the rectifier module
Slide the module along the rails on the support board up to the right position and fix the module by using the
bolts removed earlier.
II.
Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the cards with AC 80 kHz voltage.
On all cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to match fiber
plugs with socket labels, in accordance with the equipment Elementary Diagram.
III. Connect the power bus bars
Use the original bolts to connect the power terminals of the rectifier module to the DC bars.
IV. Connect the power cables
Use the original bolts to connect the power terminals of the rectifier module to the AC input line cables.
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6. Parts Replacement
6.1.3. Water cooled inverter power module
The water cooled inverter power module must be removed according to the following procedure:
I.
Disconnect the cooling circuit
Push the head of the first valve and, by applying an axial pull force, remove it from the pipe connecting such
valve to the heatsink (see drawing below).
Repeat the procedure for the second valve and remove all the coolant from the heat sink; be careful to avoid
spilling it on the nearby electronic devices (especially gate firing cards and IGBTs)
II. Disconnect the power bus bars
Remove the bolts that connect the power terminals of the inverter module both to the DC bars and to the output AC bar.
III.
Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
On all gate firing cards, unplug the optic fibers from the relevant sockets (RC and TR on the board).
IV.
Remove the inverter module
Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.
The new water cooled inverter power module must be installed according to the following procedure:
I.
Insert the inverter phase module
Slide the module along the metal rails on the support board up to the right position and fasten the mechanical
lock.
II.
Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the gate firing cards with AC voltage to the terminal block X02.
On all gate firing cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to
match fiber plugs with socket labels, in accordance with the inverter equipment Elementary Diagram.
III. Connect the power bus bars
Use the original bolts to connect the power terminals of the inverter module both to the DC bars and to the output AC bar.
IV.
Connect the cooling circuit
Insert the heat sink input and output pipes into the respective valves by pushing them in axial direction (see
drawing below).
112
WARNING
Before reapplying voltage, make sure that no residual
humidity is still present.
6. Parts Replacement
6.1.4. Water cooled rectifier power modules
The water cooled rectifier power module must be removed according to the following procedure:
I.
Disconnect the cooling circuit
Push the head of the first valve and, by applying an axial pull force, remove it from the pipe connecting such
valve to the heatsink (see drawing below).
Repeat the procedure for the second valve and remove all the coolant from the heat sink; be careful to avoid
spilling it on the nearby electronic devices (especially gate firing cards and IGBTs)
II. Disconnect the power bus bars
Remove the bolts that connect the power terminals of the rectifier module to the DC bars.
III. Disconnect the power cables
Remove the bolts that connect the power terminals of the rectifier module to the AC input line cables.
IV.
Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect the twisted cable that supplies the cards with AC 80 kHz voltage.
Unplug the optic fibers from the relevant sockets (RC and TR on the board).
V.
Remove the rectifier module
Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.
The new water cooled inverter power module must be installed according to the following procedure:
I.
Insert the rectifier module
Slide the module along the rails on the support board up to the right position and fix the module by using the
bolts removed earlier.
II.
Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the cards with AC 80 kHz voltage.
On all cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to match fiber
plugs with socket labels, in accordance with the equipment Elementary Diagram.
III. Connect the power bus bars
Use the original bolts to connect the power terminals of the rectifier module to the DC bars.
IV. Connect the power cables
Use the original bolts to connect the power terminals of the rectifier module to the AC input line cables.
V.
Connect the cooling circuit
Insert the heat sink input and output pipes into the respective valves by pushing them in axial direction (see
drawing below).
WARNING
Before reapplying voltage, make sure that no residual
humidity is still present.
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6. Parts Replacement
6.2.
Main Fans (Air cooled units only)
The fan must be removed according to the following procedure:
I.
Disconnect the cable supplying the fan
Disconnect the power supply cable from the terminal block of the motor.
II.
Remove the fan
Remove the 8 bolts that fix the fan to the cabinet and remove the fan.
The new fan must be installed according to the following procedure:
I.
Place the fan
Place the fan above the cabinet and fix it by using the 8 bolts removed earlier.
II.
Connect the cable supplying the fan
Reconnect the power supply cable to the terminal block of the motor.
6.3.
Water Pumps (Water cooled units only)
See cooling system use and maintenance manual (P MP CA ATV E 2560)
6.4.
Control Cards
NOTE
All replacement operation must be done without power
supply.
6.4.1. INTVECM card
The INTVECM card must be removed according to the following procedure:
I.
Disconnect the power supply from terminal board X1
II.
Extract all connectors of current transducer and voltage transducer from terminal boards X2A, X2B, X3A, X3B and X7
III.
Extract the flat cables from terminal board X4 and X6
IV.
Remove the teflon nuts and remove the card
The new INTVECM card must be installed according to the following procedure:
I.
Place the new card and remount the teflon nuts
II.
Insert the flat cables into terminal board X4 and X6
III.
Insert all connectors of current transducer and voltage transducer into terminal boards X2A, X2B, X3A, X3B and X7
IV.
Reconnect the power supply into terminal board X1
6.4.2. ALIM card
The ALIM card must be removed according to the following procedure:
114
I.
Remove the cover protection
II.
Disconnect the power supply from terminal board X1
III.
Extract the flat cables from terminal board X2
IV.
Remove the spacers and remove the card
6. Parts Replacement
The new ALIM card must be installed according to the following procedure:
I.
Place the new card and remount the spacers
II.
Insert the flat cables into terminal board X2
III.
Reconnect the power supply into terminal board X1
IV.
Remount the cover protection
6.4.3. SUPRB card
The SUPRB card must be removed according to the following procedure:
I.
Disconnect the profibus cable from 9 pin connector X1
II.
Remove the screws that fix the card
III.
Extract the card from the connector K4 on Scada plus card
The new INTVECM card must be installed according to the following procedure:
I.
Place the new card into the connector K4 on Scada plus card
II.
Remount the screws that fix the card
III.
Reconnect the profibus cable into 9 pin connector X1
6.4.4. SCADA PLUS card
The SCADA PLUS card must be removed according to the following procedure:
I.
Remove the SUPRB card
II.
Extract the flat cables from terminal board K1 and K2
III.
Extract the cable from terminal board X7
IV.
Remove the terminal board
V.
Remove the Teflon nuts
VI.
Remove the card and disconnect the ground cables
The new SCADA PLUS card must be installed according to the following procedure:
I.
Connect the ground cables, place tha card and fixt it by using the Teflon nuts
II.
Place the terminal board
III.
Insert the cable into terminal board X7
IV.
Insert the flat cables into terminal board K1 and K2
V.
Instal the SUPRB card
6.4.5. MODVEC-S card
The MODVEC-S card must be removed according to the following procedure:
I.
Disconnect the power supply from terminal board X5
II.
Extract the cable from terminal board X3
III.
Extract the terminal board X7
IV.
Extract the optic fibers
V.
Extract the flat cables from terminal board X1 and X8 (only in 2 parallel bridge configuration)
VI.
Extract the termination from terminal board X8 (only in single bridge configuration)
VII.
Remove the teflon nuts and remove the card
115
6. Parts Replacement
The new MODVEC-S card must be installed according to the following procedure:
I.
Place the new card and remount the teflon nuts
II.
Insert the flat cables into terminal board X1 and X8 (or termination)
III.
Insert the optic fibers
IV.
Insert the terminal board X7
V.
Insert the cable into terminal board X3
VI.
Reconnect the power supply into terminal board X5
6.4.6. FOVECM card
The FOVECM card must be removed according to the following procedure:
I.
Disconnect the power supply from terminal board X1
II.
Extract the flat cable from terminal board X2
III.
Extract the optic fibers
IV.
Extract the termination from terminal board X3
V.
Remove the teflon nuts and remove the card
The new FOVECM card must be installed according to the following procedure:
I.
Place the new card and remount the teflon nuts
II.
Insert the flat cable into terminal board X2
III.
Insert the optic fibers
IV.
Insert the termination into terminal board X3
V.
Reconnect the power supply into terminal board X1
6.4.7. INTPREA card
The INTPREA card must be removed according to the following procedure:
I.
Disconnect the power supply from terminal board XAL
II.
Disconnect the cable from terminal board XIN
III.
Disconnect the cable from terminal board XP1
IV.
Extract the optic fibers
V.
Remove the teflon nuts and remove the card
The new INTPREA card must be installed according to the following procedure:
I.
Place the new card and remount the teflon nuts
II.
Insert the cable into terminal board XP1
III.
Insert the cable into terminal board XIN
IV.
Insert the optic fibers
Reconnect the power supply into terminal board XAL
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7. Spare Parts
7.1.
POWER MODULES
7.1.1. Air Cooled Inverter Power Modules
Part Number
Module identification
Description
1000085357
MOD ATV 1K3 A33 H
Power module of Silcovert-TN 3300 V 1300 kVA air cooled
1000085340
MOD ATV 1K8 A33 H
Power module of Silcovert-TN 3300 V 1800 kVA air cooled
1000082406
MOD ATV 2K6 A33 M
Power module of Silcovert-TN 3300 V 2600 kVA air cooled
7.1.2. Air Cooled Rectifier Power Modules
Part Number
Module identification
Description
1000092503
RAD ATV 550 A33 12P
Rectifier module for 12 pulses
configuration 550 A air cooled
1000090505
RAD ATV 550 A33 24P
Rectifier module for 24 pulses
configuration 550 A air cooled
1000093667
RAD ATV 1K1 A33 12P
Rectifier module for 12 pulses
configuration 1100 A air cooled
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7. Spare Parts
7.1.3. Water Cooled Inverter Power Modules
Part Number
Module identification
Description
1000091322
MOD ATV 1K6 W33 H
Power module of Silcovert-TN 3300 V 1600 kVA water cooled
1000091324
MOD ATV 2K4 W33 H
Power module of Silcovert-TN 3300 V 2400 kVA water cooled
1000082410
MOD ATV 3K6 W33 M
Power module of Silcovert-TN 3300 V 3600 kVA water cooled
7.1.4. Water Cooled Rectifier Power Modules
118
Part Number
Module identification
Description
1000089771
RAD ATV 750 W33 12P
Rectifier module for 12 pulses
configuration 750 A water cooled
1000091319
RAD ATV 750 W33 24P
Rectifier module for 24 pulses
configuration 750 A water cooled
1000090366
RAD ATV 2K2 W33 12P
Rectifier module for 12 pulses
configuration 2200 A water cooled
7. Spare Parts
7.2. TRANSDUCERS
7.2.1. Inverter Current Transducer
Part Number
Description
ELP224763
TA – LEM 500/0,1 A (output inverter)
ELP223424
TA – LEM 1000/0,2 A (output inverter)
7.2.2. DC Voltage Transducer
Part Number
Description
ELP231543
TV – LEM 3000 V/50 mA (DC bus voltage)
1000006462
TV assembly
7.2.3. AC Voltage Transducer (AFE configuration)
Part Number
Description
ELP22760603
TV 4000 / 100:√3
7.2.4. Ground Fault Detector
Part Number
Description
ELP219767
TV – LEM 20/100 mA – 12 kV
1000088782
Ground fault detector assembly
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7. Spare Parts
7.3. POWER FUSES
7.3.1. Diode Front End 12 Pulse configuration Air Cooling – Incoming Line Fuses
Part Number
Description
1000090036
ATV 1K3 A33 12P
1000084714
ATV 1K8 A33 12P
1000090033
ATV 2K6 A33 12P
1000090035
ATV 3K6 A33 12P
1000092697
ATV 5K2 A33 12P
7.3.2. Diode Front End 24 Pulse configuration Air Cooling – Incoming Line Fuses
Part Number
Description
1000091831
ATV 1K3 A33 24P
1000091526
ATV 1K8 A33 24P
1000090036
ATV 2K6 A33 24P
1000084714
ATV 3K6 A33 24P
1000090033
ATV 5K2 A33 24P
7.3.3. Diode Front End 12 Pulse configuration Water Cooling – Incoming Line Fuses
Part Number
Description
1000084714
ATV 1K6 A33 12P
1000091832
ATV 2K4 A33 12P
1000090035
ATV 3K6 A33 12P
1000092697
ATV 4K8 A33 12P
1000092698
ATV 7K2 A33 12P
7.3.4. Diode Front End 24 Pulse configuration Water Cooling – Incoming Line Fuses
Part Number
Description
1000091833
ATV 1K6 A33 24P
1000090036
ATV 2K4 A33 24P
1000084714
ATV 3K6 A33 24P
1000091832
ATV 4K8 A33 24P
1000090035
ATV 7K2 A33 24P
7.3.5. ctive Front End configuration AC Line and Motor Fuses
Part Number
Description
1000092955
ATV 3K6 W33 AFE
1000092955
ATV 7K2 W33 AFE
7.3.6. Active Front End configuration DC Connection Fuses
Part Number
Description
Elp22962801
ATV 4K8 W33 AFE
Elp22962801
ATV 7K2 W33 AFE
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7. Spare Parts
7.4.
Firing Cards AND Thermo Switch Interfaces
Part Number
1000089193
1000089194
1000089191
1000089192
1000089333
1000089332
1000094288
1000089331
1000001531
1000089717
ELP264421
1000094826
ELP227941
7.5.
Precharge CIRCUIT (only for afe configuration)
Part Number
1000001531
1000094826
1000093106
7.6.
Description
TGUNTNB M900 EXT card
TGUNTNB M900 INT card
TGUNTNB H600 EXT card
TGUNTNB H600 INT card
TALPTNA card
TCPSA card
TCPSB card
TDIPRA card
TRAPREC card
TITOIA card
TALIMB card
Precharge transformer (only AFE configuration)
Trasformer TRAL80
Description
TRAPREC card
Precharge transformer
Precharge Fuses
Control parts
Part Number
1000083311
1000083312
1000096401
1000096402
1000096394
1000096396
1000091320
ELC452614
1000083291
1000090364
1000089394
ELP26504301
1000090359
1000092912
1000092915
1000092928
1000092951
1000095826
ELP264898
ELP26403901
ELP221237
ELP226084
ELC481318
1000073029
Description
Control Module for ATV 3300V – motor side – single configuration – DFE
Control Module for ATV 3300V – motor side – 2 parallel configuration – DFE
Control Module for ATV 3300V – motor side – single configuration – AFE
Control Module for ATV 3300V – motor side – 2 parallel configuration – AFE
Control Module for ATV 3300V – line side – single configuration
Control Module for ATV 3300V – line side – 2 parallel configuration
SCADA PLUS control card
SUPRB card
MODVEC-S card
FOVECM card
INTPREA card
INTSYNC card
ALIM card
INTVECM card for ATV 1K3 A33 / ATV 1K6 W33
INTVECM card for ATV 1K8 A33 / ATV 2K4 W33
INTVECM card for ATV 2K6 A33 / ATV 3K6 W33
INTVECM card for ATV 3K6 A33 / ATV 4K8 W33
INTVECM card for ATV 5K2 A33 / ATV 7K2 W33
XITOIA card
XPTERA card
Alim 100 W
Alim 50 W
SVGTAFK – Advanced keypad
Advanced keypad cable (2.5 m length)
121
7. Spare Parts
7.7.
PLC PARTS
Order code
1000086651
1000086653
1000086654
1000094781
1000095593
1000098916
1000086655
1000086656
1000086657
1000086658
1000086659
1000086660
1000086663
1000086662
1000086661
1000086678
1000091616
Description
Rack 5 slot
Power Supply 100/240 Vac 50/60 Hz
CPU 350
CPU 360
CPU 366
CPU 374
Master Profibus Module
Slave Profibus Module
Slave Modbus Module
Profibus Interface
Digital Imput Module
Digital Output Module
Analog Output “ALG320” Module
Analog Imput “ALG220” Module
Analog Imput „ALG620“ Module
Quickpanel view display 6”
Quickpanel view display 12”
7.8. INVERTER OUTPUT REACTORS
Order code
1000087972
1000087973
1000087974
1000087975
1000087976
1000087977
7.9.
Description
Output reactor for ATV 1K3 A33
Output reactor for ATV 1K8 A33
Output reactor for ATV 2K6 A33
Output reactor for ATV 1K6 W33
Output reactor for ATV 2K4 W33
Output reactor for ATV 3K6 W33
FANS (Air Cooling Unit Only)
Order code
Description
1000089129
Motor and Fan assembly – 50 Hz
1000089130
Motor and Fan assembly – 60 Hz
7.10. PUMPS (Water Cooling Unit Only)
See “Cooling System Use and Maintenance Manual” (P MP CA ATV E 2560).
122