Altivar 1000

Use and maintenance manual IGBT voltage source inverter

Retain for future use 3300 V
1300 - 14400 kVA
Contents
1. Scope ...................................................................................................................................................................................................................................1
2. Product Identification and Safety Rules ...............................................................................................................................................................................2
2.1. Product Identification........................................................................................................................................................................ 2
2.2. Incorporation Rules .......................................................................................................................................................................... 2
2.3. Cautionary Plates on Cabinet Front Doors ....................................................................................................................................... 3
2.5. Safety and Warning Symbols ........................................................................................................................................................... 5
3. Equipment Parts...................................................................................................................................................................................................................6
3.1. General ............................................................................................................................................................................................ 6
3.2. Converter ......................................................................................................................................................................................... 6
3.3. Inverter Power Modules ................................................................................................................................................................. 15
3.4. Rectifier Power Modules ................................................................................................................................................................ 18
3.5. Control Modules and Control Cards ............................................................................................................................................... 21
3.6. Inverter Current and DC Voltage Transducers ............................................................................................................................... 60
3.7. Inverter Firing Card and Isolated Supply ........................................................................................................................................ 60
3.8. Rectifier Bridge Firing Card ............................................................................................................................................................ 66
3.9. Insulated Transmitter Interface Card .............................................................................................................................................. 67
3.10. Rectifier Bridge Precharge Diode Card .......................................................................................................................................... 70
3.11. Precharge Circuit (AFE configuration only) .................................................................................................................................... 71
3.12. Encoder requirements and connections ......................................................................................................................................... 74
3.13. Ground Fault Detector.................................................................................................................................................................... 77
4. Converter Start Up .............................................................................................................................................................................................................80
4.1. User Interface (Keypad and PC Tool)............................................................................................................................................. 80
4.2. Drive Status Summary ................................................................................................................................................................... 84
4.3. Inverter Protections Summary ........................................................................................................................................................ 84
4.4. Parameters Reset .......................................................................................................................................................................... 85
4.5. Programming Levels ...................................................................................................................................................................... 85
4.6. Control Modes................................................................................................................................................................................ 85
4.7. Motor Rated Power EU/NEMA Selection........................................................................................................................................ 86
4.8. Quick Motor Start-Up...................................................................................................................................................................... 86
4.9. Encoder test (if present) ................................................................................................................................................................. 89
4.10. Protections Description .................................................................................................................................................................. 90
4.11. Start Up Procedure......................................................................................................................................................................... 98
5. Maintenance, Checks and Troubleshooting.....................................................................................................................................................................101
5.4. Electrical Check of an Inverter Power Module ...............................................................................................................................107
5.5. Measuring and Displaying Inverter Output Currents and D.C. Voltages ........................................................................................108
6. Parts Replacement...........................................................................................................................................................................................................110
6.2. Main Fans (Air cooled units only) ..................................................................................................................................................114
6.3. Water Pumps (Water cooled units only) ........................................................................................................................................114
6.4. Control Cards ................................................................................................................................................................................114
7. Spare Parts ......................................................................................................................................................................................................................117
7.1. POWER MODULES ......................................................................................................................................................................117
7.4. Firing Cards AND Thermo Switch Interfaces .................................................................................................................................121
7.5. Precharge CIRCUIT (only for afe configuration) ............................................................................................................................121
7.6. Control parts..................................................................................................................................................................................121
7.7. PLC PARTS ..................................................................................................................................................................................122
7.9. FANS (Air Cooling Unit Only) ........................................................................................................................................................122
7.10. PUMPS (Water Cooling Unit Only) ................................................................................................................................................122
1. Scope
Scope of this manual is to provide use and maintenance instructions, troubleshooting information and spare parts list for Altivar 1000
Medium Voltage Variable Speed Electrical Drives.
This manual, together with the other manuals and drawings here listed, is part of the equipment and is to be stored in a safe and easily-
retrievable place for the whole lifetime of Altivar 1000. These documents are to be available to technicians servicing the equipment since
contain safety, access and service rules, and complete maintenance and programming instructions.
Altivar 1000 is a configurable equipment built on job specifics needs by assembling standard basic cabinets. Manuals are the same and
apply to all models and types, electrical schematic diagrams and mechanical drawings are specific for each installation and job.
Only actions described in these manuals shall be performed on equipment. Neither other action, measurement or change of any type shall
be carried out.
Standard set of documents for ATV 3300V equipments consists of:

• Altivar 1000
Safety and Installation Manual

• Altivar 1000
Maintenance Manual

• Electric and Electronic Equipment (Boards)

General Operation and Maintenance Manual

• Altivar 1000
Programming Manual

• Altivar 1000
Active Front End Programming Manual

• Altivar 1000
Cooling System Use and Maintenance Manual (this manual)

• Altivar 1000
Electric schematic diagrams, job-specific (code different from job to job)

1
2. Product Identification and Safety Rules

2.1. Product Identification

This manual provides instructions about the IGBT Medium Voltage Variable Speed Electrical Drives designed and manufactured by
Schneider Toshiba Inverter Europe and identified by the product family name Altivar 1000 with power range from 1300 to 14400 kVA.

Related European and International Product Standard is CEI EN 61800-xx group. According to this group of Standards, Altivar 1000 is
defined as a subsystem of an Adjustable Speed Electrical Power Drive System [PDS] and, more precisely, the part of PDS defined as
Complete Drive Module [CDM].

2.2. Incorporation Rules

According to EU Machinery Directive 98/37/EC and 2006/42/EC, or outside EU applicable laws, this equipment is not a complete machine
and it shall be incorporated into a system before to be operated.

The Altivar 1000 is part of an installation consisting of other different equipments and machines grouped to form a system. All the
functional safety relating functions needed by the system shall be guaranteed by the System Integrator.

The Altivar 1000 shall be installed according to this manual and cannot be operated until the system (machinery), in which is incorporated,
has been declared complying with the “Machinery Directive 98/37/EC and 2006/42/EC” or other local applicable laws.

It has been noted that Altivar 1000 alone shall not be CE marked since it is a part of an installation consisting of other different
equipments and machines.

2
2. Product Identification and Safety Rules

2.3. Cautionary Plates on Cabinet Front Doors

CAUTION DANGER !

RISK OF DEATH OR ELECTRIC SHOCK

MAINTENANCE SHALL BE PERFORMED EXCLUSIVELY BY AUTHORIZED SKILLED

PERSONNEL

MORE THAN ONE POWER SUPPLY IS CONNECTED TO THE EQUIPMENT

LETHAL VOLTAGES CAN EXIST EVEN IF ALL SUPPLIES ARE DISCONNECTED.

WAIT 10 MINUTES BEFORE STARTING THE EARTHING SAFETY PROCEDURE

MAINTENANCE ON THIS CABINET SHALL BE PERFORMED STRICTLY FOLLOWING

THE INSTRUCTIONS SPECIFIED IN THE USER MANUALS

Standard cautionary plate on cabinet doors

3
2. Product Identification and Safety Rules

2.4. Safety and Cautionary Mandatory Rules

CAUTION! DANGER!
RISK OF DEATH, ELECTRIC SHOCK, HEAVY INJURIES TO PERSONNEL

RISK OF FIRE AND/OR DAMAGES TO EQUIPMENT AND/OR TO THE SYSTEM

It is mandatory to fully understand and strictly apply all Safety and Cautionary Rules listed in the ATV1000 - Safety and Installation
Manual;
see in particular Chapter 2 about :

- Functional Safety Hazard

- Operator Mandatory Skill
- Hazard on Accessing ATV 1000 Cabinets
- Risk to Inappropriate Use and Connection
- Minimal Safety Integration Requirements.

It is mandatory to fully understand and strictly apply all Safety Rules according to local laws and all safety site regulations.

4
2. Product Identification and Safety Rules

2.5. Safety and Warning Symbols

This manual contains different cautionary statements:

Warns against actions that can lead to hazardous scenarios, risk of death or electrical shock. Highlights
DANGER ! some hazardous situations that can arise during maintenance operations.

Procedures that must be strictly followed or operating modes that shall not be applied: highlights the risk
WARNING! of damaging the parts of the equipment.

NOTE Relates to a clarification about instructions, repair operation or any other subject.

Dangerous scenarios are highlighted using the following symbols:

Risk of death, fire or heavy injuries

The job requires the personnel is skilled for the purpose, well aware of safety rules, regulations and
standards while operating on Medium Voltage Equipments. Full knowledge of installation power supply
system and ATV 1000 diagrams is needed.

Risk of death, electric shock or heavy injuries

The job requires the personnel is skilled for the purpose, well aware of safety rules, regulations and
standards while operating on Medium Voltage Equipments. Full knowledge of installation power supply
system and ATV 1000 diagrams is needed.

5
3. Equipment Parts

3.1. General
For following aspects:

• Product outline
• Simplified electrical diagrams
• Technical data
• Overall dimensions

Refer to Chapter 3 of “Altivar 1000 Safety and Installation Manual”.

3.2. Converter
Altivar 1000 Converter consists of a NPC type, Voltage Source, IGBT inverter with both Diode Front End and Active Front End
configuration.
The converter is based on a modular structure, which main parts are the Inverter Power Modules and the Rectifier Power Modules; both
air cooling and water cooling version are available.
The Converter contains all other essential auxiliary circuits and devices: current and voltage transducers, power supplies, precharge
circuit, firing boards, ground fault detector, output reactors, safety ground switch.

6
3. Equipment Parts
3.2.1. Diode Front End (12 and 24 Pulse)
1300 to 2600 kVA - Air Cooling / 1600 to 3600 kVA - Water Cooling

Air cooling sizes:

ATV 1K3 A33 12P / ATV 1K3 A33 24P / ATV 1K8 A33 12P / ATV 1K8 A33 24P / ATV 2K6 A33 12P /
ATV 2K6 A33 24P

Water cooling sizes:

ATV 1K6 W33 12P / ATV 1K6 W33 24P / ATV 2K4 W33 12P / ATV 2K4 W33 24P /
ATV 3K6 W33 12P / ATV 3K6 W33 24P

Diode Front End 12 Pulse - Simplified Schematic Diagram

M
3

Converter

Diode Front End 24 Pulse - Simplified Schematic Diagram

M
3

Converter

7
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Air Cooling

Main Fan

Rectifier
Bridge

Inverter
Phase

Current
Transducer

Link Bus
Bar

Output
Phase Bar

Ground
Switch
Insulation
Controller
Sensor

Output
Reactor
TITOIA
Boards

8
 3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Water Cooling

Rectifier
Bridge

Inverter
Phase

Link Bus
Bar

Output
Phase Bar

TRAL80
Transformers

Insulation
Controller
Sensor

Output
Reactor

Water cooling
Pipes

9
3. Equipment Parts
3.2.2. Diode Front End (12 and 24 Pulse)
3600 to 5200 kVA – Air Cooling / 4800 to 7200 kVA – Water Cooling

Air cooling sizes:

ATV 3K6 A33 12P / ATV 3K6 A33 24P / ATV 5K2 A33 12P / ATV 5K2 A33 24P

Water cooling sizes:

ATV 4K8 W33 12P / ATV 4K8 W33 24P / ATV 7K2 W33 12P / ATV 7K2 W33 24P

Diode Front End 12 Pulse - Simplified Schematic Diagram

M
3

Converter

Diode Front End 24 Pulse - Simplified Schematic Diagram

M
3

Converter

10
3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Air Cooling

Main
Fan

Rectifier
Bridge

Link Bus
Bar

Inverter
Phase

Output
Reactor

11
 3. Equipment Parts
Converter Cubicle Drawing (12 and 24 Pulses) – Water Cooling

Rectifier
Output Bridge
Phase Bar

Current
Transducer

TRAL80
Transformers

TITOIA Inverter
Boards Phase

Insulation Output
Controller Reactor
Sensor
Water cooling
Ground
Pipes
Switch

12
 3. Equipment Parts
3.2.3. Active Front End 1600 to 3600 kVA – Water Cooling

ATV 1K6 W33 AFE / ATV 2K4 W33 AFE / ATV 3K6 W33 AFE

AFE Simplified Schematic Diagram

M
3

Converter Cubicle Drawing

Line Side
Output Reactor

Line side
Phase

Motor Side Line side

Output Reactor Phase

Line side
Phase

Motor side
Phase

Motor side
Phase

Motor side
Phase

Water
cooling
pipes

13
 3. Equipment Parts
3.2.4. Active Front End 4800 to 7200 kVA – AFE – Water Cooling

ATV 4K8 W33 AFE / ATV 7K2 W33 AFE

AFE Simplified Schematic Diagram

M
3

Converter Cubicle Drawing

DC Fuses
Line Side Output
reactor

Line side
Phase

Precharge
Board

Precharge
transformer Motor side
Phase

Water
cooling
pipes

14
3. Equipment Parts

3.3. Inverter Power Modules

The Inverter Power Module is an assembly with different standard sizes that includes IGBTs and FWD, Clamping Diodes, capacitors,
heatsink, Firing cards and Bus bar.
The heatsink is cooled by air or deionised water and is electrically connected to M, central point of the DC link circuit.

Inverter Power Module simplified schematic diagram:

PP
PP: external positive IGBT and FWD
DP
P: internal positive IGBT and FWD

P N: internal negative IGBT and FWD

M
NN: external negative IGBT and FWD
~
DP: positive CLAMPING DIODE
N
DN: negative CLAMPING DIODE

DN
FWD = Free Wheeling Diode
NN
−

15
3. Equipment Parts
3.3.1. Air Cooled Inverter Power Modules

MOD ATV 1K3 A33

This Inverter Power Module is used in the following equipment sizes:

ATV 1K3 A33 12P / ATV 1K3 A33 24P

MOD ATV 1K8 A33

This Inverter Power Module is used in the following equipment sizes:

ATV 1K8 A33 12P / ATV 1K8 A33 24P

ATV 3K6 A33 12P / ATV 3K6 A33 24P

MOD ATV 2K6 A33

This Inverter Power Module is used in the following equipment sizes:

ATV 2K6 A33 12P / ATV 2K6 A33 24P

ATV 5K2 A33 12P / ATV 5K2 A33 24P

For Inverter Power Module part number see chapter 7.

16
3. Equipment Parts
3.3.2. Water Cooled Inverter Power Modules

MOD ATV 1K6 W33

This Inverter Power Module is used in the following equipment sizes:

ATV 1K6 W33 12P / ATV 1K6 W33 24P /

ATV 1K6 W33 AFE

MOD ATV 2K4 W33

This Inverter Power Module is used in the following equipment sizes:

ATV 2K4 W33 12P / ATV 2K4 W33 24P /

ATV 2K4 W33 AFE
ATV 4K8 W33 12P / ATV 4K8 W33 24P /
ATV 4K8 W33 AFE

MOD ATV 3K6 W33

This Inverter Power Module is used in the following equipment sizes:

ATV 3K6 W33 12P / ATV 3K6 W33 24P /

ATV 3K6 W33 AFE
ATV 7K2 W33 12P / ATV 7K2 W33 24P /
ATV 7K2 W33 AFE

For Inverter Power Module part number see chapter 7.

17
3. Equipment Parts

3.4. Rectifier Power Modules

The Rectifier Power Module is an assembly with different standard sizes that includes Thyristors, Diodes, Heatsink, Firing card and
Precharge devices.
The heatsink is cooled by air or deionised water and is electrically connected to the intermediate point of the Rectifier Power Module.

This is the principle electric diagram of rectifier bridge module for 12 pulses configuration:

Precharge +
Devices

L1: Input line phase 1

L2: Input line phase 2
L1 L3: Input line phase 3
+: Output +
L2
-: Output -
L3

This is the principle electric diagram of rectifier bridge module for 24 pulses configuration:

Precharge +
Devices

L1-1: Input line phase 1-1

L2-1: Input line phase 2-1
L1-1 L3-1: Input line phase 3-1
L1-2: Input line phase 1-2
L2-1
L2-2: Input line phase 2-2
L3-1 L3-2: Input line phase 3-2
+: Output +
-: Output -

L1-2
L2-2
L3-2

18
3. Equipment Parts
3.4.1. Air Cooled Rectifier Power Modules

RAD ATV 550 A33 12P

This Rectifier Power Module is used in the following equipment sizes:

ATV 1K3 A33 12P / ATV 1K8 A33 12P /

ATV 2K6 A33 12P

RAD ATV 550 A33 24P

This Rectifier Power Module is used in the following equipment sizes:

ATV 1K3 A33 24P / ATV 1K8 A33 24P /

ATV 2K6 A33 24P

RAD ATV 1K1 A33 12P

This Rectifier Power Module is used in the following equipment sizes:

ATV 3K6 A33 12P / ATV 5K2 A33 12P

For Rectifier Power Module part number see chapter 7.

19
3. Equipment Parts
3.4.2. Water Cooled Rectifier Power Modules

RAD ATV 750 W33 12P

This Rectifier Power Module is used in the following equipment sizes:

ATV 1K6 W33 12P / ATV 2K4 W33 12P /

ATV 3K6 W33 12P

RAD ATV 750 W33 24P

This Rectifier Power Module is used in the following equipment sizes:

ATV 1K6 W33 24P / ATV 2K4 W33 24P /

ATV 3K6 W33 24P

RAD ATV 2K2 W33 12P

This Rectifier Power Module is used in the following equipment sizes:

ATV 4K8 W33 12P / ATV 7K2 W33 12P

20
3. Equipment Parts

3.5. Control Modules and Control Cards

3.5.1. General
The present paragraph includes:

− connection diagrams of the Control Modules for both Motor Side Inverter and Line Side Converter;
− description of control signals ( Control Module of the Motor Side Inverter – Control Module of the Line Side Converter);
− connections of voltage and current transducers;
− optical fiber connections;
− encoder requirements and encoder connection diagram.

The Control Module includes a main CPU Board (SCADA PLUS control card) and several firing and interface cards. The control card
performs all regulation, logic and diagnostics functions. All cards and related power supplies are placed in an assembly (Control Module);
The number of interface and firing cards depends on the inverter size: Table 1 (Line Side Control Module) and Table 2 (Motor Side
Control Module) list the cards used for each equipment size.

The cards and power supplies included in the Control Module are:

GA1, GA2: Stabilised Power Supply Units providing ±24V power supply to INTVECM interface card/s,
MODVEC and FOVECM cards, INTSYNCB cards (used in Line Side Control Module only) and
INT4TA cards (used only in Line Side Control Module of configurations consisting of several
inverter bridges in parallel), as well as the DCPT and ACCT LEM transducers.

ALIM: the card providing power supplies for the control card (SCADA PLUS).

SCADA PLUS: the control card based on a DSP (Digital Signal Processor) dedicated to control algorithms and
a 16-bit microprocessor. The card includes: two phone sockets (one of which is used for
connection to the user's terminal), 2 connectors for serial RS232 and Profibus links,
respectively, and the XM1 terminal board for signal exchange with outside equipment.

INTVECM: interface card that includes DCPT and CT burden resistors, as well as overcurrent,
overvoltage and current differential hardware protection circuits. Equipment consisting of a
single or 2 inverter bridges in parallel require one INTVEC card only.

MODVEC-S: modulator card that, driven by the CPU card, generates the waveshapes of IGBT gating
signals. Besides, this card receives the IGBT monitoring signals and implements a range of
diagnostic functions (information is given to the operator by DISP1, on board 7 segment
display).
nd
FOVECM: expansion card for the 2 parallel inverter bridge. It is equipped to transmit, by fiber-optic link,
the IGBT gating signals and receive, by fiber-optic link, IGBT monitoring signals (information is
given by DISP1, on board 7 segment display).

INTPREA: interface card that send by optic fiber the “Precharge OK” signal from INTVECM card to
TCPSA card mounted on brige rectifier (used only in DFE configuration).

INTSYNCB: interface card between synchronism transformers and SCADA PLUS control card

21
3. Equipment Parts

EQUIPMENT SIZE CONTROL CARDS of MOTOR SIDE CONTROL MODULE DFE

ALIM SCADA PLUS INTVECM MODVEC FOVECM INTPREA

ATV 1K3 A33 / ATV 1K8 A33 1 1 1 1 - 1
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33 1 1 1 1 1 1
ATV 1K6 W33 / ATV 2K4 W33 1 1 1 1 - 1
ATV 3K6 W33
ATV 4K8 W33 / ATV 7K2 W33 1 1 1 1 1 1

EQUIPMENT SIZE CONTROL CARDS of MOTOR SIDE CONTROL MODULE AFE

ALIM SCADA PLUS INTVECM MODVEC FOVECM

ATV 1K3 A33 / ATV 1K8 A33 1 1 1 1 -
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33 1 1 1 1 1
ATV 1K6 W33 / ATV 2K4 W33 1 1 1 1 -
ATV 3K6 W33
ATV 4K8 W33 / ATV 7K2 W33 1 1 1 1 1

EQUIPMENT SIZE CONTROL CARDS of LINE SIDE CONTROL MODULE

ALIM SCADA PLUS INTVECM MODVEC FOVECM INTSYNC

ATV 1K3 A33 / ATV 1K8 A33 1 1 1 1 - 1
ATV 2K6 A33
ATV 3K6 A33 / ATV 5K2 A33 1 1 1 1 1 1
ATV 1K6 W33 / ATV 2K4 W33 1 1 1 1 - 1
ATV 3K6 W33
ATV 4K8 W33 / ATV 7K2 W33 1 1 1 1 1 1

22
3. Equipment Parts
3.5.2. Control Module Electrical Diagrams
Single Inverter Sizes – DFE Configuration - Motor Side Control Module Electrical Diagram

23
3. Equipment Parts

24
3. Equipment Parts

25
3. Equipment Parts
2 Inverter in Parallel Sizes - DFE configuration - Motor Side Control Module Electrical Diagram

26
3. Equipment Parts

27
3. Equipment Parts

28
3. Equipment Parts
Single Inverter Sizes – AFE Configuration - Motor Side Control Module Electrical Diagram

29
3. Equipment Parts

30
3. Equipment Parts

31
3. Equipment Parts
2 Inverter in Parallel Sizes - AFE configuration - Motor Side Control Module Electrical Diagram

32
3. Equipment Parts

33
3. Equipment Parts

34
3. Equipment Parts
Single Inverter Sizes – AFE Configuration - Line Side Control Module Electrical Diagram

35
3. Equipment Parts

36
3. Equipment Parts

37
3. Equipment Parts
2 Inverter in parallel Sizes – AFE Configuration - Line Side Control Module Electrical Diagram

38
3. Equipment Parts

39
3. Equipment Parts

40
3. Equipment Parts
3.5.3. Control Cards
SCADA PLUS Main CPU Card

Layout of SCADA PLUS Card

SCADA PLUS Control Card

Card description:
U1: microprocessor RL1, RL2, RL3: Relays
U36: FLASH memory K3: RS232 / 485HD serial connectors
U7: EEProm K4/K5: expansion board connectors
U56: coprocessor KUA1, KUB1: UCS interface connectors (opt.)
XM1: control terminal board X3: Basic/Advanced Features Keypads
X5: Synchronous interface (Fieldbus) X7: Digital I/O expansion card (SIOVA)

41
3. Equipment Parts

Microprocessor Plus Control Terminal Block

42
3. Equipment Parts
SCADA PLUS Card jumpers and switches

Name Default Function

JP1 ON ON EErom write protection EEprom
JP2 1-2 OFF for all SVTL sides /
OFF
3 2 1 2-3 OFF for all SVTL sides
JP3 1-2 ON for all SVTL sides /
1-2
3 2 1 2-3 Open for all SVTL sides
JP4 1-2 Analog output PWM0 Analog
2-3 outputs
3 2 1 2-3 Analog output VA
JP5 1-2 Analog output ±10V or 0÷10V Analog
1-2 outputs
3 2 1 2-3 Analog output 4-20mA
JP6 1-2 Analog output PWM1 Analog
2-3 outputs
3 2 1 2-3 Analog output VB
JP7 1-2 Analog output ±10V or 0÷10V Analog
1-2 outputs
3 2 1 2-3 Analog output 4-20mA
JP8 OFF Reserved sw download /
JP13 OFF Reserved /
JP14 ON Reserved /
JP15 1-2 Connects TX232 to X3 for Keypad Advanced Serial link
1-2
3 2 1 2-3 Connects I2C – clock to X3, only for future development
JP16 1-2 Connects RX232 to X3 for Keypad Advanced Serial link
1-2
3 2 1 2-3 Connects I2C – data to X3, ,only for future development
JP17 1-2 RX - RS232 Serial link
1-2
3 2 1 2-3 RX - RS485
JP18 ON RS485 line ended on 221ohm Serial link
JP19 OFF Reserved /
JP22 ON Reserved Serial link
JP23 OFF Reserved /
ON At XM1-5 terminal, the supply (+5V) is available for encoder Encoder
SW1 - 1 OFF
OFF External power supply 12-24V
ON Load resistance (121Ω) connected to channel A (LINE-DRIVER encoder) Encoder
SW1 - 2 ON
OFF
ON Load resistance (121Ω) connected to channel B (LINE-DRIVER encoder) Encoder
SW1 – 3 ON
OFF
ON Load resistance (121Ω) connected to channel Z (LINE-DRIVER encoder) Encoder
SW1 - 4 ON
OFF
ON Current input on XM1-28/29 (R=475Ω) Analog
SW3 - 1 OFF inputs
OFF Voltage input on XM1-28/29
ON Current input on XM1-26/27 (R=475Ω) Analog
SW3 - 2 OFF inputs
OFF Voltage input on XM1-26/27
ON Pull-up to 10V on XM1-26/27 Analog
SW3 – 3 OFF inputs
OFF
ON Pull-down to 0V on XM1-26/27 Analog
SW3 - 4 OFF inputs
OFF
DP1 - 1 OFF PC In terface: ON for RS485 , OFF for RS232 /
DP1 - 2 OFF PC In terface: ON for RS485 , OFF for RS232 /
DP1 - 3 OFF PC In terface: OFF for RS485 , OFF for RS232 /
DP1 - 4 OFF PC In terface: OFF for RS485 , OFF for RS232 /

43
3. Equipment Parts

Table - SCADA PLUS control terminal block

Warnings: Do not connect voltage signals greater than 24 VDC to input connections
Function XM1 Label Description
Relay 3 RO1 Fault NO NO Fault Output Relay 5A – 250VAC
4 RO1 Fault Com COM
44 RO1 Fault NC NC 5A – 250VAC
1 RO2 Prog NO NO Configurable Output Relay 5A – 250VAC
2 RO2 Prog Com COM
43 RO2 Prog NC NC 5A – 250VAC
45 RO3 Prog NO COM
46 RO3 Prog Com NO Configurable Output Relay 5A – 250VAC
Encoder Power 5 Encoder +5V 5V-150mA-Isolated Encoder Supply-must be switched off
Supply (SW1_A :OFF) to connect external 12-24V supply
6 Encoder gnd Isolated encoder 0V
Encoder Interface 7 Channel B 5-12-24V (1024 PPR). With line driver encoder 5V connect set SW1_B to
8 Channel /B ON positon (121Ω load resistance connected to encoder output signals )
9 Channel A 5-12-24V (1024 PPR). With line driver encoder 5V connect set SW1_C to
10 Channel /A ON positon (121Ω load resistance connected to encoder output signals )
11 Channel Z (If necessary) 5-12-24V. With line driver encoder 5V connect set SW1_D to
12 Channel /Z ON positon (121Ω load resistance connected to encoder output signals)
Digital Inputs 13 DI 1 Start/Stop The application of +24 VDC will cause the drive to start and ramp up in speed
The removal of +24 VDC will cause the drive to ramp down in speed and to
stop.
14 DI 2 Prog 24V Isolated Input – Hi = Ramp speed in the reverse direction – Low = Ramp down
15 DI 3 Prog 24V Isolated Input 8mA - Programmable
16 DI 4 Prog 24V Isolated Input 8mA - Programmable
17 DI 5 Prog 24V Isolated Input 8mA - Programmable
18 DI 6 Prog 24V Isolated Input 8mA - Programmable
19 DI 7 Prog 24V Isolated Input 8mA - Programmable
20 DI 8 Drive 24V Isolated Input – Drive Enable – Hi = Drive Enabled – Low = Drive Disabled
enable
Digital 21 DO 4/DI 9(***) 24V-10mA Isolated Output /
Inputs/Outputs Input 8mA – Progammable.
22 DO 5/DI 10(***) 24V-10mA Isolated Output /
Input 8mA – Progammable.
Digital Output 23 D0 6 (***) 24V-10mA Isolated Output – Programmable
Protected with autorestoring fuse
Digital Power 24 DI supply+24V 100 mA -24V Isolated Digital Supply
Supply Protected with autorestoring fuse
25 DI /DO ground 0V Isolated Digital Supply
Analog Inputs 26 AI 1+ Isolated Programmable Differential Inputs. Inputs can be:
a)Through 5-10KΩ potentiometer.(Nom 5KΩ)
27 AI 1-
b) External Voltage Signal ±10V. Input Impedance 40 KΩ
28 AI 2+ c) External Current Signal 0/4-20mA. Input Impedance 475Ω
29 AI 2-
Analog Outputs 34 AO 1 Isolated Programm.-PWM, 0/4-20mA,0-10VDC or ±10VDC-5mA
35 AO 2 Isolated Programm.-PWM, 0/4-20mA,0-10VDC or ±10VDC-5mA
36 AI/AO ground 0V Isolated Analog Supply
37 AO 3 Isolated Programmable-0-10VDC or ±10VDC-5mA
38 AO 4 Isolated Programmable-0-10VDC or ±10VDC-5mA
39 AI/AO ground 0V Isolated Analog Supply
Analog Reference 40 +10Vdc +10VDC – 5mA potentiometer power supply
41 AI/AO ground 0V Isolated Analog Supply
42 -10Vdc -10VDC – 5mA potentiometer power supply

44
3. Equipment Parts
MODVEC-S Modulator Card
Layout of MODVEC-S Card

45
3. Equipment Parts
X1: Connector for signal exchange with SCADA PLUS card
X2: Not used for Silcovert ATV equipment
X3: Connector for serial link connection with SCADA PLUS card
X4: Not used for Silcovert ATV equipment
X5: connector for P24V/N24V power supply
X7: Logic inputs (Main Circuit Breaker closing command)
X8: Connector tor commands sent to the first FOVECM card (config. with 2 parallel bridges)
HL1: red led: ON means trip of the WDOG protection
HL2: red led: ON/OFF means proper equipment operation
HL15: green led: ON means that P6,5V power supply is available
HL16: green led: ON means that P5SMIN power supply ( from P6,5V ) is available
HL18: green led: ON means that P5MIN power supply is available.
HL19: green led: ON means that P5MAX power supply is available
HL20: green led: ON means that P24MIN power supply is available
HL22: green led: ON means that P5V power supply (obtained from P24 V ) is available
HL3: red led: ON means that gating pulses of PP, positive arm of U phase are released
HL23: green led: OFF means gating anomaly of PP, positive arm of U phase
HL4: red led: ON means that gating pulses of P, positive arm of U phase are released
HL29: green led: OFF means gating anomaly of P, positive arm of U phase
HL5: red led: ON means that gating pulses of N, negative arm of U phase are released
HL24: green led: OFF means gating anomaly of N, negative arm of U phase
HL6: red led: ON means that gating pulses of NN, negative arm of U phase, are released
HL30: green led: OFF means gating anomaly of NN, negative arm of U phase
HL7: red led: ON means that gating pulses of PP, positive arm of V phase, are released
HL25: green led: OFF means gating anomaly of PP, positive arm of V phase
HL8: red led: ON means that gating pulses of P, positive arm of V phase, are released
HL31: green led: OFF means gating anomaly of P, positive arm of V phase
HL9: red led: ON means that gating pulses of N, negative arm of V phase, are released
HL26: green led: OFF means gating anomaly of N, negative arm of V phase
HL10: red led: ON means that gating pulses of NN, negative arm of V phase, are released
HL32: green led: OFF means gating anomaly of NN, negative arm of V phase
HL11: red led: ON means that gating pulses of PP, positive arm of W phase, are released
HL27: green led: OFF means gating anomaly of PP, positive arm of W phase
HL12: red led: ON means that gating pulses of P, positive arm of W phase, are released
HL33: green led: OFF means gating anomaly of P, positive arm of W phase
HL13: red led: ON means that gating pulses of N, negative arm of W phase, are released
HL28: green led: OFF means gating anomaly of N, negative arm of W phase
HL14: red led: ON means that gating pulses of NN, negative arm of W phase, are released
HL34: green led: OFF means gating anomaly of NN, negative arm of W phase

D9 to D24: transmitters of gating signals to the firing cards of phases U, V and W

D50 to D61: receivers of monitoring signals from gating cards of positive and negative arms of phases U, V and W
DISP1 : displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been detected.
In the case of protection trip, the meaning of the coded information displayed on DISP1 can be found in paragraph 6.6.

46
3. Equipment Parts

MODVEC-S Card jumpers setting

The MODVEC card before being installed in any ATV Equipment, must be customized
 CAUTION (by setting jumpers and switches) for the actual application, as a function of equipment
size.

ATV 1K3 A33 / ATV 1K8 A33 / ATV 2K6 A33

ATV 1K6 W33 / ATV 2K4 W33 / ATV 3K6 W33

XJ1 XJ2 XJ3 XJ4 XJ5 XJ6 XJ7 SW1-SW2 SW4-SW15

1–2 2–3 2–3 2–3 2–3 Open 1–2

ATV 3K6 A33 / ATV 5K2 A33

ATV 4K8 W33 / ATV 7K2 W33

XJ1 XJ2 XJ3 XJ4 XJ5 XJ6 XJ7 SW1-SW2 SW4-SW15

1–2 2–3 2–3 2–3 1–2 Open 1–2

The switch SW3 is used to select the switching frequency value of the inverter at 780 Hz or 1000 Hz :

Fsw
SW3
[Hz]

1000

780

47
3. Equipment Parts
INTVECM Analog Interface Card

Layout of INTVECM Card

48
3. Equipment Parts
X1: P24V / N24V power supply terminal board
X2A: Terminal board for VDC1 transducer signals and PREC_OK logic output signal
X2B: Terminal board for VDC2 transducer signal and PREC_OK logic output signal
X3A: Terminal board for current transducer signals of inverter bridge no 1
X3B: Terminal board for current transducer signals of inverter bridge no 2
X4: Connector for connection to SCADA PLUS card
X5A: Not used
X5B: Not used
X6: Connector for connection with ALIM power supply card
X7: Logic inputs
X8: Not used
HL1: green led: ON means that P15V power supply is available
HL2: green led: ON means that N15V power supply is available
HL3: green led: ON means that P24V power supply is available
HL4: green led: ON means that N24V power supply is available
HL5: green led: ON means that the precharge phase has successfully ended
DISP1: displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been detected. In the case of
protection trip, the meaning of the coded information displayed by DISP 1 can be found in paragraph 6.6.

The following table shows the labels of the solder terminals of burden and gain-setting resistors of the following signals:

IDC current and phase currents in the case of single inverter bridge or two bridges in parallel (IR1/2, IS1/2, IT1/2)
DC voltages VDC1 and VDC2
Gain of signals related to phase currents IR, IS, IT

SIGNAL TERMINAL BOARD SOLDER TAG

T17 (signal) – T19 (ground)

IR1 X3A – 01
T18 (signal) – T2O (ground)
T21 (signal) – T23 (ground)
IS1 X3A – 04
T22 (signal) – T24 (ground)
T25 (signal) – T27 (ground)
IT1 X3A – 07
T26 (signal) – T28 (ground)
T33 (signal) – T35 (ground)
VDC1 X2A – 04
T34 (signal) – T36 (ground)
T13 (signal) – T15 (ground)
VDC2 X2B – 01
T14 (signal) – T16 (ground)
TO1 (signal) – TO3 (ground)
IR2 X3B – 01
TO2 (signal) – TO4 (ground)
TO5 (signal) – TO7 (ground)
IS2 X3B – 04
TO6 (signal) – TO8 (ground)
TO9 (signal) – T11 (ground)
IT2 X3B – 07
T1O (signal) – T12 (ground)
T45 – T46 ( R 204 )
IR Current gain ------------
T47 – T48 ( R 202 )
T41 – T42 ( R 199 )
IS Current gain ------------
T43 – T44 ( R 197 )
T37 – T38 ( R 194 )
IT Current gain ------------
T39 – T40 ( R 192 )

49
3. Equipment Parts
Customizing INTVECM Card

All resistors for customization of signals generated by voltage and current transducers must have tolerance ±1% and rated power 0,5 W
@ 70°C

Full scale values:

Currents on a.c. side: 5 V @ IACMAX

Voltages on d.c. side : 5 V @ VDCMAX

For customization of INTVECM cards, refer to the tables of this paragraph that indicate how to perform this operation taking into account
the equipment size and the type of Control Module (on Motor side or Line side).

ATV 1K3 A33 / ATV 1K6 W33

SIGNALS AND VALUE OF

POSITION BURDEN RESISTORS
IR1 (T17-T19) 100 // 100 // 475
IR1 (T18-T20) 6810 // 6810
IS1 (T21-T23) 100 // 100 // 475
IS1 (T22-T24) 6810 // 6810
IT1 (T25-T27) 100 // 100 // 475
IT1 (T26-T28) 6810 // 6810
IR2 (T01-T03) Open
IR2 (T02-T04) Jumper
IS2 (T05-T07) Open
IS2 (T06-T08) Jumper
IT2 (T09-T11) Open
IT2 (T10-T12) Jumper
VDC1 (T33-T35) 100
VDC1 (T34-T36) Open
VDC2 (T13-T15) 100
VDC2 (T14-T16) Open
IDC (T29-T31) Open
IDC(T30-T32) Open

ATV 1K8 A33 / ATV 2K4 W33

SIGNALS AND VALUE OF

POSITION BURDEN RESISTORS
IR1 (T17-T19) 82,5 // 82,5 // 121
IR1 (T18-T20) 1K // 22K1 // 33K2
IS1 (T21-T23) 82,5 // 82,5 // 121
IS1 (T22-T24) 1K // 22K1 // 33K2
IT1 (T25-T27) 82,5 // 82,5 // 121
IT1 (T26-T28) 1K // 22K1 // 33K2
IR2 (T01-T03) Open
IR2 (T02-T04) Jumper
IS2 (T05-T07) Open
IS2 (T06-T08) Jumper
IT2 (T09-T11) Open
IT2 (T10-T12) Jumper
VDC1 (T33-T35) 100
VDC1 (T34-T36) Open
VDC2 (T13-T15) 100
VDC2 (T14-T16) Open
IDC (T29-T31) Open
IDC(T30-T32) Open
ATV 2K6 A33 / ATV 3K6 W33

SIGNALS AND VALUE OF

POSITION BURDEN RESISTORS
IR1 (T17-T19) 82,5 // 82,5 // 82,5
IR1 (T18-T20) 82,5 // 1820 // 1820
IS1 (T21-T23) 82,5 // 82,5 // 82,5
IS1 (T22-T24) 82,5 // 1820 // 1820
IT1 (T25-T27) 82,5 // 82,5 // 82,5
IT1 (T26-T28) 82,5 // 1820 // 1820
IR2 (T01-T03) Open
IR2 (T02-T04) Jumper
IS2 (T05-T07) Open

50
3. Equipment Parts
IS2 (T06-T08) Jumper
IT2 (T09-T11) Open
IT2 (T10-T12) Jumper
VDC1 (T33-T35) 100
VDC1 (T34-T36) Open
VDC2 (T13-T15) 100
VDC2 (T14-T16) Open
IDC (T29-T31) Open
IDC(T30-T32) Open

ATV 3K6 A33 / ATV 4K8 W33

SIGNALS AND VALUE OF

POSITION BURDEN RESISTORS
IR1 (T17-T19) 82,5 // 82,5 // 121
IR1 (T18-T20) 1K // 22K1 // 33K2
IS1 (T21-T23) 82,5 // 82,5 // 121
IS1 (T22-T24) 1K // 22K1 // 33K2
IT1 (T25-T27) 82,5 // 82,5 // 121
IT1 (T26-T28) 1K // 22K1 // 33K2
IR2 (T01-T03) 82,5 // 82,5 // 121
IR2 (T02-T04) 1K // 22K1 // 33K2
IS2 (T05-T07) 82,5 // 82,5 // 121
IS2 (T06-T08) 1K // 22K1 // 33K2
IT2 (T09-T11) 82,5 // 82,5 // 121
IT2 (T10-T12) 1K // 22K1 // 33K2
VDC1 (T33-T35) 100
VDC1 (T34-T36) Open
VDC2 (T13-T15) 100
VDC2 (T14-T16) Open
IDC (T29-T31) Open
IDC(T30-T32) Open
R194, R199, R204 15K

51
3. Equipment Parts
ATV 5K2 A33 / ATV 7K2 W33

SIGNALS AND VALUE OF

POSITION BURDEN RESISTORS
IR1 (T17-T19) 82,5 // 82,5 // 82,5
IR1 (T18-T20) 82,5 // 1820 // 1820
IS1 (T21-T23) 82,5 // 82,5 // 82,5
IS1 (T22-T24) 82,5 // 1820 // 1820
IT1 (T25-T27) 82,5 // 82,5 // 82,5
IT1 (T26-T28) 82,5 // 1820 // 1820
IR2 (T01-T03) 82,5 // 82,5 // 82,5
IR2 (T02-T04) 82,5 // 1820 // 1820
IS2 (T05-T07) 82,5 // 82,5 // 82,5
IS2 (T06-T08) 82,5 // 1820 // 1820
IT2 (T09-T11) 82,5 // 82,5 // 82,5
IT2 (T10-T12) 82,5 // 1820 // 1820
VDC1 (T33-T35) 100
VDC1 (T34-T36) Open
VDC2 (T13-T15) 100
VDC2 (T14-T16) Open
IDC (T29-T31) Open
IDC(T30-T32) Open
R194, R199, R204 15K

INTVECM Card jumpers setting

ATV 1K3 A33 / ATV 1K8 A33 / ATV 2K6 A33

ATV 1K6 W33 / ATV 2K4 W33 / ATV 3K6 W33

XJ0 XJ1 XJ5 XJ6 XJ7 XJ8 XJ9 XJ10 XJ11 XJ12 XP20

2-3 1–2 2-3 Close Close Open 2-3 1-2 1-2 Open 2–3

ATV 3K6 A33 / ATV 5K2 A33

ATV 4K8 W33 / ATV 7K2 W33

XJ0 XJ1 XJ5 XJ6 XJ7 XJ8 XJ9 XJ10 XJ11 XJ12 XP20

2-3 1 -2 2-3 Close Close Open 2-3 2-3 1-2 Close 2–3

52
3. Equipment Parts
FOVECM Optic Fibres Expansion Card

Layout of FOVECM Card

X1: P24V power supply connector

X2: Connector for connection with: MODVEC card (X8 connector), when the FOVECM card under consideration is associated with
the 2nd parallel bridge a former FOVECM card (X3 connector), when the FOVECM card under consideration is associated with
the 3rd or 4th parallel bridge.
X3: Connector for connection of the FOVECM card under consideration with a latter FOVECM card (X2 connector) associated with
the 3rd or 4th parallel bridge. A termination plug (order code ELP22586908) shall be inserted in the X3 socket of the card
associated with the last parallel.

53
3. Equipment Parts
The following signals pass through X2 and X3 connectors:
• 12 IGBT gating commands;
• 12 monitor signals that check gating of positive and negative arms of the phase module;
• the summarized protection signal: 0ANGU_ESPFO;
• the reset signal: RIPRISTINO_MOD.

HL9: green led: ON means that the P24P power supply is available.
HL10: green led: ON means that the P5_ESPFO power supply is available
HL20: green led: OFF means gating anomaly of PP, positive arm of U phase
HL23: green led: OFF means gating anomaly of P, positive arm of U phase
HL26: green led: OFF means gating anomaly of N, negative arm of U phase
HL29: green led: OFF means gating anomaly of NN, negative arm of U phase
HL21: green led: OFF means gating anomaly of PP, positive arm of V phase
HL24: green led: OFF means gating anomaly of P, positive arm of V phase
HL27: green led: OFF means gating anomaly of N, negative arm of V phase
HL30: green led: OFF means gating anomaly of NN, negative arm of V phase
HL22: green led: OFF means gating anomaly of PP, positive arm of W phase
HL25: green led: OFF means gating anomaly of P, positive arm of W phase
HL28: green led: OFF means gating anomaly of N, negative arm of W phase
HL31: green led: OFF means gating anomaly of NN, negative arm of W phase
DISP1: displays the card operating mode; a lit up (non flashing) dot means that no anomaly has been; detected. In the case of
protection trip, the meaning of the coded information displayed by DISP1 can be found in paragraph 6.6.

FOVECM Card jumpers setting

The FOVECM card is used in the ATV Control Modules in the case of equipment configurations with 2 bridges in parallel ( it is not
included in the case of single inverter bridge )
This paragraph gives the tables for setting the jumpers ( XJ0, XJ1, XJ2 and XJ3 ) located on the card.

ATV 3K6 A33 / ATV 5K2 A33

ATV 4K8 W33 / ATV 7K2 W33

XJ0 XJ1 XJ2 XJ3

Close Close 1-2 1-2

54
3. Equipment Parts
INTPREA Diode Front End Precharge Interface Card

Layout of INTPREA Card

This card is used only in motor side – DFE configuration control module.

XAL: Power supply terminal board.

XIN: Terminal board for input “Precharge OK” from INTVECM card
XP: Terminal board for output signals to MODVEC-S card.
DL1: Green led: ON means that the power supply is available.
DL2: Green led: ON means that the precharge is OK
DL3: Red led: ON means protection Thyristor command error on bridge rectifier n° 1
DL4: Red led: ON means protection Thyristor command error on bridge rectifier n° 2
RC1: fiber-optic link receiver of protection “thyristors command error” from TCPSA card on bridge rectifier n° 1
TR1: fiber-optic link transmitter of “Precharge OK” signal to TCPSA card on bridge rectifier n° 1
RC2: fiber-optic link receiver of protection “thyristors command error” from TCPSA card on bridge rectifier n° 2
TR2: fiber-optic link transmitter of “Precharge OK” signal to TCPSA card on bridge rectifier n° 2

55
3. Equipment Parts
INTSYNCB Active Front End Line Voltage Interface Card

Layout of INTSYNCB Card

This card is used only in line side control module.

X1: P24V/N24V power supply terminal board.

X2: Terminal board for input synchronization signals
X3: Terminal board for output signals to SCADA PLUs card.
HL1: Green led: ON means that the P15V power supply is available.
HL2: Green led: ON means that the N15V power supply is available.

Customizing INTSYNCB Card

Values of burden
Component
resistors
T01 –T02 (R19)
6810
T03 –T04 (R20)
T05 –T06 (R21)
T07 –T08 (R22) 2 x 267K //
T09 –T10 (R23) 301K // 3,3 M
T11 –T12 (R24)

Setting
jumpers

JP1 – JP2 – JP3 – JP4 Open

56
3. Equipment Parts
3.5.4. Connections of Current Transducers, Voltage Transducers and Optic Fibres

This paragraph includes the tables that list the connections of current transducers (on the a.c. side of Inverter Bridges) to the INTVECM
card, of optic fibers from MODVEC and FOVECM cards to the TGUNTNB card and of voltage transducers (on d.c. side of Inverter
Bridges) to the INTVECM card.
The connections of the Line Side Control Module are identical to those of Motor Side Control Module.

CURRENT TRANSDUCERS (INTVECM)

INTVECM 1st and 2nd Function

inverter bridge

Name Terminals Terminals

—
IR1 M X3A-1 Current measure of U1 phase
—
IR1 + X3A-2 TADC power supply, U1 phase, positive
—
IR1 - X3A-3 TADC power supply, U1 phase, negative
—
IS1 M X3A-4 Current measure of V1 phase
—
IS1 + X3A-5 TADC power supply, V1 phase, positive
—
IS1 - X3A-6 TADC power supply, V1 phase, negative
—
IT1 M X3A-7 Current measure of W1 phase
—
IT1 + X3A-8 TADC power supply, W1 phase, positive
—
IT1 - X3A-9 TADC power supply W1 phase, negative

IR2 M
— X3B-1 Current measure of U2 phase

IR2 +
— X3B-2 TADC power supply, U2 phase, positive

IR2 -
— X3B-3 TADC power supply, U2 phase, negative

IS2 M
— X3B-4 Current measure of V2 phase

IS2 +
— X3B-5 TADC power supply, V2 phase, positive

IS2 -
— X3B-6 TADC power supply, V2 phase, negative

IT2 M
— X3B-7 Current measure of W2 phase

IT2 +
— X3B-8 TADC power supply, W2 phase, positive

IT2 -
— X3B-9 TADC power supply W2 phase, negative

In all ATV configurations, the voltage transducers are always connected to the INTVECM card according to the following table.

VOLTAGE TRANSDUCER CONNECTIONS

Label Terminals Function

VDC1 M X2A-4 DC1 bus, voltage measure

VDC1 + X2A-5 VDC1 power supply, positive

VDC1 - X2A-6 TVDC1 power supply, negative

VDC2 M X2B-1 DC2 bus, voltage measure

VDC2 + X2B-2 VDC2 power supply, positive

VDC2 - X2B-3 TVDC2 power supply, negative

57
3. Equipment Parts

OPTIC FIBERS CONNECTIONS

CARDS

MODVEC FOVECM TGUNTNB TGUNTNB

st nd
1 bridge 2 bridge card card

Name terminal terminal label component Function

A1HU1 D9 — APP 1 RC1 U11PP firing
A1HU1M D50 — APP 1 TR1 U11PP Monitoring
A1HU2 D10 — AP 1 RC1 U21P Firing
A1HU2M D53 — AP 1 TR1 U21P Monitoring
A1HU3 D11 — AN 1 RC1 U31N Firing
A1HU3M D56 — AN 1 TR1 U31N Monitoring
A1HU4 D12 — ANN 1 RC1 U41NN Firing
A1HU4M D59 — ANN 1 TR1 U41NN Monitoring
A1HV1 D15 — APP 1 RC1 V11PP Firing
A1HV1M D51 — APP 1 TR1 V11PP Monitoring
A1HV2 D16 — AP 1 RC1 V21P Firing
A1HV2M D54 — AP 1 TR1 V21P Monitoring
A1HV3 D17 — AN 1 RC1 V31N Firing
A1HV3M D57 — AN 1 TR1 V31N Monitoring
A1HV4 D18 — ANN 1 RC1 V41NN Firing
A1HV4M D60 — ANN 1 TR1 V41NN Monitoring
A1HW1 D21 — APP 1 RC1 W11PP Firing
A1HW1M D52 — APP 1 TR1 W11PP Monitoring
A1HW2 D22 — AP 1 RC1 W21P Firing
A1HW2M D55 — AP 1 TR1 W21P Monitoring
A1HW3 D23 — AN 1 RC1 W31N Firing
A1HW3M D58 — AN 1 TR1 W31N Monitoring
A1HW4 D24 — ANN 1 RC1 W41NN Firing
A1HW4M D61 — ANN 1 TR1 W41NN Monitoring
A1HU21 — D1 APP 2 RC1 U21PP Firing
A1HU21M — D20 APP 2 TR1 U21PP Monitoring
A1HU22 — D2 AP 2 RC1 U22P Firing
A1HU22M — D21 AP 2 TR1 U22P Monitoring
A1HU23 — D3 AN 2 RC1 U23N Firing
A1HU23M — D22 AN 2 TR1 U23N Monitoring
A1HU24 — D4 ANN2 RC1 U24NN Firing
A1HU24M — D23 ANN 2 TR1 U24NN Monitoring
A1HV21 — D5 APP 2 RC1 V21PP Firing
A1HV21M — D24 APP 2 TR1 V21PP Monitoring
A1HV22 — D6 AP 2 RC1 V22P Firing
A1HV22M — D25 AP 2 TR1 V22P Monitoring
A1HV23 — D7 AN 2 RC1 V23N Firing
A1HV23M — D26 AN 2 TR1 V23N Monitoring
A1HV24 — D8 ANN 2 RC1 V24NN Firing
A1HV24M — D27 ANN 2 TR1 V24NN Monitoring
A1HW21 — D9 APP 2 RC1 W21PP Firing
A1HW21M — D28 APP 2 TR1 W21PP Monitoring
A1HW22 — D10 AP 2 RC1 W22P Firing
A1HW22M — D29 AP 2 TR1 W22P Monitoring
A1HW23 — D11 AN 2 RC1 W23N Firing
A1HW23M — D30 AN 2 TR1 W23N Monitoring
A1HW24 — D12 ANN 2 RC1 W24NN Firing
A1HW24M — D31 ANN 2 TR1 W24NN Monitoring

58
3. Equipment Parts

OPTIC FIBERS CONNECTIONS

Name INTPREA card TCPSA card TCPSA card Function

terminal label component

A1 RC1
HVTHR11 TR1 “Precharge OK” signal for rectifier bridge 1
A1 TR1
HVTHR11M RC1 Rectifier bridge 1 monitoring
A1 RC1
HVTHR21 TR2 “Precharge OK” signal for rectifier bridge 2
A1 TR1
HVTHR21M RC2 Rectifier bridge 2 monitoring

59
3. Equipment Parts

3.6. Inverter Current and DC Voltage Transducers

The following tables give information about voltage and current transducers used in different configurations and sizes.

EQUIPMENT SIZE TVDC LEM VOLTAGE TA LEM CURRENT

TRANSDUCER TRANSDUCER

ATV 1K3 A33 12P/24P 2 3

ATV 1K8 A33 12P/24P 2 3
ATV 2K6 A33 12P/24P 2 3
ATV 3K6 A33 12P/24P 2 6
ATV 5K2 A33 12P/24P 2 6
ATV 1K6 W33 12P/24P 2 3
ATV 2K4 W33 12P/24P 2 3
ATV 3K6 W33 12P/24P 2 3
ATV 4K8 W33 12P/24P 2 6
ATV 7K2 W33 12P/24P 2 6

EQUIPMENT SIZE TVDC LEM VOLTAGE TA LEM CURRENT

TRANSDUCER TRANSDUCER

ATV 1K6 W33 AFE 2+2 3+3

ATV 2K4 W33 AFE 2+2 3+3
ATV 3K6 W33 AFE 2+2 3+3
ATV 4K8 W33 AFE 2+2 6+6
ATV 7K2 W33 AFE 2+2 6+6

3.7. Inverter Firing Card and Isolated Supply

Altivar Equipments include Medium Voltage IGBT Inverter Phase Modules. Each IGBT needs a gate drive card TGUNTNB that
commands IGBT turn-on and turn-off by application of proper voltage signals to its gate terminals. Insulated, turn-on and turn off logic
signals from the Control Modules reach the gate drive cards by optic fiber link.

Each Inverter Phase Module includes 4 IGBT's, of which two are indicated as "EXTERNAL" and the other two as "INTERNAL", depending
on their function.
By consequence, as for the relevant IGBTs, the gate drive cards are indicated as "INTERNAL" (TGUNTNB-INT ) or "EXTERNAL" (
TGUNTNB-EXT ). These two card types are different from each other only because of some tuning components.

The power supply of TGUNTNB cards consists of a 28V - 80 kHz square wave voltage delivered by the TALIMB card (that converts 220V-
50Hz into 200V-80kHz voltage) through a step-down transformer (TRAL80) that lowers the output voltage delivered by the TALIMB card
from 200 to 28 V (at 80 kHz).

The following drawing shows the connection diagram of the power supply of the gate drive cards located inside the Inverter Phase
Modules.

60
3. Equipment Parts

Inside the TALIMB card, located inside the Control Cubicle, three LEDs are clearly visible that monitor the operating modes of the card,
more precisely: if the green LEDs are on, the card is operating properly while the red LED, if on, means malfunction.
In the case that all LEDs are off, check the fuses inside the card, once switched off the power supply and verified that no voltage is
available at input terminals J1-1 and J1-2.

• Inside the TALIMB card the voltage reaches 200V a.c. at a frequency of
WARNING 80 kHz: getting in touch with such voltage is very dangerous for
operators' safety.

• Inside the power supply card, TALIMB, no isulation exists between the
220V - 50/60 Hz input and the 200V - 80 KHz output. An insulation
transformer is therefore always interposed on the input side. For
safety reason, the output terminal J2-2 must always be grounded;
therefore no grounding connection is allowed on the input side of the
TALIMB card.

61
3. Equipment Parts
The following table lists the IGBT firing cards and related power supply, as used by different configurations and sizes.

TALIMB TRAL80
TGUNTNB - EXT TGUNTNB - INT
EQUPMENT SIZE FIRING CARD POWER SUPPLY
FIRING CARD FIRING CARD
POWER SUPPLY TRANSFORMER
ATV 1K3 A33 12P/24P 1 2 6 6
ATV 1K8 A33 12P/24P 1 2 6 6
ATV 2K6 A33 12P/24P 1 2 6 6
ATV 3K6 A33 12P/24P 1 3 12 12
ATV 5K2 A33 12P/24P 1 3 12 12
ATV 1K6 W33 12P/24P 1 2 6 6
ATV 2K4 W33 12P/24P 1 2 6 6
ATV 3K6 W33 12P/24P 1 2 6 6
ATV 4K8 W33 12P/24P 1 3 12 12
ATV 7K2 W33 12P/24P 1 3 12 12

TALIMB TRAL80
TGUNTNB - EXT TGUNTNB - INT
EQUPMENT SIZE FIRING CARD POWER SUPPLY
FIRING CARD FIRING CARD
POWER SUPPLY TRANSFORMER
ATV 1K6 W33 AFE 1 6+6 6+6
ATV 2K4 W33 AFE 1 6+6 6+6
ATV 3K6 W33 AFE 1 6+6 6+6
ATV 4K8 W33 AFE 2 12 + 12 12 + 12
ATV 7K2 W33 AFE 2 6 12 + 12 12 + 12

62
3. Equipment Parts
3.7.1. Layout of TALIMB 80 kHz Power Supply

J1: Input power supply (50 / 60 Hz) terminal board

J2: Output (80 kHz) terminal board
FU1: 4A – 250V fuse
FU2: 4A – 250V fuse
DL16: green led: ON means that power supply of inside power circuits is available
DL16A: green led: ON means that power supply of inside control circuits is available
DL17: red led: ON means trip of hardware internal overcurrent protection (output overload or short-circuit)

63
3. Equipment Parts
3.7.2. Layout of TGUNTNB IGBT Firing Card

XAL: power supply terminal board (connected to TALPTNA card)

DL1: green led: ON means power supply available
DL2: red led: ON means power supply failure
DL3: red led: ON means protection trip due to a fault detected by the Gate Unit
RC1: fiber-optic link receiver of firing command
TR1: fiber-optic link transmitter of Gate Unit monitoring signal (no light means fault)

The INTERNAL and EXTERNAL TGUNTNB cards are different because

 CAUTION
some components have different values; therefore they cannot be exchanged between
each other and have different order codes

As far as the jumper JP1 is concerned, the customization logic is:

TGUNTNB Jumper JP1

INTERNAL 1–2
EXTERNAL 3–2

64
3. Equipment Parts
Locations of the 4 TGUNTNB cards, 2 of EXT ( external ) and 2 of INT ( internal ) type, inside the inverter phase module:

External TGUNTNB
card (APP)

Internal TGUNTNB card

(AP)

Internal TGUNTNB card

(AN)

External TGUNTNB
card (ANN)

TALPTNA card

3.7.3. Layout of TALPTNA Supply Card

XM1: 80 kHz power supply terminal board

XM2: output terminal board (connected to TGUNTNB card)

65
3. Equipment Parts

3.8. Rectifier Bridge Firing Card

3.8.1. Layout of TCPSA Thyristor Firing Card

This card is used only in DFE configuration.

XM1: 80 kHz power supply terminal board

XM2: thyristors firing command terminal board
DL1: green led: ON means power supply available
RC1: fiber-optic link receiver of “Precharge OK” signal
TR1: fiber-optic link transmitter of protection “thyristors command error” to INTPREA card
RC2: fiber-optic link receiver of protection “thyristors command error” from another TCPSA card
TR2: fiber-optic link transmitter of “Precharge OK” signal to another TCPSA card

66
3. Equipment Parts

3.9. Insulated Transmitter Interface Card

Temperature detectors (thermal switches), suited to protect the inverter in the case of malfunction of the cooling circuit, are placed on the
heatsink of each power module (inverter phase module and rectifier module).
The contacts of the thermal switches placed on the heatsinks of the phase modules of each inverter bridge, are connected to a card
(TITOIA) that receives such signals and transmits, by optic fiber link, a summarized information about contact status to a relay output
receiver card (XITOIA).
By use of these cards, insulation is implemented between the power section and the Control Module for all Inverter Equipment
configurations (from single inverter bridge to 2 parallel bridges); what is necessary because the thermal switches are installed on the
heatsinks of power modules, that are working at high voltage; thanks to the optic fiber link the relay logic results electrically insulated from
the thermal switches.
In normal operating conditions (no trip of thermal switches) all the contacts are closed, and the optic fibers transmit an uninterrupted light
flow. Tripping of any thermal switch results in tripping of the Inverter Equipment protection: “ IGBT OVERTEMPERATURE “.
Useful information, to find out the thermal switch that has tripped, is given by LEDs E2 ÷ E9 of the XITOIA card/s and E1 ÷ E2 of the
TITOIA cards.

 Each phase module includes a thermal switch (ST).

 The three contacts of the thermal switches of each three phase Inverter bridge (both on motor side and line side) are connected in series and sent to a
single input of the TITOIA card; each card has two inputs and drives two optic fiber trasmitters.
The outputs of the TITOIA cards are sent, by optic fiber link, to the XITOIA card, that has 8 optic fiber inputs and drives 8 relay
outputs, each related to an input.

The following table gives information about the optical link insulated interface cards of thermal switches and micro switch of fuses used in
different configurations and size.

EQUIPMENT SIZE TITOIA CARD XITOIA CARD

ATV 1K3 A33 12P/24P 4 1
ATV 1K8 A33 12P/24P 4 1
ATV 2K6 A33 12P/24P 4 1
ATV 3K6 A33 12P/24P 4 1
ATV 5K2 A33 12P/24P 4 1
ATV 1K6 W33 12P/24P 4 1
ATV 2K4 W33 12P/24P 4 1
ATV 3K6 W33 12P/24P 4 1
ATV 4K8 W33 12P/24P 4 1
ATV 7K2 W33 12P/24P 4 1

EQUIPMENT SIZE TITOIA CARD XITOIA CARD

ATV 1K6 W33 AFE 4 1
ATV 2K4 W33 AFE 4 1
ATV 3K6 W33 AFE 4 1
ATV 4K8 W33 AFE 8 2
ATV 7K2 W33 AFE 8 2

67
3. Equipment Parts
3.9.1. Layout of TITOIA insulated transmitter interface card

XM2: 80 kHz power supply terminal board

XM1: Logic inputs: terminal board
XM1 – 1/2: logic input no. 1
XM1 – 3/4: logic input no. 2
E3: green led: ON means that power supply is available.
E1: red led: ON means that logic input no.1 is connected to a closed contact.
E2: red led: ON means that logic input no.2 is connected to a closed contact.
TF1: transmitter (to the XITOIA card) of the logic signal of input no.1
TF2: transmitter (to the XITOIA card) of the logic signal of input no.2

68
3. Equipment Parts
3.9.2. Layout of XITOIA insulated receiver interface card

XM1: +24V DC power supply terminal board.

XM2: terminal board of output contacts
E1: green led: ON means that power supply is available.
E2/E9: red led: ON means a continuously lit optical signal on RF1 / RF8
RF1/RF8: receivers of optical signals from TITOIA card/s
K1/K8: output relay contacts

69
3. Equipment Parts

3.10. Rectifier Bridge Precharge Diode Card

3.10.1. Layout of TDIPRA precharge card
This card is used only in DFE configuration.

KK: Chatode terminal connected to precharge resistors

KA: Anode terminal connected to input line terminal

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3. Equipment Parts

3.11. Precharge Circuit (AFE configuration only)

The purpose of the precharge circuit is to charge the capacitor banks of the inverter equipment above a preset minimum voltage value, by
a limited current amplitude, before closing the Main Circuit Breaker.
The precharge sequence must be enabled only if the cooling unit is operating properly and neither protections nor interlocks are in the
disable condition.

• A wrong, or untimely closure of the Contactor Precharge (CP) when

WARNING the auxiliary a.c. supply is on, will charge the capacitors of the DC
busses to high voltage, even when the main power supply is
switched off.
• Do not tamper the micro-switches of the doors of power cubicles,
because this could result in phase modules being supplied at high
voltage while doors are open.
• Not to damage components of the precharge circuit, do not carry
out more than three consecutive precharges in 10 minutes.

Simplified schematic diagram of Precharge circuit:

TRAPREC
Board

Precharge
transformer

The following table give information about the precharge circuit components used in different size

PRECHARGE PRECHARGE RECTIFIER

EQUIPMENT SIZE FUSES
TRANSFORMER (TRAPREC)
ATV 1K6 W33 AFE 2 2 3
ATV 2K4 W33 AFE 2 2 3
ATV 3K6 W33 AFE 2 2 3
ATV 4K8 W33 AFE 4 4 6
ATV 7K2 W33 AFE 4 4 6

71
3. Equipment Parts
3.11.1. Layout of TRAPREC Precharge Rectifier Card
This card is used only in AFE configuration.

X1/X2: Input of bridge rectifier

X3/X4: Output of bridge rectifier

72
3. Equipment Parts
3.11.2. Precharge Logic
The logic sequence for converter start requires interlocks to the control card SCADA PLUS, as shown in the following time diagrams:

where:
MConD L.M., MConD L.R. = programmable delay of the logic signal "Precharge OK" (respectively for the Motor Side and
Network Side Control Module), since the instant at which the DC voltages of the intermediate
circuits have reached the value Vdcpr (set by Net Parameter menu);
MConT = timeout for Main Circuit Breaker closing, since the instant at which the "Precharge OK" signal has switched on; within such
time interval, lack of the "Circuit Breaker closed" feedback signal trips the protection PHC. This parameter sets a time
delay between the Circuit Breaker closing command and the command to switch the Control Module into the
"Synchronisation Search" mode.

Example: Active Front End ATV Equipment

UL = 3000 V

Motor side Inverter Control Module

Vinp = 3000 V
Threshold of PRECHARGE OK = 0,8 * 1,35 * 3000 = 3240 Vdc
MConD = 5 s

Line side Inverter Control Module

Threshold of PRECHARGE OK = Vdcpr = 3240 Vdc
MConD = 10 s
MConT = 2 s

(The value of the parameter MConD of the Motor side Control Module must be set lower than the setting of the same parameter in Line
side Control Module)

On closing CP, the precharge contactor, the phase of precharging capacitor banks starts: Vdc, that measures the DC Bus voltage, starts
to increase; the Control Module is informed of the start of the precharge phase by the logic input DRIVE ENABLE (terminals XM1-20 of
the card CONVEC1D); the Control Module monitors the voltage Vdc: on reaching the preset threshold value (for more details see the
"Programming Manual"), with a delay time set by the relevant parameter MConD, the signal “PRECHARGE COMPLETED” (logic output of
the "PRECHARGE OK" relay; terminals X2A 9-10 of the INTVECM A31 C card inside the Control Module) switches on; at this point it is
possible to close the Main Circuit Breaker of the Converter Equipment.
In the case that, within the preset timeout, the voltage Vdc does not reach the preset threshold value, the protection "Prec Fail" trips.

73
3. Equipment Parts

3.12. Encoder requirements and connections

3.12.1. Encoder type and connection
The default configuration for the encoder interface circuits (on SCADA PLUS card) is:

Supply voltage : 24 V
Output stage : Line Driver - signals at 5V (EIA 485)
Encoder pulse number : 1024
Output signals : bi-directional with zero pulse

The encoder pulse number is defined through [02.13] “Encoder Pulse” parameter

The encoder 24V - 500 mA supply is insulated towards all the other control supplies.

Maximum input frequency of the control card: FMAX=100KHz

The maximum speed in rpm of the encoder (motor) can be calculated using the following formula:

FMAX * 60
Re v MAX =
N ° pulses / revolution

The duration of the zero impulse mast be included

O 0
between electrical 90 and 360 .

Termination resistor for encoder line-driver: 120Ω

As regards the choice of the encoder, ASIRobicon recommend to use encoder equipped with the following:

• trip against short-circuit on the output;

• trip against polarity reversing on the supplies.
Depending from the encoder used, it is necessary to configure the SW1 switch, present on the SCADA PLUS card, as follows:

sw1 - 1 
sw1 - 2 
 ON for LINE DRIVER encoder - see diagram I
sw1 - 3 
sw1 - 4 

74
3. Equipment Parts

sw1 - 1 
sw1 - 2 
 OFF for other Encoder (PUSH PULL) – see diagram II
sw1 - 3 
sw1 - 4 

Connections diagram for LINE DRIVER encoder (24V for alimentation and 5V for signals) and for PUSH PULL encoder (24V for
alimentation and signals); for both the encoder types the 24V alimentation is internal at the control.

Diagram I – Line Driver Encoder

75
3. Equipment Parts
Diagram II – Push Pull Encoder

76
3. Equipment Parts

3.13. Ground Fault Detector

Altivar converter equipment, both in DFE and AFE configuration, is always supplied by a dedicated converter transformer and in normal operation no point of
the circuit is directly connected to ground. It behaves therefore as an insulated system in witch the first earth fault can not produce any earth fault current, so
that the ground fault can not be detected by any converter protection, except a dedicated ground protection, which is purposely included.
The ground protection function is performed by a dedicated module connected to the DC Bus and including a Hall Effect Voltage Transducer (TV LEM),
together with suitable resistance and an electronic card (XPTERA), driven by the output of such TV LEM, with the function of the detecting the flow of earth
current.

Part number: 1000088782

DFE configuration Ground Fault Detector

1000088782

77
3. Equipment Parts
AFE configuration Ground Fault Detector

1000088782

3.13.1. XPTERA electronic Card

Description
The XPTERA electronic card is supplied at ± 24 V. Check the connection between the terminal 10 of the XPTERA electronic card and
terminal E of the TV LEM voltage transducer. Terminals 22 and 23 of the XPTERA electronic card must be short-circuited.
Relays K1 and K2 release on ground fault.

XPTERA card part number: ELP26403901

ELP26403901

78
3. Equipment Parts
Customizing
XPTERA CARD
COMPONENT TORRETTE VALUE
R1 X1 – X2 Jumper
R2 X3 – X4 Jumper
R3 X5 – X6 Jumper
R4 X7 – X8 Jumper
R5 X9 – X10 Jumper
R6 X10 – X12 Jumper
R7 X13 – X14 Jumper
R8 X15 – X16 Jumper
R9 X17 – X18 Jumper
R10 X19 – X20 150Ω // 100 Ω
R11 X21 – X22 150Ω // 100 Ω
R12 X23 – X24 150Ω // 100 Ω
R23 X25 – X26 150Ω // 100 Ω
R14 X27 – X28 150Ω // 100 Ω
R15 X29 – X30 150Ω // 100 Ω

RP TEST POINT VOLT

1 M 17 2 ÷ 5,5 V tipici

Tuning procedure
When the ATV equipment is fed by the network, having checked that no leakage current to ground exists, the peak value of the signal
existing between terminals 15 and 16 (earth) of the PTERA electronic card must be measured by an oscilloscope; typical values range
from 0.5 to 4 V.
The voltage between terminals 17 and 4 (earth) of the XPTERA electronic card must be measured by a digital multimeter while the
trimmer RP1 must be adjusted so that:

Vterminal 17 to 4 = Vpeak terminal 15 to 16 + 1.5 V

Example:
Vpeak terminal 15 to 16 = 4 V

Vterminal 17 to 4 = 4 + 1.5 = 5.5 V

In the case that the ground fault protection is required to trip on a given value of the ground resistance, the procedure is as follows:
♦ connect a resistance of the required value (e. g. 25 kΩ) between one phase and ground
adjust the trimmer RP1 of the PTERA electronic card until the protection trips (releasing relay K1)

79
4. Converter Start Up

4.1. User Interface (Keypad and PC Tool)

There are two methods of user interface to the drive - programming and monitoring interface. Three keypads are available, as identified
below, as well as the PC Tool, which is discussed in Section [Link]

4.1.1. Keypad description

Main characteristics:

• Graphic Display (5 lines X 24 characters)

• 20 keys: 5 function keys: Stop, Auto, Man, Reset, Canc/Enter, 4
arrow keys, Shift, Canc/Enter, 10 numerical keys for easier access
and changing parameters
• Text message visualization
• Memory capability for storing parameters; downloading to other VFD

80
4. Converter Start Up
Key Functions

Combinations of keys Advanced keypad

Motor Stop in MAN (manual) operation

Selects MAN operation. Starts drive when MAN is hit again

Selects AUTO operation

Fault Reset. Tests fault LED

Display parameter value. Enter new value

Navigates through the levels of the system menu

Changes active digit in the programming mode
or
Navigation throughout the menu.
Modification of the value of a parameter
or Speed setting in MAN operation

Return to main screen / display

then

Access to the programming levels

then

Activates the Numeric Parameter Access

then

When in a menu returns to the top of menu structure

then

When in a menu returns to the bottom of menu structure

then

Numeric data insertion

then
Shortcut to Motor menu
then (different keys select different Menus)

Shortcut to online help

then

81
4. Converter Start Up
4.1.2. PC Tool Description
9 pin male 9 pin female

To SCADA PLUS Control To PC serial port

Board connector K3

• Connect the to the serial port RS232

• Insert the PC tool disk, that was provided with the drive, into the PC

• Execute the file [Link]; an icon is created on the desktop is used to launch the program

• To open program, double click [Link]

• Click on for communication with the drive

• Click on to create configuration file

• Click on to take away the parameters from inverter

• Click on Auto Menu

Click on 49.00 Quick Start – a window opens containing all parameters for commissioning

Box to modify
parameters
Menu

Keypad

Monitor

82
4. Converter Start Up
4.1.3. Programming using Keypad
Programming example (Programming level 1)
Set the motor rated current parameter [02.06] Mot Full Load Curr

Function Step Keypad Intermediate Keypad Advanced

1 EU-NEMA Select is displayed
Press .
2 Search for “Mot Full Load Curr”
Using
3 Goes into access parameter/programming mode and displays actual value
Press or
Highlights digit to be modified.
Use or 4
Can navigate through active digits

5
Select new value of active digit
Using or
Can change value of active digit using numeric keys
OR Numeric Keys
6 Confirms and saves new value. Returns to list of parameters.
Press
7 Returns to monitor display
then

4.1.4. Programming using PC Tool

As a guide for a complete use of the pctool program, it is possible to activate an help on line selecting the icon on the control bar;

the page visualized from the help is shown below:

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4. Converter Start Up

4.2. Drive Status Summary

Idle No trips are present: the drive is ready to be precharged

Precharge Precharge in progress
Ready Inverter ready to be started
Protection Protection occurred
Run Inverter running
Jog Inverter in Jog operation
Stopping Stop in progress
Fast stop Fast Stop in progress
Fluxing Motor magnetization
Fly Restart Fly Restart
Bus Drop Main supply loss management
DC Braking Braking in DC mode
Self Commissioning Self Commissioning motor parameters
Lock Ramp Current Current Rollback
Lock Ramp Voltage Vdc Rollback
Tune Speed Speed regulator tuning
Tune Flux Flux regulator tuning
Tune Isd Current regulator tuning
Tune Speed Speed regulator tunning

4.3. Inverter Protections Summary

Hardware Protections

Over Curr Overcurrent (IAC max total)

Over Volt DC Overvoltage (VDC max)
Extrn Trp External protection
Desaturat Desaturation
Mod Supply Loss of power supply of MODVECS card
DPRAM Err RAM dual port damage
Wdog Ext Watch dog protection
INTVEC Pr INTVECM protection
Over Temp IGBT overtermperature
ThyrComErr Thyristor command error
Mod Conf Configuration error MODVECS board

84
4. Converter Start Up
Software Protections

Prec Fail Precharge fault

Over Spd Overspeed trip
Confg Err Configuration parameters error
DSP Fail DSP program not responding
Net Fail Network Communication loss
Stall Motor Stalled
Fast Stop Emergency stop
UnderVolt Undervoltage protection
DrivSzErr Inverter size not selected
Gnd Flt Ground fault
Therm Prt Motor/inverter overload
Speed Dev Speed deviation trip
Curr Offs Offset on current transducer
SWF Error Switching Frequency selected not permitted
UnderLoad Under load fault
SpdRfLss Loss speed reference
OutPhasOut Loss of output phase
AI User Fl NTC o PTC protection from analogical input
SWF CfgErr Switching Frequency selection Error between SCADA Plus and MODVEC–S cards
Cks MODErrWrong Communication loss between SCADA Plus and MODVEC–S cards

4.4. Parameters Reset

To reset the parameters to their default values, use function Reset All [01.03] in the Main Setting family. When this function is invoked all
parameters except those pertaining to motor and drive data will be reset to their default values.

4.5. Programming Levels

There are three (3) programming levels:

• Level 1 is the quick start level

• Access code is 0001
• Minimal number of selected parameters within one menu – up to 14 parameters
• Quick start of the motor with the drive
• Level 2 is a higher level for defining process parameters to control the process and application
• Access code is 0002
• The parameters are organized in menus and families - more than 100 parameters
• This allows user-enabled macros and the setting up of the Dl/DO and AI/AO
• Level 3 is an advanced level and the detailed description of this level is given in Inverter Programming Manual PMP CA ATV E 2523.
• Access code is 0003
• Approximately 400 parameters are available

4.6. Control Modes

There are three (3) motor control algorithms available. Select the mode that is correct for the application.

• Scalar (V/Hz, V) mode – used for multiple motor applications

• Sensorless Vector Mode (SLS, S), control without an encoder feedback
• Field-oriented Control (FOC, F) – used for applications requiring tight torque/speed control

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4. Converter Start Up

4.7. Motor Rated Power EU/NEMA Selection

Select the standard that is applicable based upon location. The standard will be utilized when programming the motor parameters.

• EU – European Standard
• NEMA – United States Standard

4.8. Quick Motor Start-Up

The control is supplied with parameters set to the default values. Some of them are:

V/Hz control algorithm with linear characteristic (Programming level 1)

Parameter input line rated voltage (AC Input Voltage) to 3600V.
Speed reference from PROFIBUS.
Acceleration / deceleration ramps: 60 sec.
Current oscillation compensation: DISABLED

The motor quick start-up utilizes a minimum number of parameters. (See the following table)

Parameter Address/Name Description SETUP

Ctrl
Serial Advanced Keypad and EU Standard NEMA Mode
Address PC Tool Standard
01.01 EU-NEMA Select EU – Selects parameters 02.01 and 02.17 EU NEMA V, S, F
NEMA – Selects parameters 0202 and 0218
01.02 Motor Control Mode V/Hz Ctrl – Scalar Control V/Hz V/Hz V, S, F
SLS Ctrl - Sensorless Vector – Vector control without
Encoder feedback
FOC Ctrl – FieldOriented Control – Encoder feedback
02.01 EU - Motor Power EU - Rated motor nameplate power in Kw Motor Kw V, S, F
value
02.02 NEMA - Motor Power NEMA - Rated motor nameplate power in HP Motor HP S, F
value
02.05 Motor Voltage Motor nameplate voltage 3300V 3300V V, S, F
02.06 Mot Full Load Curr Motor nameplate current Motor FLC Motor FLC V, S, F
value value
02.08 Motor Frequency Rated motor frequency 50 Hz 60 Hz V, S, F
02.09 Mot Full Load Speed Rated motor speed – actual RPM from motor 1500 RPM 1800 RPM S, F
nameplate
02.10 Motor Min Oper Freq Minimum process operating frequency 0 Hz 0 Hz V, S, F
02.11 Motor Max Oper Freq Maximum process operating frequency 60 Hz 70 Hz V, S, F
02.17 Motor Power Factor EU Standard - Rated motor power factor 0.85 S, F
02.18 Motor Efficiency NEMA - Rated motor efficiency .95 S, F
06.03 AC input voltage Actual main input supply voltage. 3600V 3600V V, S, F
11.10 Autotuning Select Used for tuning the motor for drive operation Tune Off Tune Off S, F
Tune Off - Disabled
Self Comm - Enables Self Commissioning
Mot prm C – calculates internal parameter for
enhanced drive performance
Stand Self - Pulses are enabled but the shaft does not
move
22.12 Accel Time 1 Acceleration ramp time #1 60 s 60 s V, S, F
Typical settings
• Pump application – 30 seconds
• Fan application – 60 seconds
22.13 Decel Time 1 Deceleration ramp time #1 60 s 60 s V, S, F
Typical settings
• Pump application – 30 seconds
• Fan application – 60 seconds

Now that the parameters have been selected, the drive is ready to be started and the motor checked for correct phasing orientation.

NOTE
The motor should be uncoupled and the control modes must be V/Hz.

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4. Converter Start Up
Local Operation

The steps to accomplish the start are as follows:

1. Precharge Drive;

2. Press [Man/Start] to select the local operation (from keypad)

• Advanced keypads. The message “Manual Press enter to confirm” appears. Press [Enter/Canc] to confirm. The keypad
goes back to the display of the status and the LED “On” flashes to indicate the operation is in manual mode.

3. Press [Man/Start] button to start motor. The drive should now be running and the RUN LED lit. A speed command is required.
4. Use the UP and DOWN arrow keys to control the speed
5. Check motor’s orientation. If incorrect, change any two phases at the motor terminal’s U,V,W or modify the parameter [06.05]
Motor Phase Seq Sel from UVW to UWV and re-verify.

For V/Hz mode go to step 7. For SLS and FOC go to step 6.

NOTE

Autotuning

6. For SLS and FOC control mode, Autotuning is required using parameter [11.10]:
To identify motor parameters three commissioning procedures are available:

• Self commissioning with motor at no load = Self comm: Use this procedure when the motor is not connected to the load.
• Motor Parameter calculation = Mot prm C: Calculates internal parameter for enhanced drive performance. You need to
specify the no load current entering in programming level #3.
• Self commissioning with motor at stand still = Stand Self: Pulses are enabled but the motor shaft does not move. Use when
motor is already coupled with load.

• Self Commissioning (with motor at no load)

• With Drive Enable command OFF (IDLE status), set in Manual mode.
• Then set Drive Enable command ON: the led ON lights on.

• With motor at no load, set the parameter [11.10] to “Self comm”.

• Confirm YES when the dialog box appears. The drive will be automatically reset.
• When the drive returns to READY status, give the MAN/START command.
• Inverter starts the motor up to 90 % of “Motor Frequency” in order to perform the Autotuning procedure
• Drive status shown is “TUNING”.
• When Self Commissioning is completed the inverter stops the motor.
• The Motor Parameter Calculation is completed through the automatic execution of the “Mot prm C” procedure.
• The drive will be automatically reset.

Self commissioning procedure is completed and is possible to start the motor in automatic or manual mode.

NOTE • It is strongly recommended to use [22.12] and [22.13] at values greater or equal to default
values (60 sec.).
• If no run command is given within 200 seconds after the set of [11.10] to picklist variable
“Self Comm”, the drive return to the original condition.
• If the ATV is not in READY status, setting [11.10] to “Self Comm” is ignored.
• During the “TUNING” status, STOP command can be given. If the motor is accelerating,
the drive returns to the READY status waiting for a run command in order to complete the
self commissioning procedure. If the drive is performing measurements (motor speed
constant), the motor is stopped and a protection for “self commissioning failed” occurs. If
the motor is decelerating the STOP command has not effects on the procedure.
• During the “TUNING” status, if Drive Enable is set to off, a protection for “self
commissioning failed” occurs.

87
4. Converter Start Up
Motor Parameter Calculation

Calculates internal parameter for enhanced drive performance. By setting manually Mot prm C in the parameter Autotunning Select
[11.10] internal parameter calculation is executed automatically. It’s necessary to specify, at programming level #3, the following motor
data. The operation will calculate the parameter identified as output.

Motor Parameter calculation [11.10] = Mot prm C

Necessary Input Output
Parametri Nome Parametri Nome
[02.01] Motor Power EU* [03.01] ROTOR RESISTANCE
[02.03] Motor Power NEMA** [03.02] Stator Resistance
[02.05] Motor Voltage [03.03] Rotor Leakage induct
[02.06] Mot Full Load Current [03.04] Stat Leakage Induct
[02.07] Motor NoLoad Current [03.05] Magnetizing Induct
[02.08] Motor Frequency [03.19] Fluxing Time
[02.09] Mot Full Load Speed
[02.17] Motor Power Factor (cosϕ)*
[02.18] Motor Efficiency**

* related with EU setup

** related with NEMA setup

Self Commissioning with motor at stand still

In Manual mode and “IDLE” status, set Drive Enable command ON : the led ON lights on.
• Set [11.10] to picklist variable “Self Stand”.
• Confirm YES when the dialog box appears The drive will be automatically reset.
• When drive returns to READY status, give the “run” command
• Drive will pass from “READY” status to “TUNING” status for ten times
• Drive will be reset.
• If no error messages appear, and the drive returns to “IDLE” status, the drive is ready to run.

During the Self Commissioning with motor at stand still, the motor will not move. To erase the
NOTE
procedure, press “CANCEL” on the dialog box.

Coupling the motor

7. Couple the motor to the load.

Running the drive to full speed with the load

8. Run the drive up to full speed. If problems exist refer to the Troubleshooting Chapter in the Inverter Programming Manual.

88
4. Converter Start Up
Run in Automatic Operation

The steps to accomplish the start are as follows:

1. Close Drive Enable command:

• This is a customer input command (SCADA Plus terminal XM1-20 to XM1-24).

2. Press [AUTO] to select the operation in automatic mode and press [Enter/Canc] to confirm

3. Close Start/Stop command:

• This is a customer input command.

4. Typical speed command will come into Analog Input 1, PROFIBUS or motopotenziometer.
• This input can be a 0 -20mA, 4-20mA or 0-10V

4.9. Encoder test (if present)

1. Make sure that the connections for the encoder power supply and signals are correct.

2. Enable Speed feedback from encoder, “Speed Fdbck Select [04.04]” = Encoder.

3. Enable local control with the Keypad.

4. Precharge the inverter

5. Give a start command and speed reference other than zero, from the Keypad

6. Verify coherence between motor rotation direction, speed feedback sign and speed reference sign.
Example: reference positive – motor RST correct, clockwise rotation – encoder feedback positive

89
4. Converter Start Up

4.10. Protections Description

The present paragraph describes all the hardware and software trips implemented in the control SCADA PLUS of the
Altivar 3300V.
Each protection causes the shut-off of the inverter and the relay “R01 Fault” is denergized. Use protection code to recognize converter
damages or malfunctions.

MAXIMUM OUTPUT CURRENT TRIP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
OverCurr 002 TRIP: ATV HW TRIP - MAXIMUM CURRENT

This protection it is based on the current signal coming from the INTVECM card; the trip occurs whenever the current peak value
overcomes the IAC max - tot threshold. This value is indicated in the following table:

NUMBER OF INVERTER IN IAC max-tot

EQUIPMENT SIZE
PARALLEL INTERVENTION THRESHOLD MAX TOTAL CURRENT
ATV 1K3 A 33 1 560 Apk
ATV 1K8 A 33 1 840 Apk
ATV 2K6 A 33 1 1240 Apk
ATV 3K6 A 33 2 1680 Apk (2 x 840 Apk)
ATV 5K2 A 33 2 2480 Apk (2 x 1240 Apk)
ATV 1K6 W 33 1 560 Apk
ATV 2K4 W 33 1 840 Apk
ATV 3K6 W 33 1 1240 Apk
ATV 4K8 W 33 2 1680 Apk (2 x 840 Apk)
ATV 7K2 W 33 2 2480 Apk (2 x 1240 Apk)

MAXIMUM D.C. VOLTAGE TRIP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
OverVolt 003 TRIP: ATV HW TRIP - MAXIMUM DC BUS VOLTAGE

it is based on the DC-link voltage, acquired through a Hall effect transducer (TV LEM); it occurs whenever the voltage overcomes the
established max value (6000V); this value is set via hardware. The voltage scaling on the burden resistors is 5V @ VDCMAX.

EXTERNAL TRIP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
ExtrnTrp 004 TRIP: ATV HW TRIP - EXTERNAL TRIP FROM CONFIGURABLE DIGITAL INPUT

Protection occurrs when dedicate digital input reaches zero level.

DESATURATION:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Desaturat 005 TRIP: ATV HW TRIP - INVERTER PHASES TRIP

90
4. Converter Start Up
It is based on the monitoring signals coming from the IGBT firing card, transmitted via fibre optics, (TGUNTNB firing card connected
through the O.F. to MODVEC and FOVECM control cards).
When this protection occurs, it is possible to determine which firing card has failed by checking the status of the LEDs on MODVECS or
FOVECM cards or it is possible to read 7 elements display “Disp1” on MODVECS card. In the following table are shown the codes
displayed on “Disp1”.

Anomaly “Disp1” MODVEC or FOVECM

Gate Unit Anomaly Positive external IGBT fase U 0
Gate Unit Anomaly Positive internal IGBT fase U 1
Gate Unit Anomaly Negative internal IGBT fase U 2
Gate Unit Anomaly Negative external IGBT fase U 3
Gate Unit Anomaly Positive external IGBT fase V 4
Gate Unit Anomaly Positive internal IGBT fase V 5
Gate Unit Anomaly Negative internal IGBT fase V 6
Gate Unit Anomaly Negative external IGBT fase V 7
Gate Unit Anomaly Positive external IGBT fase W 8
Gate Unit Anomaly Positive internal IGBT fase W 9
Gate Unit Anomaly Negative internal IGBT fase W a
Gate Unit Anomaly Negative external IGBT fase W b

In the following table are shown the codes displayed on “Disp1” of MODVEC card with inverter in parallel

Anomaly “Disp 1” MODVEC “Disp 1” FOVECM 1

Angu inverter 1 0 to b
Angu inverter 2 d 0 to b

LOSS OF POWER SUPPLY OF MODVECS BOARD:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Mod Supply 006 TRIP: ATV HW TRIP - MODVEC BOARD POWER SUPPLY

It annunciates the 24V supply loss on MODVEC card.

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
007 TRIP: ATV HW TRIP - ANOMALY WITH RESET COMMAND: DRIVE
ResetFault
RUNNING WITHOUT PULSES

RAM DUAL PORT DAMAGE:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
DPRAM Err 009 TRIP: ATV HW TRIP - DPRAM TEST FAULT

It annunciates the anomaly of RAM Dual Port component.

WATCH DOG PROTECTION:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Wdog Ext 010 TRIP: ATV HW TRIP - WATCH DOG

INTVECM PROTECTION:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
INTVEC Pr 012 TRIP: ATV HW TRIP - INTVEC M BOARD PROTECTION

91
4. Converter Start Up
This trip can be due to two possible causes:

• maximum current
• maximum differential current

In both cases, the current level is monitored through the motor current signals acquired by means of three Hall effect transducers
(TA LEM) mounted on the inverter phases.

The detection of which trip has occurred (maximum current or maximum differential current or maximum DC voltage) is performed
by means of a code on 7 elements display on interface cards (NTVECM1 for single inverter and 2 inverters in parallel).

MAXIMUM CURRENT

The maximum current trip occurs whenever the trip threshold is overcome (hardware guards); the following table shows the trip threshold value
depending on the drive class and drive size:

NUMBER OF INVERTER IN MAX CURRENT

EQUIPMENT SIZE
PARALLEL TRIP THRESHOLD
ATV 1K3 A 33 1 560 Apk
ATV 1K8 A 33 1 840 Apk
ATV 2K6 A 33 1 1240 Apk
ATV 3K6 A 33 2 840 Apk per inverter
ATV 5K2 A 33 2 1240 Apk per inverter
ATV 1K6 W 33 1 560 Apk
ATV 2K4 W 33 1 840 Apk
ATV 3K6 W 33 1 1240 Apk
ATV 4K8 W 33 2 840 Apk per inverter
ATV 7K2 W 33 2 1240 Apk per inverter

The voltage scaling on the TA LEM burden resistors is 5V@ IACMAX.

DIFFERENTIAL CURRENT (only parallel configuration)

The differential current trip occurs whenever the current unbalance of each phase exceeds 50% of the rated current (for class 1 service)
of the single inverter.
In the following table are shown the codes displayed on “Disp1” Related with Converter configuration.

Single inverter

Code on“Disp1” displayed on

Anomaly
INTVECM board
Inverter max current 1
Max voltage BUS DC 1 4
Max voltage BUS DC 2 7
contemporary protections 8

Two inverters in parallel

Code on“Disp1” displayed on

Anomaly
INTVECM board
Inverter 1 max current 1
Inverter 2 max current 2
Differential current 3
Max voltage BUS DC 1 4
Max voltage BUS DC 2 7
contemporary protections 8

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4. Converter Start Up
IGBT OVERTEMPERATURE:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Over Temp 013 TRIP: ATV HW TRIP - PHASES OVERTEMPERATURE

It annunciates that one or more temperature switches (mounted on inverters, braking chopper and three-phase reactors) have
opened.

THYRISTOR COMMAND ERROR:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
ThyrComErr

Once the “Precharge OK” command from the control has been given, the drive trips after a certain time if the feedback signal
(stating that the thyristor bridge is on) is not received by the control. This protection is activated on inverter DFE configuration.

CONFIGURATION ERROR MODVECS BOARD:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Mod Conf 015 TRIP: ATV HW TRIP - MODVEC BOARD CONFIGURATION ERROR

PRECHARGE FAULT:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Prec Fail 018 TRIP: ATV SW TRIP - INVERTER PRECHARGE FAIL

Once the precharge command (DRIVE ENABLE) has been given, this drive trips after 10s if the DC-link voltage is still below 85% of the
rated value, calculated as 1,35∗ AC input voltage [06.03]

OVERSPEED TRIP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Over Spd 019 TRIP: ATV SW TRIP - OVERSPEED

The control detected a speed exceeding the threshold set by the Ovrspd flt setpoint [67.06] parameter. Only for FOC or SLS.

CONFIGURATION PARAMETERS ERROR:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Confg Err 020 TRIP: ATV SW TRIP - PARAMETER CONFIGURATION ERROR

This protection occurs for different reasons, which can be identified analysing the Config Error [78.05] parameter value.

93
4. Converter Start Up
DSP PROGRAM NOT RESPONDING:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
DSP Fail 021 TRIP: ATV SW TRIP - DSP PROGRAM LOCKED

An error occurred during a program start up in the DSP.

NETWORK COMUNICATION LOSS:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Net Fail 022 TRIP: ATV SW TRIP - PROFIBUS CONNECTION LOST

The Network communication is lost.

MOTOR STALL:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Stall 024 TRIP: ATV SW TRIP - MOTOR STALL PROTECTION TRIP

The STALL protection can be enabled only when F.O.C. control is selected; it can occur in two different situations:

• after giving the Start command, with speed reference other than zero, the speed feedback remains at zero for a period longer than
the selected time-out;
• with motor running, the difference between speed reference and feedback exceeds a settable maximum value for a period longer
than the selected time-out.

EMERGENCY STOP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Fast Stop 025 TRIP: ATV SW TRIP - FAST STOP

This protection is automatically enabled after precharge ok.

UNDERVOLTAGE PROTECTION:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Under Volt 026 TRIP: ATV SW TRIP - MINIMUM DC BUS VOLTAGE SW PROTECTION

It monitors the D.C. voltage on the DC-link; this protection is automatically enabled after the precharge of the D.C. filter capacitors is
accomplished.
The set-point value is represented by the parameter UV-VdcHS Prot Thrsed [69.01] which is a percentage of the rated voltage set by the
AC input voltage [06.03].

VDC read < UV-VdcHS Prot Thrsed threshold

EXAMPLE: AC input voltage = 3600 V Vdcnom = 3600 · 1,35 = 4860 V

UV-VdcHS Prot Thrsed = 75% = 4860 * 0,75 = 3645 V
VDC lread < 3645 V Minimum Voltage Protection

94
4. Converter Start Up
DRIVE SIZE ERROR:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
DrivSzErr 027 TRIP: ATV SW TRIP - WRONG INVERTER SIZE SETTING

This protection occurs when no inverter sizes are selected or a wrong value is set.

GROUND FAULT:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Gnd Flt 028 TRIP: ATV SW TRIP - GROUND FAULT PROTECTION

The protection occurs whenever the sum of the inverter output currents is different than zero and higher than 14% of the IAC max-
tot trip value.

EXAMPLE: ATV 1K8 A 33 IACmax = 840 Apk

IGND = Iu + Iv + Iw
IGND > 0,14 *840 A
IGND > 117,6 A Intervention of the GROUND FAULT protection

MOTOR/INVERTER OVERLOAD:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Therm Prt 030 TRIP: ATV SW TRIP - MOTOR OVERTEMPERATURE

It occurs when the allowable motor overload conditions have been exceeded.
The parameters related to this function are:

Overload [66.02] : sets the maximum allowable overload as a percentage of the rated current
Overload timeout [66.03] : sets the maximum allowable duration of such overload current.

To be enabled, this protection requires that the preset value of ImTOV be larger than 105%.

The protection trips when the following inequality occurs:

  Im TOV  2 
∫ (Is2 − In2 ) dt ≥   − In  ⋅ Im TDl
2
Is= actual motor current
  100  
 
In = rated motor current

EXAMPLE

In = 400 A rated motor current

Iov = 620 A overload current
Tsc = 60 s maximum time duration of the preset overload current

Using this data, the values to be assigned to the parameters are:

ImTov = (620/400) * 100 = 155%

ImTDl = 60s

95
4. Converter Start Up
If the value of the overload motor current is exactly 620A, the overload protection trips after 60 s.
If, on the contrary, the overload motor current is lower, or larger, than 620A, the trip time shall be, respectively, longer or shorter than 60s.
The exact value of the trip time can be calculated by the following equation:

2
 Im TOV 
  −1
t int =  100 
⋅ Im TDl
2
 Is 
  − 1
 In 

In the following image is shown the inverse time protection curve.

900

800

700

600
Time [sec]

500

400

300

200

100

0
400 500 600 700 800
Current [A]

SPEED DEVIATION TRIP:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Speed Dev 031 TRIP: ATV SW TRIP - SPEED DEVIATION

When a speed (transducer analogic or from encoder: Speed Fdbck Select parameter) is present (with VHz, SLS and FOC control), this
trip occurs if, with function enabled (Motor stall enable [67.01]) with the speed reference set at the maximum value (Motor Max Open
Freq [02.11]), speed feedback differs from the reference more than ±5%, for a period longer than a parameter Mtr stall delay time
[67.03].
If the speed reference is less-than the maximum value and speed feedback differs from the reference more than ±5%, for a period longer
than a parameter Mtr stall delay time [67.03] occurs an alarm.

OFFSET ON CURRENT TRANSDUCER:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
Curr Offs 034 TRIP: ATV SW TRIP - TA OVERCORRECTION PROTECTION

This protection occurs when there is an offset on TA analogical input.

96
4. Converter Start Up
SWITCHING FREQUENCY SELECTED NOT PERMITTED:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
SWF Error 036 TRIP: ATV SW TRIP - SWITCHING FREQUENCY NOT ALLOWED

This protection occurs with switching frequency selected not permitted.

UNDER LOAD FAULT:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
UnderLoad 037 TRIP: ATV SW TRIP - MINIMUM MOTOR LOAD

LOSS SPEED REFERENCE:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
SpdRfLs 038 TRIP: ATV SW TRIP - SPEED REFERENCE LOST

Loss of speed reference

LOSS OF OUTPUT PHASE:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
OutPhasOut 039 TRIP: ATV SW TRIP - OUTPUT PHASE LOST

This protection occurs when one motor phase isn’t connected.

ANALOGICAL INPUT NTC OR PTC PROTECTION:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
AI User FI 047 TRIP: ATV SW TRIP - PTC OR NTC TRIP

SWITCHING FREQUENCY SELECTION ERROR BETWEEN SCADA AND MODVECS:

Error code displayed on PC

Message displayed on HMI
Tool or Keypad
SWF CfgErr 048 TRIP: ATV SW TRIP - SWITCHING FREQUENCY CONFIGURATION ERROR

This protection occurs when switching frequency selection on MODVECS card (through dedicated switches) is different with
SCADA PLUS software settings.

SERIAL COMMUNICATION LOSS BETWEEN SCADA AND MODVECS:

Error code displayed on PC Message displayed on HMI

Tool or Keypad
Cks MODErr 049 TRIP: ATV SW TRIP - MODVEC BOARD CHECKSUM ERROR

Loss communication between SCADA PLUS card and MODVECS card.

97
4. Converter Start Up

4.11. Start Up Procedure

4.11.1. Preliminary Checks
Installation
• Environmental conditions check: the rooms in which the equipments are installed should be clean and without dust
• Check all the cubicle section, which must be clean inside as well
• Umidity and other materials shouldn’t be present inside the equipments

Ground Connection
This check is to be completed before startup; the connection, according to the project documents, should be checked.
Following equipment is to be checked:

• transformer
• cubicle
• motor

Cubicle Connection
The ground bar must be electrically continous in each cubicle section. All the connections used to join the cubicle sections are to be
checked. These are:

• power electronics
• logic
• signals
• optical fibres
• hydraulic circuit

Cooling System.
• visual check of all the connections and lockings
• fill the circuit following the detailed procedure
• all the circuit must be hermetic, in particular joints, connections

Connections Check.
• Check the cabling of the transformer, cubicle and motor
• Check the connection:
• between main switch and transformer
• between transformer and cubicle
• between cubicle and motor
• The connections of all the terminal blocks and auxiliary circuits
• Lockings

Voltage Measurement.
• Before power up, check if all the supply have a value according to the specified data on the electrical drawings.

4.11.2. Auxiliary Circuits Checks

These conditions must be fullfilled in order to check the auxiliary circuits:

• The precharge circuit must be open removing the precharge fuses, in order to avoid the charge of the d.c bus after an unespected
closing of the precharge contactor.
• Remove the medium voltage switch and set it in “test” position (so it’s possible to move it without voltage)

Auxiliary Power On
• Supply the auxiliary circuit following the distribution as shown in the draft
• Check that the applied voltage are correct and that all the equipment are correctly supplied
• Check the pumps rotating sense
• Start the cooling system control unit
• Check the water level until the air output is completed
• Check the fans rotating sense

Drive Parameters Configuration

Setup the correct inverter parameters, in particular:

• The motor rated data

• Inverter rated data
• The operating logic detailed in the drafts

98
4. Converter Start Up
Logics
• check the operating status of the cubicle logics.
• check the protection intervention, in particular the interfacing with the medium voltage switch (opening command after a protection)
• Remove the connection carrying the VDC1 and VDC2 signals. Simulate the two voltages with a supply unit on the ballast
resistances and start precharging phase without the fuses checking the correct sequence operation
• Start inverter running (without voltage) in VHz TN control mode and check the output voltage waveform

4.11.3. Startup
Warning: the closing of the “voltage present” switch will happen only after the precharge of the inverter and with the presence of the signal
“precharge OK”.

Precharge
• reconnect the precharging circuit as before the test (insert fuses, remove voltage simulation on ballast resistances, insert
connectors). Leave the main switch removed
• reach the status of “no protection” and close the cubicle doors
• Start the cooling unit
• Start precharging checking the behaviour of the d.c. voltages (VDC1 and 2)
• As the level of 40% of the nominal value is reached remove the command
• Start again the precharge and wait for the sequence to be completed. The two voltages VDC1 and 2 must have the same value (2%
difference allowed)
• As the main switch is still removed, this will be closed but the undervoltage protection will be activated
• Insert the main switch and repeat the sequence

After the precharging phase, the inverter is in the “ready” status and it’s possible to proceed with the running.

99
4. Converter Start Up
Running
VHz Control
• Start the inverter in local mode, with no load on the motor, VHz TN control mode, speed feedback from the encoder (if available).
Set a speed reference of 100 RPM
• Check the motor rotating sense and the speed feedback (if available), which must be positive if the motor runs in the “forward”
direction
• Proceed with the current compensation tuning if necessary
• Reach the maximum motor speed, checking all the variables involved in the rotation of the motor:
• frequency
• voltage
• current

FOC/SLS Control
• Insert the FOC TN control mode and start the inverter
• Check the motor rotating sense and the speed feedback, which must be positive if the motor runs in the “forward” direction
• Reach the maximum motor speed, checking all the variables involved in the rotation of the motor:
• speed
• frequency
• voltage
• current

Remote Test (if applicable)

• System test in remote mode
• References and feeback signals regulations
Process tests

100
5. Maintenance, Checks and Troubleshooting

5.1. Safety Prescriptions

Risk of death, fire or heavy injuries

The job requires the personnel is skilled for the purpose, well aware of safety rules,
regulations and standards while operating on Medium Voltage Equipments. Full knowledge
of installation power supply system and ATV 3300V diagrams is needed.

Risk of death, electric shock or heavy injuries

The job requires the personnel is skilled for the purpose, well aware of safety rules,
regulations and standards while operating on Medium Voltage Equipments. Full knowledge
of installation power supply system and ATV 3300V diagrams is needed.

5.2. Periodical Maintenance and Checks

The ATV 3300V is a static converter equipment using power semiconductor as power control device.
Even thought power semiconductor don’t need maintenance over component life, many auxiliary components need to be periodically
checked, and/or tested and/or cleaned. Again, some vital auxiliary paths (like air filter and water deionizing resins) shall de cleared and
substituted on a regular time schedule.
The suggested maintenance operations are reported hereunder:

1) Check the conditions of the air filters, if any.

2) Check screw terminals of power connections.

3) Check screw terminals of auxiliary connections.

5.3. Protections Troubleshooting

In normal operation, the converter control carries out checks to detect any possible anomaly, basing its analysis both on hardware and
software checks.

In the case of detected anomaly, the operator is informed by:

• a message (fault type) on the user's terminal display;

• messages on the display and lighting of the relevant leds of the INTVECM interface cards, the MODVEC modulator card and the
FOVECM pulse duplication cards.

To cancel such anomaly indications, it is first necessary to eliminate their causes, if still active, and then reset any active protection that is
stored inside the memory of the control module. This is done by applying the proper command, through a "reset" pushbutton (the Reset
function is connected to the digital input 9); or by the user's terminal, through the RS key.

The following table lists all protection signals, their possible causes and the actions to be carried out, if any, in order to eliminate the
anomaly.

101
5. Maintenance, Checks and Troubleshooting
5.3.1. Hardware Protections

USER's TERMINAL DESCRIPTION CAUSE/ACTION

DISPLAY

Over Curr Protection trip: All checks concerning equipment wiring or motor winding (insulation)
maximum instantaneous conditions must be carried out with no voltage applied to the power circuits
overcurrent at drive output and after a waiting time (10 minutes at least) to allow for discharge of
capacitor banks
These precautions are necessary for the safety of operators.
- check that neither short circuit between motor phases or phase fault to
ground exists;
- check the wiring and for correct operation of the encoder and its mechanical
coupling (FOC only );
- check that the acceleration ramp time is not too short;
- check the torque reference upper limits and torque current.

Over Volt Protection trip: A motor stop was initiated with too short deceleration time.
maximum DC bus
overvoltage; instantaneous
value of DC voltage has
exceeded the protection trip
threshold.

Extrn Trp External protection. The dedicated digital input reached level zero.
Check the state of the contacts (to be found on the Equipment Elementary
Diagram) that are connected to the terminal board to implement such logic
input, and/or other possible external protections, active through the
NETWORK.

Desaturat Protection trip: All checks concerning equipment wiring or motor winding (insulation)
Gate unit anomaly (faulty conditions must be carried out with no voltage applied to the power circuits
operation detected by the and after a waiting time (10 minutes at least) to allow for discharge of
Gate unit; one of the IGBT capacitor banks.
firing boards). These precautions are necessary for the safety of operators.

Protection trip causes:

IGBT desaturation;
Loss of power supply to firing circuits;
Suggested checks:
Check IGBTs.
Check power supply to firing circuits;

NOTE: Sometimes this protection may cut-in in case of an overcurrent event.

In such a case follow the instructions given at Over Curr.

Mod Supply Protection trip: The instantaneous value of the rectified voltage that supplies the modulator
minimum modulator supply board has fallen below the safety threshold value.
This rectified voltage is obtained from G1 power supply.

DPRAM Err Dual Port error Check microprocessor board

Vdc Min Protection trip: The instantaneous value of the DC bus voltage has fallen below the threshold
minimum DC bus voltage value. This protection is not necessary for ATV inverter and must be disabled
detected by hardware. opening the JP19 jumper on the SCADA control board.
OVER CURRENT All checks concerning equipment wiring or motor winding (insulation)
INTVEC Pr The instantaneous value of conditions must be carried out with no voltage applied to the power circuits
the output current of one drive and after a waiting time (10 minutes at least) to allow for discharge of
phase module has exceeded capacitor banks.
the protection trip threshold. These precautions are necessary for the safety of operators.
OVER CURRENT:
OVER VOLTAGE - check that neither short circuit between motor phases nor phase fault to
The instantaneous value of ground exists;
DC voltage has exceeded the - check the wiring and the correct operation of the encoder and its mechanical
protection trip threshold coupling (FOC only).
- check that the acceleration ramp times are not too short;
CURRENT UNBALANCE - check the upper limits of torque reference and torque current.
Protection trip occurs
whenever an unbalance is OVER VOLTAGE
detected among the phase A motor stop was initiated with too short deceleration time.
currents of ATV bridges in

102
5. Maintenance, Checks and Troubleshooting

USER's TERMINAL DESCRIPTION CAUSE/ACTION

DISPLAY
parallel. CURRENT UNBALANCE:
- check the wiring and the correct operation of the phase modules of all drive
bridges, their IGBT firing cards and the phase current transducers
(TA LEM);
- check security of the bolts of the drive output bars

Overt Temp The temperature of one or Check the cooling system for correct operation.
more heat sinks has
exceeded the preset limit
causing the related thermal
switch to trip.

All signals from such thermal

switches are combined as
normally closed, with contacts
series connected, and
monitored by the diagnostics
of the control module as a
single switch.
All checks concerning equipment wiring or motor winding (insulation)
ThyrComErr Internal pre-charge system conditions must be carried out with no voltage applied to the power
failure (only DFE equipment circuits and after a waiting time (10 minutes at least) to allow for
configuration). discharge of capacitor banks.

Check if the green LED D2 on the INTPREA board (control panel position) is
on.

Check the fiber optics between the INTPREA board and the TCPSA/B boards
on the rectifier bridges.

Mod Conf Modulator start-up error. Problem on the modulator board sw bootstrap (MODVEC board, control panel
position).
Change the modulator board.

103
5. Maintenance, Checks and Troubleshooting
5.3.2. Software Protections

USER's TERMINAL
DESCRIPTION CAUSE/ACTION
DISPLAY

Pre-charge fault ALL CHECKS ABOUT EQUIPMENT WIRING AND FUSE CONDITIONS
Prec Fail MUST BE CARRIED OUT WITH THE PRECHARGE KNIFE SWITCH (its
symbol can be found on the Equipment Elementary Diagram) OPEN AND
AFTER A WAITING TIME (OF 10 MINUTES AT LEAST) TO ALLOW FOR
DISCHARGE OF CAPACITOR BANKS;
THESE PRECAUTIONS ARE NECESSARY FOR THE SAFETY OF
OPERATORS.

Loss of power supply of the precharge circuit.

Check the availability of auxiliary power supply (220 - 440 V).
Besides, check that, once the precharge command has been sent, the value of
the DC bus voltage, shown as "VDC" parameter on the user's terminal display
in its Monitor mode, is not null.
Also check, by the user's terminal, that the "VInp" parameter, included in the
"Drive Parms" section, has been set at a proper value.

Check, having switched off both the Main and Auxiliary Power Supplies, the
soundness and proper operation of all components of the precharge circuit
(see on paragraph 5.4): fuses on the a.c. power supply, knife switch and
contactor, 2000 VA insulation transformer, single pole automatic breakers,
step-up transfor-mers, diode rectifiers, fuses on the D.C. side.

Over Spd This protection is active in The motor has exceeded the preset speed limit threshold.
FOC and SLS operation Check the value of the preset speed limit threshold.
modes only. The speed regulator is not correctly adjusted.

Confg Err Incorrect parameter Check the monitor parameter [78.05] Config error to understand what
configuration. configuration error has occurred.

DSP Fail Error at start of DSP program Replace the microprocessor board.

Net Fail Loss of communication Check the status of the net Master: it must be active.
network. Check that the Microprocessor Board is correctly connected to the Profibus
expansion board (Network Board or PLC Interface Board). Also check the
connection cable between the ATV and the net master for damage.
Check consistency between the profibus node setting, parameter [06.13]
Profibus ID (for PROFIBUS network) or parameter [06.14] Modbus ID (for
MODBUS network) and the drive Network address sent by the net master.

Stall Set speed not reached. Check the parameters related to the function for consistency.
The difference (in %) between Check the setting of torque and torque current limits.
the speed reference and Check the encoder for correct operation.
actual motor speed exceeded Load too high.
the value set at parameter
[67.08] Motor stall max err for
more seconds than set by use
of parameter [67.09] Motor
stall max time.

Fast Stop Emergency stop. If the protection trip is wrong:

Check the setting of parameter [65.02] Fast/coast trip enbl (family [65.00] Fast-
Coast config on the Protect Menu).
Check the digital input on the terminal block

UnderVolt Minimum DC bus voltage sw The instantaneous value of the DC bus voltage has fallen below the threshold
checked. value set by 70% of:
[06.03] AC input voltage * 1.35.
Check the value of the DC bus voltages measured by the voltage transducers
by checking the VDC parameters on the user's display (in Monitor mode).

DrivSzErr Drive size not selected. Drive size not selected.

Select the actual drive size.

Gnd Flt Ground fault. All checks concerning equipment wiring or motor winding (insulation)
The instantaneous value of conditions must be carried out with no voltage applied to the power circuits and

104
5. Maintenance, Checks and Troubleshooting

USER's TERMINAL
DESCRIPTION CAUSE/ACTION
DISPLAY
the sum of the drive output after a waiting time (10 minutes at least) to allow for discharge of capacitor
currents has exceeded the banks.
protection trip threshold. These precautions are necessary for the safety of operators.
An insulation loss occurred, either in the connection cables to the motor, or
inside the motor windings.
This protection may trip only in case one output phase is connected to ground.

Inv ThPrt Protection against inverter The inverter operated in overload conditions for a time longer than the related
overload. preset value fixed by the inverter overload class (parameter [06.08] Ovl Class
Selection).

UnderSpd Er The motor speed is under a The motor is overloaded.

preset value for a time Check the acceleration ramp.
greather than a preset time. Check the parameters [67.10] Undspd flt setpoint (minimum speed fault
setpoint) and [67.11] Undspd timeout (maximum time under the minimum
speed fault setpoint).

Mot ThPrt Protection against motor The motor operated in overload conditions for a time longer than the related
overload. preset value (parameters [66.02] Overload and [66.03] Overload timeout)

Speed Dev Motor speed different from This protection trips if the motor steady state speed is different from the set
the speed demand. reference. The motor is overloaded.

DSPFormErr DSP initialization error. Check microprocessor board.

Curr Offs Current offset. Check current transducers.

RAM Error RAM DSP error. Check microprocessor board.

SWF Error Switching frequency not Change the switching frequency parameter value (parameter [06.12] Switching
allowed. Frequency, family [06.00] Drive data, Drive Menu).

UnderLoad Loss of load. Check if Underload settings are correct for load motor shaft

SpdRfLs Loss of speed reference. Check external analog signal connections at microprocessor board terminals
(e.g. disconnected wire), and analog input configuration.

OutPhasOut Loss of one phase on motor. All checks concerning equipment wiring or motor winding (insulation)
conditions must be carried out with no voltage applied to the power circuits and
after a waiting time (10 minutes at least) to allow for discharge of capacitor
banks.
These precautions are necessary for the safety of operators.
Check connection at drive and motor terminals and the motor cable.

FP Error Floating Point Error. Check microprocessor board.

The brake status, (Digital Input) selected by [30.06] DI - Brake Status and
Open Brake Crane control: open brake [30.07] Brake open status, remains closed during the open procedure. Check
fault. parameter [30.09] Brake opening time in order to be sure to verify that
mechanical times needed for the brake opening are set correctly.

Close Brk Crane control: close brake The brake status , (Digital Input), selected by [30.06] DI - Brake Status and
fault. [30.07] Brake open status, remains opened during the close procedure. Check
parameter [30.15] Brake closing time in order to be sure to verify that
mechanical times needed for the brake closing are set correctly.

Trq Prove Crane control: Toque proving Torque proving failed because the motor torque is not greater than the
fail threshold set by [30.01] Torque proving thres. It is possible to delay the torque
proving test using the parameter [30.04] Trq prov fail time.

TrqTh High Crane control: Torque proving The torque threshold is too high, causing motor rotation during torque proving.
threshold greater than brake There is a motor rotation when the brake is closed.
torque capability

105
5. Maintenance, Checks and Troubleshooting

USER's TERMINAL
DESCRIPTION CAUSE/ACTION
DISPLAY

Brk & Run Crane control: Unwanted The brake status (Digital Input) selected by [30.06] DI - Brake Status and
brake close condition [30.07] Brake open status, indicates that the brake is closing when the motor is
running.
It appears only if the parameter [30.12] Unwanted closed mode is set to “Fault”.

AI User Fl Analog Input NTC/PTC Check the temperature of thermistor connected to analog input
management

SWF CfgErr Switching frequency The switching frequency selected through the parameter [06.12] Switching
configuration error Frequency is incompatible with the MODVEC board switch setting.
Change the parameter setting or the MODVEC SW3 switch setting.

Cks MODErr Corrupted message from Check the connection between the modulator board (MODVEC board) and the
modulator to control board. control board (SCADA board).

106
5. Maintenance, Checks and Troubleshooting

5.4. Electrical Check of an Inverter Power Module

The foIlowing paragraph gives the procedure to be followed to perform a first check of the integrity of an inverter phase module.
This test must be performed in full compliance with safety rules as shown in the “Safety and Installation Manual” PMP CA ATV E 2521.

M
∼

Disconnect the module under test by removing the bolts that connect the power terminals to the DC bars (front bar assembly) and to the
output AC bar.
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
Make available an analog multimeter (the multimeter type based on a pointer) arranged for resistance measurement (on the range Ω x 1).
Check the conditions shown in the following table:

POINTS to be TESTED VALUE

+ Terminal - Terminal

+ M Open
M + about 20 Ω

- M about 20 Ω

M - Open
M ~ Open
~ M Open
+ ~ Open
~ + about 20 Ω

- ~ about 20 Ω

~ - Open
+ - Open
- + about 80 Ω

Only analog multimeters (those endowed with a pointer) are suitable for this resistance

 WARNING measurement (on the range Ω x 1)

Do not use digital multimeters.

107
5. Maintenance, Checks and Troubleshooting

5.5. Measuring and Displaying Inverter Output Currents and D.C. Voltages
ATV 3300V Inverter Equipments are endowed with current and voltage Hall effect transducers (TA LEM and TV LEM on equipment
elementary diagrams); this makes available, inside the control module, across the load resistances of such LEM transducers, electrically
insulated signals that measure inverter d.c. voltages and output currents.
The load resistances, soldered to appropriate pins, are placed inside the card INTVECM.
The scale factors of signals is:

Equipment Size Output current scale DC bus voltage scale

ATV 1K3 A33 5 V @ 560 A 5 V @ 3000 V

ATV 1K8 A33 5 V @ 840 A 5 V @ 3000 V
ATV 2K6 A33 5 V @ 1240 A 5 V @ 3000 V
ATV 3K6 A33 5 V @ 840 A 5 V @ 3000 V
ATV 5K2 A33 5 V @ 1240 A 5 V @ 3000 V
ATV 1K6 W33 5 V @ 560 A 5 V @ 3000 V
ATV 2K4 W33 5 V @ 840 A 5 V @ 3000 V
ATV 3K6 W33 5 V @ 1240 A 5 V @ 3000 V
ATV 4K8 W33 5 V @ 840 A 5 V @ 3000 V
ATV 7K2 W33 5 V @ 1240 A 5 V @ 3000 V

Inverter output currents may be measured as voltages across load resistances of TA LEM transducers by a “ true RMS ” multimeter;
voltages on DC side may be measured across load resistances of TV LEM transducers by a DC multimeter. Both waveshapes of inverter
output currents and DC voltages may be displayed by an oscilloscope.

EXAMPLE:

Equipment size: ATV 7K2 W33

Measurements on the card INTVECM by a true RMS multimeter:

SIGNALS PINS MEASURED VALUE VOLTAGE / CURRENT

1240
IR1 T17-T19 1,52 VRMS 1,52 ⋅ = 377 ARMS
5
1240
IS1 T21-T23 1,48 VRMS 1,48 ⋅ = 367 ARMS
5
1240
IT1 T25-T27 1,51 VRMS 1,51 ⋅ = 374 ARMS
5
1240
IR2 TO1-TO3 1,50 VRMS 1,50 ⋅ = 372 ARMS
5
1240
IS2 TO5-TO7 1,47 VRMS 1,47 ⋅ = 365 ARMS
5
1240
IT2 TO9-T11 1,53 VRMS 1,53 ⋅ = 379 ARMS
5
3000
VDC1 T33-T35 3,99 VDC 3,99 ⋅ = 2394V DC
5
3000
VDC2 T13-T15 3,97 VDC 3,97 ⋅ = 2382V DC
5

108
5. Maintenance, Checks and Troubleshooting
The total output current can be so calculated:

I R = I R1 + I R 2 = 377 + 372 = 749 ARMS

I S = I S 1 + I S 2 = 367 + 365 = 732 ARMS

I T = I T 1 + I T 2 = 374 + 379 = 753 ARMS

V DC _ TOT = V DC1 + V DC 2 = 2394 + 2382 = 4776V DC

Waveform shown on the oscilloscope

IR1 (T17-T19)

2,15 Vpk

1240
I R1 _ pk = 2,15 ⋅ = 533 Apk
5

533
I R1 _ RMS ≅ = 377 ARMS
2

109
6. Parts Replacement

6.1. Power Modules

This action must be performed in full compliance with the Safety precautions that can be found in paragraph 5.1, Safety prescriptions,
of this manual.

Be sure that the inverter power supply of gate firing cards is off (switch off the power supply of the TALIMB card).

6.1.1. Air cooled inverter power modules

The air cooled inverter power module must be removed according to the following procedure:

I. Disconnect the power bus bars

Remove the bolts that connect the power terminals of the inverter module both to the DC bars and to the output AC bar.

II. Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
On all gate firing cards, unplug the optic fibers from the relevant sockets (RC and TR on the board).

III. Remove the inverter module

Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.

The new air cooled inverter power module must be installed according to the following procedure:
I. Insert the inverter phase module
Slide the module along the metal rails on the support board up to the right position and fix the module by using
the bolts removed earlier.

II. Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the gate firing cards with AC voltage to the terminal block X02.
On all gate firing cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to
match fiber plugs with socket labels, in accordance with the inverter equipment Elementary Diagram.

III. Connect the power bus bars

Use the original bolts to connect the power terminals of the inverter module both to the DC bars and to the output AC bar.

110
6. Parts Replacement
6.1.2. Air cooled rectifier power modules
The air cooled rectifier power module must be removed according to the following procedure:

I. Disconnect the power bus bars

Remove the bolts that connect the power terminals of the rectifier module to the DC bars.

II. Disconnect the power cables

Remove the bolts that connect the power terminals of the rectifier module to the AC input line cables.

III. Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect the twisted cable that supplies the cards with AC 80 kHz voltage.
Unplug the optic fibers from the relevant sockets (RC and TR on the board).

IV. Remove the rectifier module

Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.

The new air cooled inverter power module must be installed according to the following procedure:

I. Insert the rectifier module

Slide the module along the rails on the support board up to the right position and fix the module by using the
bolts removed earlier.

II. Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the cards with AC 80 kHz voltage.
On all cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to match fiber
plugs with socket labels, in accordance with the equipment Elementary Diagram.

III. Connect the power bus bars

Use the original bolts to connect the power terminals of the rectifier module to the DC bars.

IV. Connect the power cables

Use the original bolts to connect the power terminals of the rectifier module to the AC input line cables.

111
6. Parts Replacement
6.1.3. Water cooled inverter power module
The water cooled inverter power module must be removed according to the following procedure:
I. Disconnect the cooling circuit
Push the head of the first valve and, by applying an axial pull force, remove it from the pipe connecting such
valve to the heatsink (see drawing below).
Repeat the procedure for the second valve and remove all the coolant from the heat sink; be careful to avoid
spilling it on the nearby electronic devices (especially gate firing cards and IGBTs)

II. Disconnect the power bus bars

Remove the bolts that connect the power terminals of the inverter module both to the DC bars and to the output AC bar.

III. Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect from terminal block X02 the twisted cable that supplies the gate firing cards with AC voltage.
On all gate firing cards, unplug the optic fibers from the relevant sockets (RC and TR on the board).

IV. Remove the inverter module

Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.

The new water cooled inverter power module must be installed according to the following procedure:
I. Insert the inverter phase module
Slide the module along the metal rails on the support board up to the right position and fasten the mechanical
lock.

II. Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the gate firing cards with AC voltage to the terminal block X02.
On all gate firing cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to
match fiber plugs with socket labels, in accordance with the inverter equipment Elementary Diagram.

III. Connect the power bus bars

Use the original bolts to connect the power terminals of the inverter module both to the DC bars and to the output AC bar.

IV. Connect the cooling circuit

Insert the heat sink input and output pipes into the respective valves by pushing them in axial direction (see
drawing below).

Before reapplying voltage, make sure that no residual

 WARNING
humidity is still present.

112
6. Parts Replacement
6.1.4. Water cooled rectifier power modules
The water cooled rectifier power module must be removed according to the following procedure:

I. Disconnect the cooling circuit

Push the head of the first valve and, by applying an axial pull force, remove it from the pipe connecting such
valve to the heatsink (see drawing below).
Repeat the procedure for the second valve and remove all the coolant from the heat sink; be careful to avoid
spilling it on the nearby electronic devices (especially gate firing cards and IGBTs)

II. Disconnect the power bus bars

Remove the bolts that connect the power terminals of the rectifier module to the DC bars.

III. Disconnect the power cables

Remove the bolts that connect the power terminals of the rectifier module to the AC input line cables.

IV. Disconnect the optic fibers and cables supplying the gate firing cards
Disconnect the twisted cable that supplies the cards with AC 80 kHz voltage.
Unplug the optic fibers from the relevant sockets (RC and TR on the board).

V. Remove the rectifier module

Remove the bolts that fix the module to the chassy and remove the module by sliding it along the rails.

The new water cooled inverter power module must be installed according to the following procedure:
I. Insert the rectifier module
Slide the module along the rails on the support board up to the right position and fix the module by using the
bolts removed earlier.

II. Connect the optic fibers and cables supplying the gate firing cards
Connect the twisted cable that supplies the cards with AC 80 kHz voltage.
On all cards, plug the optic fibers into the relevant sockets (RC and TR on the board); make sure to match fiber
plugs with socket labels, in accordance with the equipment Elementary Diagram.

III. Connect the power bus bars

Use the original bolts to connect the power terminals of the rectifier module to the DC bars.

IV. Connect the power cables

Use the original bolts to connect the power terminals of the rectifier module to the AC input line cables.

V. Connect the cooling circuit

Insert the heat sink input and output pipes into the respective valves by pushing them in axial direction (see
drawing below).

Before reapplying voltage, make sure that no residual

 WARNING
humidity is still present.

113
6. Parts Replacement

6.2. Main Fans (Air cooled units only)

The fan must be removed according to the following procedure:

I. Disconnect the cable supplying the fan

Disconnect the power supply cable from the terminal block of the motor.
II. Remove the fan
Remove the 8 bolts that fix the fan to the cabinet and remove the fan.

The new fan must be installed according to the following procedure:

I. Place the fan
Place the fan above the cabinet and fix it by using the 8 bolts removed earlier.
II. Connect the cable supplying the fan
Reconnect the power supply cable to the terminal block of the motor.

6.3. Water Pumps (Water cooled units only)

See cooling system use and maintenance manual (P MP CA ATV E 2560)

6.4. Control Cards

All replacement operation must be done without power

 NOTE
supply.

6.4.1. INTVECM card

The INTVECM card must be removed according to the following procedure:
I. Disconnect the power supply from terminal board X1

II. Extract all connectors of current transducer and voltage transducer from terminal boards X2A, X2B, X3A, X3B and X7

III. Extract the flat cables from terminal board X4 and X6

IV. Remove the teflon nuts and remove the card

The new INTVECM card must be installed according to the following procedure:
I. Place the new card and remount the teflon nuts

II. Insert the flat cables into terminal board X4 and X6

III. Insert all connectors of current transducer and voltage transducer into terminal boards X2A, X2B, X3A, X3B and X7

IV. Reconnect the power supply into terminal board X1

6.4.2. ALIM card

The ALIM card must be removed according to the following procedure:
I. Remove the cover protection

II. Disconnect the power supply from terminal board X1

III. Extract the flat cables from terminal board X2

IV. Remove the spacers and remove the card

114
6. Parts Replacement
The new ALIM card must be installed according to the following procedure:

I. Place the new card and remount the spacers

II. Insert the flat cables into terminal board X2

III. Reconnect the power supply into terminal board X1

IV. Remount the cover protection

6.4.3. SUPRB card

The SUPRB card must be removed according to the following procedure:

I. Disconnect the profibus cable from 9 pin connector X1

II. Remove the screws that fix the card

III. Extract the card from the connector K4 on Scada plus card

The new INTVECM card must be installed according to the following procedure:
I. Place the new card into the connector K4 on Scada plus card

II. Remount the screws that fix the card

III. Reconnect the profibus cable into 9 pin connector X1

6.4.4. SCADA PLUS card

The SCADA PLUS card must be removed according to the following procedure:
I. Remove the SUPRB card

II. Extract the flat cables from terminal board K1 and K2

III. Extract the cable from terminal board X7

IV. Remove the terminal board

V. Remove the Teflon nuts

VI. Remove the card and disconnect the ground cables

The new SCADA PLUS card must be installed according to the following procedure:

I. Connect the ground cables, place tha card and fixt it by using the Teflon nuts

II. Place the terminal board

III. Insert the cable into terminal board X7

IV. Insert the flat cables into terminal board K1 and K2

V. Instal the SUPRB card

6.4.5. MODVEC-S card

The MODVEC-S card must be removed according to the following procedure:
I. Disconnect the power supply from terminal board X5

II. Extract the cable from terminal board X3

III. Extract the terminal board X7

IV. Extract the optic fibers

V. Extract the flat cables from terminal board X1 and X8 (only in 2 parallel bridge configuration)

VI. Extract the termination from terminal board X8 (only in single bridge configuration)

VII. Remove the teflon nuts and remove the card

115
6. Parts Replacement
The new MODVEC-S card must be installed according to the following procedure:

I. Place the new card and remount the teflon nuts

II. Insert the flat cables into terminal board X1 and X8 (or termination)

III. Insert the optic fibers

IV. Insert the terminal board X7

V. Insert the cable into terminal board X3

VI. Reconnect the power supply into terminal board X5

6.4.6. FOVECM card

The FOVECM card must be removed according to the following procedure:
I. Disconnect the power supply from terminal board X1

II. Extract the flat cable from terminal board X2

III. Extract the optic fibers

IV. Extract the termination from terminal board X3

V. Remove the teflon nuts and remove the card

The new FOVECM card must be installed according to the following procedure:
I. Place the new card and remount the teflon nuts

II. Insert the flat cable into terminal board X2

III. Insert the optic fibers

IV. Insert the termination into terminal board X3

V. Reconnect the power supply into terminal board X1

6.4.7. INTPREA card

The INTPREA card must be removed according to the following procedure:
I. Disconnect the power supply from terminal board XAL

II. Disconnect the cable from terminal board XIN

III. Disconnect the cable from terminal board XP1

IV. Extract the optic fibers

V. Remove the teflon nuts and remove the card

The new INTPREA card must be installed according to the following procedure:
I. Place the new card and remount the teflon nuts

II. Insert the cable into terminal board XP1

III. Insert the cable into terminal board XIN

IV. Insert the optic fibers

Reconnect the power supply into terminal board XAL

116
7. Spare Parts

7.1. POWER MODULES

7.1.1. Air Cooled Inverter Power Modules
Part Number Module identification Description

Power module of Silcovert-TN 3300 V -

1000085357 MOD ATV 1K3 A33 H
1300 kVA air cooled

Power module of Silcovert-TN 3300 V -

1000085340 MOD ATV 1K8 A33 H
1800 kVA air cooled

Power module of Silcovert-TN 3300 V -

1000082406 MOD ATV 2K6 A33 M
2600 kVA air cooled

7.1.2. Air Cooled Rectifier Power Modules

Part Number Module identification Description

Rectifier module for 12 pulses

1000092503 RAD ATV 550 A33 12P
configuration 550 A air cooled

Rectifier module for 24 pulses

1000090505 RAD ATV 550 A33 24P
configuration 550 A air cooled

Rectifier module for 12 pulses

1000093667 RAD ATV 1K1 A33 12P
configuration 1100 A air cooled

117
7. Spare Parts
7.1.3. Water Cooled Inverter Power Modules
Part Number Module identification Description

Power module of Silcovert-TN 3300 V -

1000091322 MOD ATV 1K6 W33 H
1600 kVA water cooled

Power module of Silcovert-TN 3300 V -

1000091324 MOD ATV 2K4 W33 H
2400 kVA water cooled

Power module of Silcovert-TN 3300 V -

1000082410 MOD ATV 3K6 W33 M
3600 kVA water cooled

7.1.4. Water Cooled Rectifier Power Modules

Part Number Module identification Description

Rectifier module for 12 pulses

1000089771 RAD ATV 750 W33 12P
configuration 750 A water cooled

Rectifier module for 24 pulses

1000091319 RAD ATV 750 W33 24P
configuration 750 A water cooled

Rectifier module for 12 pulses

1000090366 RAD ATV 2K2 W33 12P
configuration 2200 A water cooled

118
7. Spare Parts
7.2. TRANSDUCERS

7.2.1. Inverter Current Transducer

Part Number Description

ELP224763 TA – LEM 500/0,1 A (output inverter)

ELP223424 TA – LEM 1000/0,2 A (output inverter)

7.2.2. DC Voltage Transducer

Part Number Description

ELP231543 TV – LEM 3000 V/50 mA (DC bus voltage)

1000006462 TV assembly

7.2.3. AC Voltage Transducer (AFE configuration)

Part Number Description

ELP22760603 TV 4000 / 100:√3

7.2.4. Ground Fault Detector

Part Number Description

ELP219767 TV – LEM 20/100 mA – 12 kV

1000088782 Ground fault detector assembly

119
7. Spare Parts
7.3. POWER FUSES

7.3.1. Diode Front End 12 Pulse configuration Air Cooling – Incoming Line Fuses
Part Number Description
1000090036 ATV 1K3 A33 12P
1000084714 ATV 1K8 A33 12P
1000090033 ATV 2K6 A33 12P
1000090035 ATV 3K6 A33 12P
1000092697 ATV 5K2 A33 12P

7.3.2. Diode Front End 24 Pulse configuration Air Cooling – Incoming Line Fuses
Part Number Description
1000091831 ATV 1K3 A33 24P
1000091526 ATV 1K8 A33 24P
1000090036 ATV 2K6 A33 24P
1000084714 ATV 3K6 A33 24P
1000090033 ATV 5K2 A33 24P

7.3.3. Diode Front End 12 Pulse configuration Water Cooling – Incoming Line Fuses
Part Number Description
1000084714 ATV 1K6 A33 12P
1000091832 ATV 2K4 A33 12P
1000090035 ATV 3K6 A33 12P
1000092697 ATV 4K8 A33 12P
1000092698 ATV 7K2 A33 12P

7.3.4. Diode Front End 24 Pulse configuration Water Cooling – Incoming Line Fuses
Part Number Description
1000091833 ATV 1K6 A33 24P
1000090036 ATV 2K4 A33 24P
1000084714 ATV 3K6 A33 24P
1000091832 ATV 4K8 A33 24P
1000090035 ATV 7K2 A33 24P

7.3.5. ctive Front End configuration AC Line and Motor Fuses

Part Number Description
1000092955 ATV 3K6 W33 AFE
1000092955 ATV 7K2 W33 AFE

7.3.6. Active Front End configuration DC Connection Fuses

Part Number Description
Elp22962801 ATV 4K8 W33 AFE
Elp22962801 ATV 7K2 W33 AFE

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7. Spare Parts

7.4. Firing Cards AND Thermo Switch Interfaces

Part Number Description
1000089193 TGUNTNB M900 EXT card
1000089194 TGUNTNB M900 INT card
1000089191 TGUNTNB H600 EXT card
1000089192 TGUNTNB H600 INT card
1000089333 TALPTNA card
1000089332 TCPSA card
1000094288 TCPSB card
1000089331 TDIPRA card
1000001531 TRAPREC card
1000089717 TITOIA card
ELP264421 TALIMB card
1000094826 Precharge transformer (only AFE configuration)
ELP227941 Trasformer TRAL80

7.5. Precharge CIRCUIT (only for afe configuration)

Part Number Description
1000001531 TRAPREC card
1000094826 Precharge transformer
1000093106 Precharge Fuses

7.6. Control parts

Part Number Description
1000083311 Control Module for ATV 3300V – motor side – single configuration – DFE
1000083312 Control Module for ATV 3300V – motor side – 2 parallel configuration – DFE
1000096401 Control Module for ATV 3300V – motor side – single configuration – AFE
1000096402 Control Module for ATV 3300V – motor side – 2 parallel configuration – AFE
1000096394 Control Module for ATV 3300V – line side – single configuration
1000096396 Control Module for ATV 3300V – line side – 2 parallel configuration
1000091320 SCADA PLUS control card
ELC452614 SUPRB card
1000083291 MODVEC-S card
1000090364 FOVECM card
1000089394 INTPREA card
ELP26504301 INTSYNC card
1000090359 ALIM card
1000092912 INTVECM card for ATV 1K3 A33 / ATV 1K6 W33
1000092915 INTVECM card for ATV 1K8 A33 / ATV 2K4 W33
1000092928 INTVECM card for ATV 2K6 A33 / ATV 3K6 W33
1000092951 INTVECM card for ATV 3K6 A33 / ATV 4K8 W33
1000095826 INTVECM card for ATV 5K2 A33 / ATV 7K2 W33
ELP264898 XITOIA card
ELP26403901 XPTERA card
ELP221237 Alim 100 W
ELP226084 Alim 50 W
ELC481318 SVGTAFK – Advanced keypad
1000073029 Advanced keypad cable (2.5 m length)

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7. Spare Parts

7.7. PLC PARTS

Order code Description
1000086651 Rack 5 slot
1000086653 Power Supply 100/240 Vac 50/60 Hz
1000086654 CPU 350
1000094781 CPU 360
1000095593 CPU 366
1000098916 CPU 374
1000086655 Master Profibus Module
1000086656 Slave Profibus Module
1000086657 Slave Modbus Module
1000086658 Profibus Interface
1000086659 Digital Imput Module
1000086660 Digital Output Module
1000086663 Analog Output “ALG320” Module
1000086662 Analog Imput “ALG220” Module
1000086661 Analog Imput „ALG620“ Module
1000086678 Quickpanel view display 6”
1000091616 Quickpanel view display 12”

7.8. INVERTER OUTPUT REACTORS

Order code Description

1000087972 Output reactor for ATV 1K3 A33
1000087973 Output reactor for ATV 1K8 A33
1000087974 Output reactor for ATV 2K6 A33
1000087975 Output reactor for ATV 1K6 W33
1000087976 Output reactor for ATV 2K4 W33
1000087977 Output reactor for ATV 3K6 W33

7.9. FANS (Air Cooling Unit Only)

Order code Description

1000089129 Motor and Fan assembly – 50 Hz

1000089130 Motor and Fan assembly – 60 Hz

7.10. PUMPS (Water Cooling Unit Only)

See “Cooling System Use and Maintenance Manual” (P MP CA ATV E 2560).

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