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Power Conversion
USER MANUAL
Change Number:
Author: Srinivasan.T / EA Thufail
Design Office: SD-Massy
Reason for new revision: Initial Issue
(see last page for
modification record)
©COPYRIGHT 2012 GE ENERGY (USA), LLC AND/OR ITS AFFILIATES. All rights reserved. The information contained
herein is GE Energy Power Conversion Proprietary Technical Information that belongs to the General Electric
Company, GE Energy (USA), LLC and/or their affiliates, which has been provided solely for the express reason of
restricted private use. All persons, firms, or corporations who receive such information shall be deemed by the act
of their receiving the same to have agreed to make no duplication, or other disclosure, or use whatsoever for any,
or all such information except as expressly authorized in writing by the General Electric Company, GE Energy (USA),
LLC and/or its affiliates.
FOREWORD
The following signs require reader’s attention in this user manual.
Note:
Important!
Warning!
LIMITATION OF LIABILITY
Before following the instructions of this user manual and operating the MV7000 drive, users are advised to
refer to Section 1 of MV7000 NPP (3kV) user manual – “limitation of liability”.
SECURITY WARNING
Users shall read safety instructions available in Section 1 of MV7000 NPP (3kV) user manual.
CONTENTS
FOREWORD.............................................................................................................................................................. 2
CONTENTS ............................................................................................................................................................... 3
TABLE OF ILLUSTRATIONS
SECTION 1:
Introduction
SECTION 2:
Technical Data
SECTION 3:
Installation
SECTION 4:
Operating Instructions
SECTION 5:
Protection & Diagnostic
SECTION 6:
Maintenance & Safety
WARNING
The appropriate Standards provide details and guidelines for safely installing the
electrical equipment.
Failure to comply with the appropriate Standards may result in personal injury and/or
equipment damage.
DC Bus Configuration
In Dc bus configuration separate AFE and MB drives could be placed to form a DC bus system with one
or more AFE to inverter interface DC bus with network and several MB inverters to run motors from this
common DC bus source
1. AFE
2. MB
Active Front End (AFE)
AFE is the configuration with controlled IGBT inverters for DC link voltage generation from the supply
network. AFE has unique controls for regulation and separate start/stop sub sequence tasks apart from
the common main sequence in the PEC controller.
For high power applications, 2 AFE inverters are used in parallel outputs connected to a common DC
bus and common neutral for the DC link. This configuration is termed as Parallel AFE Configuration.
Machine Bridge (MB)
MB is the Configuration with controlled IGBT inverters for motor output voltage generation from a
connected DC link voltage input. MB has unique controls for its regulation as Inverter for the machine
model and also separate start/stop sequence tasks apart from the common main sequence in the PEC
controller.
DFE - STDA
DFE Bridge MB Bridge
Gate Driver
V 27X
27
50 A
M
59
V 34F
59 50G 99F
27
48 3
60 50
CPU
48 52F
21W
50 26W
80W 63W 86E 34F
PECe Controller
Emergency External
Stop Fault
48 52F
21W 21W
26W 26W
80W 63W 86E 34F 80W 63W 86E 34F
PECe CONTROLLER
Emergency External
Stop Fault
Cooling Unit
The features listed above are the common protection features for MV7000 Drives. Additional features
are incorporated, depending on the configuration or application or process requirement. Please refer to
the project specific documents for details and additional features.
5.3 DIAGNOSTICS
The four LED indicators on the Drive Data ManagerTM Keypad give a first indication of drive status.
The DDMTM Keypad indicators are shown in Section 4.
Turning ON the ALARM or FAULT indicator and Turning OFF the READY and RUNNING indicators indicate
a Fault condition.
5.3.1.1 Alarm
If the ALARM indicator LED is ON, indicates a fault/Warning has occurred which may not be a serious
condition to trip the drive. For important safeties, alarms often come as precondition to faults from lower
threshold detection lesser than the fault limit. The parameterization allows no presence of alarms as a
precondition to start the drive for the first start up.
Note 1 Alarms are latched (memorized). To clear an alarm, the drive RESET function is to be used. A
RESET can be achieved while the drive is running by either toggling the status of parameter
P0.06 (RESET) from the DDMTM keypad, or pressing alternatively & keys, or using remote
RESET (refer to specific project documentation for remote RESET details). The RESET will be
effective only when the Alarm/Fault condition does not persists at the time of Resetting.
Note 2 The drive will be prevented from starting until all Alarms have been cleared using the RESET
function (optional parameterization)
Note 3 Some of the alarms are also categorized with automatic reset upon the loss of alarm
condition, which is a prerequisite for some functions.
5.3.1.2 Fault
If the FAULT indicator LED is ON, indicates a fault has occurred which causes the drive to shut down. The
first Fault or Alarm time is stored and displayed on the 3 rd line of Menus 3 & 4.
Note: Faults are latched (memorized) and must be cleared before the drive can be operated again.
Carrying out a RESET as described in Note 1 above will clear faults. The RESET will be effective
only when the Fault condition does not persists at the time of Resetting.
Option
Fault Parameter of type STOP, which is OPTIONAL S
√
depending on the Drive system used/application
The three basic drive system configurations for MV7000 are columned to show how one Parameter
influences each of these configurations and the type of fault action for each configuration.
Option
Option
AFE MB
STDA
Option
Option
AFE MB
STDA
P3.020 to
P3.032 Reserve Reserve
P3.033 IGBT 1 U2+ Fault T T - T - IGBT 1 U2+ Fault 90F
P3.034 IGBT 1 U1+ Fault T T - T - IGBT 1 U1+ Fault 90F
P3.035 IGBT 1 U2- Fault T T - T - IGBT 1 U2- Fault 90F
P3.036 IGBT 1 U1- Fault T T - T - IGBT 1 U1- Fault 90F
P3.037 IGBT 1 V2+ Fault T T - T - IGBT 1 V2+ Fault 90F
P3.038 IGBT 1 V1+ Fault T T - T - IGBT 1 V1+ Fault 90F
P3.039 IGBT 1 V2- Fault T T - T - IGBT 1 V2- Fault 90F
P3.040 IGBT 1 V1- Fault T T - T - IGBT 1 V1- Fault 90F
P3.041 IGBT 1 W2+ Fault T T - T - IGBT 1 W2+ Fault 90F
P3.042 IGBT 1 W1+ Fault T T - T - IGBT 1 W1+ Fault 90F
P3.043 IGBT 1 W2- Fault T T - T - IGBT 1 W2- Fault 90F
P3.044 IGBT 1 W1- Fault T T - T - IGBT 1 W1- Fault 90F
P3.045 IGBT 1 H+ Fault T T - T - IGBT 1 H+ Fault 90F
P3.046 IGBT 1 H- Fault T T - T - IGBT 1 H- Fault 90F
P3.047 to
Reserve Reserve
P3.048
Option
Option
AFE MB
STDA
P3.063 to
P3.064 Reserve Reserve
P3.065 DFE I+ Flt high - - - T - DFE I+ high Fault – direct analog 76
P3.066 DFE I- Flt high - - - T - 76
DFE I- high Fault – direct analog
P3.067 DC Volt + Flt high T T - T - DC voltage between U+ and 0V is 59
high Fault – direct analog
P3.068 T T - T - DC voltage between U- and 0V is 59
DC Volt- Flt high
high Fault – direct analog
P3.069 T T - T - Inverter Current U ph: high Fault – 50
Inv Cur U Flt high
direct analog
P3.070 T T - T - Inverter Current V ph: high Fault – 50
Inv Cur V Flt high
direct analog
P3.071 T T - T - Inverter Current W ph: high Fault – 59
Inv Cur W Flt high
direct analog
P3.072 Zero Seq Volt Flt high T T - T - Zero Sequence Voltage High 59
P3.073 Network volt U high T - - - - 59
Network Voltage higher Fault
P3.074 Network volt V high T - - - - 59
Network Voltage higher Fault
P3.075 Network volt W high T - - - - 59
Network Voltage higher Fault
P3.076 T T √ T √ Filter line voltage UV high – direct 59CF
Ftr Volt UV high
analog
P3.077 T T √ T √ Filter line voltage VW high – direct 59CF
Ftr Volt VW high
analog
P3.078 T T √ T √ Filter current phase U high – direct 50CF
Ftr Cur U high
analog
P3.079 T T √ T √ Filter current phase W high – direct 50CF
Ftr Cur W high
analog
P3.080 Mid DC volt high T T √ T √
P3.081 DFE I+ Flt high high - - - T - DFE I+ Flt high calculated 76
Option
Option
AFE MB
STDA
P3.095 Filter cur W high high T - - T √ Filter current W high calculated 50CF
Option
Option
AFE MB
STDA
P3.161 Aux Supply OFF Flt T T - T - Aux. supply OFF Fault 48/88F
P3.162 220V Supply OFF Flt T T - T - 220V supply OFF Fault 48/88F
P3.163 400V Supply OFF Flt T T - T - 400V supply OFF Fault 48/88F
P3.164 Fan Supply OFF Flt T T - T - Fan supply OFF Fault 48/88F
P3.170 Cool unit Flow Flt T T - T - Cooling unit flow Fault 48/88F
Option
Option
AFE MB STDA
P3.173 to
P3.175 Reserve Reserve
P3.196 Watch dog from T - - - - Watch Dog Fault from MB Channel 34F
MB_Ch A Flt A
P3.197 T - - - - Watch Dog Fault from MB Channel 34F
Wdog from MB ChB Flt
B
P3.198 T - - - - Watch Dog Fault from MB Channel 34F
Wdog from MB ChC Flt
C
P3.199 - T - - - Watch Dog Fault from AFE channel 34F
Wdog frm AFE ChA Flt
A
P3.200 T - - - - Machine Bridge Ch: A not ready 34F
MB ChA not Ready Flt
while AFE running
P3.201 T - - - - Machine Bridge Ch: B not ready 34F
MB ChB not Ready Flt
while AFE running
P3.202 T - - - - Machine Bridge Ch: C not ready 34F
MB ChC not Ready Flt
while AFE running
P3.203 T - - - - Ch: A wrong Machine Bridge ID 34F
ChA Wrong MB ID Flt
Fault
P3.204 T - - - - Ch: B wrong Machine Bridge ID 34F
ChB Wrong MB ID Flt
Fault
P3.205 T - - - - Ch: C wrong Machine Bridge ID 34F
ChC Wrong MB ID Flt
Fault
P3.206 T - - - - Machine Bridge Ch: A DC Voltage 34F
MB ChA DC Discor Flt
measure Discordance Fault
P3.207 T - - - - Machine Bridge Ch: B DC Voltage 34F
MB ChB DC Discor Flt
measure Discordance Fault
Machine Bridge Ch: C DC Voltage
P3.208 MB ChC DC Discor Flt T - - - - measure Discordance Fault 34F
Option
Option
code
AFE MB STDA
90F/
P3.251 Enhanced IGBT T T √ T √ 50F/
Uc+,Uc- Flt 59F
P3.252 Reserve
90F/
P3.253 Enhanced IGBT Vc+,Vc- T T √ T √ 50F/
Flt 59F
P3.254 Reserve
P3.256 Reserve
P3.257 Mains voltage too high T - - - - 59
Flt Mains voltage too high Fault
P3.258 T - - - - 27
Mains Volt. too Low Flt Mains voltage too low Fault
P3.259 Start while Filter not T - - - - Start while filter not discharged 48
discharged Flt Fault
P3.260 T - - - - Diode Front End mode with filter 59CF
DFE+filter Flt
enabled Fault
Option
Option
AFE MB STDA
Option
Option
code
AFE MB STDA
P3.277 to
P3.288 Reserve Reserve for NPP 2nd converter
Note1 Please refer to the project specific process drawing and interface documents for process or
external faults concerned to a specific project.
Note2 Similarly, there are also Alarms concerned to process or application specific functionalities. Also
refer to the project specific documentation to know the list of Alarms concerning the project.
Option
AFE MB STDA
P4.011 Chop Temp TooHi Alm A A √ A √ Chopper Too High Temperature 73A
Alarm
P4.012 DC Link Overvolt. Alm A A - A - DC Link Overvolt Alarm 59A
Option
Option
code
AFE MB STDA
P4.013
to Reserved Reserved
P4.015
P4.016 Kinetic support On - - - A - Kinetic support On
Kinetic support not
P4.017 - - - A - Kinetic Support Not available at
available on zero
Zero Speed
speed
P4.018 DC bus simulation On
P4.019 Synchro check On
P4.020
to P4.46 Reserved Reserved
Option
Option
code
AFE MB STDA
P4.226 A A √ A √ 48A
Filter U Temp. Sensor Alm
P4.227 A A √ A √ 48A
Filter V Temp. High Alm
P4.228 A A √ A √ 48A
Filter V Temp. Sensor Alm
Option
Option
AFE MB STDA
P4.229 A A √ A √ 48A
Filter W Temp. High Alm
Filter W Temp. Sensor A A √ A √ 48A
P4.230
Alm
P4.231 to
Reserved
P4.234
Option
Option
code
AFE MB STDA
P4.299 - A √ A √
Excitation Fan Alm
P4.300
TO
P4.318
P4.319
TO Reserved
P4.320
Note: There could be also other possible reasons other than specified above
Pre-charge limitation - Only 3 pre-charging attempts in 15-minute period and the period between two
subsequent pre-charge attempts should not be less than 60 seconds. Any deviation to either of the
above conditions will lead to a Pre-charge thermal limitation. If this happens, then the operator has to
wait for 10 minutes to reset the limitation to attempt for the next pre-charge.
Safety warning- Operator MUST NOT ground the drive if the indication lamp is not ON (Green OK for
ground), Ensure DC link volt NOT greater than 50V
Attention - Care should be taken in handling a recovery once discharge fault is noticed. The
software disables the drive to restart if the DC link is not fully discharged. In case of consistent
presence of Discharge fault, do not engage in any physical contact with equipment and wait for
the service of Power Conversion personnel.
If the auxiliaries are stopped while the DC link is not fully discharged, will cause a fault. Make sure that
the auxiliaries are running till the end of full discharge. Running of auxiliaries till the complete discharge
is essential for safety operation of the drive.
For the drive with discharge relay option:
1). Failure of discharge relay
2). Detection of discharge feedback while IGBTs conducting
3). Detection of discharge open while IGBTs are OFF.
Drive enables inverter pulses only if the discharge-relay open feedback is true.
5.3.4.7 DC voltage
The control monitors the DC voltage level throughout the operation of the drive.
Any deviation of a DC measurement lesser than 80% (except application based on special transformer
design to accommodate higher de-rating limits) will cause a low DC voltage fault.
There is an over voltage alarm if the DC link voltage exceeds around 115% of the DC voltage. Gate driver
causes a trip in case of excessive dc voltage to protect the IGBT and inverter.
In normal case, de-rating of ±10 % can be well accommodated within the trip limits for DC voltage.
During normal drive operation, each IGBT is pulsing with a high frequency, so that the individual on/off
flashing is invisible. Both LED indicators appears to be ON.
In case of IGBT failure or Gate Driver board failure, diagnostic is indicated with either red LED are ON.
The combination of these red LED’s, which are ON, indicates the type of failure as shown on Figure 5- 2.
H225
H223
H223 & H224 ON = > Gate driver power supply is too low
The Gate Driver communicates with PIBe board through fiber optic status feedback. In case of the failure
diagnostic, PIBe board trips the drive and blocks all IGBT pulses.
Note: Only first fault is displayed on diagnostic LED indicators. If gate driver has not been cleared after
previous gate drive fault, red LED indicators still correspond to previous diagnostic. Refer to
Section 5.3.5.3 for gate driver reset procedure.
IGBT ON request
minimum pulse
duration
IGBT ON request
minimum pulse
duration
If gate driver detects a pulse command on fiber optic input, which is shorter than the minimum pulse
duration, a fault status is sent back to controller.
Probable causes
a) Failure of PIBe firing board in PEC controller rack
b) The characteristics of the fiber optic connected to the gate driver might be altered.
c) Failure of optical receiver of gate driver
d) No connection/Improper connection of fiber optic.
healthy fault
Optic fiber status
feedback
20 ms
Gate Driver
power supply
5.3.6.1 PERTU :
Pertu is a software visualisation tool used along with HPCi system for MV7000 PECe controller, efficient
enough to measure, visualise and record all relevant MV7000 electrical quantities measured by the PECe
system in fast sampling frequencies.
Pertu uses a target recorder (embedded in the HPCi execution engine). The configuration is full dynamic,
by subscription of a set of variables and dynamic allocation of required buffers. This recorder can
operate in 3 different modes as follows,
A Boolean value is used as an event trigger (viewed as an 'incident'). Two buffers are allocated in the
target for data storage: The first is for 'pre-incident' acquisitions, and the second for 'post-incident'. The
first buffer is permanently filled like a circular buffer. When a trigger occurs, the recorder fills (once) the
second buffer and stops, waiting for data upload by the Pertu tool. After upload, the recorder could be
restarted for next trigger. Note that an ‘Automatic mode’ could be used in order that Pertu manage itself
all required operation (except the first start). In this mode, a file will be created for each upload, and you
can have as many files as trigger occurrence.
Fast recording :
A temporary buffer is allocated in the target, and all variables values are recorded during each
application cycle. When the Pertu asks for data, it gets all records acquired since the previous request.
This mode gives you the warranty that all values are recorded at the task application cycle, without any
missing value.
Note that triggers could be defined (in the list of Boolean selected variables) to Snapshot or stop the
recording
Slow recording :
Can be used for very slow process, where it is not mandatory to have all values, synchronized with the
application cycle.
In the ‘Fast recording’ mode, this tool can also be used as 'continuous' recorder: In this case, values are
stored on the disk and it is possible to come back to a specific event and display the corresponding
curves.
With Pertu, up to 32 configurations can be used for the same recorder. For efficient functioning, each
configuration can contain up to channels of 10 numerical and 10 Boolean values.
For MV7000, all the inverter measurements can be measured including inverter and motor currents,
voltages references or feedbacks, DC link voltages etc..
This is an important utility for commissioning, fault finding, service and support.
Recordings are cached with Pertu images of the same sampling frequency of the CPU making it efficient
to diagnose electrical measured quantities precisely.
Below are few examples of a standard Pertu file utilised for MV7000 site support:
MONIPERTU is an automatic logger utility of pertu files which logs automatically pertu files based on trip
or set conditions configured in it.
This is an important utility for fault diagnostics in detail for MV7000 inverters.
MoniPert is a centralized monitoring tool for THL. It is able to manage a list of recorders, running on any
HPCi targets.
Advantages of Monipertu:
With Monipertu the user is assured of logged copy of pertu for each trigger/set conditions without
loosing the information at the set conditions.
User can retrieve all sets of pertu files for set condition without loosing them. This ensures all information
available for diagnostics for an event set condition.
WARNING
Hazardous Medium Voltages are present within this equipment. These voltages may exist
even after isolation of the main and auxiliary supply sources.
Wait at least 10 minutes after Grounding for isolation and lockout of all external supply
sources and opening doors of Medium Voltage compartments.
CONFIRM that the stored energy in ALL capacitor circuits is DISCHARGED and the drive
system GROUNDED before working on the equipment. (Refer to Section 6 of this manual for
the Grounding Procedure.)
Probable causes
a) There is no supply voltage for pre-charge transformer.
b) The Fuses of pre-charge transformer output are blown out/burned.
c) The DC voltage measurement sensor failure PIBe board analog input terminal failure.
d) The DC link capacitor damaged.
Probable causes
a) The DC link voltage is not being discharged within predetermined time after drive stop command.
b) The failure of DC voltage measurement unit PIB70x or PIBe analog input.
c) Either the main Transformer Circuit Breaker or pre-charge contactor is not opened properly, or an
external AC supply is connected to Diode Bridge.
WARNING
The stored capacitive energy within the drive has NOT DISCHARGED in the designed
manner.
Prior to the grounding of the drive, strictly ensure that main Transformer Circuit Breaker
and pre-charge contactor are OPEN, and ensure both circuits are at zero voltage (i.e. no
external AC supply connected to transformers).
Refer to the DRIVE GROUNDING PROCEDURE (especially ABNORMAL CONDITION
GROUNDING PROCEDURE) described in user manual Section 6 for recommended tools and
procedure to SAFELY DISCHARGE the capacitive stored energy within the drive.
After the drive has been safely grounded, the following procedures can be carried out.
a) Check the DC link balancing resistors and connections.
b) Check DC voltage measurement units PIB70x and PIBe analog input terminals.
Probable causes
a) A Short-circuit might have occurred on drive output.
Operations to be carried out
a) Check the external cabling to the motor terminals for any possible damage.
b) Check the motor armature windings for any possible damage.
Probable causes
a) High current through diode bridges.
5.3.7.26 ANSI Code - 98F [Remote I/O Rack Failure/PIB501 card failure Fault]
Probable causes
a) There can be an Ethernet link error between controller CPU and remote I/Os.
Our products are continuously improved. As a result, specifications are subject to change
at any time without notice, and should not be considered as contractual.