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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MMI FOR VFD 3. MMI remains out of service due to “Communication Defective line driver replaced by a new one.
Link failure”. Demultiplexer channels at control room were not working.
Same repaired.
One wire of RS232 port was found disconnected, same
rectified.
One reed relay card to be replaced (failed during
troubleshooting). MMI system put on-line bypassing Drive
status and Reset command from PC.
Replaced reed relay card. Problem solved.
MMI s/w hanging problem. Corrected version of software installed. Became OK.
MISC 4. 6A Ch-2 tripped on electrical fault. 1. “LMARG” changed from 25° to 30°. No change
Current hunting was observed in Ch-1 and tripped on observed.
R phase Overcurrent. 2. “FLALEN” and “FLASEN” changed to TRUE. No
When Ch-2 of ID Fan 6A trips, current/voltage change observed.
hunting is observed in the Ch-1 and it also trips. 3. Changed parameters “CRGAIN, FRGAIN, FRTC,
Motor foundation vibration found higher compared PLLTOL, LIMARG”. No change observed.
to other motors. 4. Finally by changing PLLMODE from 60 to 25, problem
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
was solved.
SHORTED 5. 6A Ch-2 trips with message “Shorted motor NLCB card in Ch-2 found defective. Card replaced and
MOTOR winding.” Ch–1 stopped after current hunting problem solved.
WINDING observed.
However, current drawn continues to be higher than
other fans due to poor p.f.
MISC 6. Tripping of channels due to Loose connections of Proposal for installing Anti-vibration pads on blower
cards on SEM rack. support in panel. Concurrence given by BHEL for the
same.
Anti-vibration pads put and SEM lock bars installed.
Problem solved.
MISC 7. Frequent failure of NPPB card. Heat dissipated by Proposal by customer to install bleeder resistor outside
bleeder res. is high. Bleeder resistor installed on PSFF module.
PSFF just behind mother board NPPB. Customer asked to check VFD room temperature and clean
the mesh filter on C&EXE panel. Bleeder resistor can be
mounted outside only if above remedies do not work.
Temperature in VFD Room rectified. Problem solved.
MISC 8. Self Test halts at No.23 even though channel is BHEL requested customer to furnish a print-out of self
healthy. test program to study the problem.
Customer asked to adjust offset zero on NLIB load card
FAB, FBC & FCA with BAL1 and BAL2 pots on NLCB
Allowed tolerance is 30mV. Problem solved.
MISC 9. UPS supply tripping on trf. inrush current. Spec. for trf. given by EDN to TEC with msg. to procure
120/120VAC, 1ph, trf. with 2P & 2S windings, 1 sec. trf. locally. Screen to be provided between primary and
Winding found defective. Sec. of trf. and Screen to be earthed to panel frame.
Changed transformer. Problem solved.
MISC 10. 6A Ch-1 tripped , Ch-2 not responding to speed Parameter SRCLSC changed to 1.0 as in scheme.
lower command from CRT. Current and speed of ID 4-20mA speed signal is not being recd. by Ch-1 or Ch-2.
fan stuck. 6A taken out of service manually and 6B Problem in I&C system solved. 6A taken into service.
taken into service. SRCLSC found to be 0.7 instead
of 1.0 in other channels.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 11. Erosion of cooling tubes at the tip of the Customer proposed to replace all cooling tubes (1980
tubeshoot at O/B side of ID Fan motors. Resulted tubes). Asked for advise.
in passing of external air into motor body. Motor is Referred to contact BHEL/EMRP-Mumbai for further
CACA cooled. action.
MISC 12. ID 6A Ch1 – oscillating and load currents on Told to change HPTF card in LTM1 or LTM4.
contactor not balanced. 1 phase current missing. Pulse was missing in LTM4. Changed HPTF card. Problem
Source currents balanced. 0IA load NLIB solved.
negative humps missing.
MISC 13. Repeated faults in drive due to loose connection on Recommended to install lock bars to secure control cards
SEM Rack. in the racks. SEM Lock bar installed. Problem solved.
MMI FOR VFD 14. MMI getting hung frequently. Line drivers OK. If power goes OFF, sometimes MMI PC hangs as told by
After PC rebooting the MMI PC, communication customer. EDN suggested to put the MMI PC on UPS so
gets re-established. that this will not occur. MMI put on UPS. Problem solved.
MISC 15. ID Fan 6A taking high current (400A), current of Higher current is due to higher LMARG and LIMARG as
both channels hunts in the range 320-400A. motor p.f is lower. Adjusted SRGAIN such that hunting of
speed and current stops. Problem solved.
LOAD PLL FAULT 16. 6C1 tripping on “Load PLL fault”. Gate test OK. Self HRDA, HROA, NLCB replaced. NLIB Source & Load
test OK upto 40. Channel goes back to service replaced.
every time after tripping. Tripping freq. increased.
Additional to Load PLL fault, MP alarm also coming. EDN Suggested
IMOK of HMPG and NLCB missing. Missing Leds 1. To install lock bar of SEM. HMPG/DMPB may be loose
come on after reset. in its slot.
6C1 started as slave channel after swapping HMPG 2. Clean HMPG/DMPB and pins on mother board by air
with 6C2. Load current does not come immediately blowing.
but hunts a lot. Also LED ‘0’ on HRDA card (for Load current hunting may be due to MTRFMIN and FLUXS
MAMS) flickers. Firing of load thyristors also values being slightly different than actual requirement.
flickers. Flickering stops after sometime and Suggested to lower the values of MTRFMIN and FLUXS in
channel becomes OK. Channel trips after few days. steps of 0.01 and if not sufficient again in steps of 0.05.
Problem may be due to slight drift of NLIB load side flux
calibration over the years of service.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
LOAD PLL FAULT 17. 6C1- Trips on Load PLL Fault on load. Increased LMARG from 20° to 25°.
Problem solved.
SOURCE 18. After starting the channel, as soon as current and Firing cards on all thyristor legs of Source and Load side
OVERCURRENT & voltage started building up, channel tripped on were checked. Found that jack plug on one of the source
LOAD Source Overcurrent, Load Overcurrent and side cards was not fixed properly. Same rectified and
OVERCURRENT Microprocessor Alarm. plugs of all cards were thoroughly checked.
On taking trial, current and speed developed OK. All cards removed and cleaned and checked for any
On reaching 90-100rpm, channel tripped again on abnormal marks or heating on the cards. Found OK. Dust
Microprocessor alarm. LBS O/C relay operated, accumulation was completely removed. Channel trial taken
Lock out of Source breaker operated and tripped and found OK. Changeover trials taken for both the
the breaker. IMOK LEDs of HMPG and NLCB not channels and found OK. Fan taken into service.
glowing.
MISC 19. Severe hunting of currents in Master and Slave ID Fan functions normally during service when unit is
channels when speed is brought to near minimum generating full load. Also all the waveforms of voltages and
REV.04 speed. currents in both channels found OK. Found that rubber
blocks in the coupling had deteriorated. Rubber blocks
changed. Problem solved.
SOURCE 20. Current hunting over a certain speed. At this time, Shorted LBKRS TBs on IOMA (Source breaker input).
UNDERVOLTAGE INVLIM sets to 384 (256+128). 256=STOP, Problem persisted. Checked Earthing of SEM and panel.
128=SOURCE UNDERVOLTAGE. Boiler under Found OK. Since boiler was under shutdown, channel run
R05, 0207, VI shutdown. independently. Found that the hunting problem was related
to current and not to voltage.
Changed HLCB, NLIB Source, NSFC source. Problem still
persisted. All waveforms of current, flux, voltages found
OK. CT phasing on Source side OK. Found that NLIB
Source and NLIB load were interchanged. As the
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
Firing pulse LED on one card in source bridge HTPF card on source side changed and problem solved.
(HPTF) was not steady and was flickering.
GROUND FAULT 5. Ground fault in both channels of 4B. In one channel one load side capacitor was faulty. In the
other channel, the neutral grounding of R-C circuit was
not OK. Problem in both channels solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 6. Chattering of MAMS relay in slave channel. Adjusted offset zero in NLIB Load FAB,FBC,FCA by back
charging from Master. Problem solved.
MISC 7. HMPGDMPB in 4B1 giving Bushog after few hours HMPG/DMPB card replaced.
in service. Problem solved.
GROUND FAULT 8. VFD Ground Fault problem in slave channel. See text on ground fault at the end of this document.
Cable insulation was found faulty on cable from contactor
to motor during hi-pot test to earth. Problem solved.
MISC 9. Master and Slave both start and run individually. At Back-charged slave with source breaker open and load
minimum speed, slave does not take load when Contactor closed. Adjusted FAB, FBC, FCA on NLIB-load
paralleled with Master channel. on slave with that of Master.
Slave channel paralleled. OK. Problem solved.
MISC 10. Ch-1 tripped but no annunciation on the door Initially suspected that "Stop" command was being issued
mounted printer or at remote C&I. from C&I system, but found this was not true. Channel
selector switch and Local/Remote switch on IOMA were
bypassed but trippings continued. Trippings were reported
at regular intervals.
Laptop PC was then connected to HMPG. Found that
Microprocessor was getting reset every time the drive
tripped. This was evident from the Laptop display.
This could happen only if LVSH from PSFF goes "High".
PSFF supply was cleaned by blowing air. Channel put into
service and no trippings observed.
PSFF changed as per customer requirement. No further
trippings observed.
MISC 11. 1. After overhauling, when ID Fan-B was started, it Problem is that Ch-2 is not going to LMODE=3. The
became ON & OFF many times on its own. When fan reason is that the flux levels in the machine is lesser than
speed was increased, it became normal. Again when the values set for FLUXS and MTRFMIN.
the channel was started after station tripping, same Following suggested:
problem occurred. 2. When Ch-2 was started, During the next shutdown, backcharge Ch-2 and adjust
Drive received ON command and took load also, but NLIB Load Flux values to the same as in Ch-1. Also please
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
OFF status did not go from the desk, while RUN check the FLUXS, MTRFMIN and FRSTART values in Ch-2
indication was appearing on the VFD panel. Then, are the same as in Ch-1.
Ch-1 was started first and Ch-2 started Start motor from Ch-2 and please check motor goes to
thereafter. Now drive started normally. LMODE=3.
SPD and SPM pots on NLCB do not matter for proper
starting of the drive.
SHORTED MOTOR 12. Ch-1 tripped on Shorted Motor Winding. Ch-2 made Master and Ch-1 Slave. Adjusted Load flux in
WINDING NLIB Load in Ch-1 same as in Ch-2. Channel taken into
service. Problem solved.
LOAD 13. Channel trips on Load Commutation failure as soon Invoked Gate test and found that 1 no. LED on HPTF Load
COMMUTATION as it is paralleled. side Pulse transformer card was not glowing. Replaced card
FAILURE and re-checked under Gate test mode. LED glowing OK.
R05, 0807, PH Channel taken into service. OK.
LOAD 14. Master channel is running. When Slave is paralleled When currents are steady in both Master and Slave,
COMMUTATION to Master, current in Slave is not same as in Master. CRSTART values were checked with Laptop PC and found
FAILURE Further Slave channel sometimes trips on Load to be different. Further in Master Channel, other channel
Commutation failure. running signal IOMA TB5/09,10 was TRUE. Also, the
R05, 1007, PH current reference from Master channel IOMA TB7/10,11
was positive which is OK for motoring. Therefore, fault
was in Slave (Ch-2). Changed NLCB card as this is the first
card in the signal path for current reference. Paralleled
Slave Ch-2 to Master. Problem solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 2. Channel tripping several times due to various faults. Customer feels that mother board is not giving proper
contact to SEM modules which causes frequent trips. Has
requested to change all mother boards or provide
alternative modified female connectors in mother board.
BHEL-EDN sent SEM lock bars to customer and the same
was installed on all SEM modules. Problem solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
PLL FAULT 2. Channel tripping frequently on “PLL Fault”. After SEM not earthed properly. SEM earthing done as per SEM
manual reset, channel comes into service. Earthing document. Problem solved.
GROUND FAULT 3. Slave channel tripped on Ground Fault. Flex leads at motor terminal box had got melted and
neutral point on bushing was burnt out. Motor stopped,
rectification done by putting HT Insulation tape.
MISC 4. Fan started from standstill and did not start. Fan Suspected No flux build up possibly because of melting of
did not pick up speed and was rotating very slowly in field lead connections inside motor rotor exciter.
the wrong direction.. STIM, FRSTART, CRSTART increased. Motor Started.
Parameters changed to old values and start trials taken
were successful. Old parameters retained.
Reason- High breakaway torque. Subsequent starts were
OK because oil film was formed between bearing metal &
shaft, causing lower breakaway torque.
LOAD 5. 5A2 channel tripped on ”Load Commutation failure Found thyristor in leg module LTM3 defective. Both
COMMUTATION thyristors were shorted out. Replaced leg module. Problem
FAILURE solved.
FAILURE TO 6. 6A Ch-1 started, LMODE did not increase from ‘1’ Found that snubber in STM6 was faulty. Capacitor was
START many times in spite of changing parameters like shorted. Replaced snubber. Problem solved.
MTRFMIN, FLUXS, STIM, CRSTART, FRSTART Customer asked to check bearing alignment on Fan bearing
etc. Suspected motor winding may be faulty. in next shutdown.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
LOAD 7. Channel tripping on “Load Commutation Failure” in HPTF cards changed in both channels after doing crowbar.
COMMUTATION 5B1 and “PLL Fault” in 6A1. SEM earthing done as per SEM Earthing document.
FAILURE Problem solved.
MISC 8. There was a heavy jerk on grid and due to that Changed Slave to Master and vice versa. Problem persists.
almost all 210MW units tripped out. When starting This confirmed no problem in VFD. Found problem was in
and taking ID Fans on load, found that Fan B was not Inlet damper to ID Fan. Damper was almost in closed
taking load, but Fan A was getting loaded. Currents condition and would not open. Corrected damper problem.
and voltages in both channels equal in Fan B. This Problem solved. OK.
phenomenon was present even when Fan B was run at
700 rpm.
MISC 9. When Ch-2 is individually started, Load contactor FLDCN (Field Contactor close) was not true in Ch-2 when
closes, Field contactor closes but no current in running alone. Aux. contact of Field contactor was not OK.
motor. But Ch-2 (Slave) can be paralleled with Ch- Rectified. Problem solved.
1(Master) and is OK. If Ch-1 is tripped, then Ch-2
does not take the load and its current stays at zero.
MISC 10. Top mounted blower (one of the two) on the Load was reduced to 150MW by lowering the speed and
synchronous motor was giving lot of sound and also the channel currents. The temperature of windings
needed replacement. dropped by 10 deg.C. Blower replaced and then vent load
raised. No rise in temperature of windings during change
of blowers. Problem solved.
Caution: It was advised to keep monitoring the winding
temperatures during the change and trip the motor if
winding temperature exceeded 120 deg.C. It must be
noted that there is no part load rating of the motor with
one blower of the two out of service. This is due to the
inherent construction of the heat exchanger and mounting
of blowers in the heat exchanger.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 11. Drive end bearing problem. Excessive vibration. Decision taken to change motor. Motor replaced and
following tests conducted on both channels:
R05, 1006, PH a. Exciter test Formatted: Bullets and Numbering
b. Uncoupled run
c. Coupled run
The readings compared with those recorded during
commissioning/annual overhaul, especially observing the
readings of exciter voltage and exciter current for Sl.b
and c. All readings found in order. Fan taken into service
with new motor.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 3. “Bus hog “ error on HMPG card. Inserted HMPG card properly.
Put lock bars on SEM rack.
Also checked whether EPROMS are inserted properly on
HMPG/DMPB. Problem solved.
SOURCE 4. Tripping on “Source Undervoltage when BFP started It was observed that source voltage dips below u/v set
UNDERVOLTAGE and during fast bus changeover from unit to station. value whenever MDBFP starts. This is because of very high
Source Undervoltage alarm appears immediately but Inrush current in MDBFP. Changed source u/v setting to a
“Source Low line” fault appears after sometime. lower value as per site requirement. Problem solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 7. Speed indicating at VFD panel and actual speed are BHEL has requested to adjust the mA reading as per
matching. Speed at PMS not matching. procedure given in VFD O&M manual, Vol1-Book1-Chapter
Clause 6.15.4 & 5.
EDN reply-The speed signal o/p from VFD to Plant C&I is
only for Indication Purpose & not for regulation/control.
Speed feedback on all channels adjusted. Speed reading on
PMS and actual speed are matching.
COOLING 8. Alarm “Cooling blower loss on Ch-1 and tripped on Fault resetted and drive started.
BLOWER LOSS “Loss of cooling fan”. But blowers running normal. Cooling blower contactor dropped. 415V UV has occurred
for a time greater than normal leading to this trip.
MISC 9. Fan tripped without any indication. MCB of PSFF had tripped. MCB reset and made ‘ON’. PSFF
Tripped due to failure of SEM supply. was malfunctioning in this channel.
Site concerned about momentary malfunctioning of
electronic cards since on next starts, card behaves normal.
Sometimes, no alarm is annunciated.
EDN replies that tripping of VFD channel & becoming OK
after MP reset could be due to:
a. Dust accumulation on PCBs
b. Loose connection between card & backplane connector.
All cards, Power modules, Power supplies cleaned with
blower. Problem solved.
Fan tripped without any indication. Failure of HRIA card. Failure due to RUNX relay failure.
HRIA replaced and channel restarted.
Fan tripped without any indication. Processor found hanged. Control supply made ON/OFF.
Processor normalised and restarted.
GROUND FAULT 10. Channel tripped on ground fault. Fault resetted and channel started smoothly. Problem may
be due to :
a. Loose connection in load side connections (busbars,
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
SHORTED MOTOR 13. Fan B1 tripped once on a) Load commutation failure 1. HPTK card found faulty after checking waveforms in
WINDING & LOAD b) Bridge filter fuse c) Shorted motor winding gate test mode. Replaced card.
COMMUTATION Second time on a) Load Commutation Failure 2. Y ph thyristor in field exciter module had failed.
FAILURE Third time on a) Load Commutation Failure b) Calibration of field current feedback was wrong. Same
Shorted motor winding corrected. (in A1)
I/O PROBLEM 14. Tripped on indications: Fault indications were false. Fault reset and drive
a) Motor Isolator not closed. b) RUNP missing c) restarted. Suspected UPS feeder supply problem.
Bridge filter fuse
I/O PROBLEM 15. C1 tripped on Fault resetted and channel restarted.
a. Source PLL Fault Suspected UPS feeder supply problem.
b. STARTP/RUNP missing.
MISC 16. Channel tripped. 11kV Source breaker tripped on Relay resetted and channel restarted.
IDMT O/C protection relay. No indication on VFD Malfunctioning of IDMT relay suspected.
before tripping.
MISC 17. HD of 5th harmonic of VFD system is 30%. To be 30% HD for 5th harmonic current is acceptable as it is in
confirmed. the case of all thyristor bridges. Voltage distortion is <5%
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 20. Channel tripped with Bushog Led on HMPG Same not Replaced HMPGDMPB. Checked that the 6 nos. of
resetting. EPROMs are installed correctly. Problem solved.
SHORTED MOTOR 21. Channel tripped on “Shorted Motor winding”. 1. Check thyristor healthiness.-OK.
WINDING 2. Reset and restarted - tripped.
3. Dry solder in voltage attenuator circuit on XPTN
card. Attended dry solder, Self test halted at 29 &
gate test also halted. LVSH on NPSJ card in PSFF
module was not present. NPSJ replaced and restarted.
Check to be done on Berg jumper position in XPTN during
card replacement. Channel taken into service. OK.
I/O PROBLEM 22. Channel tripping on blower loss. Blower selection contact “Bottom blower selected” not
wired to IOMA card. Same done. Problem solved.
MISC 23. HMPG card did not pass Self Test. Hangs midway. Replace HMPG Put EPROMs U22, U23, U24, U25, U02, U03
and EEPROMs U04,U05 from old card in respective slots
in the new card. Lock bar to be put in SEM Rack. Problem
solved.
GATING SUPPLY 24. Tripped on Gate supply u/v. 1. In gate test mode, HPTK card in LTM1, 1A fuse blown
UNDERVOLTAGE Replaced and started. OK.
2. MCB ‘CB2’ feeding electronic modules found tripped.
“NTRF” card in PS7 module found faulty. Replaced.
Problem solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 3. HMPG did not recognise status of running blowers HMPG found defective. Replaced the 6 EPROMs from the
even when blowers were run. Hence Source breaker defective card. Ensured that they are put in the correct
close permissive was not available. position with correct polarity. Channel started. OK.
GROUND FAULT 4. Tripping on ground fault whenever speed raised 1. Replaced HLCB card. No change observed. Original
beyond 500rpm and motor volts is 500V without card put back in SEM rack.
any fault in motor or cable. 2. 3 MOVs MOV1, MOV2 and MOV4 failed at a much
less voltage than designed.
Checked wiring in panel. Found wrong wiring. Corrected
the same. Drive taken into service. OK.
MISC 5. Cleared crowbar test. But motor not starting 1. Check whether CT feedback polarity is reversed on the
smoothly. Current going to inversion. load side. Corrected polarity of load side CT.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
LOAD PLL FAULT 8. Channel tripping on Load PLL Fault. 1. Conducted crowbar test. Test was not OK.
2. Shorted DC buses on load side with DC Link Reactor in
circuit. Conducted crowbar test. Test OK.
3. Changed NSFC load and conducted crowbar test. Test
not OK.
4. Checked all thyristors and snubbers on load side
bridge. All OK.
5. Checked pulses to gate of all load side thyristors, with
current probe. OK.
6. Removed individual thyristor module on load side. Found
that tightening studs on LTM1 was loose. Tightened
the same.
7. Conducted crowbar test after removing DC bus short
on load side. Crowbar test OK.
8. Channel taken into service. OK.
MISC 11. VFD trips on u/v condition of control supply. VFD trf. 110V/110V given for rectification sent to site.
Customer was told to check UPS feeder voltage. Changed
tap on trf. in VFD panel C & EXE cubicle feeding
electronics. OK.
MISC 12. Reference voltage keeps varying even with constant Replaced NLCB. Problem solved.
demand signal. Causes Drive hunting.
Motor speed and current changing at I&C, even Replaced NLCB. Problem solved.
though steady at panel.
SPD test point gives 14V even when speed is zero. Replaced DLCB. Problem solved.
Motor Speed and current indication at both local & Replaced NLCB Problem solved.
remote are erratic.
MISC 13. Printer works OK in test mode, but does not print Replaced Printer. Printer sent for repair to BHEL-EDN.
Status/Fault from SEM
I/O PROBLEM 14. HRDD does not give output LEDs and voltages Replaced HRDD. Problem solved. Card sent for repair to
corresponding to existing status. BHEL-EDN.
FAILURE TO 15. Motor crawling during starting and did not pick up Changed parameters FRSTART, MTRFMIN and CRSTART
START speed. to slightly higher values.
Inlet and outlet gates on ID Fan duct not closed properly.
OK.
MISC 16. Channels getting unloaded with all operating Suspected due to dust accumulation on firing cards.
conditions normal. Firing cards cleaned by air blowing. OK.
MISC 17. Drives could not go to current limit and increase the Investigation to be done by customer during shutdown at
fan speed due to clamp on speed reference from I&C system.
I&C system (Auto clamping).
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
LOAD 18. Channel tripping due to Load Commutation failure Loose connections in the CT feedback.
COMMUTATION Running normal after fault reset. Improper earthing of SEM Rack.
FAILURE SEM Rack earthed as per SEM Earthing document. Drive
taken into service. OK.
I/O PROBLEM 19. Channel tripping on Bridge Differential Pressure IOMA found faulty. Replaced IOMA.
fault when taken into service.
Channel started, after crossing min. speed, current HPTF card in source bridge found failed. Replaced and
started hunting and tripped on Load Commutation became OK.
failure. Crowbar test was done for power ckt. check,
one hump missing in current waveform.
Current hunting when channel taken into service. Load side cards not firing correctly or in sequence. One
HPTF card, both neons did not switch On/Off together.
HPTF card faulty. Replaced and Problem solved.
I/O PROBLEM 20. When RUN relay energised, BDIFSW (IOMA TB6- To be checked in test jig of repair cell at BHEL-EDN.
08) goes high, HMPG senses this as Bridge Energise RUN relay in IOMA. Check if TP8 in HRIA(2A)
Differential Pressure Fault & drive trips. goes high, JJ pin 22 on SEM header goes high, flicker of
LED I15 on HISA 1B.
IOMA checked in repair cell but no fault found. Replaced
the two mother boards on IOMA. Retested and
despatched to site. Suspected tracking problem on mother
board.
MISC 21. Slave channel and Master channel can individually Backcharge Slave with Master running and adjust FAB,
start and run. But Slave channel cannot be paralleled FBC, FCA on NLIB Load of Slave same as Master. Use the
with Master. If paralleling is done, current in slave same multimeter.
remains at zero. Found Slave adjustment was not OK. Adjusted. Problem
solved.
SOURCE 22. Source Undervoltage fault even though Source Asked to check voltage feedback circuit from HPTF
UNDERVOLTAGE voltage is OK. attenuator to NSFC and also line voltages on NSFC
backplane. Found Y phase Source attenuator not OK.
Replaced. Problem solved.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
MISC 23. Ch-1 and Ch-2 speed meters not matching. Speed meter does not have pot.
Customer advised to adjust LCI door 10V DC speed meter
after seeing counts 1024=60Hz=900rpm. Told to adjust
SPM pot only.
Problem solved.
MISC 24. Channel trips without any fault or alarm message. All SEM voltages O.K.
RUN light is ON but channel gets unloaded Gate test not O.K. Self test done. Failed in test 06:
current=0. NSFC-2C. Replaced NSFC –2C. Problem solved.
MOTOR OVER 25. System trouble annunciation appeared and Motor Load on channel reduced to half for about an hour and
TEMPERATURE Overtemperature Alarm appeared on Local panel. normalised. Temperatures came down and alarm got
Temperature scanner displayed 89 to 91 deg.C. cleared.
Similar readings found in I&C CRTs leading to Cooling blower motor found to be rotating in the reverse
conclusion that there is an actual rise in Stator direction. Direction of rotation restored to normalcy.
winding temperature. Temperature of motor reached a max. of 74 deg.C.
LOAD 26. Slave channel trips on Load Commutation Failure as Back-charged Slave (Ch-2) with Ch-1 running. Found
COMMUTATION soon as it is paralleled with MASTER at minimum unbalance in voltage on NSFC load. Found that attenuator
FAILURE speed. This is the first time after annual shutdown. resistor LTM2 on HPTF open and 10 pin connector not
inserted properly. Changed HPTF card. Channel taken into
R05, 1206, PH service. Problem solved.
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LCI CHANNELS FOR VFD – COMPENDIUM OF FAULTS
I/O PROBLEM 6. Self test Crowbar test excitation power test done 1. 1 no. HROA card found defective in 3A1. Replaced.
in Channel 1 & 2 of 3A. 2. 1 no. NSFC card replaced in 3A2.
3. Drive taken into service.
4. Cards sent for repair to BHEL-EDN.
MISC 7. Channel taking more time to start and come to BHEL stated this may happen due to additional loading of
minimum speed. the fan during starting.
This behaviour was not observed during This happens if inlet damper at ID Fan is not closed
commissioning. properly.
MISC 8. FD Fan trips when MAMSX and ALAMX relays drop Suggested to introduce time delay (off delay) of 1.5secs.
due to momentary voltage dips or voltage jerk for FD Fan tripping when MAMSX drops. Problem solved.
condition.
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MISC 9. Unbalanced field currents when channel is taken Due to irregular firing of thyristors in NHVL card.
into service. Replaced NHVL Problem solved.
MISC 10. When 220V DC fails, VFD motor contactor will not No harm to VFD system due to 220V DC supply failure.
trip even though power to motor is cut-off. I&C system will issue STOP to both channels. Load side
contactor will trip when 220V DC is re-established. Hence
no modification required.
MISC 11. ID fan tripping was provided through temp. Temp. scanners replaced. Temp. scanners used for Alarm
scanners in addition to direct C&I trippings. Any purpose only. Bearing and Winding temp. tripping is kept
malfunctioning of temp. scanner caused ID Fan through C&I only.
tripping.
MISC 12. Malfunctioning of Door interlock switches provided Door switch bypassed and ensured that door is always in
in ID Fan panel door (to trip the channel if door is locked condition during channel running. Interlock switch
opened during channel running.) causing channel will be replaced during next shutdown.
tripping.
MISC 13. When Ch-1 is running at 400A and Ch-2 is started, It seems that the flux in Ch-2 was much higher than in Ch-
Ch-2 current shot upto 600A for 1 minute and 1. Therefore Ch-2 which is the Slave channel tries to
slowly came down to 400A. correct the flux by increasing its armature current and
thus trying to de-magnetise the flux. Flux closed loop in
the slave is also in operation.
NLIB Load fluxes FAB, FBC, FCA in Ch-2 adjusted to the
same values as in Ch-1 by backcharging Ch-2. Tune up
values relating to flux in Ch-2 checked to be the same as
that of Ch-1. Problem solved.
LOAD 14. Master channel tripping on Load Commutation Found in Master channel that the ripple was very high in
COMMUTATION failure. Slave channel current remains at minimum 28Volts DC when compared to healthy channel. PSFF
FAILURE when working with Master, but OK when run replaced. Found Electrolytic capacitor in PSFF faulty in
independently. 28V DC circuit. Channel taken into service.
REV.04 Channel trips again on Load Commutation failure. Crowbar test conducted. Found one HPTK card on Load
side faulty. Changed. Master Channel taken into service.
OK. But Slave channel current goes to minimum when
Master is taken into service. Found Analog 0-10V current
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Channel current is found hunting for a load beyond 1. C1-Exciter output found abnormal. One thyristor of
350A. EVC was not conducting. Replaced & OK.
2. C2-NHVL card of EVC found defective. Replaced and
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No hunting observed.
3. Replace NLIB –Source card.
4. NHVL – only 2 lamps found glowing. Channel manually
tripped. HMPG thoroughly cleaned and restarted. No
hunting observed.
5 . FCLIM values increased. Speed meters for all 4
channels calibrated.
6. Speed regulator gain changed from 35 to 25.
EDN suggested checking of exciter feedbacks during
calibration.
FIELD LOSS 5. Feedback of NHVL card is not coming. Replaced NHVL card.
Only 2 Leds on NHVL card are glowing. HMPG, HLCB & NSFE replaced. Cards sent for repair to
BHEL-EDN.
MISC 6. Field current saturates above certain load. ID Fan was getting overloaded. Customer requested to
check whether the loading is as per the load points given in
Motor data sheet in O&M Manual. Also inlet damper
position to be checked. Problem solved.
SOURCE PLL 7. Channel tripped on Source PLL Fault. 1. Ribbon cables are tightened.
FAULT 2. If trips again, recommended to replace HLCB card.
MISC 8. Channel tripping frequently on SEM power supply BHEL recommended to decrease AC temperature in VFD
(PSFF) failure. Room for better cooling and provide internal fan for
channel. If not solved, Replace PSFF.
Recommended temperature in AC VFD room is 25°C.
Replaced MCB in PSFF. Problem solved.
MISC 9. Unequal field current in 10A & 10B. 10A taking 20A Load on 10A is more than 10B, at same speed. Hence
more current than 10B. higher stator current and also field current.
MISC 10. Motors not attaining full speed of 740rpm for 100% Motor does not have sufficient reserve torque to
demand. accelerate beyond a certain speed and excitation current
limit is being reached.
LOAD PLL FAULT 11. PLL Fault and Motor shorted winding Fault. Load side thyristor electrical connections tightened.
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MISC 13. Output Contactor was not holding after close Adjusted cam that actuates the contacts for the coil
command was given. Contactor is M/s. control circuit on the contactor. Channel taken into
Telemachanique make Magnetic latch type service. OK. Problem solved.
CR1BL33M21. Magnet face OK.
LOAD 14. Slave channel of BFP trips on Load Commutation SEM grounding, panel grounding checked and found OK.
COMMUTATION failure randomly. Changed HLCB card. Problem solved.
FAILURE
SHORTED MOTOR 15. Master channel tripping on Shorted Motor Winding. Changed Slave to Master and vice versa. Backcharged
WINDING Slave from Master. Adjusted Slave NLIB load fluxes to
same as Master. Problem solved.
LOAD 16. Slave channel of Boiler Feed Pump trips Checked Earthing of SEM and all other connections
COMMUTATION intermittently on Load Commutation Failure. This is including panel Earth Bus earthing. Found pulse height in
FAILURE accompanied by failure of one thyristor device in gate test mode on one load side module not OK. Replaced
Load side bridge. HPTK card. Suspected track problem in NTDA on one
R05, 0107, VI thyristor during gate test mode. Replaced NTDA.
Added extra wraps to DCOM from NSFC and NSFE pin
37. Replaced NSFE card as this was not passing Selftest.
Pump taken into service with both channels.
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
BRIDGE 2. “Bridge Differential Pressure” message appearing 1. Check cable connection from AFM to IO module. OK.
DIFFERENTIAL in the printer in spite of blowers running. 2. Replaced Air Flow monitor. Problem solved.
PRESSURE
LOAD PLL FAULT 3. At rated speed, fluctuations observed in main power 1. Jumper setting in HPTK Voltage attenuator circuit
supply to motor, accompanied by unbalanced corrected.
excitation parameters. 2. Exciter phase sequence wrong.
Voltage sensed by VFD was higher. Problem solved.
Motor speed could not be increased beyond 400rpm
and VFD tripping on “LOAD PLL FAULT”. EDN insisted that VFD room should be maintained dust
free.
FAILURE TO 4. Channel tripped on Microprocessor alarm. Snubber bar assembly LTM2 and LTM5 were found open.
START Replaced Snubber Bar Assembly & started.
Hunting observed. Crowbar and EVC test found OK. Load current CT feedback cable(10 pin) on SEM header
CRSTART modified from 0.3 to 0.5 and started. found reversed. Inserted in correct direction. Problem
Hunting persists. solved.
MISC 5. Run light always ON. Backplane wire wrapping problem. Corrected. Problem
solved.
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MISC 7. Self Test fails at 2001. EDN says problem is in Self test circuits only. Site asked
to go ahead with motor running. This circuit does not have
any function when drive is in service.
MISC 8. Could not go to Gate Test mode. Corrected offset zero on NLIB Load and NLIB Source
FAB, FBC & FCA with test oscillator ON by slightly
adjusting BAL1 and BAL2 potentiometers on NLCB Then
changed MTRFMIN and FLUXS to 0.2 and 0.1 respectively.
Problem solved.
MISC 9. “MAMS relay not getting reset even after VFD is HRDA card found faulty. Replaced. Problem solved.
stopped (Speed is zero).
MISC 10. Speed suddenly reached 500rpm and unit tripped on Due to sudden high set point from I&C 4-20mA signal.
furnace pressure very low. Corrected problem at I&C. Problem solved.
MISC 11. ID Fan Auto control is not working properly. Hunting Customer asked to change P & I values in PI furnace draft
in current when Furnace pressure controller is put in controller in I&C system. Problem solved.
Auto mode.
MISC 12. Controller very slow. May damage VFD/motor. Customer asked to time furnace draft PI controller at I&C
Clearance asked to make controller fast. system for optimum performance to suit system
requirement. Problem solved.
MISC 13. VFD did not stop with Stop command from DCS, Due to Bushog problem in HMPG Suspected loose
Filed stop PB. Finally stopped with Emergency Stop connection between HMPG and mother board on SEM rack.
PB from 6.6kV. HMPG cleaned and inserted in rack. Lock bar put. Problem
Speed does not vary with input signal and solved.
communication to HRDA card fails.
MISC 14. Drives reached rated currents at less than rated Current limit to be raised by raising the value of SRCLSC
speed. by 10% to increase the speed further. This can be done as
Current drawn at 705 rpm (max.) is exceeding there is margin in motor and VFD. Problem solved.
rated current in 3 motors.
MISC 15. HMPG IMOK Led was going OFF resulting in tripping Due to vibration of SEM Rack.
of 6.6kV breaker. Source of vibration-SEM Rack cooling fan. Fan replaced.
Problem temporarily removed after tightening of Problem solved.
SEM front bar plates. Problem persists & repeats
after 2 days.
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MISC 16. During starting, Stop command was being given by Due to higher time taken to achieve minimum speed of
C&I system. 145rpm from standstill. Timing in C&I increased from 30
secs to 60 secs. Problem solved.
MISC 17. One no. Neon lamp of XPTN card on load side Corresponding thyristor found failed. Replaced thyristor
thyristor module is not glowing. module and sent faulty thyristor module to BHEL-EDN for
repair.
MISC 18. Current and voltage at motor isolator switch is not There will be difference in indication upto 25Hz. Over this
matching with the corresponding values at control the indications will be nearly same. This is due to
and excitation panel. saturation in the metering core of CT at low frequency.
Indications in VFD panel to be taken as actual.
MISC 19. The maximum speed at 100% demand from control Since VFD is a current limited drive, speed can increase
room is below rated speed. i.e. 725rpm in all 3 only upto the current limit set. Customer asked to check
motors. inlet damper position and verify whether it is as per
Current drawn at 705rpm is exceeding the rated recommendation.
current of all 3 motors.
MISC 20. Microprocessor alarm appears. IMOK of HMPG and 1. Observe whether the fault appears under the conditions:
NLCB disappears and subsequent tripping of 6.6kV a. Only Auxiliaries ON, HT supply OFF to VFD
breaker occurs. b. With HT & auxiliaries ON, drive not running
c. With drive running.
Frequent tripping of Fan on various faults. 2. Check voltage levels of P5, P15, N15 & P28 supplies.
3. Check the status of Alarm Word.
4. Replace all 6 EPROMS (4 on HMPG & 2 on DMPB).
5. Check if SEM earthing is as per SEM Earthing
document.
6. Since sl.1 to 5 did not lead to any definite reason,
SEM rack was changed. The original cards were
returned. Lock bar of SEM put.
7. Problem was solved.
MISC 21. Fan tripped with Motor Overtemperature Alarm and 1. Could have been only due to fault in the circuit
Overtemperature Trip. Found MCBs CB1, CB2, CB4 connected to CB1 breaker. Checked all auxiliary
and CB13 in control panel tripped without actual circuits including 110V contactors connected to CB1
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Subsequently motor did not start and “Rotor 2. Motor opened and inspected. Found exciter wiring had
position start alarm” was observed. soot covering at some spots.
Exciter stator winding round carbonised. Motor
needs to be repaired/replaced with new one. Motor
sent to Bhopal for rectification of exciter rotor.
Received back at site.
LOAD 22. Channel tripping intermittently on Load Commutation HMPG, 5 nos. of NTDA cards changed.
COMMUTATION failure.
FAILURE Channel tripped again after few hours. Load side bridge thyristors, snubber ckt., CT circuit,
gating circuits checked. All terminations on HPTK and
NTDA cards checked for loose connections and
soldered/tightened/replaced wherever required.
Crowbar test conducted. Current feedbacks O/C Firing pulses and load side HPTK cards, NSFC, related
protection circuits checked, adjusted and started. cables checked. 2 HPTK cards on load side, reference for
Channel tripped on “Load Commutation failure” again detection of UV of gating supply was 1.3VDC while in
after few hours. others it was 1.8VDC. This reference adjusted to 1.8V in all
HPTK cards.
Gating power supply voltage was low. Corrected this to
required level. Self test and Gate test passed. Channel
taken into service.
MISC 23. HMPG and NLCB IMOK going OFF. SEM cards to be thoroughly cleaned by blowing over SEM
with blower.
Check SEM lock bar is installed correctly and firmly. SEM
module is anchored properly. Drive taken into service.
GATING SUPPLY 24. UV chattering of relay in PS7 power supply. NTRF card in PS7 changed. Problem solved.
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MISC 26. Channel LM100 Breaker from 110V UPS tripping PS70 output voltage was 84Volts DC on load. Voltage
because current taken is too high (14 Amps). When lowered to 80 Volts DC by adjustment of pot. on NTRF.
only SEM and IOMA are ON (drive stopped), the Current came down to 11 Amps. Breaker did not trip.
current is 4 Amps. When drive is started, then Problem solved.
current jumps to 14 Amps. Normally, it should be
about 11 Amps.
MISC 27. Source breaker trips on Microprocessor Alarm Found that P28 fuse on PSFF was not properly put in
through SWGR relay on IOMA even when drive not holder. Same tightened. NLIB Source changed and offset
REV.04 running. adjusted to zero on FABR, FBCR, FCAR with Source
breaker closed. Drive taken into service. Problem solved.
SOURCE 28. ID FAN is 6 pulse drive. Drive starts and goes to NLIB and NSFC load cards changed. Problem persisted.
UNDERVOLTAGE minimum speed but does not increase beyond this Found that wire had got cut in the lug and was giving loose
either in LOCAL or REMOTE reference. Source connection at IOMA TB input LBKRS. The same was re-
R05, 1206, PH Undervoltage alarm comes frequently and MAMS lugged and tightened. Problem solved.
relay chatters. Motor currents unbalanced.
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MISC 6. Com Port of one Laptop supplied for VFD is not Repaired by BHEL-site through laptop vendor.
working.
1 computer of VFD-MMI not working. Mother board replaced by computer vendor at site.
LOAD 7. Channel tripping on Load Commutation Failure. SEM earthing found not proper. Same rectified.
COMMUTATION Channel tripping intermittently on faults “Load PLL
FAILURE & LOAD Fault Load Commutation Failure, Motor Winding 3 nos. HPTK modules and 1 no. PSFF changed.
PLL FAULT Shorted & Power Supply PSFF failure.”
MISC 8. 3 MOVs of 440V 1A,2A & 3A found burnt during Fuses feeding MOVs – No failure observed. Found MOVs
inspection and maintenance work. Found incorrect burnt. Found wrong connection in panel.
connections, Advised to change all 9 MOVs 1A to 1C, 2A to 2C, 3A to 3C.
MOVs changed. Problem solved.
LOAD 9. Slave Channel tripping on Load Commutation failure. Channel back-charged with Source breaker open and Load
COMMUTATION breaker closed. FAB, FBC, FCA in NLIB load found with
FAILURE large DC offset.
Changed NLIB card and adjusted DC offsets to less than
30mV and balanced AC voltages of FAB, FBC, FCA. Channel
taken into service. OK. Problem solved.
MISC 10. Both Master and Slave channel of one ID Fan Flashover in Source side of Master channel. Master
tripped out. In Master channel, Source and Load channel isolated and Slave channel taken into service.
breaker tripped. In Slave channel, only Load breaker Found source side AC and DC filter fuses blown and also
tripped. cable tapping from busbar to filter fuses burnt. MOVs on
Source side OK. Fuses and wires replaced. All clearances
are more than adequate. Cause of flashover not known.
Channel taken into service. OK.
MISC 11. Fan-B Ch-2 tripped. Following were noticed: 1. Crowbar test done – Found O.K.
Source breaker tripped. 2. FT1 indication observed Gate Test done - Found O.K.
at VFD end. 3. HMPG IMOK LED was not glowing. Self Test done – Found O.K.
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4. There was huge current hunting only in this Primary injection tests in all 4 CTs done. Found O.K.
channel before tripping. Finally problem was traced to improper earthing in
electronic earth pit. Salt added. Drive started and found
O.K.
GATING SUPPLY 12. Channel trips on Gating Supply Undervoltage. Output voltage of 70Volts Power supply measured under
UNDERVOLTAGE Gate test mode. Showed OK 82 Volts DC. Checked voltage
of Power supply healthy signal from each of the HPTK
R05, 0207, PH cards going to XTFH diode circuits. All 12 voltages OK.
Changed XTFH card and Channel taken into service.
MISC 13. Channel tripped on Fault. Found that all LEDs on From the problem it was inferred that the problem could
HRDD are ON. FT1, FT2 and RST LEDs on NLCB be in IOMA module. Isolated by removing 28 Volts Power
R05, 0407, PH ON. 6 Amps 28V fuse on PSFF adjacent to circuit supply from PSFF connector feeding IOMA. Replaced
breaker blown. PSFF 6Amps fuse. Swithched ON PSFF. 28Volts fuse did
not blow. But all LEDs were glowing as before.
Switched OFF PSFF power supply. Removed all 4 cards in
IOMA module. Put back IOMA power supply connector on
PSFF. Switched ON PSFF. 28Volts fuse on PSFF did not
blow. Inserted one card after another in IOMA switching
OFF PSFF everytime. Found that 28Volts 6Amps fuse
blew when HRIA/2A card was inserted. Changed HRIA
card. Problem solved. Channel taken into service. OK.
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Problem solved.
MISC 6. HMPG IMOK not coming. Replaced HMPG with EPROM sets of tested card (6
EPROMS). Card sent for repair.
MISC 7. Pulses not getting distributed to thyristor stack Card XTFX in source side found defective. Replaced.
individually in gate test mode. Problem solved.
MISC 8. ID Fan ‘ON’ check back derived from its speed Automatic initiation of shutdown sequence due to ID fan
being above a certain value ‘OFF’ status will be delayed. Introduced time delay OFF
(MAMS). During starting MAMS chatters as speed logic for MAMS input at I&C. Problem solved.
hunts slightly resulting in ID Fan ON/OFF toggle.
This gives auto start to shutdown sequence.
MISC 9. VFD demand goes to max. when both ID Fans are This command is removed in I&C system as it is not
OFF. This prevents reducing the VFD demand to necessary.
min, when taking the first ID Fan into service. Problem solved.
MISC 10. ID Fan VFD given a protection trip from Source Source breaker trip due to VFD OFF condition will be
Breaker OFF condition but also source breaker is removed and instead will be given a trip command on its
given trip on VFD OFF condition, thus creating a ‘Electrical protection acted’ input being true. This is
logical problem. implemented at I & C. Problem solved.
LOAD 11. Channel tripping on Load Commutation failure LMARG was changed from 25° to 30°.
COMMUTATION Found P28 was 21.5Volts. Site asked to change this to
FAILURE minimum 24V level during gate test mode. Problem solved.
Changed back to 25° after channel was normalized.
MISC 12. Any electrical supply system jerk causes drive to Presently UPS feeding VFD is not fully commissioned and
trip. UPS is running on By-pass. Problem will not occur if UPS is
commissioned.
MISC 13. Customer expressed that ‘Auto fault Reset’ facility EDN informed that facility will not be given. It is
is not available. required that the maintenance engineer has to come to the
VFD panel to find out the fault and take corrective action
before re-setting.
MISC 14. Coil for OEN make relay found burnt in IOMA Suspected quality problem. Relay changed. OK.
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Reason unknown.
MISC 15. NLCB gives IMOK indication but fails DLCB card components R1 & C1 not matching as per
during self test of NCLB card. scheme. Changed from other card. Problem solved.
MISC 16. NLIB gives IMOK indication but fails in Self Test. Daughter board components R22, R31, R40, R23, R32, R41,
R60, R68, R72 not matching as per scheme.
Changed the components as required and also adjusted the
gains of FAB, FBC, FCA as per commissioning procedure.
Problem solved.
SOURCE 17. Drive tripped on “Source Commutation Failure”. Advised to conduct EVC test and crow bar test. Also
COMMUTATION Drive restarted and motor tripped without picking inspection of output contactor contacts advised.
FAILURE & speed on “Source Backup Overcurrent Operated”
SOURCE tripping Source breaker also.
OVERCURRENT Gate test and Crowbar tests passed. Found that one of the thyristor cells in the load side
bridge had got shorted. Replaced thyristor module & sent
the faulty module for repair to BHEL-EDN.
Problem solved.
I/O PROBLEM 18. Both channels commissioned but not able to take HROA card replaced. Simultaneous operation possible.
both into service simultaneously because of a Problem solved.
missing feedback due to HROA card. HROA card sent for repair to BHEL-EDN.
Current hunting after that.
MISC 19. Current sharing problem between channels. Actual currents were balanced. Meter on LCI channel not
showing correctly. Meter adjusted OK with pot. IM on
NLIB.
FAILURE TO 20. VFD failed to start and Rotor failed to start (Bit 1 Problem in DC field and exciter on synchronous motor.
START of ALARM WORD) displayed on printer. Motor changed in presence of BHEL-Bhopal person and it
is running OK.
MISC 21. Laptop battery back up not working. Customer has asked to send 2 battery back ups.
EDN says that Laptop PC can be fed from UPS supply
available in VFD panel. As such battery back up is not
required in laptop PC for VFD maintenance.
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MISC 22. Unit tripped on received AUTO OFF commands. Site : Logic built in VFD such that a time-delayed timer 0-
WSPOSE relevant alarm display was “Auxiliary 35secs. (set to 3secs.) drops when either of 24V or
Supply failure” 220V DC supply fails. Contacts of this timer used for
Customer requires that 24V DC and 220V DC Source drive breaker Start Perm. and its inverted status
supply failure be separated. used for generating AUTO OFF commands to source
breaker cards simultaneously.
EDN does not recommend separate logics for 24V & 220V
DC monitoring, as both 24V DC and 220V DC failures
should trip the drive.
MISC 23. High vibration noticed in fans at speed above Resonance is being observed from foundation at
650rpm (Speed at unit F.L.condition is <600rpm) speed>650rpm. However, vibration is in good zone.
BHEL-Ranipet recommends that status of spring
compression can be checked during annual maintenance
shut down.
MISC 24. VFD trips when small system jerks occur. Time delay of 2 secs. already incorporated to tide over
the problem. Customer has been asked to look into the
source of the swing/jerk and take appropriate action.
LOAD 25. When Ch-2 is started with Ch-1 running normally, 28Volts DC of SEM power supply checked and found to be
COMMUTATION Load sharing is equal, but Ch-2 tripped after 5-10 atleast 24V. Also its waveform did not have any ripple.
FAILURE hrs LMARG increased by one degree. Problem solved.
MISC 26. Heavy hunting in Slave channel when paralleled with Shutdown of Master channel taken and isolated it from
Master. Also Master current hunting when running Slave by removing connections on IOMA TBs for Rotor
REV.04 alone, but oscillations are not of large magnitude as Position/other channel running and Torque reference input
in Slave. Slave runs OK when run alone. and Torque reference output.
Crowbar test conducted on Master with Slave in service.
Found LTM2 on Slave defective. Replaced card. Master
taken into service. Found OK. But heavy hunting in Slave
continued. Found that wires were loose on IOMA TB 12
pulse Input signal 2BF IOMA TB7/16,17. Wires on TB
tightened. Slave taken into service. Problem solved.
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MISC 2. Following problems during parallel running of 2 a. Monitor 105V DC level on IOMA TB3-9,10 when RUN1
channels: & RUN2 relays in control panel drop. Check operation
a. Individual load breakers do not trip with remote of load breakers, independently by removing plug-in
trip command/local stop PB. Only Run relay type RUN relay in IOMA and simulate Load Breaker
drops & MP does not issue a trip command via operation. Source breakers must be OFF when doing
RUN relay. this test.
However process trip commands trip load side Mistake in wiring chart of Ch-2. This was the cause of
breakers at a time for both channels as Ch-2 not switching OFF when STOP command given
expected. from C&I. Problem solved.
b. During loading, fan speed rises upto 35% speed b. Observe INVLIM during normal running and when
ref. Command. And beyond that speed does not hunting happens by continuous display of INVLIM.
rise. Stator current hunts from min. to max., The value of INVLIM displayed will tell the type of
but speed does not rise. fault. Please do the following:
1. Increase LMARG to 0.3 from present 0.16. Run
drive and see if hunting persists. Hunting
persisted.
2. If it persists, Change LMARG back to 0.16. Change
resistor R60,R68, R76 in NLIB to 100K from 180K.
Run & see if hunting persists, Changed resistors.
Hunting persisted.
3. If it persists, change above resistors from 100K to
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MISC 3. Motor current calibration on VFD C&EXE panel. Run both channels at min. speed. Check LMODE=3 in both
channels. Measure trf. sec. winding current with clip-on
meter. Since trf. current = motor current, adjust
NLIB/DLIB pot. IM so that panel meter reads correctly.
Note that at minimum speed current will be minimum &
steady.
MISC 4. Running VFD when ID Fan handles air instead of flue Since density of air is much higher than flue gas, it will not
gas. Speed does not go to Maximum. be possible to run the drive to 540rpm as current will
reach the limit values before this speed.
LOAD 5. Channel tripped giving Commutation failure. 1. Changed XL compensation resistors in NLIB load R60,
COMMUTATION Both channels tripped due to fan vibration very R68, R76 from 180K to 67K. Tripping continues.
FAILURE high-process trip. Resistors changed back to original value.
2. P70 Volts output changed to 80 Volts during gate test
mode. Problem solved.
3. Vibration problem attended by mechanical
maintenance group.
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MISC 6. Channel does not start. On excitation board, only 2 1. NHVL excitation board failed in Field Exciter.
LEDs glowing on Start command. Replaced. OK. Failed board sent for repair.
Power supply unit failed. 2. PSFF module replaced. OK. Failed PSFF sent for repair.
Printer not receiving data from the MP. 3. Printer replaced.
I/O PROBLEM 7. Motor decoupled smooth in both channels. While 11 nos. Modules found defective. Replaced.
starting the fan on Ch-1, ammeter reading does not Ch-1-Polarity of CT inside excitation board was changed as
go beyond 400A whereas in running it goes upto IFB waveform not found OK. During power-up, before
600A and comes back for any speed increase restarting, MAMX in picked-up condition though HROA-R2
command. LED not glowing. Load breaker closed without any
When fan started through ch1, fan did not start, command. Self test failed in 230D. HRDD, NLCB
rotor oscillating and stator current hunting. Ch-1 suspected defective, Replaced & power On. MAMX picking
stopped and ch-2 started. Ch-1 paralleled. Found up. HROA in 1B failed. Spark observed in K3 relay body.
OK. Ch-1 OK even ch-2 stopped. Ch-1 started FU-6 blown in HROA. In MAMX, suppressor block (R-C
independently before rotor came to rest. Ch-1 does net) changed as lugging was not OK. IOMA changed. HROA
not start from rest position. connector found burnt. HRDD found defective.
All replaced. Self test passed. Fan started.
4-20mA for remote indication was not there. NLCB
changed. OSP and SPM setting was done. Fan run and
paralleled.
Ch-1 fault and not starting. All LEDs on HRDD glowing.
HRDD replaced. Remote speed indication and local speed
indication became zero. NLCB changed and ID fan started.
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When motor started through VFD Ch-2, did not start and
tripped on Source & load OverCurrent & ground faults.
During meggering on motor insulation , IR value found very
low. Problem related to Motor insulation, BHEL-Bhopal
contacted. Motor end covers opened & 1 conductor was
observed to have turned black. This was due to insulation
failure which resulted in high earth fault. Motor
replaced. Same problems observed. Also spurious
trippings/startings observed in Ch-1.
IOMA modules replaced in Ch-1 & 2. PSFF replaced in Ch-2.
Fan Run OK.
MISC 8. Ch-2 self test not passing. DC Offset not getting Additional earthing provided. NLIB card replaced. Offset
LOAD adjusted to zero volts. voltage made zero in NLIB Source & NLIB Load FAB, FBC,
COMMUTATION During trial run, Ch-1 “Commutation failure fault FCA by adjusting BAL1, BAL2 pot’s in NLCB. Self test
FAILURE & appeared. passed OK.
SOURCE NTDA card on thyristor modules resoldered wherever it
COMMUTATION was suspected dry solder present. Fans run OK.
FAILURE
I/O PROBLEM 9. Failure of IOMA modules. Seems to be a chance of voltage mix-up in P105 and IOMA
output contactor circuit. Mix-up could be from inside the
panel or from outside IOMA.
Found that there was no voltage mix-up in panel side.
IOMA modules suspected.
Sent to BHEL-EDN for repair. Found problem of open PCB
tracks on IOMA module backplane and also tracking
between PCB tracks. Backplane PCB’s on I/O module
changed. Vender de-listed. Quality problem. Problem
solved.
FAILURE TO 10. Ch-1 of ID fan-starting and running Found in Ch-2 that the load side CT polarity is reversed
START OK. after observing the waveforms of load side firing pulses
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Ch-2 (slave) of ID fan- Does not start. But runs OK w.r.t. Load side CTs. Corrected CT polarity.
after paralleling with Ch-1. Problem solved.
Tune-up parameters are same in Ch-1 & Ch-2.
LOAD PLL FAULT 11. On starting, Load breaker trips. Load PLL Fault or Found that NSFC load card was loose and not properly
Load Overcurrent or Shorted Motor Winding inserted in rack.
message appears. SUPP Led not glowing. Inserted card in rack and put SEM lock bar. Drive started
and found OK.
GROUND FAULT 12. Ch-2 tripping on ground fault intermittently and Action taken:
thereafter as soon as channel was paralleled to Ch- Checked tightness of all power connections including earth
1. bus. Found OK.
Checked SEM earthing. Found OK.
Checked gate pulses and any loose connections etc. Found
OK. Backcharged Ch-2 and checked load fluxes on NLIB
load. Found OK.
Crowbar was conducted with all doors and backcovers
open with CRSTART=0.
Found sparking on one of the load side capacitors in Fan &
filter panel. It was seen that the discharge resistor
connected across capacitor terminals was very close to
capacitor body leading to the sparking and hence ground
fault.
Corrected position of resistor and its leads for adequate
clearance from capacitor body.
Problem solved.
I/O PROBLEM 13. Channel tripping on I/O address problem. HMPG HLCB and HAIA cards changed. Problem persisted and
Bushog LED comes ON. Bushog LED on HMPG coming ON after 2 minutes. HMPG
REV.04 card changed retaining old DMPB. Channel taken into
service. Problem solved.
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LOAD PLL FAULT 14. Master channel trips on Load PLL Fault. Backcharged from Slave channel. Found that NLIB load Formatted Table
FBC AC voltage was oscillating. Changed NLIB Load card
R05, 1007, PH and set the values of FAB,FBC,FCA as in Schematic drg.
Sht. 1DA. Channel taken into service. OK. It is inferred
that OPAMPS in NLIB load may have drifting problem in
FBC circuit. Sent card to BHEL-EDN for repair.
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FAILURE TO 2. Drive not picking up speed. Runs at a speed below One load side thyristor module not firing properly.
START minimum speed continuously. Problem traced to loose connection on wire lug carrying
firing pulses. Re-crimped wire. Problem solved.
FIELD 3. Drive trips on Field Overcurrent or Field loss 415V auxiliary supply for VFD was fed from DG set. The
OVERCURRENT during start. main 11KV supply was fed from Electricity board feeder.
Since the Source Thyristor bridge and Excitation
Thyristor bridge work on the some PLL (Phase Locked
Loop), both bridges must be fed with electrical power
derived from the same power source.
Changed auxiliary power 415V source feeder. Problem
solved.
FAILURE TO 4. Motor not starting in uncoupled Found that parameters in software were parameters for
START condition. coupled condition. Changed to uncoupled condition
parameters. Motor Run. OK.
MISC 5. Motor starts and heavy vibration observed in Motor Found that no firing pulses to STM3. Also source 11kV
and fan. current unbalanced.
Changed HPTK card on STM3. Problem solved.
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MISC 2. Frequent tripping of VFD transformers on process EDN did not recommend introduction of any extra
trippings. breaker/contactor/switch giving the following explanation:
1. LCI decides to open the Load or Source breaker or
both depending on the type of fault.
2. Emergency stop conditions are rare as this represents
emergency conditions.
3. Once unit starts generating, the no. of operations of
the source breaker becomes extremely low.
4. Similar interlocks for source breaker existing in
earlier drives already supplied and in service. No
transformer failures encountered to date.
MMI FOR VFD 3. VFD MMI: Check all cabling is as per document.
1. While carrying additional tests for Line drivers 1. Check that cable connection that has been made
mounted in C&EXE panel, R+ and T+ led are glowing between the VT100 terminal and the line drivers is a
but key pressed in not getting printed on VT100 one-to-one connection, i.e. Connect the wires to the
screen. respective as follows: 2-2, 3-3, 7-7 (and connect 7
to ground) , check that individual line drivers are OK
and then conduct Loop-Back test.
2. Link fail is coming in window during Integrated 2. Check if the software is reading the MPCC card and
test for MMI system. the Reed-relay card. For this, take out the above
cards from their respective slots inside the PC. Run
the MMI.exe file. The following should happen:
a. A message will be printed out: MPCC/Reed-relay
card not in place.
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MISC 4. Current hunting problem during loading of drive Phase sequence at motor exciter terminal box changed.
motor accompanied by voltage collapse. Problem solved.
MISC 5. Loading of RPM meter and current meter. BHEL-EDN suggested to put a resistance of 200 Ohms
across the respective IOMA TBs after disconnecting
external cables. EDN to revert back after receiving the
reading on the door module meters and the mA current
through the 200 Ohms resistance.
Problem traced to higher loading in C&I. Problem at C&I
sorted out. OK.
LOAD 6. Ch-2 tripped on “Load Commutation Failure”. NSFC Load card found defective. Replaced. Problem
COMMUTATION solved.
FAILURE
GATING SUPPLY 7. 1. Ch-2 tripping on “Gating Supply dip”. 1. HPTK card of STM3 found defective. Card replaced.
DIP 2. After 12 hours running, irregular firing and no OK.
LED indication on leg STM3 reported by 2. One HPTK card of STM3 & one NSFC card found
customer. Machine did not start after stopping. defective. Replaced and Machine started.
3. During starting current going to 580A then
coming to zero and then going to 500Amps, then
stabilizes around 100-150 Amps.
BRIDGE 8. Channel Tripping on Bridge Differential Pressure. Lowered the differential pressure setting in Air Flow
DIFFERENTIAL monitor. Problem solved.
PRESSURE
SOURCE 9. Channel tripped on “Source Commutation failure” One no. SCR in STM2, all three SCRs in LTM1 and 2 SCRs
COMMUTATION when running on no-load. in LTM3 showing zero resistance. Problem cause is the
FAILURE loose connection of T2 control trf. in LCI panel.
Connection tightened. Problem solved.
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MISC 10. Current hunting problem in channels. One no. thyristor leg found defective. Replaced and
problem solved.
LOAD 11. Channel tripped on “Load Commutation Failure”. Following tests were carried out:
COMMUTATION 1. Resistance across all the thyristors checked. Found
FAILURE satisfactory.
2. Fuses in all HPTK cards checked. Found OK.
3. Self test failed in 2901 during testing of HRDA(1A),
HISA(1B) & I/O module.
Replaced HRIA (I/O 2A), HROA (I/O 2B), HISA (1B).
Fuse & 105V supply checked. Continuity of ribbon cables
from I/O module to SEM checked.
Problem persists.
Dust ingress on SEM Electronic rack cards & HPTK
thyristor pulse trf. card found to be the problem. Dust
removed by air blowing.
Problem solved. Channel taken into service.
GATING SUPPLY 12. Problem of Gating supply dip & LED not glowing in One thyristor of STM3 found short. Replaced. Gating
DIP STM3 NTDA card. supply UV problem persists.
MISC 13. Failure of as many as six thyristor legs in one unit Customer asked for an expert thorough analysis at site.
and 2 thyristors in another unit. Dust level on the cards in the electronic rack & in the
thyristor power modules found high. This found to be the
possible cause of failure after thyristor failure analysis
done at BHEL-EDN.
LOAD 14. 1. “Load commutation failure” leading to tripping Excitation circuit thoroughly checked up. Found
COMMUTATION of the fan. terminations in ‘C’ phase and the current feedback CTs
FAILURE, 2. “Source Overcurrent” fault were loose. Terminations tightened and ‘EVC Power test’
SOURCE leading to tripping of the fan. conducted.
OVERCURRENT & 3. “Field loss” fault on start-up and unable to start Problem solved.
FIELD LOSS the fan.
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MISC 15. 2x500MW plant not able to generate more than Damper position increased to 85% as per BHEL-Trichy
480MW when only 3 channels of ID Fan are recommendation. Problem solved.
available.
MISC 16. Motor currents in 2 channels of ID FAN A suddenly BHEL-EDN rep. Has explained to customer that this
shot-up from 476.95A/466.8A to problem is related to reference from I&C. Not a VFD
741.02A/749.22A, whereas speed varied from problem.
462.89/488.89 to 470.95/504.64 rpm. Sudden
increase in speed and current lasted only for a few
seconds and the values came back to their original
level.
MISC 17. Ch-2 not taking over when ch-1 tripped due to any Problem traced to failure of fuse in HROA-1B card. Same
fault. Ch-2 not starting individually. replaced.
Ch-2 started individually and in dual mode and operation
found normal.
Changeover and taking over of either channel in case the
other trips has also been found in order.
MMI FOR VFD 18. MMI of ch-2 not working. Circuits of door mounted printer port of VFD, line drivers
(VFD), line drivers (O&M), Multiplexer, Demultiplexer,
Junction base, MPCC card checked and found in order.
Data transfer and communication from SEM suspected.
Door mounted printer of VFD replaced. Problem solved.
FIELD LOSS 19. Tripping of ID Fan on field loss. Excitation system thoroughly checked. Found that in ch-2
the exciter output current was less due to non-conduction
of one thyristor. NHVL card changed. Channel cleared for
service after EVC power test and calibration.
Self test failed. One of the zener diode in IOMA Mother Board had
failed. Replaced and self test was passed.
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MISC 20. Vibration of motor current on ID Fan (sometimes in Output feedback CTs were found loose at the mounting.
the order of 80A). Output voltage waveform was Same tightened. NHVL card replaced.
found distorted. Motor current vibrations still present.
Adjustment of speed regulator gain did not reduce the
variations. SFE of ch-1 to be replaced when shutdown
available.
Ch-2 configured as Master and ch-1 as Slave and Fan put
into service. Variations not observed.
Defective card brought to BHEL-EDN for repair.
MISC 21. Unbalance of 50A in the motor current between the Ch-1 current indication at the remote(UCB) was showing
two channels of VFD. less where as in the local, the current was showing
balanced because of problem with the V/I converter in
NLCB card. Same replaced.
Problem solved. Current for both channels were balanced
at the remote. Defective card brought to BHEL-EDN for
repair.
GROUND FAULT 22. When ID Fan started after cleaning for annual During cleaning of the panels, customer has broken
maintenance, Ch-1 & ch-2 tripping on Ground fault at connection at the lug points of the HV cables connecting to
a motor voltage of about 800VAC (300rpm). This the load side filter ckts. Cables recrimped. Problem solved.
was observed on trials in single channel operation or
in dual channel mode.
LOAD 23. Channel tripped on Load Commutation Failure. 1. Check SEM earthing as per SEM Earthing document.
COMMUTATION 2. Change X(reactance) compensation resistors in
FAILURE NLIB(1D) i.e. change R60, R68, R76 from 180K to
100K Ohms & check the 3 flux reconstructed
waveforms on NLIB(1D). Change resistors to lower
values (upto 33K Ohms) till the reconstructed
waveforms are sinusoidal.
3. Change LIMARG.
All the above done but problem not solved.
Intermittent tripping of channel between period of 4 hrs
to 48hrs observed.
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MISC 25. Ch-2 tripped. HMPG not getting reset. HMPG Bushog problem. HMPG replaced. Problem solved.
BRIDGE 26. Ch-1 tripped on ‘Bridge Differential Pressure’. Dry solder problem in Tag board. Soldering done properly.
DIFFERENTIAL ‘RSFM’ resistance found dry soldered. And Problem solved.
PRESSURE disconnected from ‘Tag board resistance card’.
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MISC 27. Ch-2 Current suddenly reduced to 220A. Berg Jumper J2 on DMPB defective. Replaced. OK.
GATING SUPPLY 28. Ch-2 tripped on “gating supply dip, load commutation HPTK card of LTM4 burnt. HPTK card replaced.
DIP & LOAD failure, gating power supply loss”. HLCB card found failed. Replaced.
COMMUTATION Problem solved.
FAILURE
SOURCE PLL 29. Ch-2 tripped on ‘Source PLL Fault ’ Loose attenuation card connection in STM1.
FAULT
LOAD 30. Ch-2 tripped on ‘Load Commutation failure’. Dry solder problem in NTDA card. Card replaced.
COMMUTATION 2 nos. HPTK card changed. HMPG found failed. HMPG
FAILURE replaced. Problem solved.
GATING SUPPLY 31. Ch-1 alarm ‘Gating supply undervoltage’. NTRF card changed & channel started and channel tripped
UNDERVOLTAGE on ‘Field loss’ problem.
Field exciter board NHVL changed. Problem solved.
Channel taken into service.
GATING SUPPLY 32. Ch-2 tripped on ‘Gating supply dip’. NTRF card failure on 70V power supply. NTRF changed.
DIP Problem solved.
LOAD 33. Ch-2 tripped on “Load Commutation Failure”. 24V DC in PSFF found dipped. HROA(1B) having Motor
COMMUTATION above minimum speed changed. Problem solved.
FAILURE
MISC 34. Source Breaker trips but no Alarm or Fault lamp or Advised to change HROA relay card in IOMA module
any message on printer. Channel taken into service which energises SWGR relay. This module will have
after taking out the wires on IOMA Elmex TB SWGRX relay on it.
connecting to SWGR relay aux. contact.
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MISC 35. Gating tests and Exciter Power tests not passing in HMPG card found to be the problem. U10 IC on the HMPG
Fan-B Ch-1. cards found of Harris make.
HMPG cards replaced and Problem solved.
LOAD 36. Ch-2 randomly tripping on Load Commutation Failure. SEM Rack cleaned by blowing air. Channel taken into
COMMUTATION service. OK.
FAILURE
GROUND FAULT, 37. Channel tripping on Ground Fault and Load Channel Tripping on Ground Fault. Observed that neon Formatted Table
LOAD Commutation failure. lamps across Load Bridge Thyristors also glow when Source
COMMUTATION breaker is switched ON. Found ground fault in cable
FAILURE connecting transformer secondary and Source bridge. This
was done after isolating cable at both ends using HV
REV.04 megger and Hi-pot. Cable changed and Channel taken into
service.
Thereafter Channel tripping on Load Commutation failure
intermittently. Since all waveforms were OK, it was
inferred that the problem can be attributed to spurious
malfunction in electronic cards. NLIB(load) ,HLCB, HAIA
and Pulse distribution card XTFH changed. Problem
persisted. Grounding system of entire channel thoroughly
checked and re-inforced with additional cables from panel
earth strip to station earthing mat. Channel taken into
service. Problem solved.
MISC 38. Field Contactor chatters when Ch-1 (Master) is Since field contactor closes after Load Breaker closes,
paralleled to Ch-2 (Slave), with motor running aux. contact problem in Load breaker was suspected i.e.
R05, 1107, PH through Ch-2. No Fault or Alarm annunciation. MISOL input in IOMA changing from True to False to true
to false, even though breaker is closed.
Found contact resistance in aux. contact of Output Ckt.
Breaker not OK. Shifted wires to another contact.
Problem solved.
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LOAD 39. Slave (Ch-2) trips immediately after paralleling to Back-charged Ch-2. Found that voltages on NSFC Load
COMMUTATION Ch-1. Unbalanced. Further found that one attenuator resistor in
FAILURE R Phase load XTFH was open. Changed card. Ch-2 taken
into service. Problem solved.
R05, 1107, PH
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LOAD PLL FAULT 4. Ch-1 tripped on “Load PLL Fault”. Surge protective 1. Fan & Filter panel thoroughly cleaned.
arrestors of CT1,CT3,CT4 and CT6 which are 2. Blowing done at C&EXE, Bridge panels.
connected at TB3-01&02 got burnt and damaged the 3. Wiring checked at C&EXE, Bridge,Fan & Filter panels.
CT wiring of CT1 & CT3. 4. CT circuit checked for tightness.
5. Surge arrestors SD1, SD3, SD4, SD6 replaced. After
replacement, CT circuit checked for continuity and
links closing. Self test done and passed. Problem
solved.
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GROUND FAULT 2. Ground fault in both channels of Fan-B. Load side capacitors found faulty and neutral grounding of
R-C circuit was not O.K. Problem resolved.
GROUND FAULT 3. Ground Fault problem in Ch-2. Cable from contactor to motor was found faulty during hi-
pot test to earth. Faulty part of cable removed and joint
put. Problem resolved.
MISC 4. With Ch-1 tripped, Ch-2 not responding to speed Parameter SRCLSC found to be 0.7 instead of 1.0.
Raise command. Current and speed of ID Fan not SRCLSC changed to 1.0. Problem solved.
responding.
LOAD 5. Channel tripping with fault message “Load NSFC card changed and checking of all connectors and RC Formatted: Indent: Left: -0.13 cm,
Right: -0.13 cm
COMMUTATION Commutation Failure and Shorted Motor Winding.” Filters carried out. Power bridge on load side checked.
FAILURE/SHORTED Firing pulse LED on one card in Source bridge HPTF card on load side changed. Problem solved.
MOTOR WINDING missing.
LOAD 6. Load Commutation Failure message received on Voltage on the P70 module was measured and found to be
COMMUTATION channel and thyristors produced hissing sound 73 volts instead of 80 volts by adjusting the
FAILURE during dry firing. corresponding pot. Problem solved.
SOURCE 7. Source Overcurrent message received on channel. Earthing of XLPE cable not found either on bridge end or
OVERCURRENT Sparking found at the gland end of R phase at the the transformer end. Earthing done on the transformer
back side of the bridge panel. end. Problem solved.
GROUND FAULT 8. Ground Fault message received on channel. Voltage at NTL port of NLCB card was measured and Formatted Table
found to be 0.51V instead of 0V. The cause was found to
be unbalance of current in the three phases. On
performing the megger and hi-pot test, it was found that
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the ‘Y’ phase insulation had failed. The cable for ‘Y” phase
was replaced. Problem solved.
LOAD 9. Slave channel trips during running, on Load Crowbar test conducted and found OK. Therefore Ground
COMMUTATION Commutation failure and Ground Fault. fault suspected on load side. MOV and PT on Load
FAILURE, breaker checked, found OK. With Output breaker drawn
GROUND FAULT out, Motor AC voltage measured with respect to earth by
Motwane multimeter in High voltage range. Great care was
REV.04 taken when doing this. Voltage unbalance found. Motor
stopped. Cable fault found between Motor and Output
breaker after Hi-pot test. Note that Megger value of
failed cable was OK. Fresh joint made. Channel taken into
service. Problem solved.
SOURCE 10. Source Commutation failure occurs when channel is Crowbar test conducted, but channel tripped on Source
COMMUTATION taken into service. Commutation failure. AC side line filter capacitor checked
FAILURE and found OK. Attenuated voltages on Source NSFC and
FAB,FBC,FCA on Source NLIB found OK. HLCB changed.
REV.04 Problem persisted.
Cable connections from transformer secondary to panel
removed. Meggered transformer and found OK. Meggered
cable and found OK. Finally, XLPE HT cable earthing braid
from transformer to panel was found loose. Connection
tightened. Problem solved.
LOAD PLL FAULT 11. Drive trips on Load PLL Fault once in a while but Found that panel was not earthed. Earthed the panel from
period of tripping is regular. ground bus at rear at both ends. Completely cleaned the
R05, 1106, VI panel by air blowing. Checked all connections in Load side
filter RC circuit and MOV. Some of the bleeder resistors
across filter Capacitor leads were very close to the
capacitor case. Made these resistors lead vertical.
Channel taken into service. Problem solved.
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MISC 2. Speed and voltage not increasing at 35 Hz and DC Offset voltages at NLIB FAB, FBA & FCA was
current swinging. Pump not attaining full speed. 1.0Volts DC, when no voltage was present on Source
INVLIM getting set at 2304 & 288. bridge or Load Bridge. Adjusted NLIB (L) Offsets to
zero. Problem solved.
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GROUND FAULT 2. Motor starts and runs upto minimum speed. As soon Other channel was not available to check this fault by
as it reaches LMODE=3, channel trips on Ground backcharging.
R05, 1206, PH Fault. Motor voltage at this instance approx. 400V. Connected a 415V Source to Inverter Output. Found Line
to Neutral voltages unbalanced. Isolated Load side RC and
MOV circuits. Found Line to Neutral voltages balanced. On
further investigation, it was found that brazing on one of
the load side RC filter resistor had opened. Resistor
replaced. 415V applied. All line to neutral voltages found
balanced. Channel taken into service. No ground fault trip
observed. Problem solved.
GROUND FAULT 3. Channel trips on Ground Fault when speed reaches Fed 415V 3ph 50Hz from Auto-transformer to Load side
over minimum speed. Other channel not busbars R,Y,B in channel, with output VCB in OFF
R05, 0507, PH commissioned. Therefore, back-charging not condition. Found unbalance in FAB, FBC, FCA in NLIB-
possible. Load. Removed cable from DC Reactor to Load side
negative and also P1-P2 jumper busbar connecting Load
and Source side bridges. Unbalance on FAB,FBC,FCA
remains. Isolated Load side MOVs. Unbalance remains.
Found that connection to Y ph R-C circuit resistor
terminal wire cut-off. Replaced the wire wound resistor.
Problem solved.
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MISC 2. When START command is given from Remote, Checked whether RUN command from Common Control
Output CB closes but opens after 3 to 4 seconds. panel was ON. Found OK. Put clip on 220V Jyothi relay in
R05, 1007, PH VCB. No change. Suspected HRIA card RUNX relay 1BH49
not working. Swapped HRIA card 2A & 2B. Problem solved.
MISC 3. Master and Slave do not share equal current when Found that in IOMA TB07/10,11, the polarity of current
paralleled. When speed is raised, heavy oscillations reference going to Slave (Ch-2) was negative instead of
R05, 0607, VI occur in Slave (Ch-2). positive (Motoring condition). Changed NLCB card in
Master. Problem solved.
LOAD 4. When drive runs on single channel and higher speed All tests as given in Annexure of Compendium already
COMMUTATION and load, Load commutation failure occurs after done, but problem persists. The 180K resistors on NLIB
FAILURE three hours approximately. load R60, R68, R76 for XL compensation of motor
changed from 180K to 100K. Channel taken into service.
R05, 1107, VI Problem solved.
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GENERAL CHECKS:
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CHECKS FOR GROUND FAULT , LOAD COMMUTATION FAILURE, LOAD PLL FAULT :
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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
S S S N
S
CARD N Aluminium
SLOTS Extrusion
Aluminium
N Extrusion Z
CARDS GND
SLOTS N
SEM FRONT Y
VIEW Cu. Braid
A B
C C
A B
Front Back Front Back
C C
A B C C
CCC
4.Scrape paint on both sides on plate of nut/bolt ‘A’ and ‘B’. Exercise caution as the motherboard
pins may get bent accidentally when doing this.
5 Scrape paint on back cover on head side of screws’C’.
6.The objective of these points 1 to 5 is to ensure that PCB(mother board) ground track mentioned in
point 2 is perfectly connected to tinned copper earth bus in C & Exe, panel(Regulation
Panel in high current rectifier).
7. All Nut Bolts to have spring and plate washers. Only plated washers to be in contact with paint
scraped surfaces only. Replace if biting/toothed washers are present. Replace one at a time.
8. Check that the PCB motherboard pins have not been bent.
9. Re-check all points 1 to 8 above have been done. Check for continuity between ‘S’ and ground
copper flat.
10.Install SEM back cover carefully.
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FT1
UNLATCH
STALL ISTLINHB RD FT1
RESET INHIBIT
OR
SUPP(S)
OSFT1
FT2
10SP FT2
SUPP(L) RD
OVA(L) OR
FLT(SWRE)
FT1 AND FT2 are the first two LED’s seen from the top on the BAR LED of NLCB with
inscriptions of FT1 and FT2 respectively.
1. Description of FT1:-
The logic for the LED FT1 being ON is as given in the diagram above.
When the FT1 LED turns ON it also closes the SWGR relay in the IOMA to trip the source
breaker, if it is closed or if the source breaker is closed the permissive to close is lost.
FT1 is turned ON in case of major faults. They are the Hardware Source over-current,
Microprocessor stall (µP stall) and System Fault (Not(NSFLT)) as detailed below.
a) Hardware Source over-current (SUPP(S)) :- The currents from the 3-phase of the
source side obtained through CT’s are rectified in the analog boards to obtain a DC
current feedback IFB which is compared in the source NLIB board with the SUPP
settings to initiate source over current after 25ms.A source over current has occurred
and it persists for a period of more than 25ms. The message in case of this condition
is “Source back up over current fault”.
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b) Microprocessor stall (µP stall): To detect software malfunctioning and Software code
runaway a hardware circuit is built consisting of a tickle timer in Monoshot mode. In
the event the software does not regularly reset this timer as the software has run away
or in the case of malfunction this timer generates a stall signal.
c) System Fault (Not (NSFLT)): - Please see the Ladder logic in sheet 1FE of the LCI
scheme. This is declared under any of the following conditions: -
a. Source current imbalance. (Series 12 pulse only)
b. Source over-current.
c. Loss of cooling fan.
2. Description of FT2: -
The logic for FT2 led to turn ON is as given in the diagram in previous page. When the FT2
turns ON the fault relay IOMA also closes. Thus a fault is annunciated.
FT1 is turned ON in case of Over-speed (1OSP), Load Over current (SUPP (L)), Load over
voltage (OVA (L)) and Channel fault (NOT (NCFLT)) as detailed below.
a) Over speed (1OSP):- The speed feedback is obtained by the hardware circuit on the
NLCB from the voltage waveform of the load side. When this speed signal exceeds
the setting of OSP on the NLCB then this is actuated.
b) Load Over current (SUPP (L)): (Load backup over current fault) The currents from
the 3phases of the load side obtained from CT’s are rectified in the analog boards to
obtain a DC current feedback LIFB which is compared with the SUPP setting on the
load NLIB board to initiate load over current after 25ms. The message in this
condition is the “Load backup over current fault”.
c) Load over voltage (OVA (L))( Load AC over voltage): - The 3∅ voltages of the load
side are attenuated and available at the input of the load NLIB boards. The analog
board has a rectifier circuit converting these AC voltages to DC. This DC voltage is
compared with the OVR setting of the load NLIB board and when greater initiates a
load over voltage fault.
d) Channel fault (NOT (NCFLT)): -The NCFLT is as per ladder logic on sheet 1FE of
LCI schematic diagram. The Channel fault is declared when a hardware or software
fault occurs in the drive as per the logic in sheet 1FE.
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FAULT MESSAGES: -
1. LOSS OF COOLING FAN : -
Please refer ladder logic sheet no 1FK
LOGIC = NOT (NBLF)
3. FIELD LOSS
Please refer ladder logic sheet no 1FK
LOGIC = FLD_LOSS_FLT
10. OVERSPEED
Please refer ladder logic sheet no 1FK
LOGIC = OS
INPUT = PORT 900C BIT 7
11.GROUND FAULT
Please refer ladder logic sheet no 1FK
LOGIC = GNDF
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If field current exceeds “FCLIM” for the no of attempts given by “ FCFTIME” then the fault is declared. A penalty
function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows recovery from
non repetitive faults.
During a start up from standstill, when the motor speed has exceeded the value set by “TRSPD” and the Load PLL is
locked. Then the peak flux reading taken at every 60 deg electrical from the machine (obtained from integration of load
voltages from NLIB Load card) exceeds its previous value set by “SWINDTOL”(approx 10%). Then a Shorted Motor
Winding Fault is declared. The shorted phase can be obtained from the variable Shorted winding in ENGG mode.
If source current exceeds “LKLIMS” for the no of attempts set by “LKOCTIM” then the fault is declared. A penalty
function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows recovery from
non-repetitive faults.
If source current exceeds the limit set by “LKLIML” for the no of attempts given by “LKOCTIM” then the fault is
declared. A penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This
allows recovery from non-repetitive faults.
During normal running of the drive, if the difference between the source and load current (read in synchronous with load
frequency cycle) exceeds the limit set by “LKLIMD” for the no of times set by “STHRUTIM” then a fault is declared.
A penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows
recovery from non-repetitive faults.
During normal running of the drive, if the difference between the source and load current (read in synchronous with
Source frequency cycle) exceeds the limit set by “LKLIMD” for the no of times set by “STHRUTIM” then a fault is
declared. A penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This
allows recovery from non-repetitive faults.
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The Load voltages are attenuated thro attenuator boards , conditioned in the firing card NSFC and then integrated in the
NLIB boards. These integrated signals are used for synchronization to fire the source bridge thyristors.
Software/Hardware Phase Locked Loop (PLL) does the synchronization.
If this synchronization is lost and remains as such for a period set by “LPLLTIM” then a fault is declared.
In Case The Exciter is DC. The field DC voltage is obtained through attenuators and the NSFF circuit. The NSFF circuit
has a over voltage detector (OOV) with fixed set point. When the field DC Voltage exceeds the limit the OOV sends a
signal and the Fault is annunciated.
The processor because of extraneous reasons may run away and may do unintended tasks very frequently In such cases
the STACK builds up. It is necessary to declare a fault in such cases.
During start the speed regulator is open looped and the current command is fixed. The current command is ramped from
minimum current to a value required until motion is detected. Current reference ramps until the drive position has
changed 120 electrical degrees to maximum value of CUR_REG_REG_STRT_E. Motion is detected by looking for a
two cell pair change in the load side firings. If motion is not detected even after 5 secs then a fault is declared.
The tunes up constants are stored in the EPROM of HMPG the Processor Board, during running of the drive these
constants are loaded in to the EEPROM for operation. If there is a problem in this operation during initialization then this
fault is declared.
This fault is only in Drives using Tacho feedback with HTCA card. When the HTCA card or the tacho malfunctions then
this fault is declared.
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ALARM MESSAGES: -
1.MOTOR OVERTEMPERATURE
Please refer ladder logic sheet no 1FK
LOGIC = NOT(MOVTEMP)
2.TRANSFORMER ALARM
Please refer ladder logic sheet no 1FK
LOGIC = NOT(TTRBLE)
4.PCR OVERTEMPERATURE
Please refer ladder logic sheet no 1FK
LOGIC = NOT(PCROT)
During start when the field is energized and the field voltage is built and present but its value is lower than required then
this alarm is declared.
During run If the motor fails to start within 1 sec from start, then this alarm is declared. The rotor position is determined
from relative flux amplitudes.
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The Processor is sending and receiving data from various boards within the SEM Rack. If the response of the Board
exceeds a given time then this alarm is activated.
The Processor switches tasks by means of interrupts. This alarm is activated when the processor receives unintended
interrupts.
If the Source breaker is energized, and the source NLIB indicates a Source under voltage condition then this alarm is
declared.
The field thermal model when enabled, checks the field current with time and declares an alarm if the current has
exceeded its time limit.
The drive remote reference will have value between 4 to 20 mA. If the reference falls below a value of 4 mA then this
alarm is activated.
During the drive operation in Self-commutation mode, if the difference between the Speed reference and the Speed
feedback to the Speed regulator exceeds the set parameter “SRETOL” for a time settable by “SQTMR5” then an alarm is
declared.
A ground fault detector circuit is part of the NSFF Card on the SEM rack. This circuit detects grounds, which may occur
at the output of the Excitation module. This alarm is annunciated whenever this circuit is activated.
STATUS MESSAGES: -
To accommodate drives which run multiple motors of different ratings a tune up variable “MOTSEL” is
available. (a set of drive constants for every motor is stored separately ).
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Rev.04
Annexure-4: Procedure for conducting Crowbar test with other channel in
service in 12 Pulse drives
Crowbar test can be conducted on either Master or Slave channel with the other channel running.
On the channel on which crowbar test is to be done remove the following wires:
e. Remove and put insulation tape on wires. Connect wires back in the same TB after
finishing Crowbar test.
f. Ensure Load side Breaker/Contactor does not close by switching OFF supply in
Breaker/Contactor. Short MISOL input at IOMA TB4/05 and TB4/06 Sht 1BD/2BD
grid 21. Remove this short after Crowbar test.
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Rev.04
a) Rack out the Source 6.6kV/11kV breaker for the channel which is to be back-charged.
c) Short IOMA TB8/05 & TB8/06 Sht 1BJ/2BJ grid 23 momentarily. The load side
Breaker/Contactor closes and stays closed.
d) Motor voltage feedback is now available on NSFC load and Motor flux on NLIB Load.
e) Trip Output Breaker/Contactor by momentarily shorting IOMA TB8/07 and TB8/08 Sht
1BJ/2BJ grid 29.
The load side Breaker/Contactor opens.
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R05
Annexure-6: Procedure for Conducting Exciter test on one channel in 12 Pulse
drives with the other channel in service
Exciter Test can be conducted on either MASTER or SLAVE channel with the other channel
running by connecting a dummy load consisting of Lamps and Resistors at the output of Exciter
bridge.
In the channel on which Exciter test is to be done, remove the following wires:
a. IOMA TB5/09 Other channel running Formatted: Indent: First line: 0 cm,
Outline numbered + Level: 2 +
IOMA TB5/10 Sht 1BD/2BD grid 61 Numbering Style: a, b, c, … + Start at:
1 + Alignment: Left + Aligned at: 1.27
cm + Tab after: 1.9 cm + Indent at:
1.9 cm
b. IOMA TB7/10 Current reference to other channel
Formatted: Indent: First line: 0 cm,
IOMA TB7/11 Sht 1BF/2BF grid 55 Outline numbered + Level: 2 +
Numbering Style: a, b, c, … + Start at:
1 + Alignment: Left + Aligned at: 1.27
cm + Tab after: 1.9 cm + Indent at:
c. IOMA TB2/01 This channel running 1.9 cm
IOMA TB2/02 Sht 1BG/2BG grid 51 Formatted: Indent: First line: 0 cm,
Outline numbered + Level: 2 +
Numbering Style: a, b, c, … + Start at:
1 + Alignment: Left + Aligned at: 1.27
d. IOMA TB7/16 Current reference into this channel cm + Tab after: 1.9 cm + Indent at:
IOMA TB7/17 Sht 1BF/2BF grid 67 1.9 cm
Formatted: Indent: First line: 0 cm,
Outline numbered + Level: 2 +
e. Remove and put insulation tape on cables R,Y,B at the output of field exciter Numbering Style: a, b, c, … + Start at:
and also in wires (a) to (d) above. 1 + Alignment: Left + Aligned at: 1.27
cm + Tab after: 1.9 cm + Indent at:
1.9 cm
Connect the dummy load to Exciter bridge output. Perform Exciter test.
Connect the cables on the Exciter and wires on the IOMA TBs back in the same positions
before removal. Extreme care to be exercised while doing this test. Switch OFF circuit breakers and
power supplies whenever required.
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