NXG Fault Reference V4.0 - A1A19000864 PDF [PDF]

Zitiervorschau

FAULT REFERENCE FOR

HARMONY NXG

Manual Number: A1A19000864 Version 4.0 August 2009

CONFIDENTIAL FOR INTERNAL COMPANY USE ONLY!

Siemens Energy & Automation, Inc. Large Drives A

500 Hunt Valley Road, New Kensington, PA, USA, 15068 Phone: 724-339-9500 Customer Support Phone: Fax: 724-339-9562 Customer Support Web: Web: www.siemens.com Customer Support E-mail:

1-800-333-7421 (24-hours) www.siemens.com/automation/support-request [email protected]

For technical assistance and Field Service emergency support in the area nearest to you, please call the s 1.800.333.7421 toll-free number.

Version History

Version 1.0 (original) Version 2.0 (12258) Version 3.0 (13495) Version 4.0 (13925)

April 2004 June 2007 May 2009 August 2009

© 2009 by s. No portion of this document may be reproduced either mechanically or electronically without the prior consent of s LD A

Fault Reference for Harmony NXG

Table of Contents

Table of Contents Chapter 1: Input Line Disturbance ..............................................................................1-1 Medium Voltage Low ..........................................................................................1-1 Line Over Voltage ................................................................................................1-3 Input Phase Imbalance..........................................................................................1-5 Input One Cycle....................................................................................................1-7 Input Ground ........................................................................................................1-8 Input Phase Loss...................................................................................................1-9 Excessive Drive Losses ......................................................................................1-11 Implementation ...........................................................................................1-14 Inverse Time Curve.....................................................................................1-14 Internal Threshold .......................................................................................1-15 Scaling of Input and Output Voltages and Currents ...................................1-15 Current Scaler Adjustment in Harmony Drives with NXG Control ...........1-15 Voltage Scaler Adjustment in Harmony Drives with NXG Control...........1-16 Precharge Fault (Types 1 - 3 precharge) ............................................................1-18 Precharge Fault (Type 5 and 6 precharge) .........................................................1-19 Precharge Breaker Opened Alarm (Type 5 and 6 precharge) ............................1-21 Precharge Contactor Alarm ................................................................................1-22 Main Contactor Fault - Precharge ......................................................................1-23 Input Freq/Phasing Alarm ..................................................................................1-25 Input Protection Fault.........................................................................................1-26 Chapter 2: Input Transformer Temperature Related................................................2-1 Transformer Over Temperature............................................................................2-1 Input Reactor Temperature Related .....................................................................2-2 Chapter 3: Power Cell Related......................................................................................3-1 Cell Fault ..............................................................................................................3-1 Cell Over Temperature.........................................................................................3-2 Cap Share .............................................................................................................3-4 Link Fault .............................................................................................................3-6 Power Fuse Blown................................................................................................3-7 Control Fuse Blown..............................................................................................3-8 Control Power.......................................................................................................3-9

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IGBT Out of Saturation ..................................................................................... 3-10 DC Bus............................................................................................................... 3-11 Cell Communication Failure.............................................................................. 3-13 Output Fuse Blown ............................................................................................ 3-14 Blocking Test Failed .......................................................................................... 3-15 Switching Test Failed ........................................................................................ 3-17 Cell Fault / Modulator........................................................................................ 3-19 Bad Cell Data..................................................................................................... 3-20 Cell Configuration Fault .................................................................................... 3-21 Cell Alarm.......................................................................................................... 3-22 Cell Differential Temperature............................................................................ 3-23 Precharge Fault .................................................................................................. 3-24 Device Alarm ..................................................................................................... 3-25 DC Bus Discharge Alarm .................................................................................. 3-26 Device Failure.................................................................................................... 3-27 Six-Step Cell Initialization Fault ....................................................................... 3-28 Chapter 4: AFE Cell Related ........................................................................................ 4-1 AFE Over-current ................................................................................................ 4-1 AFE IGBT Out of Saturation............................................................................... 4-3 AFE Current Deviation ........................................................................................ 4-4 AFE Loss of Lock................................................................................................ 4-6 Left Sensor Loss .................................................................................................. 4-7 Inlet Sensor Loss.................................................................................................. 4-8 Outlet Sensor Loss ............................................................................................... 4-9 Air Temperature Warning.................................................................................. 4-10 Over Temperature Switch .................................................................................. 4-11 ADC Fail............................................................................................................ 4-12 AFE Configuration ............................................................................................ 4-13 AFE Will Not Run ............................................................................................. 4-14 Cell Protect Fault ............................................................................................... 4-16 Cell AFE Not Ready Alarm............................................................................... 4-17

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Chapter 5: Cell Bypass Related .................................................................................... 5-1 Cell Bypass Communication Failure .................................................................. 5-1 Cell Bypass Communication Alarm .................................................................... 5-2 Cell Bypass Acknowledge Fault.......................................................................... 5-3 Cell Bypass Link Fault ........................................................................................ 5-4 Cell Bypass Link Alarm ...................................................................................... 5-5 Bypass Verify Failed ........................................................................................... 5-6 Bypass Acknowledge Failed................................................................................ 5-7 Bypass Available Warning .................................................................................. 5-8 Cell Bypass Fault ................................................................................................. 5-9 Bypass Hardware Alarm .................................................................................... 5-10 Chapter 6: Motor/Output Related ............................................................................... 6-1 Over Speed........................................................................................................... 6-1 Under Load .......................................................................................................... 6-2 Motor Thermal Overload ..................................................................................... 6-3 Constant Mode.............................................................................................. 6-4 Inverse-time Modes ...................................................................................... 6-5 Inverse time with speed derating .................................................................. 6-7 Output Phase Imbalance .................................................................................... 6-10 Output Phase Open ............................................................................................ 6-11 Output Ground Fault .......................................................................................... 6-12 Instantaneous Over Current ............................................................................... 6-14 Motor Over Voltage........................................................................................... 6-15 Failed To Magnetize--Induction Motors............................................................ 6-17 Loss of Field Current--Synchronous Motors ..................................................... 6-18 Field Exciter Fault ............................................................................................. 6-19 Minimum Speed Trip......................................................................................... 6-20 In Torque Limit.................................................................................................. 6-21 In Torque Limit Rollback .................................................................................. 6-22 Pole Slip - SMDC .............................................................................................. 6-23 Motor Pull-out - PMM ...................................................................................... 6-24 Chapter 7: Low Voltage Power Supply Related ......................................................... 7-1 Power Supply ....................................................................................................... 7-1 Hall Effect Power Supply .................................................................................... 7-2

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Chapter 8: System I/O Related..................................................................................... 8-1 Wago Communication ......................................................................................... 8-1 Wago Internal Errors ........................................................................................... 8-2 Wago Configuration ............................................................................................ 8-3 Loss of Signal ...................................................................................................... 8-4 Chapter 9: Synch Transfer Related ............................................................................. 9-1 Phase Sequence.................................................................................................... 9-1 Up Transfer Failed ............................................................................................... 9-2 Down Transfer Failed .......................................................................................... 9-3 Chapter 10: User Defined Faults/Alarms .................................................................. 10-1 User Defined Faults/Alarms .............................................................................. 10-1 Chapter 11: System Related........................................................................................ 11-1 Menu Initialization Fault ................................................................................... 11-1 CPU Over Temperature ..................................................................................... 11-2 A/D Hardware.................................................................................................... 11-3 Configuration File Write Alarm ........................................................................ 11-4 Configuration File Read Error ........................................................................... 11-5 Cell Count Mismatch ......................................................................................... 11-6 System Program ................................................................................................. 11-7 Encoder Loss...................................................................................................... 11-8 Carrier Frequency Set Too Low ........................................................................ 11-9 Back EMF Timeout ......................................................................................... 11-10 Chapter 12: Modulator Related ................................................................................. 12-1 Modulator Watchdog ......................................................................................... 12-1 Loss of Drive Enable ......................................................................................... 12-3 Modulator Board Fault....................................................................................... 12-4 Modulator Configuration ................................................................................... 12-5 Weak Battery ..................................................................................................... 12-6 Chapter 13: External Serial Communication Related ............................................. 13-1 Keypad Communication .................................................................................... 13-1 Keypad Communication Loss............................................................................ 13-2 Network Communication................................................................................... 13-3 Tool Communication ......................................................................................... 13-4

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Chapter 14: Cooling Related ...................................................................................... 14-1 Pump Failures .................................................................................................... 14-1 Coolant Conductivity ......................................................................................... 14-2 Inlet Water Temperature .................................................................................... 14-3 Cell Water Temperature..................................................................................... 14-4 Low Water Level ............................................................................................... 14-5 Low Water Flow ................................................................................................ 14-6 HEX Fan ............................................................................................................ 14-7 Blowers .............................................................................................................. 14-8 Clogged Filters................................................................................................... 14-9 Transformer Coolant Over Temperature ......................................................... 14-10 NOTES ........................................................................................................................... N-1

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Fault Reference for Harmony NXG

Input Line Disturbance

1

CHAPTER

1

Input Line Disturbance

1.1 Medium Voltage Low Fault Name — Medium Voltage Low

Displayed Message

Medium Voltage Low Medium Voltage Low 1 Medium Voltage Low 2 The input voltage faults/alarms are determined as follows. The three input phases are measured via a voltage attenuator. The attenuating resistors are chosen based on the required input voltage. The attenuated three-phase input voltages are sampled at the fast loop rate of 3000 to 6000 samples per second. The square of these scaled samples is then averaged over one input cycle. For a sixty hertz input system with a 6000 Hz fast loop, this means 1 / 60 * 6000 or 100 samples. The square root of the sum of these averaged input voltage squares determine the RMS value of the input voltage. This calculated RMS value is then filtered using a 1.4 Hz low pass filter. The resultant value is known as Erms. Erms is then checked by the fault system at 300 Hz.

Description of Fault/Alarm

If, when the fault system checks the value of Erms, it is less than 55% and the drive is not running, a “Medium voltage Low” fault is generated. If the drive is running and a cell fault occurs, and the value of Erms is less than 55%, a “Medium voltage Low” fault is generated. This is done to allow ride-through and to mask the resultant cell faults from the low medium voltage. In version 2.5, this has been changed so that if the value of Erms is less than 55%, a “Medium voltage Low” fault is not generated until a cell fault occurs, whether the drive is running or not. In version 3.2, this was changed so that a “Medium Voltage Low” fault is only generated when the drive is running and the above conditions are met. If the drive is not running, no fault is generated. If the value of Erms is under 90% for an entire alarm hysteresis period, then a “Medium voltage low 1” alarm is issued. If Erms goes above 90% for an entire alarm hysteresis period, the alarm is canceled. This alarm must be enabled by SOP flag. If the value of Erms is under 70% for an entire alarm hysteresis period, then a “Medium voltage low 2” alarm is issued. If Erms goes above 70% for an entire alarm hysteresis period, the alarm is canceled. Note: This threshold is set at 80% for AFE (4Q) cells.

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Medium Voltage Low

1 Associated Parameters

The sampled voltages are scaled based on the menu parameter ID 3040 “Input voltage scaler.” This is not a simple scaling operation since there are variations in the scaling due to the available discrete values for the attenuator resistors. For this reason, the software prior to version 2.5 has stored in it a table of expected values for the attenuator resistors to be used for each available voltage. Because we never know if the specified attenuator resistors will change in the future or if new voltages will be needed, version 2.5, rather than use a table of stored values, adds an additional parameter ID 3045 “Input Attenuator Sum” in which the exact value of resistors must be specified.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Input Voltage Attenuators

Variables in Data Source

Attenuation resistors

SOP Flags that affect Operation

“MediumVoltageLowAlarm1En_O” enables the Medium Voltage Low alarm #1. Medium Voltage Low alarm #2 is enabled with the same flag.

System Location of Data Source

Resistors are located in the input/output cabinet of the drive

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

Replace board(s) Evaluate wiring and grounding practices.

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Fault Reference for Harmony NXG

Input Line Disturbance

1.2 Line Over Voltage

1

Fault Name — Line Over Voltage

Displayed Message

Line over voltage Line over voltage 1 Line over voltage 2 The input voltage faults/alarms are determined as follows: The three input phases are measured via a voltage attenuator. The attenuating resistors are chosen based on the required input voltage. The attenuated three phase input voltages are sampled at the fast loop rate of 3000 to 6000 samples per second. The square of these scaled samples is then averaged over one input cycle. For a sixty hertz input system with a 6000 Hz fast loop, this means 1 / 60 * 6000 or 100 samples. The square root of the sum of these averaged input voltage squares determines the RMS value of the input voltage. This calculated RMS value is then filtered using a 1.4 Hz low pass filter. The resultant value is known as Erms. Erms is then checked by the fault system at 300 Hz.

Description of Fault/Alarm

If, when the fault system checks the value of Erms it is greater than 120%, a “Line over voltage” fault is generated. In version 2.5, a ½ second hysteresis was added to this fault along with the ability to set this condition to be an alarm by setting a flag in the SOP. If the value of Erms is above 110% for an entire alarm hysteresis period, then a “Line over voltage 1” alarm is issued. If Erms goes below 110% for an entire alarm hysteresis period, the alarm is canceled. This alarm must be enabled by SOP flag. If the value of Erms is above 115% for an entire alarm hysteresis period, then a “Line over voltage 2” alarm is issued. If Erms goes below 115% for an entire alarm hysteresis period, the alarm is canceled. This alarm must be enabled by SOP flag.

Associated Parameters

The sampled voltages are scaled based on the menu parameter ID 3040 “Input voltage scaler.” This is not a simple scaling operation since there are variations in the scaling due to the available discrete values for the attenuator resistors. For this reason the software, prior to version 2.5, has stored in it a table of expected values for the attenuator resistors to be used for each available voltage. Because we never know if the specified attenuator resistors will change in the future or if new voltages will be needed, version 2.5, rather than use a table of stored values, adds an additional parameter ID 3045 “Input Attenuator Sum” in which the exact value of resistors must be specified.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

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Input Line Disturbance

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Fault Reference for Harmony NXG

Fault Name — Line Over Voltage Data Source

Input Voltage Attenuators

Variables in Data Source

Attenuation resistors

SOP Flags that affect Operation

“LineOverVoltage1En_O” enables the line over voltage alarm #1. “LineOverVoltage2En_O” enables the line over voltage alarm #2. Version 2.5 and above: “LineOverVoltageFaultWn_O” sets the line over voltage Trip as an alarm.

System Location of Data Source

Voltage Attenuators are located in the input/output cabinet of the drive

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

Replace board(s) Evaluate wiring and grounding practices.

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Fault Reference for Harmony NXG

Input Line Disturbance

1.3 Input Phase Imbalance

1

Fault Name — Input Phase Imbalance Displayed Message

Input Phase Imbalance

Description of Fault/Alarm

This is a feature that monitors the drive input (line) current imbalance. If the calculated imbalance exceeds the setting in the Phase Imbalance Limit parameter (Menu ID 7105 in the Drive Protection Menu), this may indicate a neutral current path or ground fault condition, or may be due to shorted windings in the transformer.

Associated Parameters

Menu ID 7105 located in the Drive Protection Menu. This parameter is a threshold for determining the trip point for the Alarm/Fault. The value has a range of 0 to 100%. The default is 40%. The CT Secondary Turns Parameter (Menu ID 3035) can also have an adverse effect if it does not match the CT used in the Drive.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The Current Transformers on Phase B and C of the Drive Input (Line) current.

Variables in Data Source

Current Transformers, wiring from the CTs to the Signal Conditioning Board, Burden Resistors located on the Signal Conditioning Board, System Interface Board, and CT Secondary Turns Parameter (Menu ID 3035).

SOP Flags that affect Operation

“InputPhaseImbalanceWn_O” sets “input phase imbalance” as an alarm. The SOP flag “InputPhaseImbalance_I” is set when the conditions are met, indicating an Input Phase Imbalance.

System Location of Data Source

The CTs are typically located in the same cabinet as the Input Transformer. The location of the Burden Resistors is at the terminal block of the Signal Conditioning Board (typically mounted on a DIN rail). The System Interface Board is located within the NXG chassis and is an ISA board plugged into the NXG ISA backplane.

Potential Issues that affect the Fault Performance

The CT Secondary Turns Parameter (Menu ID 3035) can also have an adverse effect if it does not match the CT used in the Drive. The Burden resistors located on the Signal Conditioning Board must match the rated value for the CT and Drive rating.

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Input Phase Imbalance

1

Corrective Action for Deficiencies

This may indicate a neutral current path or ground fault condition, or may be due to shorted windings in the transformer. The source may also be the CTs, Signal Conditioning Board, Burden Resistors, System Interface Board, or incorrect menu settings (see above). Verify proper symmetry of the input voltages and currents on test points of the System Interface Board VIA/TP1, VIB/TP2, VIC/TP3, IIB/TP12 and IIC/TP13.

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Fault Reference for Harmony NXG

Input Line Disturbance

1.4 Input One Cycle

1

Fault Name — Input One Cycle Displayed Message

Input One Cycle

Description of Fault/Alarm

Detects the condition of excessive reactive current in the input transformer. This is possibly an indication that one or more of the input transformer secondaries may be shorted or inrush current is too high, causing nuisance trips. This fault creates an input protection fault, and with dedicated I/O, will open the input breaker automatically. Refer to Input Protection Fault Section 1.14 for details.

Associated Parameters

Xformer protection const (Menu ID 7100) is a constant that is related to the thermal gain of the transformer. This is set at the factory and should not be adjusted. The 1 Cyc Protect integ gain (Menu ID 7080) and 1 Cycle Protect Limit (Menu ID 7081) are set at the factory and should not be adjusted.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The data source is the Input Current measurements from Phase B and C of the Current Transformers.

Variables in Data Source

It should integrate to one under normal conditions and integrate toward zero when the reactive currents get too high.

SOP Flags that affect Operation

“InputOneCycle_I” is set when this condition exists. “InputOneCycleWn_O” sets input one cycle detection to an alarm.

System Location of Data Source

The CTs are typically located in the same cabinet as the Input Transformer. The location of the Burden Resistors is at the terminal block of the Signal Conditioning Board (typically mounted on a DIN rail). The System Interface Board is located within the NXG chassis and is an ISA board plugged into the NXG ISA back-plane.

Potential Issues that affect the Fault Performance

If the trips are related to inrush current; reduce the 1 Cyc Protect integ gain (Menu ID 7080) and the 1 Cycle Protect Limit (Menu ID 7081) to avoid nuisance trips

Corrective Action for Deficiencies

Remove medium voltage and visually inspect all the cells and their connections to the transformer secondary. If the trips are related to inrush current, reduce the 1 Cyc Protect integ gain (Menu ID 7080) and the 1 Cycle Protect Limit (Menu ID 7081) to avoid nuisance trips.

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Input Line Disturbance

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Fault Reference for Harmony NXG

1.5 Input Ground Fault Name — Input Ground Displayed Message

Input Ground

Description of Fault/Alarm

Determines the average voltage from neutral point to ground. Its purpose is to protect the transformer in case one of the phases is shorted to ground. If the average voltage is greater than a menu settable trip point, the alarm is asserted.

Associated Parameters

Ground Fault Limit (Menu ID = 7106) sets the threshold of voltage for Ground Fault Detection. Ground Fault Time Const (Menu ID = 7107) sets the filter time constant for smoothing the ripple and delaying the response of the Ground Fault Detection. (Only in version 2.6 or greater.)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Input Voltage Attenuators

Variables in Data Source

Attenuation resistors

SOP Flags that affect Operation

“InputGroundFault_I” indicates a input ground fault alarm on the drive input line.

System Location of Data Source

Voltage Attenuators are located in input/output cabinet of drive.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

Replace board(s) Evaluate wiring and grounding practices.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Input Line Disturbance

1.6 Input Phase Loss

1

Fault Name — Input Phase Loss Displayed Message

Input Phase Loss The Input phase loss is an alarm that indicates that one of the line input phases to the drive may not be available. A calculated value of imbalance voltage based on measurements from the output voltage attenuators is compared to a fixed threshold of 30%. If this value exceeds this threshold, an alarm is asserted. The imbalance voltage is determined by the difference of the largest and smallest phase voltage divided by the average.

Description of Fault/Alarm

The drive begins a power rollback beginning at an imbalance of 10%, and continues linearly until maximum input power is limited to 40% at the voltage imbalance of 30%. This maximum input power level is used to clamp the output total current limit based on the output voltage. The maximum total current level in turn, is used to calculate the maximum torque current allowed (by vector subtraction of the magnetizing current) in the form of a torque limit to the speed regulator. The speed regulator uses the lowest of the many torque limits calculated for different conditions, and if this limit is the lowest, could put the drive into speed rollback.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Input Voltage Attenuators

Variables in Data Source

Attenuation resistors

SOP Flags that affect Operation

“InputPhaseLoss_I” indicates the drive has lost an input phase.

System Location of Data Source

Voltage Attenuators are located in input/output cabinet of drive.

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Input Phase Loss

1 Potential Issues that affect the Fault Performance

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

Check for proper scaling of input and output voltages Check input fuses and disconnects Corrective Action for Deficiencies

Check voltage attenuators Replace board(s) Evaluate wiring

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Fault Reference for Harmony NXG

Input Line Disturbance

1.7 Excessive Drive Losses

1

Fault Name — Excessive Drive Losses Displayed Message

Description of Fault/Alarm

Excessive Drive Losses NXG Control utilizes input power and output power calculations to determine whether an internal fault has occurred in the power circuit of the VFD. Drive Power Loss is estimated as the difference between input power and output power. This quantity is continuously checked with a pre-defined threshold that is inverse time based. If the threshold is exceeded by design margin (as listed in the following figures), then the trip occurs in a defined time period after the event. This fault creates an input protection fault, and with dedicated I/O, will open the input breaker automatically. Refer to Input Protection Fault Section 1.14 for details. Since the Drive Losses calculation depends on input and output power calculations, it is important to make sure that the following parameters are set correctly: •

Drive Input and Output Rated Values (voltage and current IDs 2010, 2020, 2030, 2040).

•

Drive Input Scalers (IDs 3030, 3040): These parameters are used to adjust the input voltage and current measurements measured by the control. Default values are 1.0 for both scalers.

•

Input CT Turns (ID 3045): This parameter represents the secondary turns on the input CT with 5 turns on the primary side. This parameter can be obtained from the VFD drawing that shows input side connections.

•

Output Scalers (IDs 3440, 3450): These parameters are used to adjust the output voltage and current measurements measured by the control. Default values are 1.0 for both scalers.

•

Low Freq Wo (ID 3060): This parameter should match the version of System Interface Board, as this parameter affects the phase-shift introduced in the measured voltage signals (and hence affects the output power calculation). This parameter should be set to: 12.566 rad/s for the 461F53.00 version of System Interface Board or 37.859 rad/s for the 461F53.02 version of System Interface Board.

Associated Parameters

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Excessive Drive Losses

1 Data Source

Input and Output Voltage Attenuators. Input Current Transducers (CT) and Output Hall Effect sensors.

Variables in Data Source

Attenuation resistors, incorrectly sized CTs, and/or Burden Resistors, incorrect voltage source from Hall Effect Power Supplies.

SOP Flags that affect Operation

“ExcessiveDriveLossesWn_O” sets excessive drive losses as an alarm.

System Location of Data Source

Voltage Attenuators are located in the input/output cabinet of the drive. Current Transducers are located with the input transformer cabinet. The Hall Effect Sensors are located in the Input/Output Cabinet. The Hall Effect Power supplies are located in the Control Cabinet. The following defines the proper method to use in determining drive ratings and establishes the proper value for the appropriate parameters. •

RATED INPUT VOLTAGE (ID 2010) Set according to input transformer primary voltage rating. Note: The input attenuator kit should always correspond to the rated primary voltage of the transformer.

•

RATED INPUT CURRENT (ID 2020) Set according to input transformer nameplate kVA rating as follows:

Rated Input Current = [(kVA rating) x (802)] / [(1.732) x (Rated nominal primary voltage) x (0.96) x (0.94)] Rated Input Current = [(kVA rating) / (Rated nominal primary voltage)] x [513.11] Example: Potential Issues that affect the Fault Performance

Input transformer nameplate reads 1250 kVA, 6600 V. Rated Input Current = [(1250) / (6600)] x [513.11] = 97.2 A •

RATED OUTPUT VOLTAGE (ID 2030) Set according to rating of the output attenuator kit. Note: This value is typically equal to or higher than the customer’s motor voltage rating.

•

RATED OUTPUT CURRENT (ID 2040) Set equal to the cell (output) current rating. Note: The output Hall Effects and burden resistors should be sized for the cell current rating.

General Note: The parameters discussed above are based on hardware used within the drive and on the design limits of drive components. These settings should not be changed in the field to match the conditions on the site unless hardware modifications have been made and approval from application engineering has been obtained.

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Fault Reference for Harmony NXG

Input Line Disturbance

Fault Name — Excessive Drive Losses A typical Harmony Drive has a full load efficiency in the range of 96.0 - 97.0%. It is at full load that the drive has maximum losses and hence it is this operating point that will be closest to the excessive losses threshold setting. If, during commissioning, the drive trips on an Excessive Drive Losses Fault, then the following steps may be followed to determine if the trip was a nuisance fault:

Corrective Action for Deficiencies

1.

Verify that the parameters listed above are correctly entered. Use VFD (project) drawings along with a visual inspection (if possible) to make the verification. A common error is made in entering the Output Current Rating. This menu entry should always be set equal to the Cell Current Rating.

2.

Run the drive to a speed-point at which measurable values of input and output, voltage and current are present.

3.

Use the table in the Startup Procedure chapter of the Harmony Manual to verify if the feedback signals on the System Interface Board (i.e. on test-points VMA, VMB, VMC, IMA, IMB, IMC, VIA, VIB, VIC, IIB and IIC) correspond to the values displayed by the drive.

4.

Manually verify that the Drive Losses are less than the threshold setting (for this type of drive and NXG software version) as listed in figure 1-1 and calculated in the following equations: Drive Losses = (Input Power - Output Power) (1) Trip Level = (Drive Losses - Input Threshold) (2) Input and Output Power can be read from the Keypad, ToolSuite or Debug Screen. In NXG software versions 2.50 and higher, the Drive Losses variable is available for display on the Keypad and ToolSuite.

5.

Increase speed (and load) to make sure that the Drive Losses are within the range of 2.5% - 4.5% of Rated Input Power (as defined in equation (1) above).

Note: Transformers rated above 5000 HP and those designed prior to summer of 2002 may have higher losses than those produced after July 2002. Drives with such units may have more than 3.5% losses at full load. Use of version 2.50 of NXG software will help if drive losses at full load are 5.0% or lower. If the measured system losses are believed to be higher than 5.0%, then discuss the issue with Application Engineering or Product Development. Comments

None

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Input Line Disturbance

1.7.1

Fault Reference for Harmony NXG

Implementation

1 Input Power

+

Drive Losses

∑

+

-

Output Power

∑

Trip Level

Inverse Time

Fault

-

Internal Input Threshold

Internal Threshold

= 3.5% in Idle State (for Liquid-Cooled Drives up to version 2.40) = 5.5% in Run State (for Liquid-Cooled Drives up to version 2.40) = 5.0% in Idle State (for Air-Cooled Drives up to version 2.40 and for all Drives for version 2.5) = 7.0% in Run State (for Air-Cooled Drives up to version 2.40 and for all Drives for version 2.5)

Figure 1-1: Block Diagram of Excessive Drive Losses Algorithm

1.7.2

Inverse Time Curve

Figure 1-2 shows the inverse time-to-trip curves as a function of Drive Losses. Each plot shows two curves - the first for Idle State and the second for Run State (slightly longer time to trip).For software versions 2.22 and lower, a fixed trip time of one second was used in lieu of the curves shown below.

Run State

Run State

Idle State

Idle State

Figure 1-2: Inverse time-to-trip curves as a function of Drive Losses

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

1.7.3

Input Line Disturbance

Internal Threshold

The internal threshold is a function of the rated drive input VA. Input VA is defined by the following parameters. •

Rated Input Voltage (2010) is the rated input voltage of the drive

•

Rated Input Current (2020) is the rated input current of the drive

For example, in Run State the internal threshold is given as: Internal Threshold (Watts) = 0.07 * Rated Drive Input VA =

* 1.7.4

0.07 * √3 * Rated Input Voltage * Rated Input Current

Note: For software versions 2.30 and 2.40, Air-Cooled and Liquid-Cooled Drives had different internal threshold settings. For versions 2.50 and higher, only one common set of threshold settings are used; these correspond to the settings for Air-Cooled Drives.

Scaling of Input and Output Voltages and Currents

Table 1-1 shows the scaling of drive input and output voltages and currents on the Signal Conditioning Board (versions 461F53.00 and 461F53.02). Full-scale values of these measured signals are scaled to drive rated values of voltage and current. Table 1-1: Scaling of drive input and output voltages and currents on the Signal Conditioning Board

Variable

Rated Value (rms) at Drive Terminals

Feedback Value Under Rated Conditions (Vpeak)

Feedback Value Under Rated Conditions (Vrms)

Input Current

Primary Current Rating of Input CT

5.0

3.54

Input Voltage

(Rated Input Voltage L-L) / 1.732

5.4

3.81

Output Current

Output Current Rating (≡ Cell Rating)

5.0

3.54

Output Voltage

(Rated Output Voltage L-L) / 1.732

5.4

3.81

Output Current Scaling: Cell current rating ≡ 3.54 Vrms Output Voltage Scaling: [(Rated output voltage L-L) / 1.732] * 1.414 ≡ 5.4 Vpeak 1.7.5

Current Scaler Adjustment in Harmony Drives with NXG Control

Summary: Current measurements are made on both the input and the output side of the Harmony Drive with NXG Control. CTs (or current transformers) are used on the input side while Hall Effect Transducers are used on the output side. In some drives, the current measurements may have an accuracy of less than 1% due to component tolerances. In such cases, the current scaler may be adjusted to obtain better than 1% accuracy on the measured currents. This document provides a procedure to estimate the value of input and output current scalers (ID 3030 and 3440). Adjustment of Current Scaler: When rated current is flowing (either on the input or output side), the expected voltage at the (corresponding) test point with NXG Control hardware is 3.536 volts rms, which is interpreted by the drive software as 1 PU. Any measured deviation from this nominal value can be compensated via the current scaler which is nominally set to 1.0.

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Input Line Disturbance

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Fault Reference for Harmony NXG

When a current equal to IMEASURED (in Amps rms) is flowing through the transducer, the current scaler can be adjusted to compensate for any current measurement error using the equation: Current scaler = 3.536 * IMEASURED / (VTP * IRATED) Where: Current scaler is the appropriate parameter for input or output 3.536 V is the nominal voltage on the test-point with rated current VTP is the measured value on the test-point with IMEASURED flowing through the transducer IRATED is the rated drive current (either on the input or output)

* 1.7.6

Note: IMEASURED (Amps rms) can be obtained using a current clamp or any similar measuring device.

Voltage Scaler Adjustment in Harmony Drives with NXG Control

Summary: Attenuator Resistors are used in Harmony Drives for scaling input and output side voltages. Two resistors are used to support the Medium Voltage (either on the input or the output). Since resistor values are available only as discrete values, the exact attenuation factor cannot be achieved for all voltage levels. In such cases, the voltage scaler may be adjusted to obtain better than 1% accuracy on the measured voltages. This document provides a procedure to estimate the value of input and output voltage scalers (ID 3040 and 3450).

*

Note: The input attenuator must be selected to match the input transformer nameplate rating. The output attenuator is typically selected to match the motor nameplate rating.

Adjustment of Voltage Scaler: The expected voltage at the test point with NXG Control hardware is 3.809 volts rms, which is interpreted by the drive software as 1 PU. Any measured deviation from this nominal value can be compensated via the voltage scaler, which is nominally set to 1.0. This adjustment is necessary for several reasons: first for tolerances in the chosen resistors, second for the use of standard values that do not match the calculation, and third for non-supported values of input voltages, which default to the 4160 V value. In any case, the voltage scaler (parameter ID 3040 for the input scaler and ID 3450 for the output scaler) can be adjusted to compensate for rated input voltage by the following equation: Voltage scaler = 3.809 / VTP

(3)

Where: Voltage scaler is the appropriate parameter for input or output 3.809 is the nominal voltage (rms) at rated voltage VTP is the measured value on the test point with rated voltage Where the voltage is not at nominal rated, or cannot be measured directly, and is not supported by the software, the voltage scaler can be approximated by substituting a calculated value based on the voltage divider formed by the selected resistor values. VTPC = Vmv * [√2 / √3] * [Rf / (R1 + R2 + Rf)]

(4)

Where: VTPC is the calculated nominal value expected for rated voltage and nominal resistor values Vmv is the nominal rated voltage

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Fault Reference for Harmony NXG

Input Line Disturbance

R1, R2 and Rf (all in Ω) are as defined in figure 1-3, which shows a simplified schematic of the attenuator circuit. Values for R1 and R2 are listed in the VFD project drawings.

Medium Voltage R1

R2 Voltage Test Point

Transorbs

Unity Gain Buffer

Rf

+

R1, R2 = Medium voltage resistors Rf = Effective value of feedback resistance

Figure 1-3: Simplified schematic of the attenuator circuit

*

Note: The voltage scaler should not be set based on the measured test point values if a second independent means does not exist to measure the voltage directly or indirectly. Doing so will provide erroneous feedback.

Software Supported Voltages: Software version 2.4 does the compensation for the voltages listed below by internally adjusting the voltage scaler using equations (3) and (4). If the rated voltage is not provided in one of the lists below, then use equations (3) and (4) to set the voltage scaler. In any case, the measured voltage at the voltage test point should be at a nominal 5.3864 at rated voltage. Output voltages supported directly in software version 2.4 (VL-L RMS): 2400, 3000, 3300, 3400, 4160, 4800, 6000, 6600, 6900, 7200, 8400, 10000, 11000, 12000, 12500, 13200, 13800, 22000 Input voltages supported directly in software version 2.4 (VL-L RMS): 2400, 3000, 3300, 3400, 4160, 4800, 6000, 6600, 6900, 7200, 8400, 10000, 11000, 12000, 12500, 13200, 13800, 22000

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Input Line Disturbance

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Fault Reference for Harmony NXG

1.8 Precharge Fault (Types 1 - 3 precharge) Fault Name — Precharge Fault Displayed Message

Precharge Fault This fault indicates that Precharge has been aborted or uncompleted. Precharge can be aborted or uncompleted due to the following reasons: 1.

The primary voltage does not build up to 90% of the rated within 30 seconds.

2.

PrechargeStartEnable_O” becomes false while precharge was in progress.

3.

Primary voltage exceeds 115% of the rated while precharge was in progress.

Description of Fault/Alarm

Associated Parameters

Parameter ID 2550: Cell Rated Voltage Parameter ID 7050: Transformer Tap Setting

Hysteresis or Delay

Faults have no delay or hysteresis

Data Source

Input Voltage Attenuators

Variables in Data Source

NXG breakout board Attenuation resistors “PrechargeFault_I” indicates precharge fault has occurred.

SOP Flags that affect Operation

System Location of Data Source

Potential Issues that affect the Fault Performance Corrective Action for Deficiencies

“PrechargeStartEnable_O” starts precharge. Incorrectly removed will cause fault. NXG breakout board is located in the control tub. Attenuation resistors are located in the input cabinet of the drive. •

Incorrect the attenuation resistor values for required input voltage.

•

Incorrect transformer tap setting.

Replace breakout board Evaluate wiring

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Fault Reference for Harmony NXG

Input Line Disturbance

1.9 Precharge Fault (Type 5 and 6 precharge)

1

Fault Name — Precharge Fault Displayed Message

Precharge Fault This fault indicates that Precharge has been aborted or is incomplete. Precharge can be aborted or incomplete due to the following reasons:

Description of Fault/Alarm

1.

Precharge contactors M2, M3, M4 and main input line contactor M1 fail to act as commanded (a valid contactor acknowledge signal is not received).

2.

M4 is not closed and M3 open within 30 seconds. The voltage may never have reached 100%, or the contactor acknowledge never came back.

3.

MainInputVoltageDisable_O becomes true while precharge is in progress. This will result in a User Abort.

4.

Input protection fault occurs while precharge is in progress. This could be from the cell or from the system.

5.

Primary voltage exceeds 115% of the rated input voltage (including tap setting) while precharge is in progress.

6.

M1 closes but no MV is detected.

7.

Low DC bus is detected while waiting for M1 close acknowledge.

8.

Medium Voltage Fault occurs while waiting for M1 to close.

9.

The precharge request, StartCellPrecharge_O, is removed prior to precharge completion.

Parameter ID 2550: Cell Rated Voltage Parameter ID 2635: Precharge Enable Associated Parameters

Parameter ID 2637: Precharge Service Mode Parameter ID 2638: Precharge Service Start Parameter ID 7050: Transformer Tap Setting

Hysteresis or Delay

Faults have no delay or hysteresis

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Precharge Fault

1

The different reasons listed above in the description of fault/alarm have different sources: Data Source

Reason 1, 2, 6: Precharge contactors M2, M3, M4 and main input line contactor M1; Reason 2, 5, 8: Input Voltage Attenuators; Reason 4, 7: Cell control board Reason 9: SOP logic

Variables in Data Source

Reason 1, 6: NXG breakout board Reason 2, 5, 8: Attenuation resistors

SOP Flags that affect Operation

“PrechargeFault_I” indicates precharge fault has occurred.

System Location of Data Source

NXG breakout board is located in the control rack. Attenuation resistors are located in the input cabinet of the drive. The cell control board is embedded within the structure of the power cell. The fault data is transmitted back to the control via the serial data stream across the fiber optic link.

Potential Issues that affect the Fault Performance

•

Wiring from the breakout board to the contactors.

•

The breakout board is broken which results in reporting incorrect status of the contactors.

•

Incorrect attenuation resistor values for required input voltage

•

Defective cell control board

•

Settings for input side could cause input protection fault

Replace board(s) Corrective Action for Deficiencies

Evaluate wiring Check Input settings

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Fault Reference for Harmony NXG

Input Line Disturbance

1.10 Precharge Breaker Opened Alarm (Type 5 and 6 precharge)

1

Fault Name — Precharge Breaker Open Displayed Message

PreChrg Breaker Opened This fault indicates that Precharge breaker was opened by type 5 and 6 precharge process due to the following fault conditions:

Description of Fault/Alarm

1.

Precharge contactors M2, M3, and M4 failed to open;

2.

The primary voltage exceeded 110% of the rated while precharge was in progress.

3.

An input protection fault was detected during precharge.

Parameter ID 2550: Cell rated voltage Associated Parameters

Parameter ID 2635: Precharge Enable Parameter ID 2637: Precharge Service Mode Parameter ID 2638: Precharge Service Start

Hysteresis or Delay

Faults have no delay or hysteresis

Data Source

Precharge contactors M2, M3, M4 and Input Voltage Attenuators

Variables in Data Source

NXG breakout board and attenuation resistors

SOP Flags that affect Operation

“PrechargeBreakerOpened_I” indicates a precharge breaker has opened.

System Location of Data Source

NXG breakout board is located in the control tub. Attenuation resistors are located in the input cabinet of the drive.

Potential Issues that affect the Fault Performance

•

Wiring from the breakout board to the contactors.

•

The breakout board is broken, which results in reporting incorrect status of the contactors.

•

Incorrect attenuation resistor values for required input voltage.

Replace board(s) Corrective Action for Deficiencies

Evaluate wiring Check input protection fault and correct

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Fault Reference for Harmony NXG

1.11 Precharge Contactor Alarm Fault Name — Precharge Contactor Alarm Displayed Message

PreChrg Contactor Alarm Applies only to type 5 and type 6 precharge. During precharge, if any precharge contactor does not respond as directed, this alarm is issued along with a precharge fault.

Description of Fault/Alarm

After precharge complete, the command to the precharge contactor is compared to feedback (acknowledge) and if they do not agree, an alarm is issued. This deals with precharge contactors only (M2, M3 and M4), and not to the main contactor (M1).

Associated Parameters

None (Type 5 or 6 must be selected and the 750V AP or 750V AP 4Q cell must be selected in order to get this alarm).

Hysteresis or Delay

During precharge, a one second delay is allowed for precharge contactor travel. After precharge, only a half second hysteresis is allowed to trigger the alarm.

Data Source

Contactor auxiliary contacts, system I/O board

Variables in Data Source

Wiring and proper operation of contactors; system I/O and breakout board.

SOP Flags that affect Operation

None

System Location of Data Source

Potential Issues that affect the Fault Performance

Precharge cabinet for contactors Control cabinet for system I/O and breakout board •

No power to contactor coils

•

Incorrect wiring of contactors and auxiliary contacts

•

Defective breakout board

•

Loose or defective cable between breakout board and system I/O board

•

Defective system I/O board

Check for control power to contactors Check wiring; check connections to breakout board Corrective Action for Deficiencies

Check cable connection between breakout board and System I/O board Replace breakout board Replace system I/O board

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Fault Reference for Harmony NXG

Input Line Disturbance

1.12 Main Contactor Fault - Precharge

1

Fault Name — Main Contactor Fault - Precharge Displayed Message

PreChrg M1 Contactor Flt Applies only to type 5 and type 6 precharge. This fault aborts precharge and the message is issued in lieu of the precharge fault. Causes:

Description of Fault/Alarm

Associated Parameters

Hysteresis or Delay

•

During precharge, the main contactor (M1) fails to operate as commanded, or takes too long to acknowledge. (Too long for type 6 is 5 seconds. Too long for type 5 is when the cell DC bus voltage is low.)

•

If not in maintenance mode, the MV Disable flag (MainInputVoltageDisable_O) is set true by the SOP, it prevents M1 from closing.

•

If M1 is reported as closed and no medium voltage (MV) is present, or the level is below 90%, or M1 is not yet closed and a Low Cell DC bus condition is detected, this fault is issued.

•

This can also occur in type 5 if the M4 contactor is open, and M1 commanded closed and no acknowledge appears but MV is detected- after a three second delay

None (Type 5 or 6 must be selected and the 750V AP or 750V AP 4Q cell must be selected in order to get this alarm). For Type 5, any condition that can cause the fault will trip immediately with the exception of the presence of MV with no M1 contactor acknowledge- which has a three second delay. For Type 6, the M1 acknowledge after command is allowed only 5 seconds before tripping. Contactor Auxiliary

Data Source

Breakout board System I/O board

Variables in Data Source

Wiring and proper operation of contactors; system I/O and breakout board.

SOP Flags that affect Operation

MainInputVoltageDisable_O - setting will cause this fault.

System Location of Data Source

Customer side (external to drive) Control cabinet for connections

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Input Line Disturbance

Fault Reference for Harmony NXG

Fault Name — Main Contactor Fault - Precharge

1

Potential Issues that affect the Fault Performance

•

No power to contactor coil

•

Incorrect wiring of contactor and auxiliary contact, and connection with breakout board

•

Defective breakout board

•

Loose or defective cable between breakout board and system I/O board

•

Defective system I/O board

Check for control power to contactor (customer side) Check wiring; check connections to breakout board Corrective Action for Deficiencies

Check cable connection between breakout board and System I/O board Replace breakout board Replace system I/O board

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Fault Reference for Harmony NXG

Input Line Disturbance

1.13 Input Freq/Phasing Alarm

1

Fault Name — Input Freq/Phasing Displayed Message

Input Freq/Phasing

Description of Fault/Alarm

AFE Input frequency out of range or the rotation of a cell’s voltage is opposite that of the transformer primary voltage as sensed by the DCR. This alarm is sensed during power-up. This alarm indicates the AFE portion of the drive will not function properly.

Associated Parameters

None

Hysteresis or Delay

Medium voltage detection is delayed by 0.4 seconds, an indeterminate amount of time is added for the input voltage PLL to lock, 3 seconds delay is added for the cell PLLs to lock.

Data Source

The cell input frequency comes from the gate driver board and cell control board. The Medium Voltage feedback is from the input attenuators via the signal conditioning board.

Variables in Data Source

None

SOP Flags that affect Operation

“InputFrequencyAlarm_I” indicates an input frequency / phasing alarm. InputFrequencyAlarmEn_O enables or disables this alarm.

System Location of Data Source

The voltage attenuators are in the input/output cabinet of the drive. The cell control board and gate driver boards are integral parts of each power cell located in the power control cabinets.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Faulty cell control board, faulty gate driver board (cell input frequency).

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board (Drive input frequency).

Replace defective board(s) Evaluate wiring.

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Fault Reference for Harmony NXG

1.14 Input Protection Fault Fault Name — Input Protection Fault Displayed Message

Input Protection Fault This fault will only occur if the system I/O board is present and a cell type that uses the advanced protocol is installed. This fault will cause the input line circuit breaker to open. In WCIII and GenIV Drives, this is done internally to the code via dedicated I/O on the Standard I/O and Break-out boards. The following conditions can result in this fault:

Description of Fault/Alarm

1.

Cell Control board detects arc occurred by cell detection hardware;

2.

Cell Control board detects bus over voltage while cell is in bypass;

3.

Cell Control board detects input over current while cell is in bypass;

4.

A one cycle fault occurs;

5.

An excessive drive loss fault occurs;

6.

Setting sop flag “SetIPFault_O” to true;

The different conditions listed above in the description of fault/ alarm have different associated parameters: Associated Parameters

Conditions 1, 2, 3: Parameter ID 2550: “Cell rated voltage” Condition 4: see section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses”

Hysteresis or Delay

Faults have no delay or hysteresis Conditions 1, 2, 3: cell control board

Data Source

Condition 4: section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses”

Variables in Data Source

SOP Flags that affect Operation

Condition 4: see section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses” “InputProtection_I” indicates an input protection fault has occurred. “SetIPFault_O” will generate this fault via the sop

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Fault Reference for Harmony NXG

Input Line Disturbance

Fault Name — Input Protection Fault

System Location of Data Source

1

Conditions 1, 2, 3: The cell control board is embedded within the structure of the power cell. The fault data is transmitted back to the control via the serial data stream across the fiber optic link. Condition 4: section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses” Conditions 1, 2, 3: Faulty cell control board

Potential Issues that affect the Fault Performance

Condition 4: section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses” Conditions 1, 2, 3: Replace the faulty board.

Corrective Action for Deficiencies

Condition 4: section 1.4 “Input One Cycle” Condition 5: see section 1.7 “Excessive Drive Losses”

∇ ∇ ∇

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Fault Reference for Harmony NXG

1

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Fault Reference for Harmony NXG

Input Transformer Temperature Related

CHAPTER

2

Input Transformer Temperature Related

2.1 Transformer Over Temperature Fault Name — Transformer Over Temperature Xformer OT Alarm Displayed Message

Xformer OT Trip Alarm Xformer OT Fault

Description of Fault/Alarm

These alarms / faults are used to indicate transformer over temperature conditions. They are strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “XformerTemperature1En_O” enables the “Xformer OT Alarm.” “XformerTemperature2En_O” enables the Xformer OT Trip Alarm. “XformerTemperatureFaultEn_O” enables the “Xformer OT Fault” fault / alarm.

SOP Flags that affect Operation

“XformerOverTempFaultWn_O” sets “Xformer OT Fault” as an alarm. “XformerOverTempAlarm1_O” set to trigger a “Xformer OT Alarm” condition. “XformerOverTempAlarm2_O” set to trigger a “Xformer OT Trip Alarm” condition. “XformerOverTempFault_O” set to trigger a “Xformer OT Fault” fault / alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Input Transformer Temperature Related

Fault Reference for Harmony NXG

2.2 Input Reactor Temperature Related Fault Name — Input Reactor Over Temperature

2

Reactor OT Alarm Displayed Message

Reactor OT Trip Alarm Reactor OT Fault

Description of Fault/Alarm

These alarms / faults are used to indicate input reactor over temperature conditions. They are strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “ReactorTemperature1En_O” enables the “Reactor OT Alarm.” “ReactorTemperature2En_O” enables the “Reactor OT Trip Alarm.” “ReactorTemperatureFaultEn_O” enables the “Reactor OT Fault” fault / alarm.

SOP Flags that affect Operation

“ReactorTemperatureFaultWn_O” sets the “Reactor OT Fault” as an alarm. “ReactorTemperature1_O” set to trigger a “Reactor OT Alarm” condition. “ReactorTemperature2_O” set to trigger a “Reactor OT Trip Alarm” condition. “ReactorTemperatureFault_O” set to trigger a “Reactor OT Fault” fault / alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Power Cell Related

CHAPTER

3

Power Cell Related

3.1 Cell Fault

3

Fault Name — Cell Fault Displayed Message

None

Description of Fault/Alarm

A cell fault has occurred. Cell fault information must be examined to determine which cell(s) and what type(s) of fault(s). This is an internal fault with no message, and is used to trip the drive and trigger the cell diagnostics. It sets the “FatalFault_I” and “Cells_I” SOP flags.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Cell control board to Fiber to Modulator board registers.

Variables in Data Source

None if fiber cables are connected properly.

SOP Flags that affect Operation

Sets the “FatalFault_I” and “Cells_I” SOP flags.

System Location of Data Source

Power Cell cabinet for Power Cells. Control cabinet, DCR for fiber optic terminations and Modulator board.

Potential Issues that affect the Fault Performance

•

Loss of fiber connections

•

Destructive failure of the power cell resulting in destruction of cell control board.

Corrective Action for Deficiencies

Bypass failed cell(s). Replace failed cell(s) during maintenance.

Comments

None

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Power Cell Related

Fault Reference for Harmony NXG

3.2 Cell Over Temperature Fault Name — Cell Over Temperature Displayed Message

3

Cell Over Temp Alarm Cell Over Temp Fault Each cell has an RTD installed to measure the temperature of the heatsink. The feedback is in the form of a PWM controlled signal sent back across the fiber link as a single bit with a 600Hz cycle rate. The modulator counts the number of active bits during this time period to retrieve the PWM duty cycle and determines the temperature based on this duty cycle. Duty cycle is nominally 0% at 74°C and 100% at 90°C. For HV Cells the duty cycle is 6% at 73.75 °C and 100% at 81.7°C. For 600 AP AFE and 750 AP cells the duty cycle is 0% at 56.63 °C and 100% at 73.37°C.

Description of Fault/Alarm

At the level set by parameter 2560 (Thermistor warn level), the temperature alarm is set after remaining at this level for half a second of hysteresis. At 80% duty cycle the temperature fault is set. Each cell has an RTD installed to measure the temperature of the heatsink. The feedback is in the form of a PWM controlled signal sent back across the fiber link as a single bit with a 600Hz cycle rate. The modulator counts the number of active bits during this time period to retrieve the PWM duty cycle and determines the temperature based on this duty cycle. Duty cycle is nominally 0% at 74°C and 100% at 90°C. At the level set by parameter 2560 (Thermistor warn level), the temperature alarm is set after remaining at this level for half a second of hysteresis. At 80% duty cycle the temperature fault is set.

Associated Parameters

Thermistor Warn level (2560) - sets the lower threshold of temperature (duty cycle) for the cell temperature alarm.

Hysteresis or Delay

Both the fault and alarm use hysteresis before being triggered. The hysteresis is 150 fault system samples or ½ second before an alarm is issued. Cell control board - creates a PWM signal in proportion to the thermistor feedback and broadcasts back to the controls through the fiber optic cable as part of the response data.

Data Source

Variables in Data Source

Modulator registers - determines the duty cycle based on the time base of the fiber optic communication and the temperature data bit logic level (counts high bits over a fixed cycle period of 600 Hz and stores the count in the register). “Thermistor warn level” (2560) sets the level of the thermistor at which the alarm level is triggered. ISA bus timing for reads. Communication validity - parity checked.

SOP Flags that affect Operation

None

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Power Cell Related

Fault Name — Cell Over Temperature System Location of Data Source

Potential Issues that affect the Fault Performance Corrective action for Deficiencies

Cell control board in Power cabinets. Modulator board in the DCR (Digital Control Rack) in the Control cabinet. •

Failure of cell communications.

•

Failure of cell control board or thermistor.

•

Failure of modulator board.

3

Replace defective parts.

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Power Cell Related

Fault Reference for Harmony NXG

3.3 Cap Share Fault Name — Cap Share Displayed Message

3

Description of Fault/Alarm

Cap Share For the 460V, 630V and 690V cells only, the Capacitor configuration in the power cell is such that two capacitors are connected in series to support the voltage in the DC link of the cell (three in series with the 690V cells). Each capacitor in the series string is configured to share equally, to prevent over-voltaging any individual capacitor. To ensure that the capacitors are sharing properly, the voltages for each capacitor in the string are monitored by comparators. Should the difference of the voltages exceed a preset limit, the comparators issue a Cap Share fault. This is hardware initiated and cannot be changed. The fault is generated by the cell control board. A cap share failure can be destructive to the capacitors in the cell. They can either leak, blow a seal, or rupture, causing destructive damage. The cap share fault is usually generated during application of Medium Voltage power due to higher inrush currents. It is usually a sign that the capacitors have abnormally high initial leakage currents after only a few weeks in voltage free storage. Evidence shows that these leakage currents diminish to normal levels after a few minutes of operation. However, currents are high enough after initial inrush to imbalance capacitor banks sufficiently to generate “Cap Share Faults” and in some cases cap failures.

Associated Parameters

There are no parameters associated with this fault.

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

The data source is the cell control board on the power cells.

Variables in Data Source

The only variables would be the tolerance of the components that make up the monitoring circuits.

SOP Flags that affect Operation

None

System Location of Data Source

The cell control board is embedded within the structure of the power cell. The fault data is transmitted back to the control via the serial data stream across the fiber optic link.

Potential Issues that affect the Fault Performance

Cap share faults are caused by defective capacitors which show an abnormally high initial leakage currents after only a few weeks in voltage free storage.

s 3-4 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Power Cell Related

Fault Name — Cap Share Inspect the cell for leaking caps or destructive damage. The cell should be replaced if damaged. Corrective Action for Deficiencies

If after an inspection, the cells appear undamaged, they can be sufficiently “repaired” at least temporarily by only 10 minutes of operation at 110% rated voltage. This is known as “reforming” the capacitor.

3

Contact the factory if this fault continues to occur after periods of power-off storage.

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Power Cell Related

Fault Reference for Harmony NXG

3.4 Link Fault Fault Name — Link Fault Displayed Message

Link

Description of Fault/Alarm

A link fault is the failure of the communications link from the cell to the DCR. The communications is a master/slave communications. A response is expected after a message goes out to the cell. If a message is not received before the next message is to go out, there is a link fault. Also, if the information packet (7 bits plus parity) has a parity fault, this is also considered a link fault.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board.

Variables in Data Source

Corrupted communications in either direction. A dirty or disconnected fiber. Loss of control power at the power cell.

SOP Flags that affect Operation

None

System Location of Data Source

Power section in the individual power cells.

3

Potential Issues that affect the Fault Performance

•

Component failure.

•

Disconnected Fiber.

•

No power at the cell - blown cell input fuses.

•

Dirty fiber connection.

•

Kinked or cut fiber optic cable.

Check that MV is applied to the cells and that other cells are not affected. Corrective Action for Deficiencies

Check for proper connection of fiber optic cables. Check for kinks or breaks in the fiber. Replace Cell control board.

Comments

None

s 3-6 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Power Cell Related

3.5 Power Fuse Blown Fault Name — Power Fuse Blown Displayed Message

Power Fuse Blown

Description of Fault/Alarm

The power fuses supply the power to the cell DC link from a 3 phase secondary winding on the transformer. There is no direct fuse loss detection, so a combination of conditions must be used to detect this fault. The condition for this fault is a Cell DC bus low condition in conjunction with Medium Voltage applied (greater than 60% rated input voltage).

Associated Parameters

There are no parameters for the DC bus overvoltage. The “Input Voltage scaler” (3040) is used to scale the Medium voltage feedback. For more detail, see the “Medium Voltage Low” fault in Chapter 1.

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

The cell DC bus indication comes from the cell control board. The Medium Voltage feedback is from the input attenuators.

Variables in Data Source

Component tolerances on the cell control board. Input Voltage Attenuators.

SOP Flags that affect Operation

None

System Location of Data Source

The voltage attenuators are in the input/output cabinet of the drive. The cell control board is an integral part of each power cell located in the power control cabinets.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Faulty cell control board (cell DC bus voltage).

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

3

Replace defective board(s) Evaluate wiring and grounding practices. None

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Power Cell Related

Fault Reference for Harmony NXG

3.6 Control Fuse Blown Fault Name — Control Fuse Blown Displayed Message

Control Fuse Blown

Description of Fault/Alarm

This fault is generated on the cell control board and is theoretically supposed to indicate that a control power fuse is blown. Based on the design of the board, however, this fault may never occur. The board is dual powered, both through the 3 phase rectifier from the control power fuses, and also from the DC bus. Thus when a fuse blows, the only indication is that the Vavail (Vavailable) okay signal from the cell goes low.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Integral to each power cell within the power cabinets.

Potential Issues that affect the Fault Performance

Since the board is dual powered, the only way for the loss of power to the board to occur would be to lose all power, resulting in a loss of communications - a link fault. In practicality, this fault will never occur in any version prior to and including version 2.4. This will have to be investigated to see if any enhancement can be made using multiple signals to deduce the fault.

Corrective Action for Deficiencies

If this fault occurs it is probably a bad cell control board. The board should be replaced.

Comments

None

3

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Fault Reference for Harmony NXG

Power Cell Related

3.7 Control Power Fault Name — Control Power Displayed Message

Control Power

Description of Fault/Alarm

This is an indication that the cell control power is below the trip level. This is a bit sent back in the running mode in response to a command issued to the cell. The circuitry is powered by dual sources. If either fails, the other supplies the required power. In the event that control power is completely lost, the cell ceases to communicate. Therefore, this fault should never occur unless the board is defective.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The cell control board is an integral board in each of the power cells located in the power cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Defective components.

•

Noise on the board.

•

Noise on the communications that would not create a parity error (i.e. two errors that result in a correct parity bit).

3

Replace board. Check fiber cables and connections. None

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Power Cell Related

Fault Reference for Harmony NXG

3.8 IGBT Out of Saturation Fault Name — IGBT Out of Saturation IGBT OOS 1

3

Displayed Message

IGBT OOS 2 IGBT OOS 3 IGBT OOS 4

Description of Fault/Alarm

The IGBT is a switching power transistor. If not driven completely into saturation (defined as having enough charge carriers in the gate drive to allow current to flow unabated), the losses in the device will quickly exceed design tolerances for thermal losses and current density, which could destroy the device. Therefore, the voltage across the device is measured to ensure that the value never exceeds the forward dropping voltage for a device fully turned on. If this voltage exceeds a threshold value established on the gate drive circuit, the cell is shut down along with the drive. The cell control board monitors this information and reports back to the DCR through the fiber optic channel to allow all cells to shut down.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Gate drivers and Cell control board.

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

The Gate driver board and Cell control board are both integral to each power cell located in the power cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Bad connection between the two boards, malfunctioning boards, possible combination errors in the communications with no parity error, noise pickup on either board within the cell.

•

Defective power device(s).

•

Bad power supply not permitting full gate drive current.

•

High di/dt signals from the gate board resulting in IGBT pulling out of saturation.

Check all cell board connections including the fiber link. Replace defective boards or IGBTs. None

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Fault Reference for Harmony NXG

Power Cell Related

3.9 DC Bus Fault Name — DC Bus DC Bus Low Warning Displayed Message

DC Bus Over Volt

3

DC Under Volt The DC bus is the link in each power cell between the input, 3-phase converter, and the output, single phase inverter. It is the source of the stored energy for the inverter and effectively isolates the input from the output sections. This is formed by a large capacitor bank with a voltage nominally designed for the rating or the cell, and that varies with input line condition and output load. The voltage level is set to a percentage of the nominal cell voltage. The three levels are determined by the nominal cell voltage and are used to protect the cells and the capacitors from damage.

Description of Fault/Alarm

The DC bus low warning - This is the first level warning that the voltage level of an individual cell has dropped below a level that can support full rated output from that cell. This level is set at approximately 72% of peak nominal DC bus voltage. For drives with 600 AP AFE and 750 AP cells, the drive will require precharging prior to the re-application of medium voltage. The DC bus over voltage - This is a fault that is used to protect the cells from an over voltage condition which could result in capacitor failure or damage to the IGBTs. Should the bus voltage exceed 140% of nominal DC bus voltage, the trip will occur. The DC under voltage trip - This is a fault condition in which the cell DC bus voltage drops below 61% of the nominal DC bus voltage. This fault is used to protect against loss of control of the cell control board.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Cell control board

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board within each power cell.

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Power Cell Related

Fault Reference for Harmony NXG

Fault Name — DC Bus

Potential Issues that affect the Fault Performance

3

•

Defective components

•

Noise

•

Loose interconnections between the boards

•

Possible bad communications back from the cell

•

Loss of Medium Voltage.

Check MV supply. Corrective Action for Deficiencies

Check connection of fiber optics. Change defective cell control board.

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Fault Reference for Harmony NXG

Power Cell Related

3.10 Cell Communication Failure Fault Name — Cell Communication Failure Displayed Message

Communication

Description of Fault/Alarm

This checks the communications from the modulator board to the cell. If a bad parity is detected, or if communications is not detected within approximately 30 microseconds, this error is detected and shuts the cell down.

Associated Parameters

None

Hysteresis or Delay

This fault delays for the length of 3 Fxmit cycles (each about 10 μsecs) of not receiving data to trip.

Data Source

Cell control board

Variables in Data Source

Defective components, noise, loose interconnections in fiber, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board in each of the power cells in the power cabinets.

Potential Issues that affect the Fault Performance

•

Dirty fiber lens or loose connection.

•

Noisy transmission at the source or destination board.

•

Defective cell control board.

3

Check fiber for kinks or loose connection. Corrective Action for Deficiencies

Check for grounding issues. Replace defective fiber or board.

Comments

Seeing this fault would indicate a false identification at the cell control board. If the communication channel to the cell is inoperable, the cell will not respond due to the nature of the master/slave communication protocol.

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Power Cell Related

Fault Reference for Harmony NXG

3.11 Output Fuse Blown Fault Name — Output Fuse Blown

3

Displayed Message

Output Fuse Blown

Description of Fault/Alarm

This fault is only applicable for 460V cells which have a fuse in the output side of the cell for use with SCR bypass.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

N/A -- doesn’t exist

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

N/A

Potential Issues that affect the Fault Performance

N/A

Corrective action for Deficiencies

N/A

Comments

None

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Fault Reference for Harmony NXG

Power Cell Related

3.12 Blocking Test Failed Fault Name — Blocking Test Failed Blocking Q1 Blocking Q2 Displayed Message

3

Blocking Q3 Blocking Q4 Blocking Timeout

Description of Fault/Alarm

During cell diagnostics, and with the presence of Medium Voltage, the cells are checked for each of four IGBT’s blocking voltage. Across each IGBT is a comparator to check the voltage. With the cells disabled, each IGBT must exhibit a voltage greater than 75 volts across the device at least once during the allowed time period. Due to the possibility of AC voltage across the devices (with inherent zero-crossings), a maximum of a half-second is allowed to pass for the test to ensure that a minimum voltage exists to set the blocking comparators at least once. If for any reason the comparators are not set and the time for the test has expired for the individual cell, the individual IGBTs that failed the blocking test are marked as faulted. The failure to block voltage is usually a sign of a shorted IGBT and it generates a cell fault, which is logged. The Blocking Timeout is not implemented.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Gate driver board. Cell control board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Gate driver and cell control boards are located in each power cell, which are in the power cabinet.

Potential Issues that affect the Fault Performance

Corrective action for Deficiencies

•

Connections between the gate driver board and the cell control board.

•

Erroneous data returned from the cell control board with no parity errors (generated before parity is assigned).

Replace Power cell.

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Power Cell Related

Fault Reference for Harmony NXG

Fault Name — Blocking Test Failed

Comments

3

Erroneous indication of the presence of Medium Voltage when it is not available or is below levels for the test to pass could give a false indication. However, if the Medium Voltage is not there, the IGBTs cannot be controlled nor will the cell communication be viable, so this is unlikely.

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Fault Reference for Harmony NXG

Power Cell Related

3.13 Switching Test Failed Fault Name — Switching Test Failed Switching Q1 Switching Q2 Displayed Message

3

Switching Q3 Switching Q4 Switching Timeout During cell diagnostics and with the presence of Medium Voltage, and after a successful blocking test for each cell, the cells are then tested for switching operation.

Description of Fault/Alarm

First the cells are tested individually again for blocking, then each IGBT is switched on and the collapse of voltage is verified. At that point the IGBT is switched off and again tested for blocking. This is repeated for each of the four IGBTs in the cell. Since each IGBT must pass the blocking test both before and immediately after the switching test, a time limit is established for the entire sequence. The sequence that each device must pass is: blocking - not blocking (switched on) - blocking, in three successive responses in order to pass. This is to ensure that a lack of voltage across the IGBT is not inadvertently used to determine an actively switched-on device. Any devices that fail to pass this test are flagged as faulted during switching, on an individual basis, and the entire cell is determined to have failed. The Switching Timeout fault is not implemented.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Gate driver boards. Cell control boards.

Variables in Data Source

Loose connections. Faulty components or failed board.

SOP Flags that affect Operation

None

System Location of Data Source

Both boards are an integral part of each power cell, and are located in the power cabinets.

Potential Issues that affect the Fault Performance

•

Noise

•

Bad connections between boards

•

Defective boards

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Power Cell Related

Fault Reference for Harmony NXG

Fault Name — Switching Test Failed

Corrective Action for Deficiencies

Check for grounding practices, loose interconnect cables, and fiber optic cables and correct any discrepancies. Replace any defective cell boards.

3 *

Note: For HV Cells, switching faults refer to any cell gating fault (e.g. OOS, not switching properly etc.). A special case exists for this cell if all four devices within a single cell show a simultaneous switching fault. This indicates invalid gating commands that will result in turning on more than one device in a single pole.

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Power Cell Related

3.14 Cell Fault / Modulator Fault Name — Cell Fault/Modulator Displayed Message

Description of Fault/Alarm

Cell Fault/Modulator All cell fault determination is based on a cell fault coming from the individual cell in Mode 0 (operation mode of the cell). When the bit is set, the modulator records the information in a fault register which is read during the fault routine. There are individual cell fault bits and individual link fault bits for every cell in the system and are grouped in registers in groups of six cells per register. Should any of these bits be set in a cell fault register, a corresponding bit is set in a master fault register in the modulator. This hierarchy speeds cell fault detection. For speed, the fault routine needs only check the master fault register for any cell faults. If a bit is set for a cell fault in the master fault register, the cell diagnostic routine is called to determine the exact nature of the cell fault.

3

During the cell diagnostic routine, each cell is read to determine its fault status. Should all the faults be checked and no fault be found (by checking the individual cell’s fault bit and checking the other diagnostic cell modes, one, two, and the switching and blocking of mode three), then the source of the fault cannot be determined. At this point, the fault was either a transitory signal that didn’t get properly latched in the modulator, or the modulator malfunctioned. Since the fault is most likely an issue with the modulator board, the fault indicates the fault as such - Cell Fault/Modulator. Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Modulator Board

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

DCR (Digital Control Rack)

Potential Issues that affect the Fault Performance

•

Intermittent error signals due to a faulty cell control board

•

Noise

•

Loose fiber optic cable connector

Check for sources of noise or grounding practice. Corrective Action for Deficiencies

Check fiber optic cable and connections. Replace defective modulator board or cell control board.

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Power Cell Related

Fault Reference for Harmony NXG

3.15 Bad Cell Data Fault Name — Bad Cell Data Displayed Message

Bad Cell Data When the cell communicates back to the modulator in the master/slave protocol, it always echoes the cell mode in the response message. This is a code - one of four modes - determined by the two least significant bits in the message byte.

3

If the cell is in normal running mode and not cell diagnostics (Mode 0 - both bits are zero) and the response is non-zero, this is a fault. Description of Fault/Alarm

Also if the cell is in diagnostics mode and either the response mode does not equal the sent mode, or the response, in a non-zero mode, returns the link fault bit set true, then this is a fault. Both of these faults show that either the modulator is malfunctioning or, more likely, the cell control board is malfunctioning. In earlier cell control boards, there was a delay of one or two responses before the mode bits changed due to timing on the cell control board. All boards exhibiting this behavior have been removed or replaced.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board or modulator board

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board is in each power cell in the power cabinet. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Faulty components on the cell control board

•

Defective modulator board

•

Noise.

Replace modulator board, then cell control board if problem persists. Check grounding practices.

Comments

None

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Power Cell Related

3.16 Cell Configuration Fault Fault Name — Cell Configuration Fault Displayed Message

Cell Config Fault

Description of Fault/Alarm

After Medium Voltage is first applied to the cells, the software reinitializes the modulator board and attempts to establish communication with the cells. While doing so, it checks the cell configuration. If no cells are found, this fault occurs.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Modulator board. Cell control boards.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Cell control boards are integral to the power cells located in the power cabinet. The modulator board is located in the DCR.

Potential Issues that affect the Fault Performance

•

A false indication of Medium Voltage feedback or scaling would begin the initialization process before the cells are powered.

•

Disconnected fiber optic cables from either the cells or the DCR fiber optic expansion board. Defective modulator board.

3

Check for proper level of Medium Voltage. Corrective Action for Deficiencies

Check for proper connection of the fiber optic cables. Replace defective modulator board.

Comments

None

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Fault Reference for Harmony NXG

3.17 Cell Alarm Fault Name — Cell Alarm

3

Displayed Message

None

Description of Fault/Alarm

A cell alarm has occurred. Cell information must be examined to determine which cell(s) and what type(s) of alarm(s). These could include cell over temperature warning level on one or more cells, or the first level of low DC bus voltage. The cells are not faulted at this point.

Associated Parameters

None

Hysteresis or Delay

Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Cell control board. Modulator board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Cell control boards are integral to the power cells located in the power cabinets. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

The alarms are early warnings of potential problems, generally an operational change such as a reduction of output torque or speed. The process controls must be adjusted to prevent an eventual drive trip.

Corrective Action for Deficiencies

None required if the cell alarms are real. A change in operating parameters may be required to prevent a fault from occurring.

Comments

An overtemp warning might be the early indicator of a bad cell or an impending cooling system failure.

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Fault Reference for Harmony NXG

Power Cell Related

3.18 Cell Differential Temperature Fault Name — Cell Differential Temperature Displayed Message

Description of Fault/Alarm

Cell Diff Temp Alarm Cell Diff Temp Fault

3

600 AP AFE and 750 AP contain sensors that monitor the inlet and outlet water temperature to the heat sink within the cell. This difference between the inlet and outlet water temperature is passed from each cell control board to the modulator. The main controller reads this difference in temperature and compares the value to the AP diff temp fault lvl parameter (2596). When the difference between the inlet and outlet water temperature exceeds the value of parameter (2596), a Cell Diff Temp Alarm will occur. When the difference between the inlet and outlet water temperature exceeds the value of parameter (2596) by more than 2°C, a Cell Diff Temp Fault will occur.

Associated Parameters

AP diff temp fault lvl (2596) sets the point at which a cell will create a AP diff temp alarm. The fault level is 2°C greater than this value.

Hysteresis or Delay

The Cell Diff Temp Alarm and Faults have no delay or hysteresis.

Data Source

Inlet and outlet thermistors, Cell control board, and Modulator.

Variables in Data Source

The inlet and outlet temperatures are filtered at 314 radians/sec.

SOP Flags that affect Operation

APCellDiffTempAlarm_I indicates a Cell Diff Temp Alarm, APCellDiffTempFault_I indicates a Cell Diff Temp Fault. APCellDiffTempFaultEn_O enables the fault.

System Location of Data Source

Thermistors and Cell control board is in each power cell in the power cabinet. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Low water flow within the cell caused by clogged input reactor (600 AP AFE cells), heat sink or hoses.

•

Faulty thermistor or loose thermistor connection.

•

Faulty cell control board.

Replace clogged components within water path, i.e., Cell, Hoses, or Input Reactor. Replace Power Cell.

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Power Cell Related

Fault Reference for Harmony NXG

3.19 Precharge Fault Fault Name — Precharge Fault

3

Displayed Message

Precharge Fault

Description of Fault/Alarm

Not implemented. (Originally intended for Gen IV cells with precharge.)

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

None

Variables in Data Source SOP Flags that affect Operation

None

System Location of Data Source

None

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies

None

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Power Cell Related

3.20 Device Alarm Fault Name — Device Alarm Displayed Message

Device Alarm

Description of Fault/Alarm

This alarm occurs when a cell has repeatedly experienced out of saturation faults. This alarm indicates that the expected life of the cell’s IGBTs may have been reduced. This alarm applies to HV, 600 AP AFE and 750 AP cells.

Associated Parameters

None

Hysteresis or Delay

This alarm will occur after 18 out of saturation faults for the same power section of the same cell.

Data Source

Gate Drivers, Cell Control Board, Modulator

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

The Cell Control Board and Gate Drivers are located within each power cell in the power cabinet. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Bad connection between the two boards, malfunctioning boards, possible combination errors in the communications with no parity error, noise pickup on either board within the cell.

•

Defective power device(s)

•

Bad power supply not permitting full gate drive current

•

High di/dt signals from the gate board resulting in IGBT pulling out of saturation.

3

Replace Cell

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Power Cell Related

Fault Reference for Harmony NXG

3.21 DC Bus Discharge Alarm Fault Name — DC Bus Discharge Alarm Displayed Message

DC Bus Discharge Alarm

Description of Fault/Alarm

This alarm occurs when the HV cell’s discharge resistor circuit does not function properly. When the input voltage to the cell is lost, the HV cell discharges the DC bus via a higher current resistor. After power down, the DC bus voltage is monitored to check if the DC bus voltage decreases at the expected rate. The DC Bus Discharge Alarm occurs if the DC bus voltage does not decrease by 25% within 30 seconds after the higher current resistor is placed within the circuit.

Associated Parameters

None

Hysteresis or Delay

This alarm uses a 30 second timer to assess the discharge rate. All filtering and hysteresis occurs due to this 30 second delay and the DC bus capacitance.

Data Source

HV cell power supply board, HV cell control board and modulator.

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

The Cell Control Board and Power Supply Board are located within each HV power cell in the power cabinet. The modulator board is in the DCR in the control cabinet.

3

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Bad connection between the two boards

•

Malfunctioning boards

•

Bad connection between the power supply board and the discharge resistor.

Check for loose connections between boards within the cell. Replace the cell control board and/or power supply board.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Power Cell Related

3.22 Device Failure Fault Name — Device Failure Displayed Message

Device Failure

Description of Fault/Alarm

This fault occurs when a cell has repeatedly experienced out of saturation faults or the cell control board has failed. This fault indicates that the expected life of the cell’s IGBTs may have been exceeded or the cell control board is not functioning properly. This alarm applies to HV, 600 AP AFE and 750 AP cells.

Associated Parameters

None

Hysteresis or Delay

This alarm will occur after 20 out of saturation faults for the same power section of the same cell OR the cell control board has failed to function properly.

Data Source

Gate Drivers, Cell Control Board, Modulator

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

The Cell Control Board and Gate Drivers are located within each power cell in the power cabinet. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Bad connection between the two boards, malfunctioning boards, possible combination errors in the communications with no parity error, noise pickup on either board within the cell.

•

Defective power device(s).

•

Bad power supply not permitting full gate drive current.

•

High di/dt signals from the gate board resulting in IGBT pulling out of saturation.

3

Replace Cell

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Power Cell Related

Fault Reference for Harmony NXG

3.23 Six-Step Cell Initialization Fault Fault Name — Six-Step Cell Initialization Fault Displayed Message

Improper Cell Type This fault occurs if six-step cell is selected (750V AP 4Q) and cells do not configure properly for any of the following reasons:

3

•

Not a 4-quad (regen) type cell

•

DSP does not acknowledge six-step enabled

•

EPLD does not acknowledge six-step enabled

The message will display the cell in question, followed by the “Improper Cell Type” message. Description of Fault/Alarm

If Fast Bypass (2600) is enabled, the cell will be bypassed. Provided enough cells are remaining, the drive will initialize with no faults. Should there not be enough cells to run, the drive will not bypass the remaining cells and will remain faulted. This is standard fast bypass operation. If not enough cells remain to run in six-step four-quadrant control, and the cells are not faulted for any other reason, the cell type can be reconfigured to “750 V AP” type and the drive can then be operated in two-quadrant control with no cells faulted, if no other cell faults exist. Otherwise, the drive cannot be run due to excessive cell faults. Re-configuration will not be automatic.

Associated Parameters

Cell voltage

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Cell control board to Fiber to Modulator board registers.

Variables in Data Source

None if fiber cables are connected properly.

SOP Flags that affect Operation

None

System Location of Data Source

Power Cell cabinet for Power Cells. Control cabinet, DCR for fiber optic terminations and Modulator board.

Potential Issues that affect the Fault Performance

Wrong cell type

Corrective Action for Deficiencies

Replace failed cell(s) during maintenance.

Comments

Applies only to six-step regenerative cells.

∇ ∇ ∇

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Fault Reference for Harmony NXG

AFE Cell Related

CHAPTER

4

AFE Cell Related

4.1 AFE Over-current Fault Name — AFE Over-current

4

Displayed Message

AFE Over-current

Description of Fault/Alarm

Cell instantaneous over-current (IOC) faults usually result in input voltage transients or instability. This fault will occur when a cell detects a current value greater than the threshold. It will fault only the affected cell. The VFD will automatically bypass the cell if fast bypass is enabled. Parameter ID 2621 “AP cell overcurrent.” For 600 AP AFE cells the current tuning parameters: Parameter ID 2589 “AP cell Id P gain” Parameter ID 2591 “AP cell Id I gain”

Associated Parameters

Parameter ID 2592 “AP cell Id D gain” Parameter ID 2593 “AP cell Iq P gain” Parameter ID 2594 “AP cell Iq I gain” Parameter ID 2595 “AP cell Iq D gain” For 750 AP 4Q: Parameter ID 2625 “Regen Shift Angle”

Hysteresis or Delay

Faults have no delay or hysteresis

Data Source

Cell control board in each power cell.

Variables in Data Source

Input IGBTs, Gate board, Input reactors (600 AP AFE cells), Hall effect transducers and cell control board.

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board and Hall effect transducers located within each power cell.

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AFE Cell Related

Fault Reference for Harmony NXG

Fault Name — AFE Over-current

Potential Issues that affect the Fault Performance

4

Corrective Action for Deficiencies

•

Excessive line voltage perturbation

•

Improper tuning of 600 AFE cells

•

Incorrect shift angle for 750 AP 4Q cells, failure or an input line reactor (600 AP AFE cells)

•

Bad hall effect

•

Failure of cell control board

•

Failure of an input IGBT

•

Improper gating of an input IGBT

Check inductance of 600 AP AFE input line reactors and replace if incorrect. If the fault repeatedly occurs with random cells, and the cells are 600 AP AFE, then the current loop tuning parameters may be incorrect. If the fault repeatedly occurs with several 750 AP 4Q cells, check the setting of the “Regen Shift Angle” (2625). Check for loose connections Check hall effects, gate drives and cell control board

Comments

For 600 AP AFE, 750 AP, and 750 AP 4Q cells, excessive line transients can cause currents in excess of the over-current setting parameter ID (2621). In these instances, there may be no equipment failure or tuning problem. In addition, the IOC processing is so fast that an out of saturation fault for an input IGBT may never be detected. See “IGBT Out of Saturation” fault (Section 3.8 and Section 4.2) for further guidance.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

AFE Cell Related

4.2 AFE IGBT Out of Saturation Fault Name — AFE IGBT Out of Saturation

Displayed Message

IGBT OOS 11 IGBT OOS 12 IGBT OOS 13 IGBT OOS 14 IGBT OOS 15 IGBT OOS 16

Description of Fault/Alarm

The IGBT is a switching power transistor. If not driven completely into saturation (defined as having enough charge carriers in the gate drive to allow current to flow unabated), the losses in the device will quickly exceed design tolerances for thermal losses and current density, which could destroy the device. Therefore, the voltage across the device is measured to ensure that the value never exceeds the forward dropping voltage for a device fully turned on. If this voltage exceeds a threshold value established on the gate drive circuit, the cell is shut down along with the drive. The cell control board monitors this information and reports back to the DCR through the fiber optic channel to allow all cells to shut down.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Gate drivers and Cell control board.

Variables in Data Source

Defective components, noise, loose interconnections between the boards, possible bad communications back from the cell.

SOP Flags that affect Operation

None

System Location of Data Source

The Gate driver board and Cell control board are both integral to each power cell located in the power cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Bad connection between the two boards, malfunctioning boards, possible combination errors in the communications with no parity error, noise pickup on either board within the cell.

•

Defective power device(s).

•

Bad power supply not permitting full gate drive current.

•

High di/dt signals from the gate board resulting in IGBT pulling out of saturation.

4

Check all cell board connections including the fiber link. Replace defective boards or IGBTs. None

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AFE Cell Related

Fault Reference for Harmony NXG

4.3 AFE Current Deviation Fault Name — AFE Current Deviation Displayed Message

AFE Current Dev.

Description of Fault/Alarm

An AFE Current Dev fault occurs only for 600 AP AFE cells. This fault indicates the cell is not able to produce the current requested. Parameter ID 2586 “AP cell control mode” must be set to “DQ,” “QD,” “Free run DQ,” or “Free run QD” to enable this fault.

4

Current tuning parameters: Parameter ID 2589 “AP cell Id P gain” Parameter ID 2591 “AP cell Id I gain” Associated Parameters

Parameter ID 2592 “AP cell Id D gain” Parameter ID 2593 “AP cell Iq P gain” Parameter ID 2594 “AP cell Iq I gain” Parameter ID 2595 “AP cell Iq D gain” Reactive current demand: Parameter ID 3046 “AFE Sat. filter”

Hysteresis or Delay

This fault has a 40 millisecond delay or hysteresis. The current levels of real and reactive current are compared to a fixed threshold every 10 milliseconds. If the either the Real or Reactive current exceeds the threshold (20%) for four consecutive samples, the cell will issue an “AFE Current Deviation” fault.

Data Source

Hall effect transducers, cell control board, modulator.

Variables in Data Source

Input reactors (600 AP AFE cells), Hall effect transducers, and cell control board.

SOP Flags that affect Operation

None

System Location of Data Source

Input reactors within the cell cabinet, Hall effect transducers, and cell control board within the cell.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

AFE Cell Related

Fault Name — AFE Current Deviation

Potential Issues that affect the Fault Performance

Failed line reactors will cause the same cell location to fault. Bad Hall effect transducers can also cause this fault. However, when this fault occurs consistently for several different cells, cell current tuning may be incorrect OR the reactive current demand to the cell is too great for the cell to produce at the present line conditions. The “AFE Sat. filter” parameter controls an algorithm that rolls back the reactive current demand to the cell so that “AFE Current Deviation” cell faults do not occur because of high line conditions. Raising the value of parameter 3046 will cause less reactive current demand to the cells at high line but with the loss of some reactive current capability. In addition, a significant line voltage imbalance (>1.5%) can also cause “AFE Current Deviation” cell faults, especially when combined with high line reactive current generation.

4

Check inductance of the input line reactors and replace if incorrect. Check Hall effect transducers and cell control board. Corrective Action for Deficiencies

Study line conditions and reactive current demand at the time of the fault. Adjust “AFE Sat. filter” parameter ID 3046 as necessary. Verify current loop tuning parameters are set correctly.

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AFE Cell Related

Fault Reference for Harmony NXG

4.4 AFE Loss of Lock Fault Name — AFE Loss of Lock

4

Displayed Message

AFE Loss of Lock

Description of Fault/Alarm

This fault occurs when the Power Cells AFE sync signal generated from the Modulator board is lost for 22 mS or the cell fails to get an update after 58 carrier cycles. Each cell receives a sync signal from the Modulator that is derived from the Voltage feedback from the line side of the Power Transformer. This signal is used by each Power cell to line up the firing signals for the AFE on each Power cell.

Associated Parameters

None - (Hard coded fault in Cell DSP)

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Cell control board Modulator and Input Voltage attenuators.

Variables in Data Source

Hard Coded at 1/45Hz (22mS) time delay or 58 Carrier cycles.

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board within each power cell. VFD NXG Modulator and Input Voltage attenuators.

Potential Issues that affect the Fault Performance

Loss of Lock → 22mS between sync Pulse or >58 Carrier Cycles. Loss of Lock normally occurs when the line frequency is too low (← 45 Hz) OR the input breaker is opened while the drive is in operation.

Corrective Action for Deficiencies

If it is determined that the line frequency did not go too low or that the input breaker did not open while the drive was in operation, replace the cell control board and or power cell.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

AFE Cell Related

4.5 Left Sensor Loss Fault Name — Left Sensor Loss Displayed Message

Left Sensor Loss

Description of Fault/Alarm

Not implemented

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

None

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

None

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies

None

4

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AFE Cell Related

Fault Reference for Harmony NXG

4.6 Inlet Sensor Loss Fault Name — Inlet Sensor Loss

4

Displayed Message

Inlet Sensor Loss

Description of Fault/Alarm

Inlet Sensor Loss is a cell alarm that indicates the water temperature thermistor resistance is too high. This alarm only applies to 600 AP AFE, 750 AP, and 750 AP 4Q cells. The nominal resistance for the inlet thermistor is 5k ohms. If the resistance of the sensor exceeds 100k ohms, the sensor is considered open and indicates the sensor is lost. Without the inlet and outlet water temperature sensors, the “Cell Differential Temperature” cell alarm and fault cannot be detected.

Associated Parameters

None

Hysteresis or Delay

This alarm relies on heavily filtered resistance data. The Source is passed through a two pole 314 radians/sec filter. The delay is the time for the resistance change to pass through the filter.

Data Source

Inlet water thermistor and cell control board.

Variables in Data Source

Hard coded two pole 314 radians/second filter and 100k ohm threshold.

SOP Flags that affect Operation

None

System Location of Data Source

Inlet water thermistor and cell control board located within the power cell in the cell cabinet.

Potential Issues that affect the Fault Performance

•

Loose connection between the inlet thermistor and the cell control board

•

Defective cell control board

•

Defective inlet thermistor

Fix any loose connections Corrective Action for Deficiencies

Replace inlet water thermistor Replace cell control board.

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

AFE Cell Related

4.7 Outlet Sensor Loss Fault Name — Outlet Sensor Loss Displayed Message

Outlet Sensor Loss

Description of Fault/Alarm

Outlet Sensor Loss is a cell alarm that indicates the water temperature thermistor resistance is too high. This alarm only applies to 600 AP AFE, 750 AP, and 750 AP 4Q cells. The nominal resistance for the outlet thermistor is 5k ohms. If the resistance of the sensor exceeds 100k ohms, the sensor is considered open and indicates the sensor is lost. Without the inlet and outlet water temperature sensors, the “Cell Differential Temperature” cell alarm and fault cannot be detected.

Associated Parameters

None

Hysteresis or Delay

This alarm relies on a heavily filtered resistance data. The Source is passed through a two pole 314 radians/sec filter. The delay is the time for the resistance change to pass through the filter.

Data Source

Inlet water thermistor and cell control board.

Variables in Data Source

Hard coded two pole 314 radians/second filter and 100k ohm threshold.

SOP Flags that affect Operation

None

System Location of Data Source

Loose connection between the inlet thermistor and the cell control board. A bad cell control board or bad outlet thermistor.

Potential Issues that affect the Fault Performance

•

Loose connection between the outlet thermistor and the cell control board

•

Defective cell control board

•

Defective outlet thermistor

4

Fix any loose connections Corrective Action for Deficiencies

Replace outlet water thermistor Replace cell control board.

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AFE Cell Related

Fault Reference for Harmony NXG

4.8 Air Temperature Warning Fault Name — Air Temperature Warning

4

Displayed Message

Air Temperature Warning

Description of Fault/Alarm

This alarm occurs when the power cell detects an air temperature greater than 60° C at the cell control board. This alarm applies to 600 AP AFE, 750 AP, and 750 AP 4Q cells.

Associated Parameters

None

Hysteresis or Delay

This alarm relies on a heavily filtered temperature data. The source is passed through a 16 radians/sec low pass filter. The delay is the time for the temperature change to pass through the filter.

Data Source

Air thermistor and cell control board.

Variables in Data Source

Fixed 16 radian/sec low pass filter and 60° C reference.

SOP Flags that affect Operation

None

System Location of Data Source

Air temperature thermistor and cell control board located within the power cell in the cell cabinet.

Potential Issues that affect the Fault Performance

•

Loose connection between the air temperature thermistor and the cell control board

•

A bad cell control board or bad air temperature thermistor

•

Restricted air flow into or out of the cell and/or loss of internal blower(s)

Check for air restrictions to the cell and clear any obstructions. Corrective Action for Deficiencies

Check for proper operation of heat exchanger blowers within the cell cabinet and repair as necessary. Fix any loose connections, replace outlet water thermistor, or replace cell control board.

s 4-10 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

AFE Cell Related

4.9 Over Temperature Switch Fault Name — Over Temperature Switch Displayed Message

Over Temp. Switch

Description of Fault/Alarm

The over-temperature switch fault occurs if water flow to the power cell is insufficient to cool the cell. The over-temperature switch fault is applicable to 600 AP AFE, 750 AP, and 750 AP 4Q cells. This fault activates when the thermal switch attached to the heat sink within the power cell opens.

Associated Parameters

None

Hysteresis or Delay

This fault relies on filtered data. The source is passed through a 50 radians/sec low pass filter. The delay is the time for the switch change to pass through the filter.

Data Source

Thermal switch and cell control board within the power cell.

Variables in Data Source

Fixed 50 radians per second low pass filter and thermal switch type.

SOP Flags that affect Operation

None

System Location of Data Source

Thermal switch and cell control board located within the power cell in the cell cabinet.

Potential Issues that affect the Fault Performance

•

Restricted water flow

•

Loose connections between the cell control board and the thermal switch

•

Defective thermal switch

•

Defective cell control board

4

Check for restricted water flow to the cell and correct as necessary. Corrective Action for Deficiencies

Fix any loose connections Replace cell control board or replace cell.

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AFE Cell Related

Fault Reference for Harmony NXG

4.10 ADC Fail Fault Name — ADC Fail

4

Displayed Message

ADC Fail

Description of Fault/Alarm

This fault occurs if the analog to digital converter within the cell control board ceases to function.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board located within the power cell in the cell cabinet.

Potential Issues that affect the Fault Performance

Failure of the cell control board.

Corrective Action for Deficiencies

Replace cell control board or power cell.

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Fault Reference for Harmony NXG

AFE Cell Related

4.11 AFE Configuration Fault Name — AFE Configuration Displayed Message

AFE Configuration

Description of Fault/Alarm

The AFE configuration fault occurs when a cell is not configured properly. The AFE configuration switch fault is applicable to 600 AP AFE, 750 AP, and 750 AP 4Q cells.

Associated Parameters

None

Hysteresis or Delay

This fault has no delay or hysteresis.

Data Source

Cell control board and modulator.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Cell control board located within the power cell in the cell cabinet. The modulator board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

4

•

Poor communication between the modulator and the cell control board

•

Bad cell control board or modulator

Check fiber optic link connections Replace cell control board or replace modulator.

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AFE Cell Related

Fault Reference for Harmony NXG

4.12 AFE Will Not Run Fault Name — AFE Will Not Run Displayed Message

4

AFE Will Not Run This fault occurs if the AFE portion is asked to run when the conditions within the cell will not allow the cells AFE portion to run. Conditions that preclude the AFE portion of the cell from running include:

Description of Fault/Alarm

•

Loss of medium voltage

•

Incorrect cell angle parameter setting

•

Momentary loss of medium voltage simultaneous with a system run command

Cell angle function Parameter ID 2598 “Set Angles” Cell angle parameters Parameter ID 2571 “AP cell angle off 1” Parameter ID 2572 “AP cell angle off 2” Associated Parameters

Parameter ID 2573 “AP cell angle off 3” Parameter ID 2574 “AP cell angle off 4” Parameter ID 2575 “AP cell angle off 5” Parameter ID 2576 “AP cell angle off 6” Parameter ID 2577 “AP cell angle off 7” Parameter ID 2578 “AP cell angle off 8”

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Cell control board, drive input voltage attenuators, system interface board.

Variables in Data Source

None

SOP Flags that affect Operation

System Location of Data Source

SystemRunRequest_O run request flag for both inverter and AFE AfeRunRequest_O run request flag for the AFE Cell control board located within the power cell in the cell cabinet. The system interface board is in the DCR in the control cabinet. The input voltage attenuator resistors are located in the input/ output cabinet of the drive

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Fault Reference for Harmony NXG

AFE Cell Related

Fault Name — AFE Will Not Run

Potential Issues that affect the Fault Performance

•

Application of the SystemRunRequest_O or AfeRunRequest_O at the same time as medium voltage is removed.

•

Incorrect input voltage feedback to the DCR.

•

AFE angle parameters not set or not correctly set.

•

Bad cell control board or gate driver board.

•

Improper power wiring between the transformer and the cells.

•

Incorrect link fiber connected to the cell.

4

Do not request drive operation simultaneously with the removal of medium voltage. Corrective Action for Deficiencies

Verify that all fiber optic links are correctly connected to the appropriate cells. Verify input voltage feedback. Apply medium voltage and use the “Set Angles” function to correctly set the cell angles.

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AFE Cell Related

Fault Reference for Harmony NXG

4.13 Cell Protect Fault Fault Name — Cell Protect Fault Displayed Message

Cell Protect Fault This fault only applies when cells that use advanced protocol are used in the system. This fault can be caused by the following conditions:

4

•

Cell Control board detected arc occurred by cell detection hardware.

•

Cell Control board detected bus over voltage while cell is in bypass.

•

Cell Control board detected input over current while cell is in bypass.

Description of Fault/Alarm

Associated Parameters

None (hard coded in cell DSP)

Hysteresis or Delay

Faults have no delay or hysteresis

Data Source

Cell control board

Variables in Data Source

None “GeneralCellProtectionFault_I” is generated when the cell cannot be communicated with. “ArcDetectedInCell_I” indicates that arc has been detected by the CCB.

SOP Flags that affect Operation

“CellInputOCInBypassDSP_ I” indicates that input current has been detected to be over 20% of the rated while the cell is in bypass. “CellBusOVInBypassDSP_I” indicates that DC bus voltage has been detected to be over 1400V while the cell is in bypass.

System Location of Data Source

Each cell.

Potential Issues that affect the Fault Performance

Cell control board is broken.

Corrective Action for Deficiencies

Replace the cell control board.

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Fault Reference for Harmony NXG

AFE Cell Related

4.14 Cell AFE Not Ready Alarm Fault Name — Cell AFE Not Ready Alarm Displayed Message

AFE Not Ready Warning This alarm only applies when AFE cells that use advanced protocol are used in the system. This alarm is caused by the following conditions:

Description of Fault/Alarm

•

Medium voltage is OK

•

Cell Diagnostics is finished

•

AfeReadyToRun_I is false

•

InvReadyToRun_I is true

4

There will be an alarm for each cell that is not ready. The alarm is shown on the second Cell Status screen (Power Cell Status 2) marked as “AFE-NR” (AFE Not Ready). This could be caused by a power line transient (in idle). Cell Input could be single phasing - not able to determine phase rotation. This is a cell level warning which will indicate any and all cells with this condition.

Associated Parameters

None (hard coded in cell DSP)

Hysteresis or Delay

Hysteresis time is two seconds

Data Source

Cell control board

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Each cell.

Potential Issues that affect the Alarm Performance

•

Cell DSP has a fault

•

Cell Params are not OK

•

Cell PLL is not locked with Free running true

•

Cell DS sync is not OK with Free running not true

•

Cell control board is broken

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AFE Cell Related

Fault Reference for Harmony NXG

Fault Name — Cell AFE Not Ready Alarm Determine cause of cell fault Re-run the angles on the cells Corrective Action for Deficiencies

Check cell input fuses Check running of Fiber Optics Replace the cell control board.

4 ∇ ∇ ∇

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Fault Reference for Harmony NXG

Cell Bypass Related

CHAPTER

5

Cell Bypass Related

5.1 Cell Bypass Communication Failure Fault Name — Cell Bypass Communication Failure Displayed Message

Cell Bypass COM Fail

Description of Fault/Alarm

This fault is generated on the MV Bypass board when it does not receive a timely command, or receives a parity error from the modulator board.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

The data source is the MV Bypass board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The MV Bypass board is located in the Medium Voltage Section of the Drive or Cell Cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

The MV Bypass board Power supply located within the Medium Voltage section of the Drive or Cell cabinet.

•

The fiber optic link between the MV Bypass board and the NXG Modulator.

•

Possible defective MV Bypass board or NXG Modulator board.

5

Check MV Bypass Power Supply and fiber optic link and/or replace. Replace MV bypass board and/or NXG Modulator board.

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Cell Bypass Related

Fault Reference for Harmony NXG

5.2 Cell Bypass Communication Alarm Fault Name — Cell Bypass Communication Alarm

5

Displayed Message

Cell Bypass Com Alarm

Description of Fault/Alarm

This is an alarm that means the MV Bypass board is not communicating with the modulator board. This alarm will only occur if the bypass system is not in use. If the bypass system is being used, a “Cell Bypass COM Fail” is asserted (see Section 5.1). This is a system level alarm covering all cells.

Associated Parameters

There are no specific parameters that affect this alarm, but the alarm will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The data source is the MV Bypass board and/or Modulator

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The MV Bypass board is located in the Medium Voltage Section of the Drive or Cell Cabinet. The Modulator is located within the NXG Control inside the Control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

The MV Bypass board Power supply located within the Medium Voltage section of the Drive or Cell cabinet.

•

The fiber optic link between the MV Bypass board and the NXG Modulator.

•

Possible defective MV Bypass board or NXG Modulator board.

Check MV Bypass Power Supply and fiber optic link and/or replace. Replace MV bypass board and/or NXG Modulator board.

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Fault Reference for Harmony NXG

Cell Bypass Related

5.3 Cell Bypass Acknowledge Fault Fault Name — Cell Bypass Acknowledge Fault Displayed Message

Cell Bypass Acknowledge

Description of Fault/Alarm

The NXG Modulator issued a command to bypass a cell, but the MV bypass board did not return an acknowledgement that the action took place. This is a system level fault.

Associated Parameters

There are no specific parameters that affect this fault.

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

MV Bypass board.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The MV Bypass board is located in the Medium Voltage Section of the Drive or Cell Cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Verify that the bypass contactor is working properly.

•

Check wiring between MV Bypass board and contactor.

•

Check/Replace the MV bypass board power supply.

•

Possible defective MV Bypass board

5

Check MV Bypass Power Supply and fiber optic link and/or replace. Replace MV bypass board or Contactor.

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Cell Bypass Related

Fault Reference for Harmony NXG

5.4 Cell Bypass Link Fault Fault Name — Cell Bypass Link Fault

5

Displayed Message

Cell Bypass Link

Description of Fault/Alarm

This fault is generated by the Modulator Bypass PLD when it does not get a timely response from the MV Bypass board. This fault is disabled if Mechanical Bypass is not active.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

MV Bypass board, Modulator board, and the Fiber Optic Link between boards.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

MV Bypass board is usually located in the Drive Cell Cabinet. The Modulator board is located in the NXG Control chassis. The Fiber Optic link is attached to both boards and bridges the control cabinet and the cell cabinet.

Potential Issues that affect the Fault Performance

Variations or inoperability of the above mentioned equipment will affect fault performance. Verify the Fiber Optic connection between the Modulator board and MV Bypass board is intact.

Corrective Action for Deficiencies

Replace Modulator board. Check/Replace MV Bypass board power supply. Replace MV Bypass board.

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Cell Bypass Related

5.5 Cell Bypass Link Alarm Fault Name — Cell Bypass Link Alarm Displayed Message

Cell Bypass Link Alarm

Description of Fault/Alarm

This is an alarm that means the MV Bypass board is not communicating with the modulator board. This alarm will only occur if the bypass system is not in use. If the bypass system is being used, a “Cell Bypass COM Fail” is asserted (see Section 5.1). This is a system level alarm covering all cells.

Associated Parameters

There are no specific parameters that affect this alarm, but the alarm will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The data source is the MV Bypass board and/or Modulator.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The MV Bypass board is located in the Medium Voltage Section of the Drive or Cell Cabinet. The Modulator is located within the NXG Control inside the Control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

The MV Bypass board Power supply located within the Medium Voltage section of the Drive or Cell cabinet.

•

The fiber optic link between the MV Bypass board and the NXG Modulator.

•

Possible defective MV Bypass board or NXG Modulator board.

5

Check MV Bypass Power Supply and fiber optic link and/or replace. Replace MV Bypass board and/or NXG Modulator board.

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Cell Bypass Related

Fault Reference for Harmony NXG

5.6 Bypass Verify Failed Fault Name — Bypass Verify Failed

5

Displayed Message

Bypass Verify Failed

Description of Fault/Alarm

A fault/alarm is asserted if the bypass contactor, which was commanded to be closed, is not verified by the MV Bypass board. This is a cell level fault.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass, and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Specific Cell bypass contactor that was commanded to activate.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

All bypass contactors are located next to each Cell in the Cell Cabinet of the Drive. Variations or inoperability of the Cell bypass system:

Potential Issues that affect the Fault Performance

•

Cell Bypass contactor

•

MV Bypass Power supply

•

MV Bypass board

•

Modulator board

•

Fiber Optic link between the Modulator and the MV Bypass board.

Verify the Fiber Optic connection between the Modulator board and MV Bypass board is intact. Corrective Action for Deficiencies

Check/Replace MV Bypass board power supply. Replace MV Bypass board. Replace Modulator board.

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Fault Reference for Harmony NXG

Cell Bypass Related

5.7 Bypass Acknowledge Failed Fault Name — Bypass Acknowledge Failed Displayed Message

Bypass Ack Failed

Description of Fault/Alarm

A fault is asserted if the bypass contactor that was commanded to be closed is not acknowledged by the MV Bypass board. This is a cell level fault.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Specific Cell bypass contactor that was commanded to activate.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

All bypass contactors are located next to each Cell in the Cell Cabinet of the Drive.

5

Variations or inoperability of the Cell bypass system:

Potential Issues that affect the Fault Performance

•

Cell Bypass contactor

•

MV Bypass Power supply

•

MV Bypass board

•

Modulator board

•

Fiber Optic link between the Modulator and the MV Bypass board.

Verify the Fiber Optic connection between the Modulator board and MV Bypass board is intact. Corrective Action for Deficiencies

Check/Replace MV Bypass board power supply. Replace MV Bypass board. Replace Modulator board.

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Cell Bypass Related

Fault Reference for Harmony NXG

5.8 Bypass Available Warning Fault Name — Bypass Available Warning

5

Displayed Message

Bypass Avail Warning

Description of Fault/Alarm

Cell bypass available is an alarm only if cell bypass is not active for the specific cell identified. This alarm is generated on a per cell basis and is a cell level alarm. Other cells that have bypass available are permitted to be bypassed.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

The alarm hysteresis is 20 fault system samples or 67 msec before an alarm is issued.

Data Source

A specific Cell bypass contactor or channel of the MV bypass board is determined to be inoperable.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

All bypass contactors are located next to each Cell in the Cell Cabinet of the Drive. The MV Bypass board is located in the Cell cabinet too. Variations or inoperability of the Cell bypass system:

Potential Issues that affect the Fault Performance

•

Cell Bypass contactor

•

MV Bypass Power supply

•

MV Bypass board

•

Modulator board

•

Fiber Optic link between the Modulator and the MV Bypass board.

Verify the Fiber Optic connection between the Modulator board and MV Bypass board is intact. Corrective Action for Deficiencies

Check/Replace MV Bypass board power supply. Replace MV Bypass board. Replace Modulator board.

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Fault Reference for Harmony NXG

Cell Bypass Related

5.9 Cell Bypass Fault Fault Name — Cell Bypass Fault Displayed Message

Cell Bypass Fault

Description of Fault/Alarm

This is a system level Fault of the Bypass system that is usually followed by a detailed cell bypass specific fault.

Associated Parameters

There are no specific parameters that affect this fault, but the fault will only occur on systems equipped with Mechanical Cell Bypass and it must be enabled in “Bypass type” (Menu ID 2520) by setting it equal to “Mech.”

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The data source is the MV Bypass board and/or Modulator.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

The MV Bypass board is located in the Medium Voltage Section of the Drive or Cell Cabinet. The Modulator is located within the NXG Control inside the Control cabinet.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

The MV Bypass board Power supply located within the Medium Voltage section of the Drive or Cell cabinet.

•

The fiber optic link between the MV Bypass board and the NXG Modulator.

•

Possible defective MV Bypass board or Modulator.

5

Check MV Bypass Power Supply and fiber optic link and/or replace. Replace MV Bypass board and/or NXG Modulator board.

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Cell Bypass Related

Fault Reference for Harmony NXG

5.10 Bypass Hardware Alarm Fault Name — Bypass Hardware Alarm

5

Displayed Message

Bypass Hardware Alarm

Description of Fault/Alarm

This alarm occurs when the mechanical bypass is enabled and the Cell Bypass warning detection detects that the bypass control board is reporting a bypass warning, but neither the bypass communication or bypass link fault bits are detected. This should never occur, therefore there must be something wrong with the MV bypass board.

Associated Parameters

None

Hysteresis or Delay

This alarm has a half second hysteresis after detection.

Data Source

MV Bypass board Modulator board

Variables in Data Source

Fiber optic connection between the boards.

SOP Flags that affect Operation

None WCIII - Precharge cabinet (FPC)

System Location of Data Source

HV - Output cabinet Gen IV - Behind control tub in the Input/Output section Gen III - Cell cabinet

Potential Issues that affect the Fault/Alarm Performance Corrective Action for Deficiencies

•

Low 72V power source to MV bypass board

•

Defective components on board

Check supply voltage to MV bypass board Replace MV bypass board

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Fault Reference for Harmony NXG

Motor/Output Related

CHAPTER

6

Motor/Output Related

6.1 Over Speed Fault Name — Over Speed Displayed Message

Over Speed Alarm Over Speed Fault

Description of Fault/Alarm

This fault and alarm are based on the absolute value of the motor speed as compared to the Overspeed limit parameter (ID 1170). The fault occurs if the motor speed is greater than Overspeed Limit, and the alarm occurs if the motor speed is greater than 95% of Overspeed Limit.

Associated Parameters

Overspeed (Menu ID 1170), Motor Frequency (Menu ID 1020)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The Motor Speed is derived from a software based Phase Lock Loop (PLL). The PLL gains are calculated internally and cannot be changed via the menu system.

Variables in Data Source

The PLL has the most impact on the Motor Speed. Since the PLL parameters are calculated, the only variables in the data source are the voltage and current measurements from the drive output. If these measurements are scaled incorrectly or if there are offsets in the measurements, they will have an impact on the Motor Speed calculation.

SOP Flags that affect Operation

“OverSpeedAlarmEn_O” enables the overspeed alarm. “OverSpeedAlarm_I” is the overspeed alarm indicator, set true when speed is greater than 95% of trip point (Menu ID 1170). “OverSpeedFault_I” is the overspeed fault indicator, set true when speed is greater than trip point (Menu ID 1170).

System Location of Data Source

This is a derived value from a software calculation. The sensor measurements of the output voltage and current hall effects will have an impact on the Motor Speed. The location of the output sensors is in the Input/Output Cabinet of most Harmony Drives.

Potential Issues that affect the Fault Performance

Refer to “Variables in Data Source” above.

6

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Motor/Output Related

Fault Reference for Harmony NXG

6.2 Under Load Fault Name — Under Load Displayed Message

Description of Fault/Alarm

6

Under Load Alarm Under Load Fault While the drive is in the RUN state, and if the “Underload enable” (Menu ID 1180) is set true and the motor torque is less than the “I underload” (Menu ID 1182) for less time than the “Under load timeout” (Menu ID 1186), an alarm is issued. While the drive is in the RUN state, and if the “Underload enable” (Menu ID 1180) is set true and the motor torque is less than the “I underload” (Menu ID 1182) for more time than the “Under load timeout” (Menu ID 1186), a fault is issued.

Associated Parameters

“Underload enable” (Menu ID 1180), “I underload” (Menu ID 1182), “Under load timeout” (Menu ID 1186)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The fault/alarm algorithm uses the derived torque (Iqs) producing current to measure the amount of load being support by the motor. The current sensors are hall effect sensors located on phases B and C of the Output/Motor cables.

Variables in Data Source

Incorrect selection of the hall effect sensors for the drive. Incorrect power source for powering the hall effect sensors. Incorrect Menu settings “Output current scaler” (Menu ID 3440).

SOP Flags that affect Operation

“UnderLoadAlarmEn_O” enables the under load alarm. “UnderLoadAlarm_I” is the Under load alarm indicator. “UnderLoad-Fault_I” is the Under load fault indicator.

System Location of Data Source

This is a derived value from a software calculation. The sensor measurements of the output voltage and current hall effects will have an impact on the Motor Speed. The location of the output sensors is in the Input/Output Cabinet of most Harmony Drives.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

System wiring from sensors to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from sensors, Signal conditioning board, or System I/O board.

•

Defective hall effect power supplies. Replace board(s) or power supplies Evaluate wiring and grounding practices.

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Fault Reference for Harmony NXG

Motor/Output Related

6.3 Motor Thermal Overload Fault Name — Motor Thermal Overload Displayed Message

Mtr Therm Over Load 1 Mtr Therm Over Load 2 Mtr Therm Over Ld Fault Thermal overload (TOL) protection of the motor can be set up using the menus shown in the Associated Parameter section. The Overload select parameter allows one of three options to be selected for motor protection.

Description of Fault/Alarm

The first model, which is called “constant,” is based on the current flowing into the motor. A Motor Thermal Overload Alarm 1 is issued as a warning to the user (of an impending overload fault) when the motor current exceeds the Overload pending parameter. When the drive current exceeds the “overload” setting, Motor Thermal Overload Alarm 2 is issued and a thermal trip timer is started. If this condition is present for a period greater than the time set in the “Overload timeout” parameter, the drive will trip and annunciate the event with Motor Thermal Overload Fault. It should be noted that both the alarms (1 and 2) have to be enabled through the SOP for the drive to display those conditions. The second and third thermal models, “straight inverse time” and “inverse time with thresholds,” respectively, use a software motor thermal model to estimate motor temperature. For these options, the “overload pending” and “overload” settings represent the motor temperature (in percent of rated) limits at which an overload warning and trip are generated. A brief description of the thermal model follows this table. “Overload select” (Menu ID 1130) selects the overload trip algorithm. Constant (fixed current-based TOL), straight inverse time or Inv Time w/ speed derating. “Overload pending” (Menu ID 1139) sets the thermal overload level at which a warning is issued. This is based on total current for “constant” and rated thermal capacity for inverse time.

Associated Parameters

“Overload” (Menu ID 1140) sets the motor thermal overload trip level at which the timeout counter starts. “Overload timeout” (Menu ID 1150) sets the time for the overload trip. This should be minimal for the inverse time algorithms since it is directly related to temperature. “Speed Derate Curve” (Menu ID 1151) sets allowable motor load as a function of speed. “Maximum Load Inertia” (Menu ID 1159) sets the maximum load inertia that the motor can line start without exceeding maximum temperature. This affects the rated thermal capacity of the motor.

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6

Motor/Output Related

Fault Reference for Harmony NXG

Fault Name — Motor Thermal Overload

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Motor Voltage and Currents from voltage attenuators and Hall Effect transducers (current).

Variables in Data Source SOP Flags that affect Operation

6

System Location of Data Source

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

* 6.3.1

“MotorThermalOverload1En_O” enables Motor Over Load 1 alarm. “MotorThermalOverload2En_O” enables Motor Over Load 2 alarm. Voltage attenuators and Hall Effect transducers are usually located in the Input/Output cabinet of the Drive. •

Incorrect menu settings or motor data

•

Variations in voltage attenuator or Hall Effect transducers

•

Possibly a bad signal conditioning board, system interface board, Hall Effect power supplies, or wiring issues.

Correct menu settings Replace defective boards or wiring issues. See below for details of the algorithm

Note: For all modes, the heating in the motor is increased by the square of the current above the motor ratings. Therefore a setting of 120% produces an increase of 44% more thermal energy into the motor – [(1.2)2 – (1.0)2 = 0.44 increase (PU)]. Constant Mode

The first model, which is called “constant,” is based on the total current flowing into the motor. A Motor Thermal Overload Alarm 1 is issued as a warning to the user (of an impending overload fault) when the motor current exceeds the “overload pending” parameter. When the drive current exceeds the “overload” setting, Motor Thermal Overload Alarm 2 is issued and a thermal trip timer is started. If this condition is present for a period greater than the time set in the “overload timeout” parameter, the drive will trip and annunciate the event as Motor Thermal Overload Fault. The Constant Mode might be appropriate for a motor having a separate blower, and operating in a constant ambient temperature, so that it has constant cooling capability regardless of speed.

*

Note: Since this method uses a single threshold level, it cannot distinguish between a relatively minor overload condition and a major one. Therefore this method is not recommended as the default. For most applications, the best protection is from the mode - Inverse Time with Speed derating.

*

Note: It should be noted that both the Alarms 1 and 2 have to be enabled through the SOP for the drive to display those conditions.

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Fault Reference for Harmony NXG

6.3.2

Motor/Output Related

Inverse-time Modes

The second and third thermal models, which are called “straight inverse time” and “inverse time with thresholds,” use a software motor thermal model to estimate motor heating. See Figure 6-1. For these options, the “overload pending” and “overload” settings represent the motor thermal mass limits (in percent of rated motor thermal mass allowance or capacity) at which the overload warning and trip are generated. This model is based on NEMA ratings as described below. A brief description of the thermal model follows.

Motor voltages, currents

Motor loss calculation

+ -

Σ

Motor parameters

1 M TH

Motor temperature

Motor cooling model

6

Speed derate curve Figure 6-1: Block Diagram of Motor Thermal Model

The motor model estimates motor temperature based on the net heat generated in the motor and its thermal mass – the amount of thermal energy input to the motor before overheating. This is generally a function of motor losses and how well a motor can cool itself, or be cooled through external means. A block diagram of the implementation is shown in Figure 6-1. The heat generated in the motor is estimated from the stator voltages, currents, and motor parameters, while an estimate of the heat dissipated by the motor due to motor cooling, is made from the allowable motor current (more on this in the following paragraph). The motor loss calculation also includes the losses generated with Dual-Frequency Braking. The thermal mass (shown as MTH) of the motor (or its heat capacity) is determined from the maximum load inertia listed in Table 20-1 of NEMA Standard MG-1 1993 Part 20.42. The user has the option of entering a known value of max load inertia as well (which can be obtained from the manufacturer). The plot in Figure 6-2 shows results from an experimental evaluation of the software thermal model with the “straight inverse time” option (fixed 100% Motor Current rating) for various levels of drive current. This curve is plotted at constant rated speed, and the threshold is fixed for calculating thermal capacity. If the “speed curve” were plotted for this mode, it would appear as a straight line fixed at 100% over the entire speed range. A 4kV, 300 Hp motor was used for this test. The experimental data shows the time taken for the estimated motor temperature to go from rated temperature to 120% of rated. This curve is quite conservative as compared to a Class 10 TOL that trips at 280 sec with 150% current and at 630 sec with 125% current.

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Motor/Output Related

Fault Reference for Harmony NXG

6 Figure 6-2: Drive Current (In Percent Of Motor Rated Current) Versus Time Taken For Motor Temperature * The data was measured with the “straight inverse time” option with the motor operating at full speed.

If “straight inverse time” protection is chosen, the motor model thermal curve is based on the Full-load current rating of the motor throughout the entire speed range.

*

Note: Since this mode uses no derating for reduced speed operation, this setting should only be used for quadratic loads (minimal torque requirements at low speed) or for when the motor is equipped with a constant-speed cooling fan. For constant loads (loading throughout the speed range), “inverse time with speed derating” should be used.

The thermal model is based on motor ratings to attempt to estimate the heating of the motor, where the main thermal input is due to motor losses in direct relationship to the total current (stator and rotor losses). The balance of heat storage (thermal input) and heat loss (cooling) determine the motor temperature, and is known as Thermal Capacity.

*

Note: This algorithm attempts to estimate this heating, but is an estimate at best, and is not intended to replace external motor thermal monitoring to protect the motor in critical applications.

As the thermal input exceeds the thermal output, the temperature of the motor increases. If this continues unabated, the motor will overheat. Therefore two levels of thermal capacity are established: one to allow for early warning and corrective action, and another for when a fault trip is impending. The control software also follows the curve for cooling when the thermal input becomes lower than the thermal output, such that a lower thermal input produces faster cooling until a new equilibrium is established and the temperature is maintained. If the user’s preference is to enter a fixed value of an allowable current level other than 100% (as with the “straight inverse time” option), the speed-derating curve can be modified to have the same desired level for all the breakpoints, thereby eliminating the speed derating and allowing a higher level of operation. This is not recommended unless the motor has a higher service factor, and a constant speed separate blower.

s 6-6 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

6.3.3

Motor/Output Related

Inverse time with speed derating

The inverse time curve with speed derating is a special case of inverse time protection. Since it derates the maximum motor rating with respect to speed, it provides the best motor protection of the three modes, especially at starting and for low speed operation. For motors without separate blowers, this is the recommended setting. If Inverse time with speed derating is used, the allowable current level used in the model is determined from the speed-derating curve entered through the keypad. This curve requires the user to enter allowable motor loads for various speed breakpoints. The default-derating curve provides breakpoints for a quadratic cooling curve (and is shown in Figure 6-3). The motor manufacturer normally provides data for this curve.

6

Figure 6-3: Default Speed-derating Curve Showing Maximum Motor Load As A Function Of Speed

This algorithm is complex in that it provides a family of curves similar to the straight inverse time mode, but with the maximum point of each curve at the operational speed, defined by the max motor load current at the speed taken from the Speed derating curve.

*

Note: The Inverse time with speed derating is the recommended setting for most applications, especially when high starting torque is needed or low speed protection is required.

*

Note: The inverse time algorithms will only work correctly if the proper Max Load Inertia is used. If this is known from the manufacturer, then this should be entered into parameter “Maximum Load Inertia” (ID 1159). If this value is zero, the NXG software will attempt to calculate the value based on the “Motor kW Rating” (1010) and the synchronous speed (based on Motor Frequency (1020) and Full Load Speed (1030)). If the values are outside of the range of the NEMA Table 20-1 from NEMA Standard MG-1 (See Table 6-1) in either HP or Synchronous Speed, then the maximum value for the synchronous speed column must be used, but must be converted from lb-ft² units to kg-m² units by multiplying the table number by 23.73. The result should then be entered into the Maximum Load Inertia parameter.

s A1A19000864: Version 4.0

6-7 CONFIDENTIAL / FOR INTERNAL USE ONLY

Motor/Output Related

*

Fault Reference for Harmony NXG

Note: To convert to HP to use this table, multiply the Motor kW rating by 0.746. Table 6-1: NEMA Table 20-1 from NEMA Standard MG-1 1993 Part 20.42 Maximum Load Inertia for Polyphase Squirrel-Cage Induction Motors in lb-ft²

HP

3600

1800

1200

900

720

600

450

400

360

327

300

100

12670

16830

21700

27310

33690

125

15610

20750

26760

33680

41550

13410

18520

24610

31750

39960

49300

12060

17530

24220

32200

41540

52300

64500

9530

14830

21560

29800

39640

51200

64400

79500

150

6

200 250

514

300

6540

11270

17550

25530

35290

46960

60600

76400

94300

350

7530

12980

20230

29430

40710

54200

69900

88100

108800

400

4199

8500

14660

22870

33280

46050

61300

79200

99800

123200

450

4666

9460

16320

25470

37090

51300

68300

88300

111300

137400

500

5130

10400

17960

28050

40850

56600

75300

97300

122600

151500

600

443

2202

6030

12250

21190

33110

48260

66800

89100

115100

145100

179300

700

503

2514

6900

14060

24340

38070

55500

76900

102600

132600

167200

206700

800

560

2815

7760

15830

27440

42950

62700

86900

115900

149800

189000

233700

900

615

3108

8590

17560

30480

47740

69700

96700

129000

166900

210600

260300

1000

668

3393

9410

19260

33460

52500

76600 106400

141900

183700

231800

286700

1250

790

4073

11380

23390

40740

64000

93600 130000

173600

224800

283900

351300

1500

902

4712

13260

27350

47750

75100 110000 153000

204500

265000

334800

414400

1750

1004

5310

15050

31170

54500

85900 126000 175400

234600

304200

384600

476200

2000

1096

5880

16780

34860

61100

96500 141600 197300

264100

342600

433300

537000

2250

1180

6420

18430

38430

67600 106800 156900 218700

293000

380300

481200

596000

2500

1256

6930

20030

41900

73800 116800 171800 239700

321300

417300

528000

655000

3000

1387

7860

23040

48520

85800 136200 200700 280500

376500

489400

620000

769000

s 6-8 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

HP

3600

1800

1200

900

720

600

514

450

400

360

327

300

3500

1491

8700

25850

54800

97300 154800 228600 319900

429800

559000

709000

881000

4000

1570

9460

28460

60700 108200 172600 255400 358000

481600

627000

796000

989000

4500

1627

10120

30890

66300 118700 189800 281400 395000

532000

693000

881000 1095000

5000

1662

10720

33160

71700

128700 206400 306500 430800

581000

758000

963000 1198000

5500

1677

11240

35280

76700 138300 222300 330800 465600

628000

821000

1044000 1299000

6000

11690

37250

81500 147500 237800 354400 499500

675000

882000

1123000 1398000

7000

12400

40770

90500 164900 267100 399500 565000

764000 1001000

1275000 1590000

8000

12870

43790

98500 181000 294500 442100 626000

850000 1114000

1422000 1775000

9000

13120

46330 105700 195800 320200 482300 685000

931000 1223000

1563000 1953000

10000

13170

48430 112200 209400 344200 520000 741000 1009000 1327000

1699000 2125000

11000

50100 117900 221900 366700 556000 794000 1084000 1428000

1830000 2291000

12000

51400 123000 233500 387700 590000 845000 1155000 1524000

1956000 2452000

13000

52300 127500 244000 407400 622000 893000 1224000 1617000

2078000 2608000

14000

52900 131300 253600 425800 653000 939000 1289000 1707000

2195000 2758000

15000

53100 134500 262400 442900 681000 983000 1352000 1793000

2309000 2904000

*

Note: The gaps in Table 6-1 are present in the NEMA standard.

s A1A19000864: Version 4.0

6-9 CONFIDENTIAL / FOR INTERNAL USE ONLY

6

Motor/Output Related

Fault Reference for Harmony NXG

6.4 Output Phase Imbalance Fault Name — Output Phase Imbalance Displayed Message

Output Phase Imbal

Description of Fault/Alarm

Output Phase Imbalance is fixed as an alarm. This alarm detects the condition that an imbalance exists in the three output phases. This may be tied in with a neutral current path or ground fault condition, or may be due to shorted windings in the motor. The Drive software calculates value known as the negative sequence vector. Under normal balance load conditions, the value is zero. If value increases, it indicates the three phase output is becoming unbalanced. If this value exceeds the limit setting “Phase Imbalance Limit” (Menu ID 1244), an alarm is asserted. This condition is ignored during the “Auto Tuning” and “Magnetizing” state of the Drive.

Associated Parameters

“Phase Imbalance Limit” (Menu ID 1244) determines the alarm assertion point.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The fault/alarm algorithm uses the derived negative sequence currents. The current sensors are hall effect sensors located on phases B and C of the Output/Motor cables.

Variables in Data Source

Incorrect selection of the hall effect sensors for the drive. Incorrect power source for powering the hall effect sensors.

SOP Flags that affect Operation

“OutputPhaseImbalance_I” indicates output phase imbalance condition.

System Location of Data Source

This is a derived value from a software calculation. The sensor measurements of the output voltage and current hall effects will have an impact on the Motor Speed. The location of the output sensors is in the Input/Output Cabinet of most Harmony Drives.

6

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

System wiring from sensors to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from sensors, Signal conditioning board, or System I/O board.

•

Defective hall effect power supplies.

Replace board(s) or power supplies. Evaluate wiring and grounding practices.

s 6-10 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

6.5 Output Phase Open Fault Name — Output Phase Open Displayed Message

Output Phase Open

Description of Fault/Alarm

This Fault is disabled in all versions of NXG software.

Associated Parameters Hysteresis or Delay Data Source Variables in Data Source

6

SOP Flags that affect Operation System Location of Data Source Potential Issues that affect the Fault Performance

s A1A19000864: Version 4.0

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Motor/Output Related

Fault Reference for Harmony NXG

6.6 Output Ground Fault Fault Name — Output Ground Fault Displayed Message

Output Ground Fault

Description of Fault/Alarm

Output Ground Fault is an Alarm. Refer to figure 6-4. The NXG software calculates the motor neutral voltage (Vgnd). The variables used are described below. Y0 represents the instantaneous volt-seconds on the motor neutral. Y0DC is the average (or DC component) value of Y0. Typically, this component is quite small and does not affect the estimated value of ground voltage, Vgnd. Y0AC is the (filtered) AC component of Y0. Vgnd is the motor neutral voltage; the equation converts volt-seconds to voltage in per-unit. Frequency represents the stator frequency that is measured (separately) by the control. DC gain is the dc-gain of the integrators and is used to convert Y0DC (in dc volt-seconds) to motor volts. The dc-gain is fixed by the hardware circuitry used in the System Interface Board or System I/O Board (NXGII).

6

Associated Parameters

The Ground Fault Limit parameter (ID 1245) allows the user to adjust the threshold level at which the control issues a Ground Fault Alarm. A comparison of the calculated ground voltage, Vgnd, with the Ground Fault Limit parameter is performed in software to determine a Ground Fault. Default value of this parameter is 5.0%. The user can set the filter time constant of the “Low Pass Filter” through parameter ID 1246. Default value of this parameter is 0.017sec, approximately corresponding to one cycle of 60Hz.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Voltage Attenuators

Variables in Data Source

Variations in voltage attenuation resistors

SOP Flags that affect Operation

“OutputGroundFault_” indicates a ground fault at the drive output

System Location of Data Source

Voltage Attenuators are located in the input/output cabinet of the drive. Current Transducers are located within the input transformer cabinet. The Hall Effect Sensors are located in the Input/Output Cabinet. The Hall Effect Power supplies are located in the Control Cabinet.

s 6-12 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

Fault Name — Output Ground Fault

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

Replace board(s) Evaluate wiring and grounding practices.

6 HARMONY VFD CABLE

VFD Neutral

A1

A2

A3

A4

A5

B1

B2

B3

B4

B5

A B

Induction Motor C

C1

C2

C3

C4

Motor chassis

C5

Power Cells

Attenuator Resistors

Vma

Ya

Vmb

Yb Yc

Vmc Chassis Ground

~0Ω

Control Ground

PROCESSOR (Motor neutral voltage calculation)

Integrators A/D CONV.

Y0 = (Ya + Yb + Yc)/3 Y0DC = AVG [Y0] Y0AC = LowPassFilter [Y0 – Y0DC] Vgnd = Y0AC * Freq + Y0DC / DCgain

Figure 6-4: Motor neutral voltage calculation

s A1A19000864: Version 4.0

6-13 CONFIDENTIAL / FOR INTERNAL USE ONLY

Motor/Output Related

Fault Reference for Harmony NXG

6.7 Instantaneous Over Current Fault Name — Instantaneous Over Current

6

Displayed Message

IOC

Description of Fault/Alarm

The IOC is a hardware fault and is composed of analog circuitry that measures the level of the total current feedback and compares it to an adjustable level. The adjustable level is a programmable threshold utilizing an 8 bit DAC. This fault is never masked.

Associated Parameters

“Drive IOC Setpoint” (Menu ID 7110) determines the threshold for the IOC fault assertion. The default value is 150%.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The current feedback from the hall effect sensors on phases B and C of the Drive output.

Variables in Data Source

Incorrect selection of the hall effect sensors for the drive. Incorrect power source for powering the hall effect sensors.

SOP Flags that affect Operation

“IOC_I” indicates an IOC has occurred.

System Location of Data Source

The location of the current sensors is in the Input/Output Cabinet of most Harmony Drives. The sensor outputs are wired to the signal conditioning board, then to the system interface board. On the system interface board is the circuitry of deriving the threshold level for the total current. This signal is wired to the Modulator Board that contains the DAC and comparator circuitry.

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies

•

Incorrect IOC setting in the menu (Menu ID 7110).

•

Incorrectly sized Hall Effect sensors for Drive rating.

•

Defect in circuitry on the Signal Conditioning Board, System Interface, or Modulator Board.

Check IOC Setting (Menu ID 7110). Check wiring between boards, replace defective boards.

s 6-14 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

6.8 Motor Over Voltage Fault Name — Motor Over Voltage Displayed Message

Motor Over Volt Alarm Motor Over Volt Fault

Description of Fault/Alarm

The Motor Over Voltage detection is used to sense motor voltages outside of the limits for the motor. If the motor voltage exceeds 90% of the Motor trip volts menu setting, an alarm is asserted (if enabled through the SOP). If the motor voltage exceeds the motor trip volts, then a fault is asserted.

Associated Parameters

“Motor trip volts” (Menu ID 1060). Sets the trip point for a Motor Over Voltage condition. If the alarm is enabled, it will be asserted at 90% of the “Motor trip volts” (Menu ID 1060).

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Voltage Attenuators

Variables in Data Source

Variations in voltage attenuation resistors

6

“MotorOverVoltageAlarm_I” indicates that the motor voltage is within 90% of the trip point (Menu ID 1060). SOP Flags that affect Operation

“MotorOverVoltageFault_I” indicates that the motor voltage is greater than the trip point (Menu ID 1060). “MotorOverVoltageAlarmEn_O” enables the motor over voltage alarm.

System Location of Data Source

Potential Issues that affect the Fault Performance

Voltage Attenuators are located in the input/output cabinet of the drive. •

Incorrect resistor values for required input voltage.

•

System wiring from attenuators to Signal Conditioning board.

•

Defective Signal Conditioning Board, System Interface board, or Analog I/O board.

•

In NXGII chassis, defective system wiring from attenuators, Signal conditioning board, or System I/O board.

s A1A19000864: Version 4.0

6-15 CONFIDENTIAL / FOR INTERNAL USE ONLY

Motor/Output Related

Fault Reference for Harmony NXG

Fault Name — Motor Over Voltage The measured motor voltage exceeds the threshold set by the Motor trip volts (1160) parameter in the Limits Menu (1120). An improperly set up or tuned drive usually causes this fault.

Corrective Action for Deficiencies

Actions: 1. Verify that the motor and drive nameplate settings match the corresponding parameters in Motor Parameter Menu (1000) and Drive Parameter Menu (2000). 2.

Verify that the signals on the VMA/TP5, VMB/TP6, and VMC/TP7 test points on the System Interface Board are operating properly with in ±6V. If an incorrect voltage is noted, check the voltage attenuator or replace the System Interface Board or System I/O board (NXGII).

6

s 6-16 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

6.9 Failed To Magnetize--Induction Motors Fault Name — Failed To Magnetize Displayed Message

Failed To Magnetize For induction motors only, the motor’s magnetizing current reference (Ids ref) is monitored. If the current reaches 80% of the maximum load current for longer than 5 times the flux ramp rate, an alarm or fault, depending on the SOP setting of “FailedToMagnetizeFaultWn_O,” is asserted. This feature basically prevents excessive reactive current to the motor.

Description of Fault/Alarm

Notes: •

During high starting torque mode, the trip time used is the flux ramp rate.

•

For induction motors with pole pairs greater than or equal to 5 (10 pole machines or greater), the limit is 95% of maximum load current

Associated Parameters

“Flux ramp rate” (Menu ID 3160) the timeout period is 5 times the ramp rate. “Stator Resistance” (Menu ID 1080) must be set per the motor name plate.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The current feedback from the hall effect sensors on phases B and C of the Drive output.

Variables in Data Source

Incorrect selection of the hall effect sensors for the drive. Incorrect power source for powering the hall effect sensors.

SOP Flags that affect Operation

“FailedToMagnetizeFault_I” indicates that the drive failed to magnetize the motor. “FailedToMagnetizeFaultWn_O” sets failed to magnetize as an alarm.

System Location of Data Source

The location of the current sensors is in the Input/Output Cabinet of most Harmony Drives. The sensor outputs are wired to the signal conditioning board, then to the system interface board.

Potential Issues that affect the Fault Performance

•

Incorrect menu settings as indicated above.

•

Incorrectly sized Hall Effect sensors for Drive rating.

•

Defect in circuitry on the Signal Conditioning Board, System Interface, or Modulator Board.

6

Check menu setting. Corrective Action for Deficiencies

Check sensors, power supplies, and wiring between boards Replace defective boards

s A1A19000864: Version 4.0

6-17 CONFIDENTIAL / FOR INTERNAL USE ONLY

Motor/Output Related

Fault Reference for Harmony NXG

6.10 Loss of Field Current--Synchronous Motors Fault Name — Loss of Field Current Displayed Message

Description of Fault/Alarm

Loss of Field Current The motor’s field current reference (Ids Ref) is monitored. If the current reaches “LossOfFieldLevel” for the timeout time (1142), an alarm or fault is asserted, depending on the SOP setting of “LossOfFieldFaultWn_O.” This occurs only with synchronous motor control due to field exciter failure or loss of power to the exciter. Note: During SMDC startup sequence, this time is extended to 100 times the menu setting.

6

Associated Parameters

“LossOfFieldTimeout” (1142) “LossOfFieldLevel” (1141)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The current feedback from the hall effect sensors on phases B and C of the Drive output.

Variables in Data Source

Incorrect selection of the hall effect sensors for the drive. Incorrect power source for powering the hall effect sensors.

SOP Flags that affect Operation

“LossOfFieldFault_I” indicates that the field control of a synch motor has failed. “LossOfFieldFaultWn_O” sets loss of field as an alarm.

System Location of Data Source

The location of the current sensors is in the Input/Output Cabinet of most Harmony Drives. The sensor outputs are wired to the signal conditioning board, then to the system interface board.

Potential Issues that affect the Fault Performance

•

Incorrect menu settings as indicated above.

•

Incorrectly sized Hall Effect sensors for Drive rating.

•

Defect in circuitry on the Signal Conditioning Board, System Interface, or Modulator Board.

Check if the power supply to the exciter is energized. Corrective Action for Deficiencies

To determine if the field exciter is operating correctly, reduce Flux demand (3150) to 0.40, increase Accel time 1 (2260) to a larger value, and run the motor with 5% speed demand. If the drive magnetizing current reference (Idsref) does not go to zero, then the field exciter is not working (or is not adjusted properly).

s 6-18 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

6.11 Field Exciter Fault Fault Name — Field Exciter Fault Displayed Message

Field Exciter Fault

Description of Fault/Alarm

If the drive is being used with a synchronous motor, the drive is commanded to run and the system program flag “ExciterErrorNotOkToRun_O” is true, then this fault is generated.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

System program generated. The system program is generally coded to monitor the field exciter digital output to generate this fault.

Variables in Data Source SOP Flags that affect Operation

None “FieldExciterFault_I” indicates a field exciter fault has occurred. “ExciterErrorNotOkToRun_O” is used to generate this fault.

System Location of Data Source

Depends on system program.

Potential Issues that affect the Fault Performance

Errors are possible in system program logic or failure of field exciter.

Corrective Action for Deficiencies

6

Correct system program. Check field exciter and wiring.

s A1A19000864: Version 4.0

6-19 CONFIDENTIAL / FOR INTERNAL USE ONLY

Motor/Output Related

Fault Reference for Harmony NXG

6.12 Minimum Speed Trip Fault Name — Minimum Speed Trip

6

Displayed Message

Minimum Speed Trip

Description of Fault/Alarm

If motor speed is below the “Zero Speed” (Menu ID 2200) for 15 seconds, an alarm or fault is asserted. If the “Zero Speed” (Menu ID 2200) is set to zero, the alarm/fault is disabled.

Associated Parameters

“Zero Speed” (Menu ID 2200) sets the threshold for the trip point. If set to zero, the alarm/fault is disabled.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The Motor Speed is derived from a software based Phase Lock Loop (PLL). The PLL gains are calculated internally and cannot be changed via the menu system.

Variables in Data Source

The PLL has the most impact on the Motor Speed. Since the PLL parameters are calculated, the only variables in the data source are the voltage and current measurements from the drive output. If these measurements are scaled incorrectly or if there are offsets in the measurements, they will have an impact on the Motor Speed calculation.

SOP Flags that affect Operation

“LowMotorSpeedFault_I” indicates that low motor speed condition exists. “LowMotorSpeedFaultEn_O” enables this fault/ alarm. “LowMotorSpeedFaultWn_O” changes the fault to an alarm.

System Location of Data Source

This is a derived value from a software calculation. The sensor measurements of the output voltage and current hall effects will have an impact on the Motor Speed. The location of the output sensors is in the Input/Output Cabinet of most Harmony Drives.

Potential Issues that affect the Fault Performance

Refer to “Variables in Data Source” above.

s 6-20 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Motor/Output Related

6.13 In Torque Limit Fault Name — In Torque Limit Displayed Message

In Torque Limit

Description of Fault/Alarm

When the Drive reaches it maximum current output and stays there for more than 1 minute, an “InTorqueLimit_I” is asserted. This assertion is always an alarm. The torque limit is determined by a number of different sources:

Associated Parameters

•

Motor Rating Limits

•

Single Phasing Limit

•

Under Voltage Limit

•

Field Weakening Limit

•

Braking

•

Cell Over Load Limit

6

The algorithm uses the lowest of these limits to determine that it is in torque limit.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The torque limit is part of the drive control algorithm. The control uses the current and voltage sensors from the input and output of the drive.

Variables in Data Source

The current and voltage sensors can have incorrect ratings for the drive, or incorrect attenuation resistors for voltage, or incorrect burden resistors for current feedback.

SOP Flags that affect Operation

“InTorqueLimit_I” indicates the drive is in torque limit for more than 1 minute. “InTorqueLimitEn_O” enables the alarm.

System Location of Data Source Potential Issues that affect the Fault Performance

The current and voltage sensors are usually located in the input/ output cabinet of the drive. •

Incorrectly sized sensors for Drive rating.

•

Defect in circuitry on the Signal Conditioning Board, System Interface, or Modulator Board.

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Motor/Output Related

Fault Reference for Harmony NXG

6.14 In Torque Limit Rollback Fault Name — In Torque Limit Rollback Displayed Message

In Torq Limit Rollback

Description of Fault/Alarm

When the Drive reaches it maximum current output and stays there for more than 20 minutes, an “InTorqueLimitRollback_I” is asserted. This assertion is always an alarm. The torque limit is determined by a number of different sources:

6

Associated Parameters

•

Motor Rating Limits

•

Single Phasing Limit

•

Under Voltage Limit

•

Field Weakening Limit

•

Braking

•

Cell Over Load Limit

The algorithm uses the lowest of these limits to determine that it is in torque limit.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

The torque limit is part of the drive control algorithm. The control uses the current and voltage sensors from the input and output of the drive.

Variables in Data Source

The current and voltage sensors can have incorrect ratings for the drive, or incorrect attenuation resistors for voltage, or incorrect burden resistors for current feedback. “InTorqueLimitRollback_I” indicates the drive is in torque limit for more than 20 minutes.

SOP Flags that affect Operation

“InTorqueLimitRollbackEn_O” enables this alarm / fault. “InTorqueLimitRollbackWn_O” sets in torque limit rollback as an alarm.

System Location of Data Source Potential Issues that affect the Fault Performance

The current and voltage sensors are usually located in the input/ output cabinet of the drive. •

Incorrectly sized sensors for Drive rating.

•

Defect in circuitry on the System I/O Board, Breakout Board or Modulator Board.

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Motor/Output Related

6.15 Pole Slip - SMDC Fault Name — Pole Slip Displayed Message

SM Pole Slip The conditions triggering a Pole Slip fault are:

Description of Fault/Alarm

•

Control algorithm is set to “SMDC” (Control type 2050)

•

Drive must be in the “Run” state (only)

•

Output motor speed is equal to or exceeds rated slip

•

All conditions are met for a minimum of 1 second

When all conditions are met, the “PoleSlip_I” SOP fault flag is set true, and the indication message “SM Pole Slip” is displayed.

6

The Pole Slip event can seriously damage components of the motor’s brushless excitation system, and asynchronous operation can quickly cause the motor to overheat.

Associated Parameters

Control Type (2050) (Slip is generally set to 2% as a default for this mode). Full Load Speed (1030) (determines slip).

Hysteresis or Delay

This fault has a delay of 1 second once the conditions are set. Output voltage attenuators

Data Source

System I/O board Field exciter

Variables in Data Source

Rated slip setting

SOP Flags that affect Operation

“PoleSlipFaultWn_O” set for alarm, not fault

System Location of Data Source

Potential Issues that affect the Fault Performance

DCR for signal feedback conditioning and field exciter command. Power cell cabinet for output attenuators. •

Improper slip setting

•

Field exciter not working correctly

•

Load too great to break free

Check settings. Corrective Action for Deficiencies

Check exciter circuitry. Check load.

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Fault Reference for Harmony NXG

6.16

Motor/Output Related

Motor Pull-out - PMM Fault Name — Motor Pull-out

Displayed Message

PMM Motor Pull-out Flt This fault is only active in the PMM motor control mode. Fault occurs under the following conditions:

Description of Fault/Alarm

•

PMM control algorithm selected

•

Drive is in Run State

•

The Speed Regulator is enabled (after start-up sequence)

•

The Flux Feedback (FluxDS) is less than 30%

The fault is automatically enabled if in PMM mode.

6

This detects that the drive is not locked onto the voltage feedback from the motor, and therefore the output voltage vector is not aligned with the flux vector and can produce no torque. Control Type (2050) Associated Parameters

Motor parameters (1000) Drive parameters (2000)

Hysteresis or Delay Data Source

None Output attenuators System I/O board

Variables in Data Source

Wiring, values, Motor parameter setup

SOP Flags that affect Operation

None Output cabinet for attenuators

System Location of Data Source

Potential Issues that affect the Fault Performance

Control cabinet for System I/O board (DCR rack), and Breakout board •

Improper motor or drive settings

•

Improperly sized attenuators for voltage feedback

•

Defective system I/O, or Breakout board

Check motor settings Corrective Action for Deficiencies

Check voltage attenuators and scaling Replace system I/O Replace Breakout board

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Low Voltage Power Supply Related

CHAPTER

7

Low Voltage Power Supply Related

7.1 Power Supply Fault Name — Power Supply Displayed Message

Power Supply

Description of Fault/Alarm

The power supply sends a signal to the control system whenever it loses AC input. Since the control system cannot operate without this power supply, this fault should not be visible on the display until power has been re-established. This power supply signal automatically causes the modulator to shut off the cells with no other control system intervention.

Associated Parameters

None

Hysteresis or Delay

No delay or hysteresis

Data Source

Control system power supply

Variables in Data Source

None

SOP Flags that affect Operation

“PowerSupplyFault_I” flag is set on fault

System Location of Data Source

Control cabinet

Potential Issues that affect the Fault Performance

The signal comes from the power supply, goes through the System Interface to the Modulator Board. This signal path must be intact.

Corrective Action for Deficiencies

Check that the power supply has AC voltage.

7

Check the signal from the power supply. Check modulator board. Comments

None

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Low Voltage Power Supply Related

Fault Reference for Harmony NXG

7.2 Hall Effect Power Supply Fault Name — Hall Effect Power Supply

7

Displayed Message

Hall Effect Pwr Supply

Description of Fault/Alarm

The outputs of the Hall Effect power supplies are monitored by circuitry on the System Interface board. This circuitry then sends a status signal via the modulator to the control system software. This power supply fail signal automatically causes the modulator to shut off the cells with no other control system intervention.

Associated Parameters

None

Hysteresis or Delay

No delay or hysteresis

Data Source

System interface board, Hall Effect Power Supplies

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Control cabinet

Potential Issues that affect the Fault Performance

None Check that the Hall Effect power supplies have AC voltage.

Corrective Action for Deficiencies

Check the wiring from the power supplies. Check the system interface board. Check modulator board.

Comments

None

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System I/O Related

CHAPTER

8

System I/O Related

8.1 Wago Communication Fault Name — Wago Communication Displayed Message

Wago Communication Alarm Wago Communication Fault

Description of Fault/Alarm

When there are problems communicating with the Wago, the system will produce a “Wago Communication Alarm.” If the problem persists and if enabled, a “Wago Communication Fault” will be issued. If the “Wago Timeout” parameter is non-zero, this parameter will be sent to the Wago on initialization. This will cause the Wago to take action on its own and reset its modules whenever this timeout period is exceeded after a communication loss.

Associated Parameters

“Wago timeout” ID 2850.

Hysteresis or Delay

There is approximately 5 seconds between the issuance of a “Wago Communication Alarm” and the issuance of a “Wago Communication Fault.”

Data Source

Wago modules

Variables in Data Source

None

SOP Flags that affect Operation

“DisableWagoCommunicationFault_O” disables the Wago Communication Fault.

System Location of Data Source

Wago modules

Potential Issues that affect the Fault Performance

None

8

Check Wago coupler and configuration settings. Corrective Action for Deficiencies

Check Wago power supply. Check cable between CPU and Wago.

Comments

None

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Fault Reference for Harmony NXG

8.2 Wago Internal Errors Fault Name — Wago Internal Errors Wago Internal Fault Wago Coupler Fault Wago Flt After Module Displayed Message

Wago Fault At Module Wago Internal Alarm Wago Coupler Alarm Wago Alm After Module Wago Alm At Module

8

Description of Fault/Alarm

These are errors reported by the Wago system to the drive.

Associated Parameters

None

Hysteresis or Delay

There is approximately 30 seconds between the issuance of a Wago internal alarm type and the issuance of a Wago internal fault type.

Data Source

Wago communication coupler

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Wago communication coupler

Potential Issues that affect the Fault Performance

Wago modules must be properly installed in Wago rack.

Corrective Action for Deficiencies Comments

Make sure Wago modules are properly installed. Replace bad Wago modules. None

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System I/O Related

8.3 Wago Configuration Fault Name — Wago Configuration Displayed Message

Wago Configuration

Description of Fault/Alarm

If any of the parameters “Analog Inputs,” “Analog Outputs,” “Digital Inputs,” or “Digital Outputs” is non zero, then the Wago must respond with the exact same values contained in each of these parameters, or a fault is issued.

Associated Parameters

Parameter

ID

Analog inputs

2810

Analog outputs

2820

Digital inputs

2830

Digital outputs

2840

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Wago

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Wago modules

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Loose Wago modules

•

Bad Wago modules

•

Incorrect number of Wago modules installed

•

Incorrect number of Wago modules entered in parameters

8

Check Wago configuration. Check parameter settings. None

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Fault Reference for Harmony NXG

8.4 Loss of Signal Fault Name — Loss of Signal Displayed Message

“Loss of Signal ##” - where ## is equal to 1 to 24, or “Int AI# Loss of Signal” - where # is equal to 1 to 3. These faults / alarms are used to indicate a loss of analog input signal. If an analog input is selected as the source for one of the drive inputs: “Analog Input #1,” “Analog Input #2,” “Analog Input #3,” “Analog Input #4,” “Analog Input #5,” “Auxiliary Input #1,” or “Auxiliary Input #2,” a loss of signal condition occurs when the selected analog input’s input current goes below that drive input’s associated “Loss Point Threshold” parameter.

Description of Fault/Alarm

Further, if the associated drive input is not currently controlling the motor when a loss of signal occurs, an alarm is issued. If the associated drive input is currently controlling the motor when a loss of signal occurs, an action will take place corresponding to the drive input’s associated “Loss of Signal Action.” If an analog input is not selected as a source for one of the drive inputs but it is selected as a source for a comparator, a loss of signal action is enabled via the SOP. Further, the loss of signal action (fault or alarm) is determined by the SOP. For analog inputs that meet these criteria, the loss of signal set point is fixed at 3 ma.

8 Associated Parameters

See Table 8-1 at the end of this chapter.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Wago analog inputs for messages displayed as “Loss of Signal ##” or System I/O board analog inputs for messages displayed as “Int AI# Loss of Signal.”

Variables in Data Source

None

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System I/O Related

Fault Name — Loss of Signal For the 24 loss of signals associated with the Wago modules, the following flags apply:

SOP Flags that affect Operation

System Location of Data Source

Potential Issues that affect the Fault Performance

•

“LossOfSignal1En_O” through “LossOfSignal24En_O” enables the corresponding loss of signal fault / alarm for the associated analog input if it is used only as data for a comparator.

•

“LossOfSignal1Wn_O” through “LossOfSignal24Wn_O” sets the corresponding loss of signal to be an alarm for the associated analog input if it is used only as data for a comparator.

For the 3 loss of signals associated with the System I/O board, the following flags apply: •

“InternalLossOfSignal1En_O” through “InternalLossOfSig-nal3En_O” enables the corresponding loss of signal fault / alarm for the associated analog input if it is used only as data for a comparator.

•

“InternalLossOfSignal1Wn_O” through “InternalLossOfSig-nal3Wn_O” sets the corresponding loss of signal to be an alarm for the associated analog input if it is used only as data for a comparator.

8

Wago modules’ analog inputs for messages displayed as “Loss of Signal ##” or System I/O board analog inputs for messages displayed as “Int AI# Loss of Signal.” •

Parameter settings

•

Correct Wago modules for messages displayed as “Loss of Signal ##” or System I/O board for messages displayed as “Int AI# Loss of Signal.”

Corrective Action for Deficiencies

Check Wago wiring and modules for correct type and proper operation for messages displayed as “Loss of Signal ##” or System I/O board wiring for messages displayed as “Int AI# Loss of Signal.”

Comments

None

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System I/O Related

Fault Reference for Harmony NXG

Table 8-1: Loss of Signal Associated Parameters

Parameter Name

8

ID

Analog input #1

4100

Source

4105

Type

4110

Loss point threshold

4140

Loss of signal action

4150

Analog input #2

4170

Source

4175

Type

4180

Loss point threshold

4210

Loss of signal action

4220

Analog input #3

4232

Source

4233

Type

4234

Loss point threshold

4237

Loss of signal action

4238

Analog input #4

4332

Source

4333

Type

4334

Loss point threshold

4337

Loss of signal action

4338

Analog input #5

4342

Source

4343

Type

4344

Loss point threshold

4347

Loss of signal action

4348

Auxiliary input #1

4500

Source

4510

Type

4520

Loss point threshold

4550

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System I/O Related

Parameter Name

ID

Loss of signal action

4560

Auxiliary input #2

4580

Source

4590

Type

4600

Loss point threshold

4630

Loss of signal action

4640

Comparator parameters

N/A

Comp 1 A in variable

4811

Comp 1 B in variable

4812

Comp 2 A in variable

4821

Comp 2 B in variable

4822

Comp 3 A in variable

4831

Comp 3 B in variable

4832

Comp 4 A in variable

4841

Comp 4 B in variable

4842

Comp 5 A in variable

4851

Comp 5 B in variable

4852

Comp 6 A in variable

4861

Comp 6 B in variable

4862

Comp 7 A in variable

4871

Comp 7 B in variable

4872

Comp 8 A in variable

4881

Comp 8 B in variable

4882

Comp 9 A in variable

4891

Comp 9 B in variable

4892

Comp 10 A in variable

4901

Comp 10 B in variable

4902

Comp 11 A in variable

4911

Comp 11 B in variable

4912

Comp 12 A in variable

4921

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Fault Reference for Harmony NXG

Parameter Name

8

ID

Comp 12 B in variable

4922

Comp 13 A in variable

4931

Comp 13 B in variable

4932

Comp 14 A in variable

4941

Comp 14 B in variable

4942

Comp 15 A in variable

4951

Comp 15 B in variable

4952

Comp 16 A in variable

4961

Comp 16 B in variable

4962

Comp 17 A in variable

4412

Comp 17 B in variable

4413

Comp 18 A in variable

4418

Comp 18 B in variable

4419

Comp 19 A in variable

4424

Comp 19 B in variable

4425

Comp 20 A in variable

4430

Comp 20 B in variable

4431

Comp 21 A in variable

4436

Comp 21 B in variable

4437

Comp 22 A in variable

4442

Comp 22 B in variable

4443

Comp 23 A in variable

4448

Comp 23 B in variable

4449

Comp 24 A in variable

4454

Comp 24 B in variable

4455

Comp 25 A in variable

4460

Comp 25 B in variable

4461

Comp 26 A in variable

4466

Comp 26 B in variable

4467

Comp 27 A in variable

4472

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System I/O Related

Parameter Name

ID

Comp 27 B in variable

4473

Comp 28 A in variable

4478

Comp 28 B in variable

4479

Comp 29 A in variable

4484

Comp 29 B in variable

4485

Comp 30 A in variable

4490

Comp 30 B in variable

4491

Comp 31 A in variable

4497

Comp 31 B in variable

4498

Comp 32 A in variable

4503

Comp 32 B in variable

4504

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Fault Reference for Harmony NXG

8

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Synch Transfer Related

CHAPTER

9

Synch Transfer Related

9.1 Phase Sequence Fault Name — Phase Sequence Displayed Message

Phase Sequence

Description of Fault/Alarm

Sign of input line frequency and output motor operating frequency are opposite.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Input and Output voltage sensors

Variables in Data Source

The voltage attenuators and current transducers

SOP Flags that affect Operation

“PhaseSequence_I” indicates that the phase sequence of the drive input and output are different. “PhaseSequenceEn_O” enables this fault / alarm. “PhaseSequenceWn_O” sets “phase sequence” as an alarm.

System Location of Data Source

Input/Output Cabinet

Potential Issues that affect the Fault Performance

Incorrect wiring sequence of the drive input or output power.

Corrective Action for Deficiencies

Correct sequence by changing the input or output cable connections.

9

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Fault Reference for Harmony NXG

9.2 Up Transfer Failed Fault Name — Up Transfer Failed Displayed Message

Up Transfer Failed

Description of Fault/Alarm

Time-out has occurred from request to up synch transfer.

Associated Parameters

“Up transfer timeout” (Menu ID 2760)

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Internal software timer

Variables in Data Source

None “UpTransferFault_I” indicates that an up transfer fault/alarm

9

SOP Flags that affect Operation

occurred. “UpTransferFaultEn_O” enables the Up Transfer Failed fault.

System Location of Data Source

Software

Corrective Action for Deficiencies

Increase menu setting, or set to zero to disable time out.

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Synch Transfer Related

9.3 Down Transfer Failed Fault Name — Down Transfer Failed Displayed Message

Down Transfer Failed

Description of Fault/Alarm

Time-out has occurred from request to down synch transfer.

Associated Parameters

“Down transfer timeout” (Menu ID 2770)

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

Internal software timer

Variables in Data Source

None

SOP Flags that affect Operation

“DownTransferFault_I” indicates that a down transfer fault/alarm occurred. “DownTransferFaultEn_O” enables the Down Transfer Failed fault.

System Location of Data Source

Software

Corrective Action for Deficiencies

Increase menu setting, or set to zero to disable time out.

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Fault Reference for Harmony NXG

9

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User Defined Faults/Alarms

CHAPTER

10

User Defined Faults/Alarms

10.1 User Defined Faults/Alarms Fault Name — User Defined Displayed Message

Determined by SOP

Description of Fault/Alarm

These alarms / faults are used to indicate user-defined problem conditions. They are strictly an SOP function with the drive software only providing alarm hysteresis support and message display functionality.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None

SOP Flags that affect Operation

10

“UserFault1Wn_O” through “UserFault64Wn_O” set the corresponding fault to an alarm. “UserFault1_O” through “UserFault64_O” trigger the corresponding fault / alarm.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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System Related

CHAPTER

11

System Related

11.1 Menu Initialization Fault Fault Name — Menu Initialization Displayed Message

Menu Initialization

Description of Fault/Alarm

This fault occurs when a parameter file is downloaded into the drive via the serial port; the old values have been erased, and then there are problems using the new values in the system.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis

Data Source

Downloaded parameters via serial port

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

N/A

Potential Issues that affect the Fault Performance

Old configuration file “C:\config.cfg” is read only

Corrective Action for Deficiencies Comments

11

Re-download parameter file Check if configuration file “C:\config.cfg” is read only None

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11.2 CPU Over Temperature Fault Name — CPU Over Temperature Displayed Message

11

CPU Temperature Alarm CPU Temperature Fault

Description of Fault/Alarm

CPU temperature is obtained by querying the CPU board. When the temperature is above 70 degrees Celsius, an alarm is issued. When the temperature is above 85 degrees Celsius, a fault is issued if it has been enabled via the SOP.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

CPU board

Variables in Data Source

None

SOP Flags that affect Operation

“CpuTempFaultEn_O” enables the CPU Temperature Fault

System Location of Data Source

CPU card rack

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies

Check cooling system in control cabinet for proper air flow, dust, or clogged filters Lower ambient air temperature

Comments

None

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System Related

11.3 A/D Hardware Fault Name — A/D Hardware Displayed Message

A/D Hardware Alarm A/D Hardware Fault

Description of Fault/Alarm

This alarm is set if the system A/D conversion board has detected a hardware error. A hardware error may be generated if the analog section supply is missing or below 12V, if one of the regulators fails, or if one of the converters does not complete a conversion. A hardware error will result in the A/D board going Not Ready. If this condition is true for ten consecutive checks, a fault will be issued.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

A/D board in rack

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

A/D board in rack

Potential Issues that affect the Fault Performance Corrective Action for Deficiencies Comments

11

•

Loss of 12V power supply

•

Bad A/D converter board

Check 12V power supply Replace A/D converter board None

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11.4 Configuration File Write Alarm Fault Name — Configuration File Write Alarm Displayed Message

Config File Write Alarm

Description of Fault/Alarm

This alarm is issued if an attempt to write a configuration file to the disk fails.

Associated Parameters

None

Hysteresis or Delay

No delay or hysteresis

Data Source

N/A

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

System compact flash disk

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies Comments

Make sure files on flash disk are not read-only or corrupt. Replace flash disk. None

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System Related

11.5 Configuration File Read Error Fault Name — Configuration File Read Error Displayed Message

Config File Read Error

Description of Fault/Alarm

This fault is issued if an attempt to read a configuration file from the disk fails.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis.

Data Source

N/A

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

System compact flash disk

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies Comments

Make sure files on flash disk are not read-only or corrupt. Replace flash disk. None

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Fault Reference for Harmony NXG

11.6 Cell Count Mismatch Fault Name — Cell Count Mismatch

11

Displayed Message

Cell Count Mismatch

Description of Fault/Alarm

The number of cells determined to be in the hardware configuration does not match the number of cells entered as a parameter. The modulator board counts the number of cells responding after a global reset, and uses that number counted, fills any missing cells in a rank with at least one cell, fills in ranks when a cell appears beyond the missing cells, and utilizes bypass information to determine the entire cell configuration. If it does not agree with the parameter times 3 (3 cells in each rank), a fault is issued and the drive will not run until these numbers agree.

Associated Parameters

Installed cells/phase (2530). This entered number times three is the total expected cell count.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Modulator board. Cell control board. Menu parameter.

Variables in Data Source

Menu parameter

SOP Flags that affect Operation

None

System Location of Data Source

Cell control boards are integral to each power cell in the power cabinet. The modulator board is in the DCR as is the menu parameter software.

Potential Issues that affect the Fault Performance

•

Entering an incorrect number of cell ranks in parameter (2530).

•

Disconnected fiber optic cables.

•

Defective modulator board.

•

False indication of applied Medium Voltage.

•

If the MV is incorrect and a few cells have enough power, this could lead to a false indication.

Check the number of cell ranks and enter the correct number. Corrective Action for Deficiencies

Make sure all cells are properly connected to the DCR by fiber optic cable and are communicating. Replace defective modulator board.

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Fault Reference for Harmony NXG

System Related

11.7 System Program Fault Name — System Program Displayed Message

System Program

Description of Fault/Alarm

This fault is issued if the selected SOP file is missing, corrupt, or contains errors.

Associated Parameters

None

Hysteresis or Delay

No delay or hysteresis

Data Source

Compact flash disk

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Compact flash disk

Potential Issues that affect the Fault Performance

None

Corrective Action for Deficiencies Comments

Check if file on disk is corrupt Replace compact flash disk None

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System Related

Fault Reference for Harmony NXG

11.8 Encoder Loss Fault Name — Encoder Loss Displayed Message

Encoder Loss

Description of Fault/Alarm

Fault/Alarm indicating that the speed of the encoder differs from the internal software PLL by an amount greater than the threshold set in “Encoder loss threshold” menu. “Encoder loss threshold” (Menu ID 1310)

Associated Parameters

“Encoder 1 PPR” (Menu ID 1290) “Encoder filter gain” (Menu ID 1300) “Encoder loss response” (Menu ID 1320)

11

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Encoder

Variables in Data Source

“Encoder loss response” (Menu ID 1320) can be set to fault the drive and stop, or change to open loop vector control and continue to operate.

SOP Flags that affect Operation

None

System Location of Data Source

Usually on motor

Potential Issues that affect the Fault Performance

•

Noise

•

Bad encoder module

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Fault Reference for Harmony NXG

System Related

11.9 Carrier Frequency Set Too Low Fault Name — Carrier Frequency Set Too Low Displayed Message

Carrier Frq Set Too Low

Description of Fault/Alarm

If the carrier frequency is set too low for the number of cell ranks such that the effective switching frequency (2 * # cell ranks * Fcarrier) is below 1550, then the minimum bandwidth or 750 radians cannot be guaranteed.

Associated Parameters

Carrier frequency (3580) Installed cells/phase (2530)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Parameters

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

System parameters

Potential Issues that affect the Fault Performance

Parameters entered incorrectly for system configuration

Corrective Action for Deficiencies

Enter a higher carrier frequency

Comments

None

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System Related

Fault Reference for Harmony NXG

11.10 Back EMF Timeout Fault Name — Back EMF Timeout Displayed Message

Back EMF Timeout

Description of Fault/Alarm

The software timed out waiting for the Motor Back EMF Voltage to decay to a safe level for cell device testing or cell bypass.

Associated Parameters

“Max back EMF decay time” (Menu ID 2580)

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Motor voltage

Variables in Data Source

Output Voltage Attenuators

SOP Flags that affect Operation

“BackEmfTimeout_I” indicates that the drive time out is waiting for the back emf of the motor to decay to a safe level

System Location of Data Source

Input/Output Cabinet

Potential Issues that affect the Fault Performance

•

Not enough time for the voltage to decay.

•

Not enough cells to support the potential voltage.

11 ∇ ∇ ∇

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Modulator Related

CHAPTER

12

Modulator Related

12.1 Modulator Watchdog Fault Name — Modulator Watchdog Displayed Message

Modulator Watchdog Flt Whenever the Modulator issues a drive enable to the cells, which is a permissive to switch the IGBTs, the watchdog on the modulator board is enabled. The watchdog ensures that the commands to the modulator are updated on a regular basis.

Description of Fault/Alarm

The update to the modulator is based on the carrier and the number of cells. This determines the sampling rate of the drive software, which ranges from approximately 3000 Hz to 6000Hz. If a new set of values is not written to the modulator within four sampling rate periods, the watchdog assumes that the drive software is no longer responding and shuts down the drive enable to the cells, disabling their output simultaneously, and sets a watchdog timeout flag in the modulator master fault register. This is sampled by the software and logged as a fault if any of the processes are still operational in the drive software. Carrier frequency (3580)

Associated Parameters

Installed cells/phase (2530) These determine the update sampling rate only.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Modulator board

Variables in Data Source

Timing Engine registers based on calculated values

SOP Flags that affect Operation

None

System Location of Data Source

Modulator board in DCR in control cabinet

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Modulator Related

Fault Reference for Harmony NXG

Fault Name — Modulator Watchdog

Potential Issues that affect the Fault Performance

•

Excessive numbers of interrupts from the Ethernet port has been shown to cause a disruption of the Fast Loop, which operates at the sampling frequency.

•

A defective modulator board or a crash of the Real Time Operating System (RTOS).

•

Noise can also cause the CPU board to malfunction resulting in a watchdog timeout.

Look for potential grounding problems. Corrective Action for Deficiencies

Install an Ethernet Switch to alleviate bogus traffic on that port or disconnect it completely if possible. Replace defective modulator board.

12

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Fault Reference for Harmony NXG

Modulator Related

12.2 Loss of Drive Enable Fault Name — Loss Of Drive Enable Displayed Message

Loss Of Drive Enable

Description of Fault/Alarm

This fault can occur only if there is a fault of the modulator board or there is noise on the ground plane on the modulator board. Since all external signals or faults that can cause a drive trip are latched, this fault can only occur if the register to request the drive enable is set, there are no faults latched in the Master Fault register, there is no active CR3 (E-Stop - Drive Inhibit), and the drive enable that exists on the modulator is not seen on the feedback register internal to the modulator board.

Associated Parameters

No Associated Parameters

Hysteresis or Delay

No Hysteresis - Worst case delay is 3.33 msec. (The software scan update rate of the fault control loop.)

Data Source

Modulator Registers

Variables in Data Source

ISA bus location (fixed by application protocol)

SOP Flags that affect Operation

“LossOfDriveEnableEn_O” enables the Loss of Drive Enable fault.

System Location of Data Source

Modulator Board in the VFD control card rack

Potential Issues that affect the Fault Performance

Corrective Action for Deficiencies Comments

•

Defective modulator board.

•

Intermittent Noise on the ground plane to modulator board.

12

Replace board. Evaluate and eliminate ground plane noise source. None

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Modulator Related

Fault Reference for Harmony NXG

12.3 Modulator Board Fault Fault Name — Modulator Board Fault Displayed Message

Modulator Board Fault

Description of Fault/Alarm

Whenever a cell fault is detected, the fault routine starts the cell diagnostic routine. If no cell fault is found, this fault is displayed. The Cell fault indication is from the Modulator master fault register.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Modulator board register. Cell diagnostic routine.

Variables in Data Source

None

SOP Flags that affect Operation

None

System Location of Data Source

Modulator Board is in the DCR in the control cabinet.

Potential Issues that affect the Fault Performance

This could be caused by noise on the ISA bus or on the modulator board triggering a false cell fault.

Corrective Action for Deficiencies

12

Comments

Check grounding practices. Change modulator board. None

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Fault Reference for Harmony NXG

Modulator Related

12.4 Modulator Configuration Fault Name — Modulator Configuration Displayed Message

Modulator Configuration During initialization of the modulator board, a series of self-tests are performed to ensure that the modulator is functioning properly. Tests performed include checking for:

Description of Fault/Alarm

•

Missing or misplaced EPLD

•

Proper firmware version and part number in EPLDs

•

Proper programming on the modulator look-up tables (LUTs)

•

Proper ISA PLD version or part number

•

Proper connection to the fiber optic expansion board

•

Proper operation of the modulator registers

If any of these tests fail during initialization, this fault is generated and recorded. Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Modulator board

Variables in Data Source

Improper programming of the EPROMS on the board

SOP Flags that affect Operation

None

System Location of Data Source

Modulator board in the DCR in the control cabinet

Potential Issues that affect the Fault Performance Corrective Action for Deficiencies

•

Noise on the backplane of the DCR.

•

Defective or improperly programmed modulator board.

12

Replace modulator board. Review grounding of the DCR.

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Modulator Related

Fault Reference for Harmony NXG

12.5 Weak Battery Fault Name — Weak Battery Displayed Message

Modulator Battery Low

Description of Fault/Alarm

The modulator board has battery-backed RAM onboard for the storing of the fault and historic logs. When the battery voltage is below a fixed threshold on the detection circuit, it issues the weak battery alarm.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Modulator board register

Variables in Data Source

Placement of the battery jumper

SOP Flags that affect Operation

None

System Location of Data Source

Modulator board in the DCR located in the control cabinet.

Potential Issues that affect the Fault Performance

A jumper is supplied to disconnect the battery to prevent drainage during long periods of storage. If the jumper is disconnected while running, it will give a false indication of weak battery. If the jumper is connected to the battery during storage, or if the board is stored at elevated temperatures, the battery can drain faster, leading to a shortened shelf life.

12 Corrective Action for Deficiencies

Comments

Check battery jumper position for proper connection. Replace modulator board if battery is defective. Loss of battery availability affects the fault and historic log storage only when control power is cycled. A weak battery will not adversely affect a drive that is continuously supplied with control power.

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Fault Reference for Harmony NXG

External Serial Communication Related

CHAPTER

13

External Serial Communication Related

13.1 Keypad Communication Fault Name — Keypad Communication Displayed Message

Keypad Communication

Description of Fault/Alarm

This fault / alarm was designed to indicate keypad communication problems. It currently is not functional in the software.

Associated Parameters

None

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

N/A

Variables in Data Source

N/A “KeypadCommunicationEn_O” enables this fault / alarm.

SOP Flags that affect Operation

“KeypadCommunicationWn_O” sets keypad communication loss as an alarm.

System Location of Data Source

N/A

Potential Issues that affect the Fault Performance

N/A

Corrective Action for Deficiencies

N/A

Comments

None

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External Serial Communication Related

Fault Reference for Harmony NXG

13.2 Keypad Communication Loss Fault — Keypad Comm Loss (old) Drive Not Communicating (new) Displayed Message

Keypad Comm Loss – or – Drive Not Communicating

Description of Fault/Alarm

This fault indicates communications from the drive to the keypad have been disrupted. Once communications is restored, the message will go away and the updated drive data will be displayed.

Associated Parameters

None

Hysteresis or Delay

Once the drive stops sending communication packets to the keypad, the keypad processor displays this message. Initially on power-up, the delay is 2 minutes to allow time for the drive software to boot. After that, a loss of communications from the drive of only 9 seconds will bring this up.

Data Source

Message is developed internal to the keypad software. Normal display data comes from the drive.

Variables in Data Source

N/A

SOP Flags that affect Operation

None

System Location of Data Source

N/A

Potential Issues that affect the Fault Performance

13

•

This fault results primarily when the NXG process thread for the keypad halts for some reason.

•

A bad cable that supplies power to the keypad, but corrupts the data will produce this fault.

•

Defective keypad.

Check for functionality of NXG (drive) code. Check for loose cables inside the DCR

Corrective Action for Deficiencies

Re-boot DCR to see if problem goes away – if so, then something is wrong with the DCR. Make sure the CPU watchdog is enabled to kill all threads in case of a malfunction. If DCR is functioning properly, check and replace keypad cable. Change out defective Keypad.

Comments

This fault occurs most frequently when the processor thread that updates the keypad display has stopped running. If all cables are secure, the problem is usually within the DCR.

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Fault Reference for Harmony NXG

External Serial Communication Related

13.3 Network Communication Fault Name — Network Communication Displayed Message

Description of Fault/Alarm

Network 1 Communication Network 2 Communication These fault(s) / alarm(s), when enabled via the SOP, indicate a loss of communication with the field bus network(s). “Network Timeout” ID 9934 for network 1 and ID 9935 for network 2.

Associated Parameters

“Modbus Address,” “Modbus Plus Address,” “Profibus Address,” “DeviceNet Address,” “Control Net Address,” “DH+ Address,” “Global Receive Address” must be set as applicable to the installed network(s). The appropriate parameters required for proper network configuration will appear or disappear from the menus when the network type is selected.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

Network interface(s)

Variables in Data Source

None “Network1CommunicationEn_O” enables the network 1 communication fault / alarm.

SOP Flags that affect Operation

“Network2CommunicationEn_O” enables the network 2 communication fault / alarm. “Network1CommunicationWn_O” sets network 1 communication loss as an alarm.

13

“Network2CommunicationWn_O” sets network 2 communication loss as an alarm. System Location of Data Source

Internal Modbus or modules on communication board.

Potential Issues that affect the Fault Performance

Network setup and protocol must be correct as well as the interconnecting wiring. Check for proper cabling between systems.

Corrective Action for Deficiencies

Check for proper baud rate. Check proper network address. Check for proper working network hardware.

Comments

None

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External Serial Communication Related

Fault Reference for Harmony NXG

13.4 Tool Communication Fault Name — Tool Communication Displayed Message

Tool Communication

Description of Fault/Alarm

This fault / alarm was designed to indicate Drive Tool communication problems. It currently is not functional in the software.

Associated Parameters

N/A

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

N/A

Variables in Data Source

N/A “ToolCommunicationEn_O” enables this fault / alarm.

SOP Flags that affect Operation

“ToolCommunicationWn_O” sets tool communication loss as an alarm.

System Location of Data Source

N/A

Potential Issues that affect the Fault Performance

N/A

Corrective Action for Deficiencies

N/A

Comments

None

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Fault Reference for Harmony NXG

Cooling Related

CHAPTER

14

Cooling Related

14.1 Pump Failures Fault Name — Pump Failures Displayed Message

One Pump Not Available Both Pumps Not Available

Description of Fault/Alarm

These alarms / faults are used to indicate pump failure conditions. This is strictly an SOP function, with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “OnePumpFailureEn_O” enables the “One Pump Not Available” alarm. “AllPumpsFailureEn_O” enables the “Both Pumps Not Available” fault / alarm.

SOP Flags that affect Operation

“AllPumpsFailureWn_O” sets “Both Pumps Not Available” an alarm. “OnePumpFailure_O” set to trigger a “One Pump Not Available” alarm condition. “AllPumpsFailure_O” set to trigger a “Both Pumps Not Available” fault / alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

Fault Reference for Harmony NXG

14.2 Coolant Conductivity Fault Name — Coolant Conductivity Displayed Message

Coolant Conduct > 3 μS Coolant Conduct > 5 μS

Description of Fault/Alarm

These alarms / faults are used to indicate coolant conductivity problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “CoolantConductivityAlarmEn_O” enables the “Coolant Conduct > 3 μS” alarm. “CoolantConductivityFaultEn_O” enables the “Coolant Conduct > 5 μS” fault / alarm.

SOP Flags that affect Operation

“CoolantConductivityFaultWn_O” sets “Coolant Conduct > 5 μS” to an alarm. “CoolantConductivityAlarm_O” set to trigger a “Coolant Conduct > 3 μS” alarm condition. “CoolantConductivityFault_O” set to trigger a “Coolant Conduct > 5 μS” fault / alarm condition.

14

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

14.3 Inlet Water Temperature Fault Name — Inlet Water Temperature Displayed Message

Coolant Inlet Temp > 60°C Coolant Inlet Temp < 22°C

Description of Fault/Alarm

These alarms / faults are used to indicate coolant temperature problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “InletWaterTempHighEn_O” enables the “Coolant Inlet Temp > 60°C” fault / alarm. “InletWaterTempLowEn_O” enables the “Coolant Inlet Temp < 22°C” fault / alarm.

SOP Flags that affect Operation

“InletWaterTempHighWn_O” sets “Coolant Inlet Temp > 60°C” as an alarm. “InletWaterTempLowWn_O” sets “Coolant Inlet Temp < 22°C” as an alarm. “InletWaterTempHigh_O” set to trigger a “Coolant Inlet Temp > 60°C” fault / alarm condition. “InletWaterTempLow_O” set to trigger a “Coolant Inlet Temp < 22°C” fault / alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

Fault Reference for Harmony NXG

14.4 Cell Water Temperature Fault Name — Cell Water Temperature Displayed Message

Cell Water Temp High

Description of Fault/Alarm

This alarm / fault is used to indicate cell water over-temperature conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “CellWaterTempHighEn_O” enables the “Cell Water Temp High” fault / alarm.

SOP Flags that affect Operation

“CellWaterTempHighWn_O” sets “Cell Water Temp High” as an alarm. “CellWaterTempHigh_O” set to trigger a “Cell Water Temp High” fault / alarm condition.

14

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Fault Reference for Harmony NXG

Cooling Related

14.5 Low Water Level Fault Name — Low Water Level Displayed Message

Coolant Tank Level < 30" Coolant Tank Level < 20"

Description of Fault/Alarm

These alarms / faults are used to indicate coolant tank level problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “LowWaterLevelAlarmEn_O” enables the “Coolant Tank Level < 30” alarm. “LowWaterLevelFaultEn_O” enables the “Coolant Tank Level < 20” alarm / fault.

SOP Flags that affect Operation

“LowWaterLevelFaultWn_O” sets “Coolant Tank Level < 20” as an alarm. “LowWaterLevelAlarm_O” set to trigger a “Coolant Tank Level < 30” alarm condition. “LowWaterLevelFault_O” set to trigger a “Coolant Tank Level < 20” fault / alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

Fault Reference for Harmony NXG

14.6 Low Water Flow Fault Name — Low Water Flow Displayed Message

Low Coolant Flow < 60% Low Coolant Flow < 20%

Description of Fault/Alarm

These alarms / faults are used to indicate coolant flow problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “LowWaterFlowAlarmEn_O” enables the “Low Coolant Flow < 60%” alarm. “LowWaterFlowFaultEn_O” enables the “Low Coolant Flow < 20%” alarm / fault.

SOP Flags that affect Operation

“LowWaterFlowFaultWn_O” sets “Low Coolant Flow < 20%” as an alarm. “LowWaterFlowAlarm_O” set to trigger a “Low Coolant Flow < 60%” alarm condition “LowWaterFlowFault_O” set to trigger a “Low Coolant Flow < 20%” fault / alarm condition.

14

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Fault Reference for Harmony NXG

Cooling Related

14.7 HEX Fan Fault Name — Hex Fan Loss One HEX Fan Displayed Message

Loss All HEX Fans All HEX Fans On

Description of Fault/Alarm

These alarms / faults are used to indicate HEX fan problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “LossOneHexFanEn_O” enables the “Loss One Hex Fan” alarm. “LossAllHexFanEn_O” enables the “Loss All Hex Fans” fault / alarm. “AllHexFansOnEn_O” enables the “All Hex Fans On” alarm.

SOP Flags that affect Operation

“LossAllHexFanWn_O” sets “Loss All Hex Fans” as an alarm. “LossOneHexFan_O” set to trigger a “Loss One Hex Fan” alarm condition. “LossAllHexFan_O” set to trigger a “Loss All Hex Fans” fault / alarm condition. “AllHexFansOn_O” set to trigger an “All Hex Fans On” alarm condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

Fault Reference for Harmony NXG

14.8 Blowers Fault Name — Blowers Displayed Message

One Blower Not Avail All Blowers Not Avail

Description of Fault/Alarm

These alarms / faults are used to indicate blower problem conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “OneBlowerLostEn_O” enables the “One Blower Not Avail” alarm. “AllBlowerLostEn_O” enables the “All Blowers Not Avail” fault / alarm. “AllBlowersLostWn_O” sets the “All Blowers Not Avail” as an alarm.

SOP Flags that affect Operation

“OneBlowerLost_O” set to trigger a “One Blower Not Avail” alarm condition. “AllBlowerLost_O” set to trigger an “All Blowers Not Avail” fault / alarm condition.

14

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

s 14-8 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

Cooling Related

14.9 Clogged Filters Fault Name — Clogged Filters Displayed Message

Clogged Filters

Description of Fault/Alarm

This alarm / fault is used to indicate clogged filter conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “CloggedFiltersEn_O” enables the clogged filters fault / alarm.

SOP Flags that affect Operation

“CloggedFilters_Wn_O” sets “clogged filters” as an alarm. “CloggedFilters_O” set to trigger a filter is clogged (blocked) condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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Cooling Related

Fault Reference for Harmony NXG

14.10 Transformer Coolant Over Temperature Fault Name — Transformer Coolant Over Temperature Displayed Message

Xfrm Cool OT Trip Alarm

Description of Fault/Alarm

This alarm / fault is used to indicate transformer over temperature conditions. This is strictly an SOP function with the drive software only providing alarm hysteresis support and consistent text message display.

Associated Parameters

None - unless comparators are used in SOP for these conditions.

Hysteresis or Delay

Faults have no delay or hysteresis. Alarms use hysteresis before being triggered. Before version 2.3, the alarm hysteresis was 30 fault system samples or 1/10 second before an alarm was issued. After version 2.3, the alarm hysteresis is now 150 fault system samples or ½ second before an alarm is issued.

Data Source

SOP

Variables in Data Source

None “XformerWaterTempHighEn_O” enables the “Xfrm Cool OT Trip Alarm.”

SOP Flags that affect Operation

“XformerWaterTempHigh_O” set to trigger a “Xfrm Cool OT Trip Alarm” condition.

System Location of Data Source

Determined by SOP

Potential Issues that affect the Fault Performance

Determined by SOP

Corrective Action for Deficiencies

Determined by SOP

Comments

None

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A1A19000864: Version 4.0

Fault Reference for Harmony NXG

NOTES

NOTES

s A1A19000864: Version 4.0

N-1 CONFIDENTIAL / FOR INTERNAL USE ONLY

NOTES

Fault Reference for Harmony NXG

s N-2 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0

Fault Reference for Harmony NXG

NOTES

s A1A19000864: Version 4.0

N-3 CONFIDENTIAL / FOR INTERNAL USE ONLY

NOTES

Fault Reference for Harmony NXG

∇ ∇ ∇

s N-4 CONFIDENTIAL / FOR INTERNAL USE ONLY

A1A19000864: Version 4.0