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2300 V, 18-Pulse Non-Regenerative Drive User`s Manual

1. H g H E A H H H H H H H O O QO o O O O D o O 0 O O O O q O 0 O 0 q e O 0 o Oo Oo Oo o Oo O TNI JIE Ee JIE Bel lell nit 4 i Ae 4 Ob na a Cys Ss a 5 H E JE uw HO d ee 183 e e 15 e ej i 9 Po me e 2 aa i oS j Cm h e e o 909 ToO AONO E rg OKOA SO rg TOZO E cse JE WI Ho ie jeg Go i DE 0 o o go o o 9 e oO Qo ac 00 Qo oio Qo E 9 OIM qup OM 2 9 eu a Q Elo i e E E id f Qp b 9 O b 9 9 8 b 8 6 9 9 9G e 9 9 PHASE PHASE B PHASE C Figure C 5 Phase Leg Assembly Pha
2. BAO ag H64 R Figure C 9 Panel Assembly Source Cabinet 74 e Appendix C Parts Assembly Drawings 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 S46 DT gh ya A o 8 Le 2AA 4 WA 3 LAL H89 e N N C LA J SZ HIO9 bell WE a H55 este pn B 1e H56 X H63r za SII9 m sm H55 H55 H56 456 H63 ES Figure C 10 Panel Assembly Source Cabinet Appendix C Parts Assembly Drawings 9 75 GEK 105490 Innovation Series Medium Voltage AC Drives Notes 76 e Appendix C Parts Assembly Drawings End of manual To C3 GE Industrial Systems Documentation Design Rm 291 1501 Roanoke Blvd Reader Comments Salem VA 24153 6492 USA General Electric Company Fax 1 540 387
3. DC Link Capacitor Assembly Figure C 1 66 Appendix C Parts Assembly Drawings 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 HE3 E E326 S SS Figure C 2 Back Panel Assembly Load Cabinet Appendix C Parts Assembly Drawings e 67 GEK 105490 Innovation Series Medium Voltage AC Drives IGBT BU GB BUS E 9 9 H54 IGBT BUS 173C9255AMP I H273 AC BUS SUPPORT 173C9255BKPII jaw a5 warti rar BI mii can EL aran SS ear D ec os AES aa pp ea em ss a za 7 I I ci I T EN H272 ES somn SE H273 0 p ELE AC BUS SUPPORT ra ES Am Er cp pn T Wa d RU TE HII7 HS4l HI20 L1 LE m m moon ou H272 HI32 T TT LA r3 Lr a Lr Lr m Lr H L H H U TU N SEI Wi FIG HI37 ISO VIEW TOP VIEW Figure C 3 Back P
4. 14 C 9 Panel Assembly Source Cabinet 74 4 1 Example of DDI Fault Display Screen 20 C 10 Panel Assembly Source Cabinet 75 5 1 IGBT Module Location in 2300 V Drive Heat Exchanger Assembly 34 List of Tables Table Title Page 2 T Key BUNCHONS ees coop se tapete beue titan 7 2 2 Drive Fault Status Indicators 11 2 2 Bar Graph Display Characteristics 12 4 1 Fault Code Description 20 fie List of Figures List of Tables Table Title Page 6 1 Parts List for Source Cabinet 35 6 2 Parts List for Load Cabinet 37 6 3 Parts List for Control Cabinet 40 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary 7 Eguipment Overview This manual describes the 2300 V non regenerative model of GE s Innovation Series medium voltage ac drives The purpose of the manual is to assist the user in operating and maintaining this drive Section 1 introduces drive features and defines the manual contents Its purpose is to present a general product overview for the reader as follows Section Topic Page 1 1 Introduction to the Drive eaaa l 1 2 Hardware Overview w wmneewwnsa l 1 3 Software Overview eee 4 1 4 Techni
5. wwwnnnanannea 1 1 3 Software Overview eee 4 1 4 Technical Characteristics 4 1 5 Technical Assistance 5 1 6 Related Documents eee 5 2 2 Using the Keypad aa 8 2 3 Reading the Display 10 2 3 1 Drive Health State Icons 11 2 3 2 Animated Metess v w 12 2 4 Menu Selections wwwwea 13 2 4 1 Review FaultsS w e 13 2 4 2 Parameter Configuration 13 2 4 3 Contrast Adjustment Screen 14 2 4 4 Software Version Screen 14 IntroductioN wwweemnnwnwa 15 3 2 Maintenance Schedule 15 3 3 Maintenance Record 15 3 4 Tools Materials Needed 15 3 5 Power On Checks eee 16 3 6 Power Off Checks eee 16 3 6 1 Before Starting Maintenance 16 3 6 2 Dust Removal wwmwenenasa 16 3 6 3 Loose Connections 17 3 6 4 Damaged Insulation
6. 17 3 6 5 Contactors and Relays 17 3 6 6 Printed Wiring Boards 17 3 7 Short Circuit Damage sess 18 Section Heading 4 2 Types of Eaults ww 19 4 3 Fault Indication 19 Introc TESTE ead ON Dm INDE IAM MEN 43 A 2 Identifying the PA 43 A 2 Renewal Parts List w 43 A 2 2 Part Number Structure 44 A 3 Warranty Terms sees 45 A 4 How to Order PartsS 45 A 4 1 Understanding the Drive Nameplate 45 B 1 Introduction eeeeeeee anane a nenun ene 47 C l Introductio saananing EA aa apak 65 Table of Contents 09 i GEK 105490 Innovation Series Medium Voltage AC Drives List of Figures Figure Title Page Figure Title Page 1 1 Outline of Typical 2300 V 18 Pulse 6 1 Parts List Structure Source Cabinet 35 Innovation Series Drive 2 6 2 Parts List Structure Load Cabinet 37 1 2 Overview of Drive Hardware Structure 3 6 3 Parts List Structure Control Cabinet 40 2 1 DDI As Seen From Front of Drive 7 A 1 Sample Part Number for Order Specific 2 2 Sample of Status Screen Display 10 JASSETHIDIY ie eE
7. 89 AC line volts low Alarm Low ac source voltage is threatening to trip the drive Primary Causes Main transformer taps set incorrectly Line voltages too low Alarm threshold incorrectly set 26 Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 4 1 Fault Code Description Continued 90 AC line over freq Trip High ac source frequency has tripped the drive Primary Causes Line frequency too high 9 AC line freq high Alarm High ac source frequency is threatening to trip the drive Primary Causes Line frequency too high go AC line under freq Trip Low ac source frequency has tripped the drive Primary Causes Line frequency too low 93 AC line freq low Alarm Low ac source frequency is threatening to trip the drive Primary Causes Line frequency too low 94 Stat charger timeout Trip The static charger is unable to completely charge the dc bus Normal charge operation terminates when the dc bus reaches 90 of its nominal level At this point the charger is turned off and the switch gear is closed If after around 70 seconds of charging the dc bus does not reach this threshold then this fault is generated and the charging sequence is aborted Primary Causes Static charger failure Dc bus capacitor leaking 95 Static charger failed Trip The dc bus charging procedure was aborted because the static charger report
8. Suppressor 110 V ac MXA SNTRIP Switch lineswitch LSW1 Transformer auto option Transformer CPT1 SSH CS3P40 104X105CD 001 IS200CTBCG1A MCRCO40ATD MPOCAES SSH CRC3 280 173C9249ABG01 323A5743AXG01 IS215ACLAH1AZZ DS200GDPAG1AZZ 323A5743AZG01 104X122AA 371 238B4952P09 104X109AD 076 BMC LPJ5SP WTHH 06268 RITHPS4109 110 RITHPS4109 220 173C8998AA G01 MCRAO40ATJ 68A7958P1 00F 104X123AG 028 PDAS10ISPA32G12 MPOAAE2 104X203DB 003 PDTHOOAUTOXFMR 9T58K0073 2300V 18 Pulse Non Regenerative Drive User s Manual Preliminary Warranty and Renewal Parts A Appendix A of this manual provides information to help the user identify and obtain replacement parts It is organized as follows Section Heading Page Ade troduction eeu cie Ee eo aaa ee 43 A 2 Identifying the Part esses 43 A 2 1 Renewal Parts List 43 A 2 2 Part Number Structure 44 Ae Warranty TO coss nete Re aaa IUE 45 A 4 How to Order Parts 45 A 4 1 Understanding the Drive Nameplate 45 GEK 105490 A 1 Introduction When ordering a replacement part for a GE drive the customer needs to know e How to accurately identify the part e Ifthe part is under warranty e How to place the order This information helps ensure tha
9. Keypad Help BICM is reporting that one of its clock lines is not working 3 Rack pwr supply lost Trip This alarm occurs when logic on the BICM board cannot detect the presence of one of the power supplies being generated by RAPA or RAPB The power supplies monitored include P5 P15 N15 and 124 These supplies are distributed via the backplane to control boards including BICM 124 is also brought to ATBA for use in customer I O Primary Causes Short across one of the monitored power supplies Power supply module failure Possible Board Failures BICM RAPA or RAPB CABP Backplane Keypad Help BICM is reporting that one of its power supplies is not working Section 4 Faults and Troubleshooting e 21 GEK 105490 Innovation Series Medium Voltage AC Drives Table 4 1 Fault Code Description Continued 38 DC bus imbalance Trip This fault occurs when the magnitude of the upper and lower half of the dc bus circuits in the bridge differ by more than 1096 of nominal A typical Nominal dc bus voltage would be 3500V so a difference of around 350V would trigger this fault Keypad Help Software detected that the difference between the upper and lower dc bus voltages was greater than 1096 of Nominal 39 DC pos bus over volt Trip Hardware detection of overvoltage on the positive dc bus Keypad Help Hardware detection of overvoltage on the indicated dc bus 40 DC neg bus over volt Trip Hardware detection of overvoltage on t
10. Drive Fault State Indicators Displayed when the drive has Icon Drive the following fault conditions Display Status Trip Alarm Overrid Param None AN Alarm state Flashing Trip fault 2 3 1 4 Drive Direction This icon indicates the direction of motion currently selected see Figure 2 6 This does not necessarily match the direction of motion as viewed from motor shaft utm Fg Figure 2 6 Drive Direction Icons 2 3 1 5 Motion The icon in this position is one of three indicators see Figure 2 7 Note that the Drive Ready Not Ready icons are mimics of the Start key A diagonal line through the symbol means that the drive is not ready to run XN DRIVE NOT READY TO RUN i lt DRIVE READY TO RUN or NOT RUNNING lt MOTION see Figure 2 8 Figure 2 7 Motion Icons When the drive is running speed feedback is not zero the animated motion icon appears in this position It rotates see Figure 2 8 in the direction selected with the direction arrow key described in Table 2 1 n Tur n Tur NS Qs e Qs cC G Figure 2 8 Animation of the Motion Icon Section 2 Drive Diagnostic Interface e 11 GEK 105490 2 3 2 Animated Meters The animated meters of the Status screen display see Figure 2 2 are bar graphs Table 2 3 defines charac teristics of the bar graphs for the four types of pa rameters displayed Refer to Figure 2 9 A variable shown as a bar grap
11. SEC 001 00000 12 M A Time indication Future feature Figure 2 12 Sample Fault Detail Screen 2 4 2 Parameter Configuration There are two types of parameters that an operator can edit and set using the menus e Option parameters display a list of items options for an operator to select For example True False is an option parameter e Numeric parameters display a list of valid digits that the operator selects to create a number Appendix B provides diagrams of available drive parameters Section 2 Drive Diagnostic Interface 9 13 GEK 105490 To edit a parameter from the DDI 1 Goto the Main Menu shown in Figure 2 10 a If in another Menu screen press the Menu key on the keypad b If in a Status screen press the Menu key twice 2 Use the down arrow key to highlight the Parameter Configuration menu item This brings up the drive Parameter screen see Fig ure 2 13 which lists the parameters and their cur rent settings 4 PARAMETERS PN Cap Buff I2 1 Pole Pairs 2 0000000 L R1 0 4500000 AN R2 0 2 701739 L_Sigma 0 0099250 umm L Sigma St 0 0056977 E Sim Mode Request 0 0099250 Ns P Figure 2 13 Sample Drive Parameter Screen 3 Use the up down arrow keys to index through the list to the parameter you want to change 4 To select the parameter for editing press the Enter key or right arrow key This brings up that parameter s configuration scree
12. refer to the individual board publication If the board contains onboard software refer to the individual board publication for instructions To install a board into a rack a Slide the board into the correct slot 1n the rack CAUTION Boards that mount in the rack are mechani cally keyed so that they can only be installed into the correct slot Do not attempt to defeat or override these interlocks Doing so will damage the electronics b Begin seating the board by firmly pressing the top and bottom of the board at the same time with your thumbs c Finish seating the board in the slot by starting and then tightening the screws at the top and bottom of the board Tighten the screws evenly to en sure that the board is seated squarely To install a board that 1s seated with standoffs a Place the board onto the standoff in the same ori entation as the board that had been removed b Secure the boards by replacing and tightening the screws that had been removed Reconnect all cables making sure that they are properly seated at both ends 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary 5 3 Replacing IGBT Modules If an IGBT fails all four IGBT power modules for that phase should be replaced Additionally the IGDM board IS200IGDM in the affected phase was probably damaged during the failure so must be replaced too In the 2300 V drive each phase consists of a singu lar heat
13. CB1 15 A Contact NC SS1 Contact NO SS1 Filter door Keypad assembly Operator Interface Keypad cover Light green L1 Light red L2 Light amber L3 Pushbutton red PB1 Pushbutton black PB2 Switch selector SS1 336A6406P 1 TEC36015WL CRI04PXCO CRI04PXC1 RSP 91927619 IS2020DDIAG1AZ 173C9226KGP1 E CR104PLG82G CR104PLG82R CR104PLG32M CR104PBG92R1 CR104PBG10B1 CR104PSG35B Section 6 Drive Parts Lists e 41 GEK 105490 Innovation Series Medium Voltage AC Drives Table 6 3 Parts List for Control Cabinet Continued Assembly Name I O Assembly Miscellaneous Space Heater Option 42 e Section 6 Drive Parts Lists Contact 4 NO SCP Contactor for SCP Board CTBC terminal board 1 0 Relays 24 V D SS CP SP Suppressor 24 V dc relay Suppressor SCP TB amp I O assembly left sidewall TB amp I O assembly right sidewall Board ACLA Application Control opt Board GDPA Power Supply 2PTB NO AUTOFXMR option Capacitor ride thru GDPA CRT1 2 opt DIN rail starters Fuse GDPA Board 120 V dc 1 5 A Fuses CPT1FU1 2 5 A 600 V Jumper TB starters Light convenience 110 V option Light convenience 220 V option Lockout lineswitch Relay 110 V ac MXA SNTRIP Res PRECH ride thru RPCRT opt Resistor ride thru bleeder RBRT1 opt Starters
14. PDFP1000A5V1 5Q Resistor 7 500 W cO CO Switch micro fuse PH1 3 Section 6 Drive Parts Lists e 35 GEK 105490 Innovation Series Medium Voltage AC Drives Table 6 1 Parts List for Source Cabinet Continued Assembly Name Part Description Part Catalog No Qty Blower Assembly Blower assembly 173C9255EFG02 EN Buswork Bus ac conn to linefuse lower 173C9255JNP5 3 Bus ac conn to linefuse middle 173C9255JNP4 3 Bus ac conn to linefuse upper 173C9255FLP15 3 Bus DB conn pos 1 173C9255FLP20 E Bus DB conn pos 2 178C9255FLP22 2 Bus DB conn pos 3 178C9255FLP23 2 Bus DB conn neg 1 173C9255FLP21 E Bus dc conn neg 173C9255JGP 1 1 Bus dc conn neg 2 178C9255FLP19 E Bus dc conn pos 178C9255FLP17 E Bus dc conn pos 2 173C9255FLP18 E Diode Assembly 18 Pulse Bus ac phase 1 MID pos 1 173C9255ERP1 3 Bus ac phase 2 LT TOP neg 0 173C9255ESP 3 Bus ac phase 3 RT BOT neg 1 173C9255ETP1 3 Diode 3600 V 1500 A source PDDP1002Q36Q15 18 Fuses ac incoming 1000 A 1000 V 323A2433P14 9 Harness ac line fuse 336A3594AE G03 E Harness VATF SRC TFBA DM 336A3594AD G32 E Harness VATF SRC bus fiber optic 336A3594AD G05 E Heat exchanger large 173C9255BXG01 2 Heat exchanger small 173C9255BZG01 2 Phase leg assemblies diode EUP DD1200S
15. and materials listed below may be needed when performing preventive maintenance on the drive O High quality tools including screwdrivers and pliers designed specifically for working with electrical wiring systems Socket set Hex wrench Torque wrench Electrical tape Fine file Clean dry cloth L1 D D D D L1 Oo Soft bristled brush such as a paintbrush Section 3 Preventive Maintenance 9 15 GEK 105490 Mild solution of distilled water and household or laboratory detergent see section 3 6 6 step 4 O Isopropyl alcohol O Insulation resistance tester High voltage detector such as a tic tracer using an insulated pole of appropriate length Source of dry low pressure compressed air Vacuum cleaner with non metallic nozzle and finely woven high efficiency filter Fuse puller O Replacement components if required including fuses wiring cabling and door filters 3 5 Power On Checks The following preventive maintenance procedures need to be conducted with power on within the con trol cabinet only WARNING With power applied dangerous voltages exist in the equipment circuitry 1 While the equipment is running open the control cabinet door The fan should be located underneath the board rack 2 Without touching any circuitry look to see that the fan is still running 3 If it is not turn off power to the equipment then replace the fan The fan is held in place by fou
16. exchanger assembly with four IGBT mod ules and one clamp diode module see Figure 5 1 All four IGBTs should be replaced as a matched set the white letter on the face of the IGBT module I J K L M must be the same for all four de vices Note At a minimum the IGBTs for the two de vices in the upper positions of the heat exchanger should be replaced as a matched set of two and the IGBTs for the two de vices in the lower positions should be re placed as a matched set of two The following procedures describe steps to remove the IGBT modules from the heat exchanger assem bly and install new ones Removal Remove cables to the three IGDM boards as follows Note Refer to section 5 2 for general board han dling guidelines including precautions to prevent board and cable damage a Inspect the cable connections to verify that the cables are labeled with the appropriate connector names This will simplify recon nection b Remove the cabling to the IGDM c Secure the cables out of the way 2 Remove the two 5 16 kepnuts from the ac bus 3 GEK 105490 Remove the IGBT laminated bus by loosening the 28 captive bolts from the IGBT and clamp diode modules and the 6 captive bolts from the capacitor laminated bus CAUTION Care must be taken when handling these buses If epoxy coating is chipped or scratched buses must be replaced Remove the IGDM board by loosening the four
17. slotted screws on the board These screws are cap tive in the board and should not be removed Remove the IGBTs from the heat exchanger by removing the 14 20 bolts lock washers and flat washers from the eight IGBTs Replacement l Clean the heat exchanger mounting surface of dirt and old thermal grease Note Make sure that IGBTs are installed as matched sets as detailed at the beginning of this section Apply a thin film 6 mils thick of Dow Corning 340 Silicone Grease or equivalent to the back of each new IGBT module Orient each IGBT module in the same position as the old IGBT module and start the eight 14 20 bolts lock washers and flat washers Temporarily tighten the mounting bolts in diagonally opposite corners using the pattern supplied with the IGBT module Then tighten these same bolts to 44 in Ibs torque in the opposite of step 4 using the same pattern as step 4 Visually inspect the IGBT buses for chips scratches or cracks in the epoxy coating Also look for me chanical deformation or other damage If buses are marred or damaged replace them before proceeding to step 8 Place the IGBT bus back into place over the IGBT and clamp diode modules Section 5 Component Replacement e 33 GEK 105490 Phase A Heatpipe Assembly Innovation Series Medium Voltage AC Drives Phase B Heatpipe Assembly Phase C Heatpipe Assembly Heatpipe Heat Exchanger Replace th
18. state of the art hardware compo nents and microprocessor based control circuitry Managed by powerful application software and menu based tuneup tools with protectives the drive delivers the optimal ac output as needed by a customer s application Drive features include e Heatpipe fan combination for space efficient maximum rated cooling e Medium voltage IGBTs insulated gate bipolar transistors in a proven bridge configuration e aminated bus to eliminate need for snubbers e Liquid filled capacitors e 18 pulse input to enhance power quality e 3 level inverter for a cleaner output waveform e Protective hardware coupled with continuous software controlled fault monitoring e Door mounted operator control unit with both digital and graphical display e Menu driven monitoring and tuneup tools with fault display help functions e Optional PC based configuration tools 1 2 Hardware Overview The 2300 V non regenerative drive is physically arranged into a lineup of three enclosures e Source rectifier cabinet e Load inverter cabinet e Control cabinet Figure 1 1 illustrates this drive lineup Figure 1 2 shows the drive hardware structure including the main components of the three units The drive s source unit is fed by a separate 18 pulse transformer and switchgear configuration that steps down a 4160 V input from the customer power source Cable entry can be either at the top or bottom of the unit
19. surface This can cause intermittent problems that are hard to find 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Check for and remove accumulated dust as follows 1 Clean bus bars and standoff insulators with a clean dry cloth do not use any solvents 2 Using a fine filtered vacuum cleaner with a non metallic nozzle remove dust and dirt from wiring and electrical components Note Make sure that the air source is directed so that dust and foreign matter is removed rather than relocated CAUTION Do not use high pressure compressed air which may damage components 3 Inspect cabinet air filters if equipped Shake or vacuum filters clean or replace as required 3 6 3 Loose Connections Vibration during equipment operation can loosen mechanical and electrical connections and cause intermittent equipment failure Additionally dust and moisture in loose connections can cause loss of low level signals at terminal boards and also thermal runaway at bus connections 1 Check all hardware and electrical connections and tighten if needed 2 Tighten or replace any loosened crimp style lugs 3 Tighten or replace all loose or missing hardware 4 nspect printed wiring boards for correct seating and check that any plugs wiring and bus connec tors are tight CAUTION To prevent component damage caused by static electricity treat all boards with static sensitive handling tec
20. until the switch gear is ready to close Primary Causes Switch gear not racked in Customer switch gear permissive not met Section 4 Faults and Troubleshooting 9 25 GEK 105490 Innovation Series Medium Voltage AC Drives Table 4 1 Fault Code Description Continued 76 HtSink DB rise high Alarm Keypad Help Measured heatsink temperature is greater than ambient by an amount exceeding heatsink rise alarm level Measured heatsink temperature is greater than ambient by an amount exceeding heatsink rise alarm level Two measured heatsink temperatures differ by an amount exceeding heatsink imbalance alarm level 82 HtSink blower failed Trip The drive is in a run mode and the cooling fans are not running Primary Causes Blower motor overload or failure Keypad Help Either the source or load bridge blower motor starter is open 86 AC line overvoltage Trip High ac source voltage has tripped the drive Primary Causes Main transformer taps set incorrectly Line voltages to high Fault threshold incorrectly set 87 AC line voltage high Alarm High ac source voltage is threatening to trip the drive Primary Causes Main transformer taps set incorrectly Line voltages too high Alarm threshold incorrectly set 88 AC line under volt Trip Low ac source voltage has tripped the drive Primary Causes Main transformer taps set incorrectly Line voltages too low Fault threshold incorrectly set
21. 11 ENV50140 EN61000 IEEE 347A IEC 146 CE NEMA for Medium Voltage CSA UL CSA UL and CE 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary 1 5 Technical Assistance For assistance contact General Electric Company Product Service Engineering 1501 Roanoke Blvd Salem VA 24153 6492 USA Phone 001 540 387 7595 Fax 001 540 387 8606 1 6 Related Documents The following publications also apply to the your Innovation Series drives and may assist in under standing the system GEI 100256 Receiving Handling and Storage of Innovation Series Equipment GEK 105487 Innovation Series Medium Voltage AC Drives Installation Instructions L GEH 6333 Control System Toolbox GEK 105490 Additionally the following documents provide requi sition specific information about the customer s equipment System drawings including outlines layouts and elementary diagrams D Renewal Parts listing see Appendix A Note If differences between the general product documentation and the requisition specific documentation exist the requisition docu mentation should be considered the more ex act representation of a customer s equipment or system configuration GE Industrial Control Systems supplies the applicable documents to its customers to support the equipment provided in a requisition system The contract documents define the terms of the docu ment distribution Section 1 Equipmen
22. 1A E Board IVSH Shield for IVFB board IS200IVSHG1A 1 Buswork Ac Board SHCA shunt DS200SHCAG1BZZ 3 Bus phase A to shunt 173C9255BEP1 1 Bus phase A vertical out 173C9255BQP 1 1 Bus phase A extension 173C9255JQP 1 1 Bus phase A shunt bus 173C9255BMP E Bus phase B to shunt 173C9255BFP 1 1 Bus phase B vertical out 173C9255BRP1 1 Bus phase shunt to out 173C9255BNP1 2 Bus phase C to shunt 173C9255BGP 1 1 Bus phase C vertical out 173C9255BSP1 1 Section 6 Drive Paris Lists 9 37 GEK 105490 Innovation Series Medium Voltage AC Drives Table 6 2 Parts List for Load Cabinet Continued Assembly Name Part Description Part No Qty Cable Assemblies Harness BICM 336A3594AE G12 EN amp Buswork Load control to door 336A3594AE G08 1 Load control to load 336A3594AE G11 B Load control to panel 336A3594AE G07 1 Load control to source 336A3594AE G10 1 Door 336A3594AE G09 1 Door panel 336A3594AE G17 B CPFP VATF SCTL IGDM 336A3594AD G01 1 Load ground bleeder circuits 336A3594AE G04 1 Load IVFB shunts 336A3594AD G07 1 Load SCTL bus 336A3594AD G19 1 Load VATF bus 336A3594AD G23 1 Load VATF IVFB 336A3594AD G02 1 Load LTB BICM S36A3594AE G15 1 Capacitor Assembly DSM3CAPSA1002M001 DSM3CAPSA1002M001 1 Capacitor dc link 2000 V 2160 uF PDC01000
23. 33K1 1 RTD resistance thermal device 336A3584AA G03 2 Door Filter Filter door RSP 91927619 E Dynamic Brake Assembly Board TFBA Temperature Feedback IS200TFBAH1AZZ EN Option Board IGDM IGBT Gate Driver IS200IGDMH1AZZ 2 Harnessing DB assm IGDMs 336A3594AD G22 E Harnessing DB IGDM VATF TFBA 336A3594AD G31 E Harnessing DB assm CPFP IGDM 336A3594AD G21 E Harnessing DB assm fiber optic 336A3594AD G28 E Harnessing DB assm fiber optic 336A3594AD G30 E Harnessing DB assm VATF to bus 336A3594AD G29 B Heatpipe assembly 173C9255DYG01 1 Laminated bus 173C9255AMP4 1 RTD resistance thermal device 336A3584AE G02 2 Transistor IGBT DBS 1 S2 EUPHFZ1200R33KF 2 Space Heater Option Heater space SS1152 o 36 Section 6 Drive Parts Lists 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Load Cabinet Panel Assembly Blower Boards Printed Bwana AG gu eem Capacitor Assembly Wiring Boards i Harness Assembly Buswork Door Fiter Interface Phase Log Option Figure 6 2 Parts List Structure Load Cabinet Table 6 2 Parts List for Load Cabinet Assembly Name Part Description Part No aty Blower Assembly Blower assembly 173C9255EFG02 E Board Printed Wiring Boards Board IVFB Current Feedback IS200IVFBG
24. 8615 GE Internal DC 8 278 8651 We welcome comments and suggestions to make this publication more useful Your Name Today s Date If needed how can we contact you Fax N Your Company s Name and Address Job Site BAND o Phone No GE Requisition No E mail Your Job Function How You Use This Publication Publication No Address Publication Issue Revision Date General Rating Excellent Good Fair Poor Additional Comments Contents O O O O Organization O O O O Technical Accuracy O O O O Clarity O O O O Completeness O O O O Drawings Figures O O O O Tables O O O O Referencing O O O O Readability O O O O Specific Suggestions Corrections information that could be expanded on and such Page No Comments Other Comments What you like what could be added how to improve and such Overall grade Compared to publications from other manufacturers of similar products how do you rate this publication O Superior O Comparable O Inferior O Do not know Comment Detach and fax or mail to the address noted above Place stamp here GE Industrial Systems Documentation Design Rm 291 1501 Roanoke Blvd Salem VA 24153 6492 USA GE Industrial Systems General Electric Company 1540 387 7000 1501 Roanoke Blvd www GEindustrialcom Salem VA 24153 6492 USA
25. 932AR G02 336A4932AS G02 336A4932AQ G01 336A6405G1 364358020EB001 336A3594AE G12 336A3594AE G08 336A3594AE G11 336A3594AE G07 336A3594AE G10 336A3594AE G09 336A3594AEG06 336A3594AE G17 336A3594AD G11 336A3594AE G15 336A3594AE G16 336A3594AE G05 336A3594AE G14 336A3594AE G13 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Assembly Name Control Module Door Components GEK 105490 Table 6 3 Parts List for Control Cabinet Continued Control GDPA CPFP Fiber optic FOSA TFBA Simplex Fiber optic FOSA TFBA Simplex Fiber optic IGDM FOSA Duplex Fiber optic IVFB FOSA Duplex Fiber optic SCTL FOSA Duplex Fiber optic VATF FOSA Duplex Fiber optic VATF FOSA Harness spaceheater Ride thru option 336A3594AD G26 336A3594AD G10 336A3594AD G25 336A3594AD G09 336A3594AD G08 E 336A3594AD G20 336A3594AD G06 336A3594AD G24 33644932BD G01 S36A3594AE G18 Control board module Rack with CAPB backplane board Fan assembly rack Board BAIA Application I O Board BICM Bridge Interface Board DSPX Processor Board FOSA Fiber optic Interface Board RAPA Rack Power Supply DSMCARDA1001M001 173C8536ALG2 104X215CA 003 IS200BAIAH1 AZZ E IS200BICMH1AZZ IS200DSPXH1AZZ IS200FOSAG1AZZ IS200RAPAG1AZZ Cable CAPB J20 to keypad 10 Ft Circuit breaker disconnect
26. Assembly Wire Connections EWA 3 PLAC V 72 e Appendix C Parts Assembly Drawings 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 339 S60 H96 S59 Bees S14 H96 E Figure C 8 Snubber Assembly Rear View Appendix C Parts Assembly Drawings 9 73 GEK 105490 Innovation Series Medium Voltage AC Drives 173C9255JX 108 56 Y eS y VS S e TRITANI S C SS gy 2 A MER i i Gra L 9 7 N YA Jd a n d NA NI M Ira dh YA D n P
27. DI for local control GE Innovation Series DRIVE HEALTH ICONS al pe ee FS lt Heartbeat DISPLAY 894 49 V 0 75 150 L Provides both analog AC Amp Load Control State and digital represen 0 03 A 0 75 150 AN lt Fault State tation of drive func voltage Magn pi a wa rive Direction tions and values and a P 2 157 text based menus 0 25 W ER 7 m T lt Motion N 4 Navigation Drive Controls KEYPAD oe Organized into two X A AA lt RUN functional groups oe a eed JA Faults vy navigation keys and UC gE pe TS MI drive control keys pete 1 i D i a m jen Menu go Pene Jog lt STOP Run and Stop keys Eo y WA AE uas E set to the side for EI ka c Na 4 easy access gee gm ges SORS gun Escape Enter Figure 2 1 DDI As Seen From Front of Drive Section 2 Drive Diagnostic Interface 9 7 GEK 105490 Innovation Series Medium Voltage AC Drives 2 2 Using the Keypad Navigation keys are used to e Select the type of display Status or Menu see The keypad enables a user to access drive values and section 2 3 to control the drive The keys are membrane type pushbuttons that perform their operation when pressed e Move through and select the DDI s menu ite
28. FB Blower AC Assembly Assy Module Module Board Assy Buswork Assys Base Figure 1 2 Overview of Drive Hardware Structure Section 1 Equipment Overview 3 GEK 105490 1 3 Software Overview The drive application program consists of functional software modules building blocks These combine to perform per system reguirements Block definitions and configuration parameters see Appendix B are stored in EEPROM Variables are stored in RAM Tuneup and diagnostic software 1s transparent to the user Operator control is provided as menu driven selections on the door mounted interface unit DDI see Section 2 The drive continually monitors per formance and outputs the results on the DDI display as animated meters icons and digital values Additional menus allow the operator to examine and reset any detected faults An optional Windows based configuration tuneup and monitoring software package is available for use on a connected personal computer PC This Control System Toolbox provides online help functions in cluding parameter diagrams Refer to the toolbox manual GEH 6333 for details 1 4 Technical Characteristics Parameter Rating 3000 hp continuous 2500 hp continuous 2100 hp continuous Power Input Voltage variation Frequency Power quality Displacement power factor Power Output Voltage Current Frequency Current THD Requirement 700 A no overload 600 A with 150 overlo
29. GEK 105490 Innovation Series Medium Voltage AC Drives 2300 V 18 Pulse Non regenerative Drive User s Manual Preliminary Copy Innovation Series Low Voltage AC Drives Publication GEK 105490 Issue date 1997 11 24 2300 V 18 Pulse User s Manual Preliminary Copy Non Regenerative Drive 0 1997 by General Electric Company USA All rights reserved Printed in the United States of America These instructions do not purport to cover all details or variations in equipment nor to provide every possible contingency to be met during installation operation and maintenance If further information is desired or if particular problems arise that are not covered sufficiently for the purchaser s purpose the matter should be referred to GE Industrial Control Systems This document contains proprietary information of General Electric Company USA and is furnished to its customer solely to assist that customer in the installation testing operation and or maintenance of the equipment described This document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the written approval of GE Industrial Control Systems Innovation is a trademark of General Electric Company Windows is a registered trademark of Microsoft Corporation 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Safety Symbol Legend WARNING Indicates a proced
30. K 105490 2 3 Reading the Display The DDI uses both text symbols icons and ani mated graphics to present drive status and configura tion data There are two selectable types of display screens e The Status screen uses animated meters bar graphs with associated text to display drive per formance data for four parameters see Figure 2 2 This is the default screen that displays after drive startup following an initialization screen TEXT IDENTIFYING ANIMATED DRIVE PARAMETER METERS DC Voltage 894 49 V AC Amp Load Us DS A Voltage Magn 460 66 V Power 0 25 W Innovation Series Medium Voltage AC Drives e The Menu screen lists and provides access to menu based functions for adjusting parameters and resetting faults see Figure 2 3 With either type of display screen the righthand side contains active icons that continually represent the drive health whether it is functioning correctly and running state The operator chooses the desired screen by pressing either Status or Menu in the keypad s Navigation section see Figure 2 1 DRIVE HEALTH amp STATE ICONS HEARTBEAT CONTROL STATE FAULT STATE DRIVE DIRECTION MOTION Figure 2 2 Sample of the Status Screen Display SELECTABLE FUNCTION SCREENS MAIN MENU REVIEW FAULTS PARAMETER CONFIGURATION CONTRAST ADJUSTMENT SOFTWARE VERSION No icon here means no fault Figure 2 3 Sample of the Main Menu Screen Displ
31. N ai when an operator examines a fault using the DDI or 12 Gnd flt coarse configuration tools Figure 4 1 shows a sample dis pee A A RESET FAULTS NOW um play JA Table 4 1 lists the drive faults and their probable E P cause Figure 4 1 Example of DDI Fault Display Screen Table 4 1 Fault Code Description 1 Illegal call Trip Bad lllegal sequencer call to a task The appropriate Seq Reg bit must be set before a task is called For developers only 2 Illegal seq state Trip llegal sequencer state Seq St has been set to an illegal value Contactor feedback not connected MA Dly Tm is set too short 3 Cont failed to close Trip Possible Causes MA Fbk Enb is set amp no feedback connected 4 Local flt Trip Local permissive ckt open on Run command or Standby command E stop circuit is open Check ATB for connections to terminals 8 10 and 12 and Jmpr J2 5 Trip flt req by tool Trip Tip fault generated from executing the monitor uf command 6 Run during init Trip Run or standby command was issued during drive initialization Command was ignored 7 Over Speed Trip Speed feedback rpm exceeded the Overspeed threshold Ovr Spd Thr Motor speed is too high or The Ovr Spd Thr is set too low 8 Timed overcurrent Trip One of the phase currents has exceeded the allowed threshold longer than the allowed time 9 EE flash corrupted Trip The memory containing
32. Outputs amp Mapping 49 Analog Inputs Outputs lt Mapping 50 Sequencing Overview wi 51 General SUA aaa agan aa naka aga s 252 Fault Reset Logic Stop Commands General Sequencing vewewmmmw 53 Permissives Ready to Run Run Command Regulator Commands General Seque Hi clle iius eese anaa ses Eo Deo rose be Sha na 54 Contactor Brake Control General SA Ia 55 Reference Regulator Enables Speed Reference Generation 56 Speed Reference Ramp vv swmww 57 Speed Torque OVeOfVT16 WW 58 Speed Ki iioi aha anan Bak angan rando debet eps 59 Speed OR Regulator evewwmmmw 60 Motor Control Interface lt 61 MOO ODIUOD cisci ag aa ajaa a a Udo p dc Pak ag 62 Capture Buffer Configuration 63 GEK 105490 B 1 Introduction The drawings in this section reflect a typical 2300 V non regenerative drive configuration They are in cluded as a guide for the user For specific and exact information on the parameters for a specific system refer to the requisition documentation Section 2 of this manual provides instructions on using the door mounted Drive Diagnostic Interface DDI for viewing and changing parameter values WARNING To prevent personal injury or equipment damage caused by equip
33. Q20021 6 6 Capacitor MCAP1 1 uF 68A7184P31 1 Laminated bus 173C9255AMP2 1 Laminated bus 178C9255EGP2 1 Resistor bleeder BRES1 6 27 ko 323A2439P 13 6 Resistor ground MRES1 3 10 kQ 323A2439P8 3 Resistor ground MRESS 6 20 kQ PDRP100M20N500W 2 Door Filter Filter Door RSP 91927619 4 Interface Module Board CPFB Gating Power Distrib IS200CPFPG1AZZ E Fuse CPFP board 4A 250 V 323A2396P18 3 Board SCTL Static Charger IS200SCTLG1AZZ 1 Fuse SCTL board 120 V dc 1 5A 104X109AD__076 1 Board SCTT static charger transfm IS200SCTTG1AZZ 1 Board VATF Voltage Attenuator IS200VATFG1AZZ 2 Capacitor ground 97F8698 1 DIN rail relay 238B4952P09 1 Relay 24 V de fuse failure MCRAO40ATJ 3 Suppresser relay BSLR2K 3 38 e Section 6 Drive Parts Lists 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 6 2 Parts List for Load Cabinet Continued Assembly Name Part Description Part No Qty Phase Leg Assembly Phase leg A heat exchanger core DSMSHTEXA1002M001 EE Phase leg B C heat exchanger core DSM3HTEXA1001MO01 2 Board IGDM gate driver IS200IGDMH1AZZ 12 Board TFBA temperature feedback IS200TFBAH1AZZ 3 Diode clamp IGBT Ph A C one of EUP DD1200S33K1 or 3 the listed per option PRX RM1200HD 66S 3 Transistor IGBT 3300 V 1200 A one E
34. Section 1 Equipment Overview e 1 GEK 105490 Innovation Series Medium Voltage AC Drives The load unit positioned between the source and The control unit contains the microprocessor based control units receives input from each It produces assemblies and the operator interface devices In controlled ac output to the motor with an option for cluded is the door mounted Drive Display Interface either a top or bottom power cable exit DDI through which the user implements tuneup and monitor functions DIMENSIONS ARE IN MILLIMETERS N Veo M RA 0 ds gs O Soy 4 45 Mos o Lo e M d C A C NV C Yg A gt INA Em Maxs a o Figure 1 1 Outline of Typical 2300 V OPERATOR 18 Pulse Innovation Series Drive INTERFACE UNIT 2 e Section 1 Equipment Overview 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Innovation Series Remote Parts 18 Pulse Non Regen 2300 V Drive Switchgear Tools Tachometer 18 Pulse Transformer Source Cabinet Control Cabinet Assembly Assembly Frame Panel Subassy Xfrmr Interior Frame Module Panel 18 Pulse AC Snubber Dynamic Door Subassy Diode Assy Module Brake Assy Assy Interface f i Buswork Control Module Assembly nacK Control Backplane Frame Panel Subassy Phase Leg Capacitor Interface IV
35. UP FZ1200R33KF1 or 3 of the listed per option PRX CM1200HA 66S 3 Heat exchanger 178C9255EEG0 3 Laminated bus 173C9255AMP1 3 Shunt one of the following per option 300 A shunt A B C 259B246BSP300 3 500 A shunt A B C 259B246BSP50 3 600 A shunt A B C 259B246BSP600 3 800 A shunt A B C 259B246BSP800 3 1000 A shunt A B C 259B246BSP1000 3 Thermistor RTD T2 Ph A C 386A3584AA G01 3 Space Heater Option Heater space 8152 ES Section 6 Drive Paris Lists 9 39 GEK 105490 Innovation Series Medium Voltage AC Drives Control Cabinet Panel Assembly Cable Assemblies Buswork Door Control Module Components I O Assembly Miscellaneous Space Heater Option Figure 6 3 Parts List Structure Control Cabinet Table 6 3 Parts List for Control Cabinet Assembly Name Part Description Cable Assemblies Buswork CABP J6 to ATBA 62 in length CABP J7 to ATBA 62 in length CABP J8 to meter CABP J9 to Toolport CCOM bus Control sidewall Control sidewall door Control to load Control sidewall Control to source Control door Control panel to sidewall Control door to panel Control GDPA CPT BICM Control panel no autotransformer Control panel with autotransformer Control panel wires Control BICM Control BICM 40 Section 6 Drive Parts Lists 336A4
36. UPS MULTIPLE PANELS UNITS CA HH CASE CD CURE DRIVE UNIT PN PANEL ASSEMBLY CI CORE INVERTER UNIT SEQUENCE PRLIJECT UNIQUE ORDER MONTH YEAR PRODUCT gt TO LINE REQ N GE SALEM VA Figure A 5 Sample Drive ML Catalog Number Item Number DATA NAMEPLATE L Identifies drive type and size Pi D8CK lt Ba Requisition Number gt REO 7161AN13642 ITEMZ 1000 for GE Factory identification am ML 3VPHB575CD001 SERIAL SHPHB575CD001001 amp _ Material List 7 Serial Number Shop order amp date HOIST GANTRY 41 DRIVES l NM Number code for GE Factory identification DRAWINGS ELEM 246B8500AA DUTL LAYO 139D2200AA MISC Associated a INST 3VPHB5751B01 MISC ee and VOLTS 480 V VOLTS 450 V nstructions cower AMPS 365 A power AMPS 440 A Power Application IN HERTZ 60 HZ OUT POWER 185 KW Data PHASE 3 PH FREQ TO HZ PH ROTATION AC OVRLD CAP 160 10 SEC SERVICE FACTOR 1 MOTOR FIELD VOLTS AMPS Figure A 4 Typical Drive Nameplate Appendix A Warranty and Renewal Parts e 45 GEK 105490 Innovation Series Medium Voltage AC Drives Notes 46 e Appendix A Warranty and Renewal Parts 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary B Drive Parameters Appendix B of this manual provides flow diagrams for the drive parameters as follows Title Page Inyerter OVELVICW Wa 48 Digital Inputs
37. Warranty Terms The GE Terms and Conditions brochure details prod uct warranty information including warranty period and parts and service coverage The brochure is in cluded with customer documentation It may be ob tained separately from the nearest GE Sales Office or authorized GE Sales Representative A 4 How to Order Parts Parts still under warranty may be obtained directly from the factory General Electric Company Product Service Engineering 1501 Roanoke Blvd Salem VA 24153 6492 USA Phone 001 540 387 7595 Fax 001 540 387 8606 Renewals spares or those not under warranty should be ordered by contacting the nearest GE Sales or Service Office Be sure to include O Complete part number and description Drive serial number Drive Material List number A 4 1 Understanding the Drive Nameplate Refer to Figure A 4 The drive s nameplate located on the back of the door provides information that spe cifically identifies the drive or cabinet s components and configuration This 1s important when ordering parts or documents or contacting GE for assistance The material list ML number also called catalog number is a unique number structured to provide in formation about the equipment see Figure A 5 The ML number links the equipment to its requisition drawings components materials specification item and shipping documents 3V AAA 123 xxii UNIT AND SEQUENCE NUMBER DF COMPONENTS LU LINE
38. ad for 60 Sec 500 A with 200 overload for 60 Sec 10 50 60 Hz with no derating IEEE 519 gt 95 0 2300 V 700 A continuous with no overload at rated load 0 200 Hz 4 or less 4 e Section 1 Equipment Overview Innovation Series Medium Voltage AC Drives Parameter Inverter type Modulation Bridge type Bridge isolation Bridge isolation from control Environment Operating temperature ambient Humidity Altitude Cooling Enclosure Storage temperature Lifetime Maintainability Medium time to repair Vibration Acoustic noise EMI RFI Clearances Standards Requirement Voltage source 3 level neutral point clamped PWM space vector 3 level Diode line converter IGBT inverter NEMA IEC 146 1 1 Fiber optic 0 to 40 C 32 F to 104 F at rated load 50 C 122 F with derating 5 95 relative non condensing Normal operation 0 1000 m Extended operation 1000 3000 m with a 696 per 1000 m derating Shipping Maintain pressure of 70 to 106 kPa Heatpipe air heat exchanger Forced convection via blower NEMA Type 1 IP20 general purpose vented 25 C to 70 13 F 158 F ambient 20 years with proper application Controls 10 minutes Power electronics 30 minutes 0 075 mm peak acceleration 10 57Hz 1 0g 57 150 Hz tested per IEC 68 2 6 Test F Sub C 78 db Emissions and Immunity per EN550
39. alance timer has expired Primary Causes 136 AC line watchdog Trip A phase imbalance or loss of line condition has persisted on the ac line feeding Interruption of power feed to drive phase sequence Primary Causes 137 AC line rev phs seq Trip One or more of the ac line voltages feeding the diode source assembly are out of Incorrect cabling of main conductors from power transformer Incorrect cabling on power transformer primary 137 Invalid IPN Trip Invalid IPN The Part Number that has been entered is not a valid combination of fields Please check the nameplate and re enter the number 138 AC line vfb offset Trip The voltage feedback offset being calculated for line voltage feedbacks is above the allowable threshold The system integrates the voltages seen on the ac input terminals The results of this integration should be near zero since the input waveform is a sine wave If the input line line voltages integrate to a non zero value above a predefined threshold this fault is generated Primary Causes Bad VCO Circuit Incorrect sensor wiring Large dc current component through transformer Possible Board Failures VATF SRC Possible Wiring Faults Check wiring of VATF SRC sensor inputs to phase leg Section 4 Faults and Troubleshooting e 29 GEK 105490 Innovation Series Medium Voltage AC Drives Table 4 1 Fault Code Description Continued 139 AC line PLL failed Trip This fault occurs when the source PLL h
40. anel Assembly Showing IGBT Bus Load Cabinet 68 Appendix C Parts Assembly Drawings 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 173C 9255JWGOI I173C9255JD60l S142 H272 Eis 173C9255kKR GOI OPTION H272 Figure C 4 Back Panel Assembly Load Cabinet Appendix C Parts Assembly Drawings e 69 GEK 105490 Innovation Series Medium Voltage AC Drives
41. as not locked to an ac waveform when is was expected to Once the switch gear is closed by the charging sequence the PLL is expected to lock within 1 0 second Primary Causes No voltage feedback on VATF SRC Incorrect sensor wiring Main breaker not closing correctly Possible Board Failures VATF SRC Possible Wiring Faults Check wiring of VATF SRC sensor inputs to phase leg 30 e Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Component Replacement 2 Section 5 of this manual provides guidelines for replacing components during repair It is organized as follows Section Heading Page os Beor SP esae ai aa Escena dei tor dod 3l 5 2 Replacing Printed Wiring Boards 31 5 2 1 Handling Precautions 3l 5 2 2 Replacement Procedures 32 5 3 Replacing IGBT Modules 33 WARNING This equipment contains a potential hazard of electric shock or burn Only adequately trained persons who are thoroughly fa miliar with the equipment and the instruc tions should maintain this equipment To prevent electric shock while servicing the equipment personnel must understand and follow all safety requirements for working around dangerous voltages GEK 105490 5 1 Before Starting WARNING Power must be de energized before performing any adjustments servici
42. aults Measured heatsink temperature is less than ambient by an amount exceeding RTD alarm level Keypad Help Measured heatsink temperature is less than ambient by an amount exceeding RTD alarm level 59 HtSink DS sensor bad Alarm This alarm occurs when the measured heatsink temperature is less than the measured ambient temperature by an amount that exceeds the value of p a rameter sensor detect trip IVI The fault clears when the measured heatsink temperature is greater than the measured ambient temperature The main purpose of this fault is to detect the absence of a thermal sensor input from the heatsink or the failure of the sensor itself Primary Causes The heatsink thermal sensor input is not pre sent The heatsink thermal device alarm threshold sensor detect trip IVI is set incor rectly The heatsink thermal sensor is defective Possible Board Failures BICM Possible Wiring Faults Measured heatsink temperature is less than ambient by an amount exceeding alarm level Keypad Help Measured heatsink temperature is less than ambient by an amount exceeding alarm level Measured heatsink temperature is less than ambient by an amount exceeding alarm level 24 Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 4 1 Fault Code Description Continued 63 BICM card overtemp Trip This fault occurs when the RTD mounted on BICM mea
43. ay 10 e Section 2 Drive Diagnostic Interface GEK 105490 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary 2 3 1 Drive Health State Icons These icons are displayed on the righthand side of every screen There are five positions with each representing a specific functional group as follows see Figure 2 2 e Heartbeat e Control state e Fault state e Drive direction e Motion The icon at each position can change depending on the drive s health or state These groups and their icons are described below 2 3 1 1 Heartbeat The heartbeat icon is a data link OK indicator It is as an animated line whose center raises and lowers see Figure 2 4 to show that the link is alive okay Displayed when drive does not respond to queries for status Animation of Heartbeat icon gue mg SWEET RE Ene Figure 2 4 Icon for Heartbeat and Data Link OK 2 3 1 2 Control State This indicator is one of the alphabetic symbols shown below in Figure 2 5 The drive must be in the local mode L displayed to enable starting from the DDI REMOTE N J L Or F or T Figure 2 5 Control State Icons LOCAL TEST 2 3 1 3 Fault State An icon in this position indi cates that an error has been detected in the drive This error can be an overridden parameter alarm state or trip state see Table 2 2 Alarms and trips can be cleared using the menus as described in section 2 4 1 Table 2 2
44. bsence of a thermal sensor input from the heatsink Primary Causes The heatsink thermal sensor input is not pre sent The undertemperature threshold is set incorrectly No power to TFBA board or TFBA board failure Possible Board Failures BICM TFBA CPFP Possible Wiring Faults Thermal sensor input to TFBA is missing or damaged Keypad Help Indicated RTD feedback reads below threshold 22 Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Table 4 1 Fault Code Description Continued GEK 105490 This fault occurs when the measured heatsink temperature is less than the undertemperature threshold specified by the threshold parameter The main purpose of this fault is to detect the absence of the thermal sensor input from the heatsink Primary Causes The heatsink thermal sensor input is not pre sent The undertemperature threshold is set incorrectly No power to TFBA board or TFBA board failure Possible Board Failures BICM TFBA CPFP Possible Wiring Faults Thermal sensor input to TFBA is missing or damaged Keypad Help Indicated sensor feedback reads below threshold There is indication that one of the fuses feeding the diode source assembly has opened Primary Causes Loss of 124 supply on CTBC feeding this string Shorted diode in source bridge Keypad Help AC Source line fuse is blown or 24V power supply fail Thermal modeling of the dynam
45. cal CharacteristicS 4 1 5 Technical Assistance 5 1 6 Related Documents eee 5 Section 2 Drive Diagnostic Interface Describes the door mounted operator interface used to set monitor and maintain the drive locally Section 3 Preventive Maintenance Provides guidelines for keeping the drive in good running condition Section 4 Faults and Troubleshooting Lists and defines drive fault messages with troubleshooting suggestions if the fault occurs Section 5 Component Replacement Provides guidelines for replacing components during repair Section 6 Drive Parts Lists Contains parts lists of the drive s electronic and wiring components Appendix A Warranty and Renewal Parts Con tains information on how to identify and obtain war ranty and spare parts Appendix B Drive Parameters Provides flow diagrams of drive parameters Appendix C Assembly Drawings Parts List Con tains drawings that show the drive s assembly struc ture and identifies the parts of the assembly Refer to the Table of Contents for the organization of these sections GEK 105490 1 1 Introduction to the Drive The Innovation Series medium voltage ac drive is an IGBT based 3 level pulse width modulated PWM inverter It is designed for high performance and efficiency in the variable speed control of a 2300 V ac induction motor The drive combines
46. d agitating the board in isopropyl al 3 Inspect the overcurrent protection devices for cohol then air drying for a few hours damage to insulation and contacts see sections 3 6 4 and 3 6 5 Replace or repair as needed 4 Check and replace any open fuses 18 0 Section 3 Preventive Maintenance 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Faults and Troubleshooting 4 Section 4 of this manual lists and defines the relevant fault messages for the inverter drive with trouble shooting suggestions It is organized as follows Section Heading Page 4 1 Introduction es 19 4 2 Types of FaultsS ea 19 4 3 Fault Indication lt es 19 4 4 Fault DescriptionSs 20 Table 4 1 is a list of the faults with possible causes GEK 105490 4 1 Introduction The drive software includes selftest diagnostics to aid in troubleshooting When these tests detect an unfa vorable condition they output fault indications to a display An operator can then examine the fault and clear it as applicable 4 2 Types of Faults There are currently two types of fault conditions supported for the drive e Trip faults indicate a more serious condition that needs to be corrected Therefore it trips the drive The condition should be corrected bef
47. ed a fault during its operation Primary Causes Static Charger failure 96 SWGR fail to close Trip The drive tripped because the ac line switch gear would not close when co m manded or opened unexpectedly Primary Causes Switchgear defective Switchgear opened via external command 97 Vdc lt 200v after 5sec Trip When charging with the static charger the dc bus failed to ready 200 Vdc within 5 seconds The charge sequence has been aborted Primary Causes Static Charger failure Dc Bus shorted Dc Feedback not working Section 4 Faults and Troubleshooting e 27 GEK 105490 Innovation Series Medium Voltage AC Drives Table 4 1 Fault Code Description Continued 105 Pulse test config Trip Pulse test pulse pattern and timer configuration is invalid 106 Ckt board list fail Trip Board electronic ID read procedure failed during initialization 107 Voltage offset Trip Voltage offset was invalid when the drive was started 108 DC bus undervolt alm Trip Dc link voltage is less than undervoltage level with drive stopped 109 Task 1 exec overrun Alarm No keypad help defined The device has identified improper or missing boards in its rack Check board seating board type and revision 114 Ain1 Low Alarm Alarm Analog Input 1 low level detected The level of Ain 1 is below the threshold level of Ain 1 Thr 115 Aini Low Trip Trip 116 Ain2 Low Alarm Ala
48. ese two IGBT modules as a matched set of TWO only Replace these two IGBT modules as a matched set of TWO only Heatpipe Heatpipe Heat Exchanger Heat Exchanger 9 o o o 9 o o o o o o o o o o o um um um E o g g o o pi pi Oo o g E o o d d o Figure 5 1 IGBT Module Location in 2300 V Drive Heat Exchanger Assembly 8 Make sure that the 28 captive bolts for the IGBT and clamp diode modules and the 6 captive bolts for the capacitor laminated bus are in the correct position 9 Torque these bolts to 95 in lbs 10 Install the two 5 16 kepnuts onto the ac bus 11 Install each of the IGDM boards with the four Captive screws Note In most instances of IGBT module failure the IGDM board in the affected phase is also damaged and must be replaced 34 e Section 5 Component Replacement 12 L5 14 15 16 Torque to 13 in Ibs Install the cabling to the IGDM board the label for each cable connection should match the con nector name on the board Verify proper orientation of the connectors before installation Cable connections are me chanically keyed Visually inspect buses cable connections and bolted connections for correct installation Check that no tools debris or hardware is left 1n the drive before energizing it 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Drive Parts Lists Section 6 of this manual provides parts lists of the d
49. eter Not functional MET L R Menu Navigation Takes user to next level up in menu tree Escape DN Entry of Parameter Takes user back to list of parameters L R Drive Menu Navigation Takes user to next level down in menu tree Entry of Parameter Accepts editing of parameter 8 e Section 2 Drive Diagnostic Interface 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 2 1 Key Functions Continued Key Active Drive Function Drive Control Keys Reset L R Resets faults Faults fol Uu Inverter drives Toggles direction of drive for Run and Jog commands The currently vy selected direction is shown with an icon see section 2 3 1 4 Source drives No function Remote WR Toggles mode of the drive between local and remote The currently selected mode is 7 shown in the right side of the display with an R Remote or L Local L Inverter drives Jogs drive in the selected direction at the configured jog speed Source drives No function We Inverter drives Increments Decrements the Local Speed Reference associated with the di DDI Run Stop commands Source drives No function L Local Run command from the DDI The drive must be in Local mode to execute the Run command An error screen displays if pressed while running in Remote mode L R Local Stop command from the DDI The drive can be stopped in Local or Remote mode Section 2 Drive Diagnostic Interface 9 9 GE
50. h is over range when it is either greater than 100 or less than 100 The over range mark is shown with a vertical bar through the bar graph at the 100 and the 10096 marks Innovation Series Medium Voltage AC Drives Not Over Range Figure 2 9 Sample Bar Graph Displays Table 2 3 Bar Graph Display Characteristics eiii sd Numeric Display Units in Bargraph DC Voltage Magnitude of dc bus voltage VDC Fil Percent of dc per unit volts VDC PU AC Amp Load Magnitude of ac line current Mag Fil Percent of source top rated current PU Voltage Magn Magnitude of ac line voltage Line Mag Fil Percent of ac line top rated voltage V PU Power Dc bus power DC Bus Pwr Percent of top rated dc bus power Pwr PU 12 e Section 2 Drive Diagnostic Interface 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary 2 4 Menu Selections Figure 2 10 shows the four selectable items on the DDI s Main Menu display Each selection leads to other menu screens where an operator can review and modify data as needed MAIN MENU REVIEW FAULTS PARAMETER CONFIGURATION CONTRAST ADJUSTMENT SOFTWARE VERSION DI X Figure 2 10 Selections on Main Menu Display To access the options under any menu 1 Use the up or down arrow keys to highlight the desired menu item 2 Press the Enter or right arrow key to select this item To return to the previous menu screen press the Escape ke
51. he lower dc bus Keypad Help Hardware detection of overvoltage on the indicated dc bus 41 DC overvoltage Trip DC bus feedback indicates an overvoltage condition 42 DC under voltage Trip DC bus feedback indicates an undervoltage condition 43 LPPA gnd alarm Alarm Lp Gnd A Fil exceeds level of Lp Alm On Turns off when below Lp Alm Off Can inhibit by setting Lp Alm Off 44 LPPA gnd fit Trip Lp Gnd A Fil exceeds level of Lp Alm Thrs Can inhibit by setting Lp Alm Off 45 LPPA fuse blown Alarm LPPA module detects that the MOV fuse has blown Can inhibit by setting Lppa Inh 46 X stop Trip X stop circuit is open and is configured as Trip fault 47 Run req amp xstop open Trip X stop circuit is open and a run request was issued 48 BICM card temp low Trip This fault occurs when the sensor mounted on BICM measures a temperature which is less than the undertemperature threshold specified by the threshold parameter Primary Causes The heatsink thermal sensor input is not present The undertemperature threshold is set incorrectly Ambient temperature is too low Airflow to the rack is blocked Possible Board Failures BICM Keypad Help Indicated sensor feedback reads below threshold 49 HtSink DB temp low Trip This fault occurs when the measured heatsink temperature is less than the undertemperature threshold specified by the threshold parameter The main purpose of this fault is to detect the a
52. hniques Use a erounding strap when handling boards or components To prevent equipment damage do not re move insert or adjust board connections while power is applied to the equipment GEK 105490 3 6 4 Damaged Insulation Wires and cables with damaged insulation are danger ous when carrying electricity They can also intermit tently short causing equipment and functional failure l Check all wires and cables for fraying chipping nicks wear or rodent damage Check all wires and cables for signs of overheating or carbonization Repair minor low voltage insulation damage with a good grade of electrical tape If a damaged cable carries high voltages replace the cable Replace any cables or wires that have more than mild damage 3 6 5 Contactors and Relays l If possible manually trip the device to ensure that it works properly Inspect contacts on open as opposed to sealed contactors and relays Discoloration and rough contact surfaces are normal If beads have formed because of severe arcing a Dress the contact faces with a fine file Do not use emery cloth or sandpaper b Identify and correct the cause of arcing c Refer to the component s publication for de tailed instructions on maintenance repair and replacement procedures 3 6 6 Printed Wiring Boards If boards in a module are dirty l Vacuum to remove dust from around the board connections before and after u
53. ic braking resistor assembly indicates the pac k age has exceeded it s rating Primary Causes Incorrect configuration of DB thermal model DB resistor package has not been sized correctly for application Keypad Help DB resistor exceeded thermal rating 54 Ambient temp low Trip 55 AC line fuse blown Trip 56 DB resistor overload Trip 57 DB resistor hot Alarm Thermal modeling of the dynamic braking resistor assembly indicates the pac k age is nearing it s rating Primary Causes Incorrect configuration of DB thermal model DB resistor package is marginal for application Section 4 Faults and Troubleshooting 9 23 GEK 105490 Innovation Series Medium Voltage AC Drives Table 4 1 Fault Code Description Continued 58 HtSink DB sensor bad Alarm The main purpose of this fault is to detect the absence of a thermal sensor input from the heatsink or the failure of the sensor itself This alarm occurs when the measured heatsink temperature is less than the measured ambient temperature by an amount that exceeds the value of p a rameter sensor detect trip Ivl The fault clears when the measured heatsink temperature is greater than the measured ambient temperature Primary Causes The heatsink thermal sensor input is not present The heatsink thermal device alarm threshold sensor detect trip IVI is set incor rectly The heatsink thermal sensor is defective Possible Board Failures BICM Possible Wiring F
54. ment Screen 2 4 4 Soflware Version Screen To check the version of software being run select Software Version from the Main Menu screen see Figure 2 10 This brings up a screen with the infor mation see Figure 2 17 UN aaa DDI Software Version 01 02 01 A L v Press ESCAPE to Continue Ne E Figure 2 17 Sample Software Version Screen 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Preventive Maintenance J Section 3 of this manual defines practices and proce dures that help keep the drive in good running condi tion This information is organized as follows Section Topic Page J l TOG CUO saanane gan pn roe ba aaa ro ak baga aa 15 3 2 Maintenance Schedule 15 3 3 Maintenance Record 15 3 4 Tools Materials Needed 15 3 5 Power On Checks eee 16 3 6 Power Off Checks een 16 3 6 1 Before Starting Maintenance 16 3 6 2 Dust Remowal eee 16 3 6 3 Loose Connections 17 3 6 4 Damaged Insulation 17 3 6 5 Contactors and Relays 17 3 6 6 Printed Wiring Boards 17 3 75 Short Circuit Damas sasabana aa pad esso ees 18 WARNING This equipment c
55. ment malfunction only adequately trained personnel should modify any programmable machine Appendix B Drive Parameters 9 47 GEK 105490 Innovation Series Medium Voltage AC Drives Notes 64 e Appendix B Drive Parameters 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary Parts Assembly Drawings C Appendix C of this manual is intended to help the user in two Ways e Provide a visual guide for parts replacement see Section 5 e Help identify the drive parts see Section 6 Note Only preliminary drawings were available at the time this manual was issued There fore the drawings in this appendix are not a complete set They are currently intended to be used only as a guide since they do not contain either verified or final information Future revisions of this manual are intended to correct this deficiency Appendix C is organized as follows Figure Title Fig C 1 DC Link Capacitor Assembly 32 Fig C 2 Back Panel Assembly Load Cabinet 33 Fig C 3 Back Panel Assembly Showing IGBT Bus Load Gro AA a An ga aaa 34 Fig C 4 Back Panel Assembly Load Cabinet 35 Fig C 5 Phase Leg Assembly Phase A Phase B aud Phase cedo aba aab a aa audor deos 36 Fig C 6 Phase Leg Assembly 37 Fig C 7 Snubber Assembly Wire Connections 38 Fig C 8 Snubber Assembly Rear View 39 Fig C 9 Panel Assembly Source Cabine
56. ms and released including fault options see section 2 4 As shown in Figure 2 1 the DDI keypad is arranged e Select and modify parameters items see section into functional groups of keys as labeled Navigation 2 5 and Drive Controls Drive control keys enable a user to locally manage the drive Table 2 1 defines these keys and their functions In the column labeled Active an L indicates local and an R indicates remote Table 2 1 Key Functions Key Active Function Navigation Keys Fs L R Takes user to status screen where four parameters are shown in digital numbers or bar tatus graph form A set of health icons see section 2 3 1 provides additional drive status s information a L R If pressed while in a Menu screen see section 2 3 takes the user to the Main Menu Menu When pressed while in a Status screen takes user to last menu screen we L R Menu Navigation Used to highlight reverse video an item in a menu of options E ede Entry of Numeric Parameter Used to index through numbers 0 9 when editing a pm parameter v Entry of Option Parameter Used to index through 1 n choices is Section 2 4 2 defines numeric and option parameters jr We L R Menu Navigation Right arrow selects an item in a menu of options Left arrow takes user EUN to next level up in menu tree E Entry of Numeric Parameter Used to select a digit when editing a parameter Entry of Option Param
57. n see Figures 2 13 and 2 14 The New Value line is highlighted 4 Press Enter to accept Esc to leave e Brake absent New Value Brake present AN Present Value Brake absent um Name Brake Absent E Em x Figure 2 14 Sample Option Parameter Screen Press Enter to accept Esc to leave Tach pulses per rev New Value Present Value Low Limit 0 High Limit 0 Name Tach_PPR J 240 PPR 240 PPR OD Ere Figure 2 15 Sample Numeric Parameter Screen 14 e Section 2 Drive Diagnostic Interface Innovation Series Medium Voltage AC Drives 5 If the selection is an option parameter a Highlight the option using the down arrow key b Press the Enter key to accept the parameter entry If the selection is a numeric parameter a Using the up down arrow keys to index through the valid digits 0 1 2 3 4 5 6 7 8 9 b Enter the new number one digit at a time by pressing the Enter key or right arrow key to make each digit entry 6 Press the Escape key to get back to list of drive parameters 2 4 3 Contrast Adjustment Screen To adjust the contrast of the DDI screen select Con trast Adjustment from the Main Menu screen see Figure 2 10 This brings up a another screen with instructions see Figure 2 16 a UN CONTRAST ADJUSTMENT a HOLD UPARROW TO INCREASE L HOLD DNARROW TO DECREASE PRESS ESCAPE WHEN DONE t NG E Figure 2 16 Sample Contrast Adjust
58. ng or other act re quiring physical contact with the electrical components or wiring Before starting the equipment must be prepared as follows 1 De energized 2 Tagged and locked out 3 Discharged the dc link has a minimum discharge time of 5 minutes 4 Tested for zero voltage using an approved tester for the voltage level being measured 5 Safety grounded Do not deviate from these conditions If safety require ments cannot be met completely or if you do not under stand them do not work on the equipment 5 2 Replacing Printed Wiring Boards Because of upgrades boards of different revision levels may not contain identical hardware However GE ensures backward compatibility of replacement boards 5 2 1 Handling Precautions CAUTION To prevent component damage caused by static electricity treat all boards with static sensitive handling techniques Printed wiring boards may contain static sensitive components Therefore GE ships all replacement boards in antistatic bags Use the following guidelines when handling boards 1 Store boards in antistatic bags or boxes 2 Use a grounding strap when handling boards or board components Section 5 Component Replacement 31 GEK 105490 5 2 2 Replacement Procedures WARNING To prevent electric shock turn off power to the board then test to verify that no power exists in the board before touching it or any connected circuits Removal 1 P
59. nplugging Remove the boards per the instructions in Section 5 2 Be sure to observe the personal and equipment safety instructions Vacuum to remove dust from the board and con nections A soft bristled brush may be used to loosen dirt Section 3 Preventive Maintenance 9 17 GEK 105490 Innovation Series Medium Voltage AC Drives 4 If excessively dirty boards may need to be washed 3 7 Short Circuit Damage as follows If a short circuit occurs overcurrent protective devices on the circuit should cut off power to the equipment This normally prevents electrical damage except at the point of the short However the heat produced by an electrical arc can carbonize some organic insulating Harsh chemicals and solutions will damage the materials which then lose insulating qualities board Do not use solvents containing ammonia aldehydes alkalis aromatic hydrocarbons or ketones a Usea soft bristled brush to scrub the board in a lukewarm 37 7 C 100 F mild solution of distilled water and household or laboratory de tergent After repairing the cause of the short and before re applying power 1 Inspect the system thoroughly for damage to con ductors insulation or equipment Replace if found b Rinse thoroughly by dipping the board several times in fresh lukewarm distilled water Do not soak the board l l 2 Check insulation resistance c Dry the board by shaking off excess water im mersing an
60. ons of the number identify the type of equipment and location of manufacture A part falls into one of four categories e Order specific assemblies Major assemblies or items that make up a specific drive constructed from common assemblies e Common assemblies Subassemblies used in many GE drive products not just a specific drive e Components Individual parts that make up as semblies e Printed wiring boards These categories and the makeup of their part numbers are defined below A 2 2 1 Order Specific Assemblies These parts make up the particular drive Other items obtained specifically for the order may also use a similar part number structure which provides information about the equipment see Figure A 1 3V XYZ999 PR 001 L Unit identification number Assembly type Component Identifies manufacturer as GE Industrial Control Systems Salem VA PR for standard product LU for lineup CA for case Figure A 1 Sample Part Number for Order Specific Assembly A 2 2 2 Common Assemblies Common assemblies are subassemblies used as components of order specific assemblies Common assemblies are not de signed for a particular drive but provide a function used in other GE products A common assembly part number consists of the num ber 56 followed by an alphanumeric character It may contain up to 14 characters For example 36C774524AAG46 is the part number for a drive cable 44 e Appendix A War
61. ontains a potential hazard of electric shock or burn Only adequately trained persons who are thoroughly familiar with the equipment and the instructions should maintain this equipment To prevent electric shock while servicing the equipment personnel must understand and follow all safety requirements for working around dangerous voltages GEK 105490 3 1 Introduction Periodic preventive maintenance extends equipment operating life and minimizes downtime This involves specific power on and more intensive power off checks when permitted With both checks necessary repairs should be undertaken when needed 3 2 Maintenance Schedule For maximum benefit preventive maintenance needs to be performed at scheduled intervals by a qualified technician The required frequency for each procedure depends on e How much the equipment is used e Ambient environmental conditions refer to Section 1 for environmental specifications The schedule should include an inspection of wiring and components before re applying power after an overcurrent trip 3 3 Maintenance Record GE recommends that the customer keep a detailed record of maintenance such as a log book for every drive This record serves two purposes e It verifies that all equipment is routinely checked e It aids troubleshooting and prevention of equip ment failure by providing a history of equipment maintenance and problems 3 4 Tools Materials Needed The tools
62. ore the drive is restarted e Alarm faults report conditions that should be noted but that are not serious enough to shut down or trip the drive Some alarm faults can clear them selves if the condition subsides on its own Other wise the drive must be stopped for an operator to clear this type of fault 4 3 Fault Indication The drive notifies an operator that a fault condition has occurred by displaying an indicator on the two operator interfaces the local Drive Diagnostic Inter face DDI and a connected PC running the drive configuration tools On the DDI a fault symbol appears in the right side of the display AN The operator can then use the keypad to access the fault alarm description and to clear the fault see Chapter 2 for details Not flashing on steady indicates an alarm Flashing indicates a fault The drive configuration tools use a Windows based PC display The word Alarm or Trip appears in the lower right corner of the screen when a fault occurs The operator can access a description and clear the fault using the tool functions Manual GEH 6333 describes these tools and this feature Section 4 Faults and Troubleshooting e 19 GEK 105490 Innovation Series Medium Voltage AC Drives inti FAULT ALARM 4 4 Fault Descriptions e e ISI ASOR A fault is identified by an assigned number and Va NP Fault Display abbreviated description Both of these are displayed NA gg A
63. r screws 16 0 Section 3 Preventive Maintenance Innovation Series Medium Voltage AC Drives 3 6 Power Off Checks Power off checks involve cleaning the equipment and checking for wear and damage through visual inspec tion and functional tests 3 6 1 Before Starting Maintenance WARNING Power must be de energized before per forming any adjustments servicing or other act requiring physical contact with the elec trical components or wiring Before starting the equipment must be prepared as follows 1 De energized 2 Tagged and locked out 3 Discharged the dc link has a minimum discharge time of 5 minutes 4 Tested for zero voltage using an approved tester for the voltage level being measured 5 Safety grounded Do not deviate from these conditions If safety re quirements cannot be met completely or if you do not understand them do not work on the equipment 3 6 2 Dust Removal CAUTION Build up of dust on electrical components and wiring can damage components and cause mis operation Build up of dust on components can increase operat ing temperature reducing their normal life On standoff insulators it can collect enough moisture to produce a current path from bus bars to chassis ground Dust especially metallic dust on wire surfaces can cause tracking between connector pins Tracking is usually capacitive in nature and involves a build up of electrical charge along the wire
64. ranty and Renewal Parts Innovation Series Medium Voltage AC Drives A 2 2 3 Components Components are the basic parts that make up assemblies They represent the lowest discrete level of a system Component part numbers consist of a combination of alphanumeric characters that define the class and specific item Figure A 2 shows a sample 104X 109 1ADOS38 L Item or rating 500 V 3 2 A FNQ Component type fuse Component Figure A 2 Sample Part Number for Component A 2 2 4 Printed Wiring Boards A printed wiring board is identified by an alphanumeric part catalog number stamped near its edge Figure A 3 describes the structure of a board s part number Note All digits are important when ordering or replacing any board The factory may substitute later versions of boards based on availability and design en hancements However GE Industrial Control Systems ensures compatibility of replace ment boards IS 200 DSPX G AAA L Artwork revision Functional revision Functional revision Group variation Functional acronym Assembly level Manufacturer DS amp S for GE in Salem VA Backward compatible Not backward compatible 3G normal coating H conformal coating 4200 indicates a base level board 215 indicates a higher level assembly or added components such as PROM Figure A 3 Sample Board Part Number GEK 105490 2300V 18 Pulse Non Regenerative Drive User s Manual Preliminary A 3
65. repare the drive as defined in section 5 1 2 Open the drive s cabinet door Test any electrical circuits before touching them to ensure that power is off 3 Carefully disconnect all cables as follows CAUTION To prevent damage to cable and wire con nections hold only the connector not the cable when pulling them To prevent equipment damage do not re move insert or adjust board connections while power is applied to the equipment Foracable with a pull tab carefully pull the tab Fora screw terminal connector loosen the screw at the top of each terminal and gently pull each wire free Fora fiber optic connector press and hold the latch on the mating cable connector while pulling 4 Carefully remove the board as follows Some boards are mounted on standoffs with screws Remove the screws to release the board For boards mounted within a rack loosen the screws at the top and bottom of the board near the board ejector tabs The screws are captive in the board front and should not be removed The board can then be unseated by raising the ejector tab 32 e Section 5 Component Replacement Innovation Series Medium Voltage AC Drives Installation l On the replacement new board set all jumpers pots and switches in the exact position as those on the board being replaced If a board revision has added or eliminated a config urable component or readjustment is needed
66. rive s electronic and wiring components These lists do not include sheet metal braces and other items not typically replaced nor common hardware items such GEK 105490 This section is presented as follows Table Title 6 1 Parts List for Source Cabinet 35 6 2 Parts List for Load Cabinet 37 6 3 Parts List for Control Cabinet 40 Figures 6 1 through 6 3 show the structure of the source load and control cabinets The parts tables are organized according to that structure aS SCIEWS Appendix A provides information for ordering war ranty and replacement parts Source Cabinet Panel Assembly Ac Snubber Module Diode Assembly Blower Assembly Buswork Dynamic Brake Assembly Option Space Heater Door Filter Option Figure 6 1 Parts List Structure Source Cabinet Table 6 1 Parts List for Source Cabinet Assembly Name Part Description Part Catalog No Qty Ac Snubber Module Filter l enibber module with DB DSM3SNBRA1002M001 E Snubber module without DB DSM3SNBRA1002M002 1 VATF voltage attenuator IS200VATFG1AZZ 2 Capacitor filter 3 uF 1500 W 68A7184P6A 9 Fuses filter 5A 1500 V PH1 3 9 336A3594AE G01 PDDT1000V571DA 323A2439P1 1 PDFPMICROSWITCH Harness snubber wires MOV 575 V 770 J
67. rm Analog Input 2 low level detected The level of Ain 2 is below the threshold level of Ain 2 Thr 117 Ain2 Low Trip Trip 121 IGDM DB 1 card flt Trip This is a hardware generated fault It occurs when the bridge control has lost communications with the indicated IGDM module This communication occurs via fiber optic cable between the FOSA and the indicated IGDM During normal operation the IGDM transmits continuous light back to FOSA Any loss of this signal triggers this fault Several unrelated situations can cause the light to stop transmitting Primary Causes CPFP power supply failure IGDM failure DSAT fault on the corresponding IGBT was detected Possible Board Failures IGDM CPFP FOSA BICM Possible Wiring Faults Fiber optic connection between FOSA and IGDM Power distribution wiring from CPFP Keypad Help Fiber optic communications with the indicated IGDM module has been lost This indicates a DSAT fault on the IGBT or that the IGDM board itself has failed 28 Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 4 1 Fault Code Description Continued This indicates a DSAT fault on the IGBT or that the IGDM board itself has failed 135 AC line transient Alarm A phase imbalance or loss of line condition exists on the ac line feeding the drive Primary Causes Interruption of power feed to drive the drive and the phase imb
68. s 44 2 3 Sample of Main Menu Screen Display 10 A 2 Sample Part Number for Component 44 2 4 Icon for Heartbeat and Data Link OK 11 A 3 Sample Board Part Number 44 2 5 Control Status ICOnS 11 A 4 Typical Drive Nameplate 45 2 6 Drive Direction consi 11 A 5 Sample Drive ML Catalog Number 45 227 MONI ON 11 C 1 DC Link Capacitor Assembly 66 2 8 Animation of Motion Icons 11 C 2 Back Panel Assembly Load Cabinet 67 2 9 Sample Bar Graph Displays 12 C 3 Back Panel Assembly Showing IGBT Bus 2 10 Selections on Main Menu Display 13 Eoad Or oy halal a IN AAA CN EORR itus 68 2 11 Sample Fault Display Screen 13 C 4 Back Panel Assembly Load Cabinet 69 2 12 Sample Fault Detail Screen 13 C 5 Phase Leg Assembly Phase A Phase B 2 13 Sample Drive Parameter Screen 14 Pase AA AA n No 70 2 14 Sample Option Parameter Screen 14 C 6 Phase beg Assembly ia a 71 2 15 Sample Numeric Parameter Screen 14 C 7 Snubber Assembly Wire Connections I2 2 16 Sample Contrast Adjustment Screen 14 C 8 Snubber Assembly Rear View 73 2 17 Sample Software Version Screen
69. se A Phase B and Phase C 70 e Appendix C Parts Assembly Drawings GEK 105490 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary SHI 7 m e t 67 119 H54 H96 Figure C 6 Phase Leg Assembly Appendix C Parts Assembly Drawings e 71 Innovation Series Medium Voltage AC Drives GEK 105490 ey SO BAS 7 5 7 Y y SEK pf AoA E S Y pow JK V NN DIE IO FUSEHOL DER S ew B S PLAC V S Figure C 7 Snubber
70. sures a temperature which is more than the over temperature threshold specified by the threshold parameter Primary Causes The over temperature threshold is set incorrectly Ambient temperature is high Lack of airflow to control rack Possible Board Failures BICM 65 HtSink DS over temp Trip This fault occurs when the temperature measured on the indicated heatsink exceeds the designed maximum temperature The bridge trips at this point to protect the IGBTs from thermal damage Primary Causes Airflow to the heatsink is not sufficient Blower is not operating correctly Possible Board Failures BICM Keypad Help Measured heatsink temperature is above overtemperature thres h old 66 HtSink Aovertemp Trip Measured heatsink temperature is above overtemperature threshold 67 HtSink B over temp 68 HtSink C over temp SES temperature threshold specified by the threshold parameter Primary Causes The over temperature threshold is set incorrectly Ambient temperature is marginal Lack of airflow to control rack Possible Board Failures BICM 69 BICM card hot Alarm The RTD mounted on BICM measures a temperature which is near the over 75 Switchgear not ready Alarm The permissive string to close the main switch gear is not present This permi s sive string ends at BTBH 8 and includes customer contacts used to open the main The primary purpose of this fault is to prevent charging of the dc bus
71. t 40 Fig C 10 Panel Assembly Source Cabinet 41 Appendix A contains information for ordering war ranty and renewal parts GEK 105490 C 1 Introduction The drawings in this section are exploded view type drawings that show how the drive is assembled Each part of the assembly is identified with a numbered callout These numbers are tied to a table that provides a part number and description for each callout Note The parts tables for these drawings were not available to include in this Preliminary is sue of the drive manual These drawings use the following conventions for callouts CTQ Critical to quality Optional work Work content for this operation is optional per requisition Standard work Work content for this operation is standard for all requisitions Verify work Work that must be checked after this operation is complete QUUD Appendix C Parts Assembly Drawings e 65 Innovation Series Medium Voltage AC Drives GEK 105490 S5599 S60 H96
72. t GE can process the order accurately and as soon as possible To minimize system downtime if repair is needed GE recommends that the customer keep a set of spare parts onhand The Renewal Parts Quotation see sec tion A 2 1 lists recommended spares A 2 Identifying the Part A drive component or part is identified by its as signed part number and description The part num ber is normally found on a nameplate on the component The description is included in the parts tables in Chapter 6 and in the system renewal parts list A 2 1 Renewal Parts List The Renewal Parts Quotation is a separate document that lists the parts of a complete system This list ap plies specifically to the equipment furnished on a customer s particular application requisition at the time of shipment It includes e Part numbers and descriptions e Quantity used e Recommended spares to keep onhand e Normal delivery cycle for obtaining each part GE provides the Renewal Parts Quotation with the drive s custom instructions If this document is missing contact the nearest GE sales office or service representative to obtain a replacement copy You need to provide the following information see Figure A 4 to correctly identify the system O Requisition number O Material List number Item number Appendix A Warranty and Renewal Parts 9 43 GEK 105490 A 2 2 Part Number Structure A GE part number is structured so that different por ti
73. t Overview 9 5 GEK 105490 Innovation Series Medium Voltage AC Drives Notes 6 e Section 1 Equipment Overview 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Drive Diagnostic Interface Section 2 of this manual provides information to help the user understand how operate the Drive Diagnostic Interface DDI It is organized as follows Section Heading Page ZEE PIE OGG KO eoe costos aaa aaa a a BG aa a aaa aUe naa aaa 7 2 2 Using the Keypad vevewmmmw 8 2 3 Reading the Display 10 2 3 1 Drive Health State Icons 11 2 3 2 Animated Metess v w 12 2 4 Menu Selections eee 13 2 4 1 Review Faults eee 13 2 4 2 Parameter Configuration 13 2 4 3 Contrast Adjustment Screen 14 2 4 4 Software Version Screen 14 2 1 Introduction Refer to Figure 2 1 Innovation Series drives in clude a door mounted operator control unit the DDI This feature provides a simple easily accessed means for a user to set monitor and maintain the drive locally The operator can use the DDI to perform the following common tasks e Monitor speed current e Start Stop functions e Adjust a configuration parameter e Reset a fault condition Each drive has its own D
74. the device parameters was found to be bad during initialization The device should not be run 10 Run w flux decay Trip The command flux is higher than 296 of rated flux when drive starts Attempt to restart drive quickly after bridge is turned off 11 EE erase failed Alarm Preparation of memory for next parameter save operation has failed Next parameter save operation is expected to be invalid 12 Gnd flt coarse Trip Filtered sum of A B C phase currents is greater than fast ground fault trip thres h old 13 Gnd flt filtered Trip Discriminated magnitude of A B C phase currents is greater than discriminated ground fault trip threshold Discriminated magnitude of A B C phase currents is greater than discriminated ground fault alarm level 20 Section 4 Faults and Troubleshooting 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table 4 1 Fault Code Description Continued 18 Tune up failed Trip Auto Tuneup failed to start Autotune task not scheduled Message stack not initialized 19 Motor data invalid Trip Motor Control Rule Calc failed Flux sat curve not monotonic L sigma curve not monotonic Rated flux did not converge 20 TOC pending Alarm One of the phase currents has exceeded the allowed threshold longer than the allowed time Reduce current to avoid a trip 21 System flt Trip System permissive ckt open on Run command or Standby command E stop circ
75. uit is open Check ATB for connections to terminals 14 16 and 18 22 Run before MA closed Trip Contactor A was not found to be closed when a Run command was issued 23 Flying restart disabl Trip The drive is required to be stopped if the drive is not in Flying Restart mode The dc bus voltage dropped below Pd Act Lvl and stayed below Pd Hoy Lvl for longer than Pd Tm 28 R1 Init Saturation Trip Resistance of Stator and Cable measured during preflux is out of bound The motor control will not use this measurement R1 Alrm Enb available to mask 29 R2 meas in limit Trip Online R2 adaption output saturation Saturation levels are 80 and 40 Check Sat curve motor thermal model and ambient rotor resistance param eters 30 Tach loss Trip Tach feedback estimated speed is filtered and compared to Tac Err Thr2 for fault triggering Fault mask Tac Los Fit and compared to Tac Err Thr2 for fault triggering Fault mask Tac Los Alrm Dynamic switch to tachless mode Tach feedback estimated speed is filtered 36 BICM card clock fail Trip This alarm occurs when FPGA logic on the BICM board cannot detect the pre s ence of either one of its clock signals One of the clocks it is looking for is generated by a crystal on the BICM itself and the other is transmitted via the rack backplane from DSPX Primary Causes Board or connector failure Possible Board Failures BICM DSPX CABP Backplane
76. ure practice condition or statement that if not strictly observed could result in personal injury or death CAUTION Indicates a procedure practice condition or statement that if not strictly observed could result in damage to or destruction of equipment Note Indicates an essential or important procedure practice condition or statement Safety Symbol Legend ea GEK 105490 Innovation Series Medium Voltage AC Drives WARNING This eguipment contains a potential hazard of electric shock or burn Only personnel who are adeguately trained and thoroughly familiar with the eguipment and the instructions should install operate or maintain this eguipment Isolation of test eguipment from the eguipment under test presents potential electrical hazards If the test eguipment cannot be grounded to the equipment under test the test equipment s case must be shielded to prevent contact by personnel To minimize hazard of electrical shock or burn approved grounding practices and procedures must be strictly followed WARNING To prevent personal injury or equipment damage caused by equipment malfunction only adequately trained personnel should modify any programmable machine b e Safety Symbol Legend 2300 V 18 Pulse Non Regenerative Drive User s Manual Preliminary GEK 105490 Table of Contents Section Heading Page 1 1 Introduction to the Drive l 1 2 Hardware Overview
77. y left arrow key or follow onscreen in structions 2 4 1 Review Faults The DDI displays a Fault State icon see Table 2 2 to indicate if the drive is running correctly When either a trip or an alarm fault occurs the operator can view information and clear the fault as described below To access a list of the drive s faults a Go to the Main Menu If already in a menu screen press the Menu key on the keypad Ifin a Status screen press the Menu key once or twice b Select the Review Faults menu item This brings up the Fault Display screen see Figure 2 11 Note Faults are displayed in order of occurrence with the most recent fault at the top GEK 105490 2 To see detail on a particular fault select that fault on the Fault Display screen highlight the item then press the Enter key or right arrow key This brings up the Fault Detail screen see Figure 2 11 3 Faults can be reset cleared either of two ways a In the Fault Display screen select the Reset Faults Now menu item highlight and press the Enter key or right arrow key Or b On the keypad press the Reset Faults key 4 Fault Display m 13 Gnd flt filtered L 12 Gnd flt coarse 108 DC bus undervolt alm AN RESET FAULTS NOW m c Ne A Figure 2 11 Sample Fault Display Screen 4 N SELECTED FAULT PRESS ESCAPE DC BUS undervolts Dc bus feedback indicates an undervoltage condition DAY

2300 V, 18-Pulse Non-Regenerative Drive User`s Manual

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