Hitachi Part-1 (Hvs026) 200a Rev00

8/20/2019 Hitachi Part-1 (Hvs026) 200a Rev00

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HIVECTOL-HVI-E Part 1 Trouble shooting guide

This is the instruction manual for medium voltage direct inverter(HIVECTOL-E), Trouble shooting

guide.

describes how to investigate and repair any troubles. Since quick and appropriate

repairmen is required at a trouble occurrence, the composition of is centered on procedure flowaccording to phenomena. Therefore not include operating principle, hardware specifications, etc., for which

please refer to relevant parts given hereunder.

Some trouble repairing works involve human safety items. Before the work, be sure to read through

safety

precautions given on subsequent pages.

Introduction

Readers intended for

This manual is destined for persons in charge of maintaining electric equipment who are sufficiently versed in

electrical knowledge.

Composition of HIVECTOL-HVI-E instruction manual

The composition of this manual is shown hereunder.

Part 1 Trouble shooting guide

The troubleshooting guide describes the procedure used to determine the seriousness of failure from various

situations, as well as how to reset the device or investigate failure causes.So, when this product experiences problems, please refer to this part 1.

This first part also includes excerpts of the contents of parts 2 and 3. For details of maintenance and

maintenance tools, please refer to the second and third parts.

Part 2 Maintenance Tool (hereinafter referred to as “M.TOOL”)

M.TOOL refers to communication with the control board using the PC (M.TOOL). The part 2 describes the

procedures for control setting and collecting the trace back data, etc.

Part 3 Hardware Specifications and Maintenance

The part 3 describes the hardware specifications, appearance, and structure of the Direct Inverter. It also

describes maintenance methods, such as part replacement.


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Precautions for safety

For correct run, maintenance or checkup, carefully read the entire instruction manual and related literature

beforehand. Familiarize yourself with all device knowledge, safety information and precautions prior to

operation. Indications of danger, warning and caution underline dangerous and important information.

● The main circuit voltage of 3000V～11000V AC is applied in the panel. Do not get in nor

put any foreign matter in nor get a part of your body, rod or others near the panel when the main

circuit is energized.

● In the panel, there are smoothing electrolytic capacitors and, even after turning off the main

circuit, a voltage may remain. Make it a rule to touch the electric circuitry only after checking

yourself whether any potential is present or not. Do the check by the galvanoscope after turning

off the LED display of the cell inverter.

●Do not use the spare items other than our recommendation when replacing a part. Operation

when an equivalent function items other than recommendation are used is not guaranteed.

● For avoiding electric shock, a protective cover is mounted on the high voltage section.

Do not remove the protective cover while the voltage is applied.

(There is no protective cover about the hanging door type. )

● Before turning on, put in place the protective cover if removed for maintenance, etc.

(There is no protective cover about the hanging door type. )

● Weight of cell inverter is 28kg. Be careful enough not to fall.

Be sure to use lifter of exclusive use for desertion of cell inverter.

Since it is dangerous, do not perform supporting directly by hands by any means.

! CAUTION


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1. Outline of trouble shooting 1-1

2. Trouble code list 1-3

2.1 Graphic Panel Display Function 1-3

2.2 Failure display screen 1-4

2.3 Factor of major / Alarm display screen 1-4

2.4 Major fault factor codes 1-5

2.5 Alarm factor 1-7

2.6 Control circuit PCB abnormal factor 1-8

2.7 Cell inverter fault factor 1-9

2.8 Others 1-10

2.9 Interlock factor 1-11

3. LED display of each PCB 1-12

3.1 Control PCB (HVS026) 1-12

3.2 Driver interface PCB (HVS026) 1-13

4. Trouble shooting by fault factors 1-14

4.1 Major fault trouble shooting 1-15

4.2 Other faults 1-33

4.2.1 Light fault 1-33

4.2.2 Control PCB abnormal 1-34

4.2.3 Controller power source abnormal 1-35

4.3 Interlock factor 1-36

4.3.1 CONNECTOR NOT INSERTED 1-36

4.3.2 MAIN CIRCUIT BREAKER OFF 1-36

4.3.3 I/F ABNORMAL 1-36

4.3.4 MAJOR FAULT 1-36

4.3.5

HV CUB MAJOR FAULT 1-36

4.3.6

EMERGENCY STOP 1-36

4.3.7 MOTOR COOLING FAN STOP 1-36

4.3.8

MOTOR RUNNING 1-36

4.4

Supplemental documented procedures 1-37

4.4.1

Relay input and output identification procedure 1-37

CONTENTS


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5. How to get trace-back data 1-39

5.1 Starting of maintenance tool 1-39

5.2 Invoking Trace-back Command 1-41

5.3 Sampling Trace-back Data 1-42

5.3.1 Trace-back data acquiring 1-42

5.3.2 Forced logging data acquiring 1-46

5.4 Numerical display 1-47

5.5 Trend Display 1-53

5.6 Fault Factor Display 1-56

5.7 Cell Inverter fault factor 1-59

6. DETAILS OF VARIOUS CHECK ITEMS 1-62

6.1

IGBT Soundness Check 1-62

6.1.1 Property of IGBT 1-62

6.1.2 Soundness check method 1-62

6.2 CT Output Check 1-63

6.3 Optical Cable Identification Train 1-64

6.3.1 Wiring Composition of Optical Cable 1-64

6.3.2

Composition of Optical Communication 1-65

6.3.3 Optical cable identification procedure 1-66

7. Cell inverter exchanging procedure 1-68

7.1 Detaching of hanging door 1-68

7.2 Detaching of cell inverter 1-68

7.3 Drawer of Cell Inverter 1-69

7.4

Repair work 1-69

8. Replacing the control PCB 1-70

8.1 Replacing the Control PCB 1-70

8.2 Loading method of software and control constant 1-71

8.3 Setup of VR and DIP SW 1-77

8.3.1

Setup of DIP SW 1-77

9. Parts replacing procedure 1-78

9.1 Fuse 1-78

9.2 Current detector 1-79

10. Other notes 1-80

10.1 Fault reset method 1-80


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1. Outline of trouble shooting

If a trouble has occurred, it is important to locate and remedy it for preventing its recurrence.

However, device recovery and facility startup take precedence often.

There are different trouble circumstances.

(1) So fatal that parts must be replaced

(2) Resetting the trouble allows a recovery but, for locating it, measuring instrument, etc. must be

connected

(3) The cause is distinct and just resetting the trouble allows a recovery

(4) So slight that the run can be pursued without trouble reset

They are remedied by particular methods.

The present manual includes procedures of judging the seriousness from the circumstances of trouble

occurrence and restoring the devices or locating the trouble.

The procedure is outlined in Fig. 1.1.

1-1


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NO

YES

(Light fault)

YES

Trouble

occurrence

NO

You are requested to send us trouble

conditions and trace-back data

Check the operating

conditions and eliminate the

factor

Acquire trace-back data and

record the run conditions and

notify them to us

If factor cannot be located,check the condition of panel

inside parts by sequence.

Judge whether caused by high

rank system or HIVECTOL

Judge the fault cause

By display on HIVECTOL-

HVI-E panel, check the fault

factor indication

Major fault?

System factor?

Referring to trouble shooting of

corresponding code, investigate and

restore. Parts may have to be replaced.

After resetElectrolytic capacitors are installed in main circuit

and potential may remain. After high voltage power

supply cutting, 10 minutes should pass, and work

after checking that the LED display in a Cell Inverter

has gone out.

Fig. 1.1 Processing flow at trouble occurrence

1-2


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2. Trouble code listThe graphic panel on the control The graphic panel on the unit surface has a function that displays not

only commands and feedback but also factors for failure.

This section describes such failure factors.

2.1 Graphic Panel Display FunctionAs shown in Figure 2.1, the graphic panel (hereinafter referred to as the “GP”), mounted on the control

panel has a function to display not only the operation conditions, such as the motor speed, but also the

factors for failure and the causes for turning OFF the main circuit.

Action for failure begins with checking the displayed items on the GP. In order to take prompt action,

therefore, it is necessary to fully understand the display function of the GP. This section describes the GP

display function, particularly focusing on the displayed items to be checked when failure occurs and when

the operation restarts. (For details of the GP display function and operation method, please refer to “Part2

– Maintenance Tool.”)

In case of failure, the screen will be automatically switched to the failure display screen, as shown in

Figure 2.1. (This automatic screen switching function is designed to display the factors for serious failures

taking precedence over those considered minor when they occur at the same time.) * Figure 2.1 shows thestructure of the 3.3 kV unit.

1-3

Inverter Panel

Control Panel

Graphic Panel

Emergency Stop(PBS)

Fig.2.1 Installation location of GP and the failure display

Switch that displays details of faults

Switch for

turn a page

Number of factorsReset switch

Display of

details of faults


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1-4

2.2 Failure display screen

Figure 2.2 is the failure screen. The change from the failure display screen to the failure display screen

has the following condition.

(1)Manual change by pushing “FAULT" switch on watch display screen

(2)Automatic change due to a major fault

(3)Automatic change due to a Alarm fault(Note)

Figure2.2 Monitoring display screen（Sample）

(Note) The setting of the control constant decides

whether to display the failure display screen

automatically at an Alarm occurrence.

The setting of an automatic change is the following constant.

Refer to the record of the trial run for a set value.

V/00C0038_#Bit2

1 : Automatic change ON 2: Automatic change OFF


2.3 Factor of major / Alarm display screen

The factor of the major fault and the Alarm is displayed at the center of the screen.

The generated failure name is displayed on the screen.The failure name that the number attaches to the

head of the name is a major fault.

(For instance,(1)OVERCURRENT)

In similar the Alarm is attached “(AL)”. (For instance ,(AL)SPEED REF VALUE ERROR(＜2mA))

The number in () of a major fault shows the order of faults occurring. The displayed factor is different

according to facilities.

Refer to the completion drawing of the delivery equipment for details of the factor name.


Switch for

turn a page


Display of

details of faults

Figure2.3 Factor of major / Alarm display screen


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2.4 Major fault factor codes

Table 2.1 gives fault factor codes indicated at major trouble occurrences with details of troubles.

The trouble respectability refers to whether just resetting recovers from trouble or not.

For further details of respective troubles, refer to "4. Trouble shooting by fault factors".

Table 2.4 Major fault factor

1-5

No.

1

2

3

4

5

6

7

8

910

11

12

13

14

15

16

17

18

19

20

21

22

23

24

Fault message

START FAILURE

CTL POWER DROP

OVERCURRENT(SOFT)

OVERCURRENT(HARD)

OVERVOLTAGE

OVERLOAD

MAIN CIRCUIT POWER DROP

CONNECTOR NOT INSERTED

AC VOLTAGE ABNORMALAC CURRENT ABNORMAL

GROUND DETECTED

INV COOLING FAN STOP

TR COOLING FAN STOP TD

CUBICLE OVERHEAT(>60℃)

TRANSFORMER OVERHEAT

U PHASE CELL FAULT

V PHASE CELL FAULT

W PHASE CELL FAULT

U PHASE SERIAL SIGNAL DOWN

V PHASE SERIAL SIGNAL DOWN

W PHASE SERIAL SIGNAL DOWN

U PHASE DRV IF FAULT

V PHASE DRV IF FAULT

W PHASE DRV

IF FAULT

Contents

The start failed.

The AVR power supply for the control substrate has decreased.

The current that exceeded the maximum rating of the electric motor flowed.

The current that exceeded the maximum rating of the inverter device flowed.

The voltage of the motor exceeded the over voltage level.

The current that exceeded the rated load flowed to the motor for 1 minute or more.

The input voltage has decreased.

The connector of each PCB has the uninsertion connector.

The voltage detecting circuit did not function correctly.The current detection circuit did not function correctly.

One phase of either of the three-phase circuit output did earth fault.

When the inverter board cooler fan drove, the inverter device stopped.

The transformer cooling fan stops when the VFD drives, and set time has passed.

The contact at the temperature detection (60℃) in the cubicle operated.

The winding temperature of a multiple transformer exceeded the trip setting value.

The failure occurred by the U phase cell inverter.

The failure occurred by the V phase cell inverter.

The failure occurred by the W phase cell inverter.

Optical serial communications of U phase detected abnormality (disconnection) .

Optical serial communications of V phase detected abnormality (disconnection) .

Optical serial communications of W phase detected abnormality (disconnection) .

The driver interface substrate of U phase did not function correctly.

The driver interface substrate of V phase did not function correctly.

The driver interface substrate of W phase did not function correctly.


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When major faults have occurred, from the first to the third fault factors can chronologically be displayed.

Fault factors are sampled every 60ms and faults produced within 60ms are regarded as occurring

simultaneously. For example, if 2 faults have occurred within first 60ms, both of them are handled as the

first fault factors and if, within next 60ms, 2 faults have further occurred, the 2 constitutes the second fault

factors. The second and the third faults are separated only if they are at least 60ms apart. For example, if

a fault has occurred 1 second after the first fault, the former is handled as the second fault and all faults

which occur at least 60ms thereafter are handled as the third faults.

(See Fig. 2.4.1)

60ms 60ms 60ms

The third fault factorThe first fault factor The second fault factor

Trouble

occurrence

1sec

Fig. 2.4.1 Time series of fault factors

The error code consists of number which indicates the time series and sequential number in the order of

occurrence within the same time zone.

For example, if a our put over current(soft detection) occurred first, U1 cell inverter fault occurred the

after (60 ms more) and, 60 ms further later, Out put Power abnormal occurred, the indication will be:

The fault indication remains even after eliminating the cause.

For the method of clearing the major fault indication, refer to "10.1 How to clear the error display".

1-6


Switch for

turn a page


Display of

details of faults

Figure2.4.2 Factor of major / Alarm display screen


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2.5 Alarm factor

Fig. 2.5 shows display screen at the time of alarm occurrence, and Table 2.5 shows fault factor and

contents of light fault. Trip does not carry out only by Alarm notifying fault.

However, "over load 1" and "motor cooling fan stop" serve as major fault by predetermined time

continuation. When you display fault factor display screen at the time of Alarm occurrence，Push "fault"

switch under each screen.

Fig. 2.5 Alarm factor display screen

(Note 2.5)

It becomes abnormalities when motor primary current integral value(KII4･t)exceeds predetermined level.

For example, if motors of 150% 1min are operated at 150% and 30 sec over when detection level is

50%,failure will occur.

1-7

No.

1

2

3

4

5

6

7

8

Fault message

(ALARM)OVERLOAD RUNNING

(ALARM)SPEED REF VALUE ERROR(55℃)

(ALARM)TRANSFORMER OVERHEAT

(ALARM)MOTOR OVERHEAT

(ALARM)INV COOLING FAN STOP

Contents

Load of motor exceeds rated one.

The speed command signal(4-20mA) became 2mA or less.

When driving, the transformer panel cooling fan stopped.


The winding temperature of a transformer exceeded the warning setting value.

The winding temperature of a motor exceeded the warning setting value.

When driving, the inverter panels cooling fan stopped.


Switch for

turn a page


Display of

details of faults

Figure2.5 Factor of major / Alarm display screen


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2.6 Control circuit PCB abnormal factor

Figure 2.6 is a display screen of the control circuit PCB abnormal.

Control circuit PCB's abnormality has the case to happen by chance as various conditions come in

succession and the case which breaks down due to single defects of parts. It is necessary to exchange the

control circuit PCB when relapsing even if it is GR(General Reset).

Refer to "8.1 exchange procedure of control circuit PCB" for details.

Table 2.6 shows details of a control circuit PCB abnormal code.

Fig. 2.6 Control circuit PCB abnormal display screen

Table 2.6 Control circuit PCB abnormal code

1-8

No. Fault code Cont ent s

1 0001 WDT (watch dock timer) occurred.

2 0002 General unjust (Invalid) command was executed.

3 0004 Slot unjust (slot error) command was execut ed.

4 0008 CPU address error occurred.

5 0010 DMAC/DT C address error occurred.

6 0020 Overflow occurred in the stack.

7 0040 CRC error occurred.


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2.7 Cell inverter fault factor

Fig. 2.7 .3 is the screen which displays the contents of a fault factor of a cell inverter.

When cell inverter fault occurs, the contents of a fault factor generated within the cell inverter unit can be

displayed. The fault factor code displayed on Table 2.7.1 at the time of cell inverter fault generating and

its contents of fault are shown. This screen is displayed by choosing a cell inverter displaying a fault

factor from the cell inverter information screen of Fig. 2.7.2. The cell inverter fault factor display method

is shown below.

① Push "cell information" switch in screen lower part of display of face of a board (as for "cell

information" switch, only fault factor display screen is displayed).

②Display of face of a board changes to cell inverter information screen of Fig. 2.7.1 by operation of ①

③ If "cell inverter selection switch" is pushed, it will change to cell inverter fault factor screen of Fig.

2.7.3 automatically.

Figure 2.7.1 Phase select screen (Detail of fault)

Fig. 2.7.3 Cell inverter information screen

1-9

Phase select switch

Figure 2.7.2 - Phase cell No. select screen

Cell No. Select switch

Table 2.7 Cell inverter fault factor

No.

1

2

Fault message

DC OVERVOLTAGE

CELL CONTROL POWER DOWN

Contents

The DC voltage exceeded the over voltage level.

The input voltage of the DRVIF PCB has decreased.

Display of details of faults

Switch for turn a page

Number of factors


(Cell

inverters in the back and

forth is displayed.)


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2.8 Others

When the control circuit PCB is an off-line

mode, Figure 2.8 is displayed.

It is displayed, when control software is non-

loading or DIPSW of a control PCB is an off-

line mode setup.

Fig. 2.7 Off-line mode screen

1-10


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2.9 Interlock factor

The motor might not be able to be driven though it is not a fault.

In this case, investigate the factor referring to the interlock display screen in Figure 2.9, because there is a

possibility that the interlock is not complete. Interlock factor is shown in Table 2.9.

Fig. 2.9 Interlock display screen

Table2.9 Interlock factor

1-11

No. Signal name Contents

1 MAJOR FAULT Major fault factor has not been removed.

2 EMERGENCY STOP Emergency stop is operated.3 ALARM Alarm fault factor has not been removed.

4 CONNECTOR NOT INSERTED Non-inserted connector exists in connector of control PCB

5 PROCESS INTERLOCK FAILURE The interlock signal (from DCS) has not been approved.

6

7

8

9

MOTOR RUNNING

AC415V POWER DOWN Auxiliary power (AC415V) is not a normal

Motor is not stopped.

MOTOR INTERLOCK FAILURE The interlock signal (from DCS) has not been approved.

Number of factors

Display of details of faults



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3. LED display of each PCB

On PCB, LED and check terminal for checking operating state are mounted.

LED, mounting location of check terminal, and the contents of display are explained below.

3.1 Control PCB (HVS026)

Fig. 3.1 Parts arrangement on control circuit PCB(HVS026)

Table 3.1 Display on control circuit PCB

1-12

LED display Check terminal

Device The contents of display color Device Contents

LD1 PLC interface normal Green TP1 Maker use

LD2 CTL PCB normal Green TP2 Maker use

LD3 WDT error Red TP3 Maker use

LD4 Initial normalcy Green TP4 Maker use

LD5 Pulse output state Green

LD6 DI pulse source normal Green

LED

“P48”

MPU and the peripheral circuitry of it are mounted so that the control PCB may variously control

the inverter. Refer to 3 part (Hardware Specifications and Maintenance)for details.

Figure 3.1 shows the installation position of control PCB from the component placement of control PCB

and the externals structure of the control panel. This figure is used to confirm the LED display on PCB.

Table 3.1 shows the meaning of the LED display.

Control panel

(Door open)Control PCB (HVS026)


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1-13

Table 3.2.2 Display on control circuit PCB

LED display

Device The contents of display color

LD1 Pulse generating state Green

LD2 Main circuit capacitor charge condition Red

LD3 Error condition Red

LD4 Power source normal condition Green

3.2 Driver interface PCB (HVS750)

Driver interface PCB is PCB that consolidated the function of interface PCB, driver PCB, and power

supply stabilization PCB. Refer to 3 part (Hardware Specifications and Maintenance)for details. Figure

3.2.1 shows the part arrangement of the driver interface PCB. Figure 3.2.2 shows the installation position

of the driver interface PCB from externals.

Figure 3.2.1 Part arrangement of the driver interface PCB

Driver interface PCB


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4. Trouble shooting by fault factors

The following explains the investigating and restoring procedure by error codes.

At trouble shooting, be sure to observe the precautions stated below

●Before investigating, checking or replacing the parts, turn off

power and check for presence of potential. Otherwise, there might be

an electric shock.

●For any investigation, do not touch the panel interior with main

power ON.

●Cell inverter unit has the following weight. When replacing the

unit, use the furnished lifter. Otherwise, you might get injured by tip

over or drop.

● When locating a trouble, get trace-back data first, which contains an important

information for it. To cope with any necessity of replacing parts or circuit PCBs,

prepare required tools beforehand.

● Some parts are mounted in locations where working space is hard to secure

and it is necessary to check beforehand whether the work is possible with

available tools or not.

Caution

Danger

1-14


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4.1 Major fault trouble shooting

When major failure occurs, from table, check fault No. corresponding to fault factor displayed on display

panel, and eliminate fault factor according to correspondence chart.

Note: Failure analysis must be performed based on the trace back data. In case of major failure, therefore,

the trace back data must be collected first. (For collecting the trace back data, see Section 5.) After

collecting the data, eliminate the failure factors according to the failure number chart.

Table 4.1.1 Major fault factor

Note 1. Refer to table 4.1.2(Start fault factor).

Note 2. Refer to table 4.2.3(Light fault).

Note 3. Refer to table 4.1.3(Cell inverter Start fault factor).

1-15

No.

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

Fault message

START FAILURE

CTL POWER DROP

OVERCURRENT(SOFT)

OVERCURRENT(HARD)

OVERVOLTAGE

OVERLOAD

MAIN CIRCUIT POWER DROP

CONNECTOR NOT INSERTED

AC VOLTAGE ABNORMAL

AC CURRENT ABNORMAL

GROUND DETECTED

INV COOLING FAN STOP

TR COOLING FAN STOP TD

CUBICLE OVERHEAT(>60℃)

TRANSFORMER OVERHEAT

U PHASE CELL FAULT

V PHASE CELL FAULT

W PHASE CELL FAULT

U PHASE SIRIAL SIGNAL DOWN

V PHASE SIRIAL SIGNAL DOWN

W PHASE SIRIAL SIGNAL DOWN

U PHASE DRVIF FAULT

V PHASE DRVIF FAULT

W PHASE DRVIF FAULT

Contents

The start failed

The AVR power supply for the control substrate has decreased.

The current that exceeded the maximum rating of the electric motor flowed.

The current that exceeded the maximum rating of the inverter device flowed.

The voltage of the motor exceeded the over voltage level.

The current that exceeded the rated load flowed to the motor for 1 minute or more.

The input voltage has decreased.

The connector of each PCB has the uninsertion connector.

The voltage detecting circuit did not function correctly.

The current detection circuit did not function correctly.

One phase of either of the three-phase circuit output did earth fault.

When the inverter board cooler fan drove, the inverter device stopped.

The transformer cooling fan stops when the VSD drives, and set time has passed.


The winding temperature of a multiple transformer exceeded the trip setting value.

The failure occurred by the U phase cell inverter.

The failure occurred by the V phase cell inverter.

The failure occurred by the W phase cell inverter.

Optical serial communications of U phase detected abnormality (disconnection) .

Optical serial communications of V phase detected abnormality (disconnection) .

Optical serial communications of W phase detected abnormality (disconnection) .

The driver interface substrate of U phase did not function correctly.

The driver interface substrate of V phase did not function correctly.

The driver interface substrate of W phase did not function correctly.

Detail factor

Note1

Note2

H1

H1

H2

H3

H4

H5

H6

H7

H8

H9

H9

H10

H11

Note3

Note3

Note3

H12

H12

H12

H13

H13

H13

No.

1

2

3

4

5

6

7

Fault message

U PHASE SIRIAL SIGNAL DOWN

V PHASE SIRIAL SIGNAL DOWN

W PHASE SIRIAL SIGNAL DOWN

U PHASE CELL NO. SETTING ERROR

V PHASE CELL NO. SETTING ERROR

W PHASE CELL NO. SETTING ERROR

PRECHARGING BUSY

Contents

It was in the state of the optical cable disconnection of U phase.

It was in the state of the optical cable disconnection of V phase.

It was in the state of the optical cable disconnection of W phase.

The U-phase cell number was not set correctly.

The V-phase cell number was not set correctly.

The W-phase cell number was not set correctly.

Optical transmission did not function correctly within a set time.

MAIN CIRCUIT BREAKER ABNORMAL8 The circuit breaker was not closed by the close command.

Table 4.1.2 Start fault factorDetail factor

H12

H12

H12

H16

H16

H16

H17

-

No.

1

2

Fault message

DC OVERVOLTAGE

CELL CONTROL POWER DOWN

Contents

The DC voltage exceeded the over voltage level.

The input voltage of the DRVIF PCB has decreased.

Table 4.1.3 Cell inverter Start fault factorDetail factor

H14

H15


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Fault No.H1

GP

display・OVERCURRENT(HARD)

・OVERCURRENT(SOFT)

Display screen

Fault factor display

Detector composition

Over current detection detects output voltage of current detector connected between inverter and motor with

comparator of soft and hard circuit in control PCB as compared with over current level.

HCTW

CP

HVS026CTL

DIHard current level

AI CMP≧

Fault display

･

･

･

HCTU

IMINV

OC level

Major fault stop

Soft detection

Hard detection

Fault display

Major fault stop

>

>

HCTU U phase current detector

HCTW W phase current detector

CTL Control PCB

Main causality of fault

(1) IGBT fault of cell inverter

(2) Fault of DC detector (HCTU, HCTW)

(3) Incorrect setup of over current level

(4) Fault of fault detector

(5) Fault of works system

The contents of enquiry

!

DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before

starting enquiry.

・Make sure that High voltage direct inverter unit is stopped operating→Check blockage of power

receive breaker.・Make sure that the master circuit DC voltage is“0V”→LED putting out lights in cell inverter

Major enquiry items

(1) Enquiry of motion situation (trace back data, motion situation of high rank)

→ Trace back's details are referred to term 5.

(2) Output voltage enquiry of current detector (Is it sine wave or isn't there any offset? )→Refer to terms 6.2.

(3) Set point enquiry of over current （Set point should check test run account. )

・over current setup(hard) －V/00C00380・・・・・■■■■×1mV

・ over current setup(hard) －V/00C00094・・・・・■■□□ ×5%

(4) Soundness check of IGBT →Refer to 6.1 terms.

1-16


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Fault No.H2

GP

display OVERVOLTAGE(SOFT)Display screen



Output over voltage carries out AI of the output voltage FB to control PCB, and compares and detects motor

primary voltage FB and output over voltage level which were calculated by soft circuit.


(1) Fluctuation of receiving voltage

(2) Direct current voltage upsurge by regeneration motion

(3) Fault of voltage detector

(4) Fault of cell inverter

(5) Incorrect setup of output over voltage level


!

DANGER


starting enquiry.

・Make sure that High voltage direct inverter unit is stopped operating→Check blockage of powerreceive breaker.

・Make sure that the master circuit DC voltage is“0V”→LED putting out lights in cell inverter

Major enquiry items



(2) Output voltage identification of voltage detector

(3) Soundness check of IGBT →Refer to 6.1 terms.

(4) Set point enquiry of output voltage abnormal detection level （Set point should check test run report. ）

・Soft circuit setup・・・For setup VRAM－V/C001FC■■□□×1%+100%

CTL Control PCB

FLT Filter

PTUV Voltage detector UV(PT)

PTVW Voltage detector VW(PT)

CMP≧

AI

AI

･

･

･

INV

PTUV

PTVW

IM

CTL

Fault display

Major fault

stop

V1

arithmetic

>

HVS026

FLT

Detection level

1-17


22/84


Fault No.H3

GP

display OVERLOADDisplay screen



It carries out AI using the inverter AC detected by current detector into control PCB,

overload characteristic is calculated by ∑ I4t integral arithmetic of soft circuit, and overload is detected.

HCTW

･

･

･

HCTU

IMINV



CTL Control PCB

Main causality of fault(1) Increase of motor load

(2) Abnormality in setting of detection level

(3) Fault of exchange current detector

(4) Fault of machine system

HVS026CTL

CMP≧

CMP≧ t

I4

AI

AI

I1

arithmetic

Fault display

Major fault

stop

>

Overload

detection level

Integral starting

current level


!

DANGER


starting enquiry.・Make sure that High voltage direct inverter unit is stopped operating→Check blockage of powerreceive breaker.


Major enquiry items



(2) Output voltage enquiry of current detector (Is it sine wave or isn't there any offset? )→Refer to terms 6.2.

(3) Enquiry of set point of fault detection level (set point should check test run report.)

・Integral stating level V/C00120■■□□ (×1%+100%)

・Over load detection level V/C00120□□■□ (1:125%,1 minute )

1-18


23/84


Fault No.H4

GP

display MAIN CIRCUIT POWER DROPDisplay screen



Main circuit power failure is detected by comparator of hard circuit in control PCB in voltage of multiplex

transformer tertiary winding as compared with power failure detection level. Power return is comparing

with Power return detection level at soft circuit.

CTL Control PCB

TR Transformer

TD Time Delay


(1) Power failure of power receiving power source

(2) Fault of transformer forｍomen power failure detection

(3) Fault of fault detection circuit

(4) Incorrect setup of power failure setting level


!

DANGER


starting enquiry.


receive breaker.・Make sure that the master circuit DC voltage is“0V”→LED putting out lights in cell inverter

Major enquiry items



(2) It is voltage enquiry of transformer for power failure detection at the moment.

(3) Set point enquiry of detection level of power failure / power return Check Set point by test run report.

・ power normal level setup・・・For setup VRAM－V/C000E0 □□■■×1%

・ power failure level setup・・・For setup VRAM－V/C00384 ■■■■×1mV

HVS026CTL

DI

AI CMP<

TD

CP

Main TR

TR for moment

power failure detection

Power return

disregard level

Fault display

Major faultstop

>

>

1-19

Power failure

level set


24/84


Fault No.H5

GP

display CONNECTOR NOT INSERTEDDisplay screen



It carries out DI of the abnormalities in connector insertion in hard circuit in control PCB, and detects them

by soft circuit.

CTL Control PCB

CN3,8～12 Connector


(1) Un-inserting of connector .

(2) Fault of control PCB .


!

DANGER


starting enquiry.



Major enquiry items(1) Enquiry of motion situation (trace back data, motion situation of high rank)


(2) It investigates whether connector is inserted.

→It exchanges control PCBs, when connector is inserted normally

HVS026CTL

DI

CN3

CN8

CN9

CN10

CN1

CN12

>>

Fault display

Major fault

stop

1-20


25/84


Fault No.H6

GP

display AC VOLTAGE ABNORMALDisplay screen



It carries out AI of the output voltage FB to control PCB, and it compares output voltage unusual level from

difference of voltage reference and voltage FB, and detects by soft circuit. Detection level is proportional to

voltage directive.


(1) Voltage FB line and open circuit of output cable

(2) Looseness of connector or TB



(5) Incorrect setup of output voltage unusual level


!

DANGER


starting enquiry.



Major enquiry items



(2) Output voltage identification of voltage detector

(3) It investigates looseness of connector and TB, and open circuit.

(4) Soundness check of IGBT→Refer to 6.1 terms.

(5) Set point enquiry of output voltage abnormal detection level （Set point should check test run report. ）

・Soft circuit setup・・・For setup VRAM－V/C0006C □□■■ ×5%

CTL Control PCB

PTUV Voltage detector UV(PT)

PTVW Voltage detector VW(PT)

CMP≧

AI

AI

Disregard level

+

－

･

･

･

INV

PTUV

PTVW

IM

CTL

Fault display

Major fault

stop

V1

arithmetic

Voltage

reference >

V*

HVS026

1-21


26/84


Fault No.H7

GP

display AC CURRENT ABNORMALDisplay screen



It carries out AI of the current FB to control PCB, and current value detects under on abnormal level by soft

circuit as compared with output current abnormal level.


(1) Open circuit of current FB line, output cable, and motor

(2) Looseness of connector or TB

(3) Fault of current detector


(5) Incorrect setup of output current abnormal level


!

DANGER


starting enquiry.



Major enquiry items



(2) Output voltage identification of current detector → Refer to 6.2 terms.

(3) It investigates looseness of connector and TB, and open circuit.

(4) Soundness check of IGBT→Refer to 6.1 terms.

(5) Set point enquiry of output current abnormal detection level （Set point should check test run report. ）

・Soft circuit setup・・・VRAM－V/C0007C ■■□□×1%

CTL Control PCB



CMP＜

AI

AI

･

･

･

INV IM

CTL

Fault display

Major fault

stop

I1

arithmetic

>

HVS026

Detection level

HCTW

HCTU

1-22


27/84


Fault No.H8

GP

display GROUND DETECTEDDisplay screen



Ground detection carries out AI of the ground voltage to control PCB, and detects it by soft circuit as

compared with ground detection level. Detection level is proportional to speed.


(1) Wiring ground between inverter motors

(2) Ground of motor

(3) Fault of ground detector

(4) Incorrect setup of ground detection level


!

DANGER


starting enquiry.



Major enquiry items



(2) Insulation to the earth situation enquiry of wiring between inverter motors

(3) Insulation to the earth situation enquiry of motor

(4) Set point enquiry of ground detection level (set point should check test run report.)

・Soft circuit setup・・・For setup VRAM－V/C0011C □□■■×0.1V

CTL Control PCB

GDT Ground detection PCB

IF I/F PCB

FLT Filter

CTL

CMP≧

AI

FLT

EB

GDT

Neutral point

HVS610

>>

>

Fault display

Major fault

stop

HVS026

1-23

s p e e d

detection level


28/84


Fault No.H9

GP

display INV CUB COOLING FAN ABNORMALDisplay screen



Abnormality in cooling fan are operation of thermal relay for taking care of cooling fan (ceiling fan) of

inverter board, or voltage reduction detection of cooling fan. Therefore, it carries out DI of electromagnetic

contactor for cooling fan motion, and the contact of power source normal detection relay, and detects by

soft circuit.

88F* Electromagnetic contactor for cooling fan motion

49F* Thermal relay

52 Answerback of power receiving breaker

FFB Breaker

FAN Cooling fan


(1) Cooling fan's motor breaks down.

(2) Cooling fan locked physically.

(3) Cooling fan power source lowered.

(4) Incorrect setup of thermal relay trip level

(5) Fault of DI circuit

(6) Thermal relay is turned on.


!

DANGER


starting enquiry.



Major enquiry items


→ Trace back's details are referred to term 5. (2) ON / OFF identification of breaker for cooling fans

(3) Identification of thermal relay trip and set point

(4) Soundness identification of DI circuit → refer to 4.4.1 terms.

(5) Cooling fan's check of operation

HVS026CTL

49F*88F*

FAN

FFB*

88F*

AC400/440V

DI5 NOT 52

>

Fault display

Major faultstop

1-24


29/84


Fault No.H10

GP

display CUBICLE OVERHEATDisplay screen



Temperature rise in cubicle carries out DI of the thermo switch (it turns on at 55℃) installed in inverter

cubicle to control PCB, and detects it by soft circuit.


(1) Upsurge of ambient temperature

(2) Prolonged motion in the over load condition

(3) Blinding of air filter

(4) Fault of cooling fan power source



!

DANGER


starting enquiry.



Major enquiry items



(2) Enquiry of ambient temperature

(3) Enquiry of air filter dirt

(4) Cooling fan's check of operation

(5) Soundness identification of DI circuit →Refer to 4.4.1 terms.

CTL Control PCB26C Thermo switch for cubicles

HVS026CTL

DI6

>

Fault display

Major fault

stop

26C

･

･

･

1-25


30/84


Fault No.H11

GP

display TRANSFORMER OVERHEATDisplay screen



Multiplex transformer superheating carries out DI of the thermo switch installed in transformer board to

control PCB, and detects it by soft circuit.


(1) Continuation of overload operation

(2) Upsurge of ambient temperature

(3) Abnormalities of thermometer



!

DANGER


starting enquiry.



Major enquiry items

(1) Enquiry of motion situation (trace back data, motion situation of high rank)→ Trace back's details are referred to term 5.

(2) Enquiry of ambient temperature

(3) Soundness identification of DI circuit →Refer to 4.4.1 terms.

CTL Control PCB

TR Transformer cubicleT1 Transformer attached thermometer

H1 Transformer attached thermo switch

HVS026CTL

DI

>

Fault display

Major fault

stopH1

TR

T1

>

1-26


31/84


Fault No.H12

GP

display OPTICAL COMMUNICATION ABNORMALDisplay screen



When light which is carrying out loop for every four cell inverters (see the 6.4th term for details) intercepts,

it causes abnormalities in transmission. It generated in fault of Optical cable broken and driver interface

PCB, and has detected in soft circuit of control PCB.


(1) Open circuit of optical cable

(2) Fault of driver interface PCB

(3) Receipt power supply abnormal or fuse breakdown

(4) Loosening or disconnection of connector


!

DANGER


starting enquiry.



Major enquiry items



(2) Open circuit enquiry of optical cable →Refer to 6.4 terms.

(3) Enquiry of interface PCB→LED display identification (3.2 terms)

1-27

HVS750

DRVIF

HVS026CTL

52DIO/E

E/O

HVS750

DRVIF

HVS750

DRVIF

HVS750

DRVIF

Fault display

Major fault stop

Major fault stop

>

>

CTL Control PCB

DRVIF Driver Interface PCB

E/O Electricity / optical signal conversion device

O/E Light / electrical signal converter


32/84


Fault No.H13

GP

display ** CELL INV FAULTDisplay screen



* When cell inverter breaks down (refer to fault factor table 4.1.2), it has notified * cell inverter fault to

control PCB by intercepting output of optical sign by driver interface PCB. It is carrying out loop of the

optical cable for every four cell inverters (see the 6.4th term for details).

"**" shows serial number of broken cell inverter.



(2) Fault of driver PCB


(4) Optical cable open circuit


!

DANGER


starting enquiry.



Major enquiry items



(2) Identification of cell inverter fault factor→Refer to 2.5 terms.

(3) Enquiry of driver interface PCB →LED display, connector enquiry (refer to 3.2 terms)

(4) Open circuit enquiry of optical cable → refer to 6.4 terms.

CTL Control PCB




HVS750

DRVIF

HVS026CTL

52DIO/E

E/O

HVS750

DRVIF

HVS750

DRVIF

HVS750

DRVIF

Fault display

Major fault stop

Major fault stop

>

>

1-28


33/84


Fault No.H14

GP

display DC OVERVOLTAGEDisplay screen



As compared with over voltage detection level, it detects direct current over voltage, and is carrying out DI

of the direct current voltage inputted into driver interface PCB to control PCB.

Main causality of faultOver voltage

(1) Motion situation is regeneration condition.

Under voltage

(1) Secondary voltage depression of multiplex transformer

(2) Investigating looseness of connector and TB, and open circuit.

Common



(3) Fault of driver-interface PCB


!

DANGER


starting enquiry.


receive breaker.


Heavy enquiry items(1) Enquiry of motion situation (trace back data, motion situation of high rank)


(2) Electrolytic capacitor enquiry

(3) Enquiry of driver interface PCB →LED display identification (Refer to 3.2 terms)

(4) Insertion identification of connector

1-29



S/P Serial/parallel conversion

E/O E/O Electricity / optical signal conversion device

CTL Control PCB

HFC1,2 High rap Fuse

Voltage

reduction

detection

DI52

E/O O/E

CNV

HFC1

HFC2

Fault display

Major fault stop

Major fault stop

>

>

HVS026HVS750

DRVIF

CTL

Cell INV

!

DANGER


34/84


Fault No.H15

GP

display DRIVER POWER DROPDisplay screen



Driver power source depression detects voltage reduction of power source for driver PCBs of each cell

inverter within driver interface PCB, and is carrying out DI to control PCB.


(1) Fault of driver power source

(2) Fault of driver PCB


(4) Fault of IGBT, fuse broken



!

DANGER


starting enquiry.


receive breaker.


Major enquiry items



(2) Output voltage enquiry of driver power source

(3) Enquiry of driver PCB -> LED lighting enquiry (3.3 terms)

(4) Enquiry of interface PCB→ LED lighting enquiry (3.2 terms)

(5) Investigating looseness of connector and TB, and open circuit.

(6) Soundness identification of IGBT→ refer to 6.1 terms.

(7) Fusing identification of fuse

CTL Control PCB O/E Light / electrical signal converter

DRV Driver PCB HFC1,2 High rap Fuse

OVdetection

DI52

E/O O/E

CNV

HFC1

HFC2

Fault display

Major fault stop

Major fault stop

>

>

HVS026HVS750

DRVIF

CTL

Cell INV

1-30


35/84


Fault No.H16

GP

display DIP SW SETTING ABNORMALDisplay screen



Abnormalities in DIP switch setting detect condition of DIP switch of driver interface PCB of each cell

inverter by driver interface PCB, and it is carrying out DI to control PCB. As compared with normal setting

condition, it has detected using the DI signal.


(1) The mistake is found in a set number of the DIP switch.





!

DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition beforestarting enquiry.



Major enquiry items



(2) DIP switch setting identification (Setup should check commissioning report.)

(3) Optical cable open circuit identification→Refer to 6.4 terms.

(4) Enquiry of driver interface PCB →LED display identification (refer to 3.2 terms)

(5) Confirmation of loosening or disconnection of connector

CTL Control PCB




1-31

DI

52

=O/EE/O

DRVIF

HVS750

DIP

Switch

Conditiondetection

CMP

Set value

Fault display

Major fault stop

>

CTL HVS026


36/84


Fault No.H17

GP

display PRECHARGING BUSYDisplay screen



Initial charge tie up carried out DI (optical transmission) of the voltage establishment by driver interface

PCB from main circuit voltage of each cell inverter during initial charge, and has detected it by soft circuit.

It generates also at the time of DIP switch un-setting of driver interface PCB up.


(1) Initial charge power source blockage

(2) Bad conditions of initial charge circuit

(3) Fault of driver interface PCB ,Un-setting of DIP switch up.

(4) Depression of driver and driver interface power source




!

DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition beforestarting enquiry.



Major enquiry items



(2) Initial charge power source FFB and voltage enquiry in control panel

(3) Enquiry of thermal relay trip of initial charge circuit, and set point

(4) Enquiry of driver interface →LED display and DIP switch setting identification (refer to 3.2 terms)

(5) Supply voltage enquiry of driver interface, and connector CN1 insertion identification (refer to 3.2 terms)

(6) Open circuit enquiry of optical cable → refer to 6.4 terms.

HVS026CTL

DI

DRVIF HVS750

CMPCMP E/O

Cell-INV Unit

Power source

establishment level

Under initial charge

Fault display

Major fault

stop

>

>

CTL Control PCB


DRVIF Driver interface PCB

1-32


37/84


4.2 Other faults

4.2.1 Light fault

The Alarm may:

①Cause no problem even if left unremedied

②Transfer to major fault after certain lapse of time.Tables 4.2.1 give their respective remedial procedures.

Table 4.2.1.1 List of Minor Failure Factors

1-33

No.

1

2

3

4

5

Fault message

(ALARM)OVERLOAD ALARM

(ALARM)SPEED COMMAND ERROR

(ALARM)TRANSFORMER UNIT

(ALARM)CUBICLE OVERHEAT(>55℃)

(ALARM)TRANSFORMER OVERHEAT

Action

The motor load exceeded the rated load.

The speed command signal (4 – 20 mA) dropped to 2 mA or less.

The cooling fan of the transformer unit stopped during the operation.

The unit temperature detection contact (55 degrees) was activated.

The winding temperature of the multiplex transformer exceeded the alarm set value.

No.

1

Fault message

(ALARM) SPEED COMMAND ERROR

Action

Check the speed command and set the speed within the set value.

Table 4.2.1.2 Action for minor failure that allows you to continue operation

Table 4.2.1.3 Action for minor failure that becomes a serious failure

No.1

2

3

Fault message(ALARM)OVERLOAD ALARM

(ALARM) TRANSFORMER

UNIT COOLING FAN STOP

(ALARM) UNIT TEMPARETURE RISE

ActionThe motor load exceeded the rated load.

Check whether the cooling fan of the transformer unit has stopped. (The serious

failure “Transformer Unit Cooling Fan TD” will occur within a set time while the

circuit breaker is ON.)

Check the ambient temperature, operation conditions (overload), filter clogging,

cooling fan operation, and DI circuit error. (The serious failure “Unit Temperature

Rise” will occur when the unit temperature exceeds 60 degrees.

4

(ALARM) MULTUPLEX TRANSFORMER

OVERHEAT

Check the ambient temperature, operation conditions (overload), filter clogging,

cooling fan operation, and DI circuit error. (The serious failure “Unit Temperature

Rise” will occur when the unit temperature exceeds the preset temperature.


38/84


4.2.2 Control PCB abnormal

If abnormalities of control PCB occur at the time of online mode, "abnormalities in controller" screen is

shown. A trouble of the control circuit PCB is attributable to:

①Malfunction of component part on circuit PCB

②Power voltage fluctuation or other external factors.

The trouble is very hard to locate

When abnormalities display of control PCB occurs, Operate GR switch of control PCB. (Fig. 4.2.1)

Exchange control PCBs, when GR switch operation back and abnormalities recur.

PUSH

Enlargement

GR switch

Fig. 4.2.2 GR switch operation

1-34


39/84


4.2.3 Controller power source abnormal

If the control power (± 15 V) drops while in online mode, “Controller Power Failure” occurs. The possible causes are:

①Defective components in the board;

② External factors, including voltage fluctuations of the power supply; or

③ Failure of the control power AVR.

If the control power is not available, failure factors cannot be displayed. If the power of the graphic panel

on the unit surface is available, the “Offline Mode Screen” is displayed.

Check as follows:

① Check whether the LEDs of the control board (HVS026) are turned ON.

② Check whether the LED of the control power AVR is turned ON.

③ Check the voltage of the control power AVR.If the control power AVR has no trouble and if all LEDs on the control board are turned OFF, replace the

control board.

1-35

Installation position of AVR for control source

(Sample)

Control PCB (HVS026)

Figure 4.2.3 Installation position of AVR for control source and the control PCB.


40/84


4.3 Interlock factor

Although fault has not occurred, when you cannot operate, investigate pending interlock by interlock

factor display screen of face of a board display.

4.3.1 CONNECTOR NOT INSERTED

Confirm whether the connector of control PCB (HVS020) is completely inserted.

There are some parts where connectors of the number of same poles are used. Confirm connector No.

described to the cable is corresponding to the printed circuit PCB.

4.3.2 MAIN CIRCUIT BREAKER OFF

Check whether main circuit breaker 52 cuts and it is in condition.

4.3.3 I/F ABNORMAL

Check whether high rank I/F is operating normally.

4.3.4 MAJOR FAULT

Refer to the contents of major failure

4.3.5

HV CUB MAJOR FAULT

Check whether power receiving 49 and 51 are operating. While operating, it can consider abnormalities of

power receiving circuit or works system.

4.3.6

EMERGENCY STOP

Check whether emergency stop operation is carried out.

4.3.7

MOTOR COOLING FAN STOP

Check whether fan for motor cooling is operating.

4.3.8

MOTOR RUNNING

Check whether motor is rotating.

1-36


41/84


4.4 Supplemental documented procedures

4.4.1

Relay input and output identification procedure

Contact signal inputted into control PCB is changed into signal (memory) which software finally

recognizes via photo coupler.

Moreover, digital signal outputted from control PCB is outputted by relay contact.

The contents of standard DI/DO signal are shown in Table 4.4.1.1-2 (Please refer to description of

operation, and schematic diagram for details) .

NO

Confirm whether there

is not loosening in the

connector of the

control circuit PCB.

【Example of display 】

When D11, 5, 7, 8 and 9, and DO0 and 1 are ON

YES

Normal

Abnormal

Input is normal. Investigate whether other points are abnormal.

If trouble cannot be located notify us phenomenon and trace-back data.

Is data

Input ON: Lit

Input OFF: Not lit ?

Has it become?

Confirm display (ON/OFF)

of the signal input on the

"DIO" screen of the display

unit.

Turn on/off input

source contact

Control PCB faulty

Replace control PCB

Restart available

Connector insertion is defective

Connector insertion

1-37


42/84


Table 4.4.1.2 Contents of DO signal

(Note) According to system, as for DI 1,2, 8, 9, 11～14, the contents of signal and condition at the

time of normal operation are changed.

(Note) According to system, as for DO1～7, the contents of signal and condition at the time of

normal operation are changed.1-38

Signal name Cont ent s of signalAt normal

runninRemarks

DI0 Hard Suppression OFF Emergency stop command signal

DI1 ―

DI2

DI3Main circuit breaker 52 turn on

answerback ON 52 answerback signals

DI4 Transformer overheat OFFThermal relay for temperature rise

detection of multiplex t ransformer

DI5Cooling fan normalcy in

Inverter panelON

with thermal relay for cooling fans in

inverter panel C.T.T

DI6 Temperature rise in board OFFThermal relay for temperature rise

detection in inverter board

DI7 Inverter board door closed ON Door closed switch detection relay

DI8 ―

DI9 ―

DI10 Inverter run command OFF Inverter operation directive signal

DI11 ―

DI12 ―

DI13 ―

DI14 ―

DI15Cooling fan normalcy in

transformer panelON

with thermal relay for cooling fans in

inverter panel

C.T.T

Signal name Cont ent s of signalAt normal

runninRemarks

DO0 Inverter heavy fault ONHeavy fault accrual sign (t urn off by

failure)

DO1 ―

DO2 ―

DO3 ―

DO4 ―

DO5 ―

DO6 ―

DO7 ―

Table 4.4.1.1 Contents of DI signal


43/84


5. How to get trace-back data

The description here concerns how to get data necessitated for analyzing troubles.

The trace backing data is gathered with a maintenance tool.

For further details, refer to manual "Part 2 Maintenance tool".

5.1 Starting of maintenance tool

Click “M.TOOL.exe” to start.

Turn ON the computer and start Windows.

If the “M.TOOL for Windows” has not yet been installed on the hard disk, copy the data

from the M.TOOL CD-R.

The initial setting screen (Figure 5.1.1) appears when the “M.TOOL for Windows” starts.

Connect the serial interface connector (COM1) of PC, and the connector on the display unit

on the surface of a control panel (Fig. 5.1.2) by a RS-232C cable.

* Make connection of PC and a RS-232C cable first at the time of connection.

Startup completed

1-39

Select communication device and type name, in the initial setting screen (Figure 5.1.1).


44/84


Fig. 5.1.2 Allocation of connecter for communication in display unit of the face of a board

1-40

Graphic panel

VSD(VFD)

Control panel

Acrylic cover

Maintenance tool connector

Stop tool for acrylic cover

Fig. 5.1.1 Initial setting screen


45/84


5.2 Invoking Trace-back Command

Track command is invoked by pushing the [F5] key on the Figure 5.2.1 Start of Track command. Once it

is invoked, Figure 5.2.2 Trace back menu screen appears on the screen.

Figure 5.2.1 Start of Track command

Figure 5.2.2 Trace back menu screen

1-41

Please push F5 (Track) key.

Please select

" 1. Collection of Logging data"


46/84


5.3 Sampling Trace-back Data

① Choose the menu option [1.Collection of Logging data] on the Figure 5.2.2 Trace back menu screen.

(Use the [↑] or [↓] key to choose an appropriate menu option, and push the [Enter] key.)

② The screen moves to Figure 5.3.1 Logging data collection menu screen. Choose either

[1. Normal collection of data] or [2. Compulsion collection of data] on this screen.


[2. Compulsion collection of data] is chosen when the logging data currently in operation is acquired

forcedly. For forced acquiring, see "VOLUME II MAINTENANCE TOOLS.”

Figure 5.3.1 Logging data collection menu screen

5.3.1 Trace-back data acquiring

1-42

Please select this menu option, if you

wish to acquire the logging data which is

stored in case of fault.

Please select this menu option, if you

wish to acquire the logging data currently

in operation.


47/84


③ If [1. Normal Data Collection] is selected, the screen for selecting the data to be collected (Figure

5.3.2) appears. Use either the [↑] or [↓] key to select the data to be collected, and press the [Enter] key.

The lowest number in the [No.] column on the screen shows the latest failure data.

The “State” column shows the following information:

[Uncollection]: There is uncollected data in the area.

[Collected]: The data in the area has been collected.

[No data]: There is no data in the area.The [Logging stop time] column shows the time and date of when a failure occurs.

Press the [R] key. Then, the latest information in the control board will be read and the screen will be

updated.

1-43

Figure 5.3.2: Screen for Selecting Data to be Collected

>

The right time is not displayed unless time of PC suits it, since failure accrual time is computed from time

of PC (personal computer).


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④ When you choose the data, the screen moves to “Output file name input screen“ (Figure 5.3.3), on

which you may enter up to Sixty-four half-size (one-byte) characters as the output file name.

If the same file name as you have just entered already exists, a message " The file already exists. Can I

overwrite? [Y/N] " appears on the screen. If you wish to overwrite, push the [Y]. If you change the name

to another, push the [N] and re-enter the file name.

Figure 5.3.3 Output file name input screen

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Figure 5.3.4 Comment input screen

Input the file name by 64 characters or less.

⑤ When you input the output file name, the screen moves to “Comment input screen“ (Figure 5.3.4), on

which you may enter up to Fifty half-size (one-byte) characters as the comment.

Press the [Enter] key if you do not enter a comment.

Input the comment by 50 characters or less.


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⑥ As soon as a comment is entered, data collection begins.

If there is no space for storing the data in the HDD, the message, “File making error(empty capacity of the

current drive)” is displayed. In this case, make sure that the HDD has enough space, and collect the data

again.

During data acquiring, the screen as shown in Figure 5.3.5 is displayed, on which the data being acquired

and the amount of acquired data are displayed.

When all the logging data are acquired, the following message appears:

" The collection of data ended. Please push any key. " Push the [SPACE] key.

(The screen returns to Figure 5.3.1 Logging data collection menu screen.)

Figure 5.3.5 Screen display gathering trace back data

⑦ Now you have finished data acquiring. The contents of the acquired data may be displayed by

choosing the menu option [2. Display of Logging data] on the Trace back menu screen.(Figure 5.2.2)

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Displayed when all the data collecting is completed

These values are counted during data acquiring.

File name is displayed.


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5.3.2 Forced logging data acquiring

Forced logging data acquiring is used to acquire logging data while the inverter is normally running. To

acquire data, choose the menu option [3. Compulsion collection of data] on Figure 5.3.1 Trace back data

collection menu screen. Forced data acquiring cannot be made unless logging is performed. When you

choose forced acquiring while logging is stopped, a message

“Because logging has stopped, data cannot be compulsorily gathered.”appears.

Push the space key. To make sure that logging is working, you may find it by observing that the No. 8

display on the digital readout is counting. During logging, choose an item, and a message

“May I compulsorily gather data? [Y/N]”

appears. If you wish to acquire, push the [Y] and if not, push the [N] key. Once you push the [N] key, the

screen moves to Figure 5.3.1. If you press the [Y] key, the screen moves to Figure 5.3.3 Output file name

input screen. Remaining steps after the step of entering file name are the same as those for regular data

acquiring.

! CAUTION

When you choose forced data acquiring, logging stops for about one to three seconds. In case that serious

fault occurs during logging stop, the fault data cannot be stored in the flash memory.

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5.4 Numerical display

① On Figure 5.4.1 ”Trace back menu screen”,choose the menu option [2. Display of Logging data].



② The screen moves to Figure 5.4.2 File selection screen , on which you may choose a

file. Use the [↑] or [↓] key to choose a file, and push the [Enter] key.

Figure 5.4.2 File selection screen

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Please select

“ 2.Display of Logging data “

File information is displayed


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③ When you choose a file, the screen moves to Figure 5.4.3, on which you may use the

[↑] or [↓] key, and push the [Enter] key.

Figure 5.4.3 Logging data display menu screen

④ When you choose the menu option [1 Numeric Display], the screen moves to Figure 5.4.4 “Selection

screen at output point.”. Use the [↑] or [↓] key to choose an

appropriate menu option, and push the [Enter] key .

Figure 5.4.4 Selection screen at output point

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Please select

“ 1.Numeric Display “

Please select

“ 1.Display “


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⑤ When you choose the menu option [1. Display] on Figure 5.4.4 “Selection screen at output point”, the

screen moves to Figure 5.4.5 “Numeric display data selection screen “. Use the [↑] or [↓] key to choose an

appropriate menu option, and push the [Enter] key.

If you choose the menu option [1. 0.3ms Cycle Logging], Figure 5.4.6 appears and

if you choose the menu option [2. 30ms Cycle Logging], then Figure 5.4.7 appears.

Figure 5.4.5 Numeric display data selection screen

Figure 5.4.6 Output item selection screen (0.3ms cycle)

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⑥ In order to choose the item to display, input the number on the left-hand side of an output item by

double figures.

The number of the items which can be chosen is a maximum of eight.

Press the [Enter] key, when you carry out selection closing of the item to output.

The screen moves to Figure 5.4.8 “Numeric display screen “.

[Example]

To let the numbers 1, 3, 10, 11, and 12 on Figure 5.4.6, push the [space][1], [space][3], [1][0], [1][1],

[1][2], and [Enter] keys in this order .

Figure 5.4.7 Output item selection screen (30ms cycle)

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Explanation of a use key:

[ESC] Aborts entering numeric key entry, returning the screen to Figure 5.4.5.

[↓] Displays the next page.

[↑] Displays the previous page.

[PrtSc] Prints out the screen currently being displayed.

1 3 10 11 12

[space][1] [space][3] [1][0] [1][1] [1][2] [Enter]

When the item number is one digit(1～9),

then press the [0] or [space] key first

Select End


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Fig. 5.4.8 Numerical display of logging data

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Figure 5.4.9 Output format choice display screen

⑦ When you choose the menu option [2.File] on Figure 5.4.4 “Selection screen at output point “, the

screen moves to Figure 5.4.9 “Output format choice display screen “. Select the desired output format.

Next the screen moves to Figure 5.4.10 “Output file name input screen “, on which you may enter up to

Sixty-four half size characters as the output file name.

If there is a file with the same name as you entered, a message

" The file already exists. Can I overwrite? [Y/N] "

appears on the screen, prompting your confirmation.

If you wish to overwrite, push the [Y]. Or if you wish to enter another name, push the [N].

When you enter [N], re-enter the file name


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Figure 5.4.10 Output file name input screen

⑧ Once the output file name is entered, file output is started.

The file will be stored in the “Trace Data “ folder in which the M.TOOL has been installed.

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Input the file name by 64 characters or less.


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5.5 Trend Display

① On Figure 5.5.1 “Trace back menu screen“, choose the menu option [2. Display of logging data].


② The screen moves to Figure 5.5.2 “File selection screen “. Use the [↑] or [↓] key to choose an

appropriate file, and push the [Enter] key.

Figure 5.5.2 File selection screen

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Please select

“ 2.Display of Logging data “

File information is displayed


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③ When you finish choosing the file, the screen moves to Figure 5.5.3 “Logging data display menu

screen “. Use the [↑] or [↓] key to choose the menu option [2. Trend display], and push the [Enter] key

Figure 5.5.3 Logging data display menu screen

Figure 5.5.4 Selection screen at output point

④ When you choose [2. Trend Display], the screen moves to Figure 5.5.4 “Selection screen at output

point “.

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Hitachi Part-1 (Hvs026) 200a Rev00

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