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REVISION HISTORY
Rev. A Description Initial Release ERO/ECN # 056802
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9-1
TROUBLESHOOTING
SYMPTOMS AT OPERATOR'S CONTROL CONSOLE
The first indication of a malfunction will probably be noted at the Operator's Control Console. Status and Alarm lights in the Console provide information on system conditions. In addition, the operator will immediately be aware of abnormal response to his controlling actions. The symptoms as witnessed at the Control Console can be most useful as guides in identifying the specific cause of a malfunction. A number of such symptoms are listed below together with crossreferences to other sections in this manual where detailed explanations are presented.
NO RESPONSE TO A THROTTLE
If there is proper throttle signal input at TB3-15 is common) in the SCR cubicle, there is no problem in the Operator's Control Console. The SCR Control Module may be defective but before reaching this conclusion, verify that an Enable signal is present on one of the Enable inputs (120 VAC, AC1, at TB3-8, 9, 10 or 11). With Throttle and enable present, the SCR Control Module should function but other factors may still block DC output. See TROUBLESHOOTING SCR CONVERTER AND CONTROLS, in this Section.
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10399-75 Rev. A
9-2 NO RESPONSE TO A THROTTLE (Concluded) If throttle signal is not reaching TB3-15, there may be a break in the circuit to the Operator's Control Console or a malfunction in the Console. See OPERATOR'S CONTROL CONSOLE THROTTLE CIRCUITS, MANUAL AND FOOT (in Section 7) for Control Console circuit details. The throttle circuit from the Control Console also includes assignment switching as explained in THROTTLE SWITCHING (in Section 4). 4. There is a problem in SCR gating. If item 3 is responsible, the Power Limit indicating light will be illuminated. This means that the AC generating equipment on-line is being crowed to its limit. If another unit is available, it should be brought into service, if not, the problem may be relived by reducing power as much as possible to other loads. Problems with the SCR bridge are covered in TROUBLESHOOTING SCR CONVERTER AND CONTROL (in this section).
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9-3 its preset KW or KVAR limit. Setting of these limits is covered in METERING MODULE OPERATION AND CALIBRATION (in Section 2). Output of the Power Limit module causes a phase-back in the SCRs and thus limits the power and current they can draw. In this way, the AC generating units are protected from overloads that would cause damage or shutdown. The illuminated light indicates that the limit is functioning (see also SCR OUTPUT BELOW NORMAL, in this section) but does not necessitate any immediate operator response. Occasional illumination of this light is acceptable if it only occurs momentarily when a heavy load is started or changing speed. Prolonged illumination indicates that the engine/generator sets are being operated continuously very close to their absolute limits. Another generating unit should be brought on line to pick up part of the load. As noted in SCR OUTPUT BELOW NORMAL (in this section) there may be an undesirable DC power limitation when Power Limit is active. proper performance of major equipment. For example, failure of oil supply or cooling air can be disastrous. Alarm connection points are shown on logic diagrams, cubicle wiring schematics, auxiliary motor controllers, etc.
SCR ALARM
A SCR Alarm condition exists when the SCR-ON light is flashing. One of these for each SCR Cubicle is located on the Status Panel at the SCR Service Cubicle and another on the Operator's Control Console. This alarm indicates that an SCR fuse has blown or the SCR bridge has reached maximum, safe operating temperature. The blown fuse situation is covered in LOSS OF SCR OUTPUT (in this section). Overtemperature of the heatsinks in the SCR may be due to blower failure, obstruction in the path of the cooling air or build-up of foreign material on the heat sink surfaces. The condition must be rectified to prevent destruction of SCRs from excess temperature in the Silicon crystal.
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10399-75 Rev. A
9-4
1. Is a control input signal reaching the engine actuator? While cranking, there must be a DC signal, of proper polarity, and approximately full throttle level (the order of 10 volts) to force fuel injection. 2. If a control signal is present, is the actuator responding and moving the fuel rack to its open position? 3. If no actuator signal is present and one can be measured at the card rack (TBL24 & 25), check for AC signal from the magnetic Pick-up on the engine (TB2-26 & 27). With the engine at cranking speed, there must be at least 1.0 volt AC before the Governor module can deliver actuator signal. This AC can be read with a low range VOM test meter. 4. Confirm that there is no alarm light illuminated on the metering module. If an engine shutdown was initiated by an alarm condition, this alarm will remain latched until reset and will prevent engine starting. (See METERING MODULE AND RELATED ELEMENTS, in Section 2.) 5. If no Actuator Signal is developed with the foregoing conditions satisfied, the Governor module is probably defective. Before a final decision, confirm that proper battery power is reaching the card rack (TB 1-25, 26 & 27). An absolute minimum of 11 volts is necessary for each polarity. (See BATTERY OPERATIONS, in Section 2.) 6. Failure to start with Actuator Signal at the engine establishes that there is a problem in the fuel delivery system.
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9-5
1. Are proper connections made to the governor paralleling input at TB2-28 & 29 on the card rack? See GOVERNOR MODULE OPERATION AND CALIBRATION (in Section 2). 2. Is the load Gain Control on the card rack motherboard properly adjusted? Procedure for this adjustment is included in GOVERNOR MODULE OPERATION AND CALIBRATION (in Section 2). 3. If the preceding checks do not clear the problem, replace the Governor Module. If the new module does not eliminate the malfunction, replace the original module and proceed to 4. 4. Replace the Metering Module. An incorrect KW signal from this module to the Governor module through the motherboard would have the effect of misinforming the Governor on the power its generator was delivering. NOTE: Keep a detailed record of the changes made and the results. Any module returned to the factory for repair should be accompanied with a note describing the checks that lead to its replacement. This applies equally to all returns for repair.
IMPROPER LOADSHARING
A new engine/generator is brought on line by closing its Circuit Breaker when conditions are acceptable. This is done with the Engine Control Switch on the Governor module set at RUN. Very little load (KW) is picked-up at this point. The switch is then moved to LOAD, which should cause the new machine to assume its share of the total load, over a time interval of about 3 seconds. If it fails to do this, check the following:
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10399-75 Rev. A
9-6
An undervoltage alarm can also result from Regulator malfunction. However, the exciter field coils and wiring or the rectifiers in the brushless exciter may be responsible. See VOLTAGE REGULATOR OPERATION AND CALIBRATION (in Section 2). A reverse power alarm indicates that the generator that the generator failed to deliver power. This could be due to malfunction of the Governor Module or to a deficiency in full delivery to the engine. A reverse sequence alarm signals that a three-phase connection error exists in the cable to the generator. A-B-C phase sequence must be maintained throughout the AC switchgear.
TROUBLESHOOTING
10399-75 Rev. A
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9-7 4. With AC input to the Power Module, there should be DC output. If not, the module is defective. 5. If there is DC output, the problem is in the exciter or in the field leads to it. Field resistance varies between manufacturers but readings in the range 20-50 ohms are typical. Some fields are arranged in two circuits that permit series or parallel connection. All coils must be energized with one connection or the other. 6. If AC voltage cannot be obtained in step 3, read the generator bus voltage directly. This should be about 10% of the rated machine voltage. Absence of voltage indicates that a polarity reversal has been made in the DC leads to the exciter field. See "Voltage Build-up" in VOLTAGE REGULATOR OPERATION AND CALIBRATION (in Section 2).
2.
3.
VOLTAGE INSTABILITY
The Regulator should maintain a steady voltage level from the generator. With the generator operating at rated speed, there should be no fluctuation or oscillation in voltage reading. If this is not true, the Stability adjustment needs correction, using the procedure described in VOLTAGE REGULATOR OPERATION AND CALIBRATION (in Section 2). If there is erratic fluctuating of voltage, there may be a defective component in the regulator. Before replacing the Regulator module, check the battery input voltage at TB 1-25, 26 & 27. A level below 11 volts on either polarity can cause improper circuit response in the Regulator. See COMMON ELEMENTS POWER PATHS FROM THE BATTERIES, in Section 2.
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10399-75 Rev. A
9-8
7. Positions 7, 8 and 9 provide readout of essential operating voltages for the electronics. Any omission or significant departure in value of these will cause malfunction of the Control Module. The voltages are developed in the module from AC input by a small power transformer on the back of the assembly. 8. Positions 10, 11 and 12 do not give meter readout. The pulses can only be evaluated with a scope.
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9-9 GATING FAILURE If any SCR is not gated in proper sequence, its contribution to the DC output is lost. Full DC voltage cannot be obtained and the regular ripple pattern will be broken. A scope is needed to view the bridge output to confirm the gating failure and to identify the SCR involved. The abnormal fluctuation in output voltage leads to rough motor operation that can be detected in the area near the motor. Gating failure may be caused by: 1. Failure of a Hard Fire Circuit. 2. Omission of a pulse or pulses from the Control Module. This may be caused by loss of a Sensing Voltage input or by a circuit component failure in the Control Module. 3. Break in the gate lead. 4. Open gate in an SCR. visual inspection, a small pin projects from the switch on a blown device. Fuses can be replaced without removing the bridge phase cells. Before replacing them, the reason for blowing should be determined. A possible short circuit on DC motor leads or electrical breakdown within the motor should be checked. If a motor is stalled and cannot start, this could also be responsible. SCR failure also results in fuse blowing, as covered in SCR FAILURE (in this section). The SCRs should always be checked before new fuses are installed.
SCR FAILURE
SCRs usually fail by short-circuiting. This results in one or more short-circuits across the AC input and the blowing of fuses. Voltage spikes and overheating are the principal reasons for SCR failure. IF a snubber (dV/dt) network opens, its spike protection action is lost and its associated SCR is in jeopardy. See SNUBBER CIRCUITS (dV/dt) CIRCUITS (in Section 3). When SCRs need replacement, the snubber circuits must be checked and placed in good order. A damaged SCR can only be identified by resistance measurement. Opening of the DC positive and negative buses to a phase cell isolates the SCRs for checking. Any ohmic reading, other than virtual open circuits with both polarities, makes the device a suspect.
LOW DC OUTPUT
This subject is covered generally in SCR POWER OUTPUT BELOW NORMAL (in this section) but one additional point requires note. A malfunction in the Regulator Board that affects FRV output could be responsible. If the FRV range from 7.5 to zero, volts are not available due to electronics circuit failure; the bridge output will be restricted. FRV range and performance can be measured at the Test Panel on SW. position 5.
BLOWN FUSE
See also LOSS OF SCR OUTPUT (in this section). Complete loss of DC power and an SCR Alarm indicates is evidence of a blown fuse on the SCR bridge. The specific fuse or fuses affected can be identified by
SCR DRIVE SYSTEM TECHNICAL MANUAL TROUBLESHOOTING
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10399-75 Rev. A
9-10
Stage 1 is completed when contactors 12+ and 12- are closed to complete the DC power path. This is always the first requirement. (Item 8 in LOAD ASSIGNMENT THE NECESSARY CONDITIONS, in Section 4) Stage 2 is completed when the NO contact on 12+ in the path around the throttle switch is closed to bypass the switch. (Item 10, 133-12) Stage 3 is completed when the NO switch on 12-, shown above the contactor bridge, closes to Enable the SCR Control Module. (Item 9 in LOAD ASSIGNMENT THE NECESSARY CONDITIONS, in Section 4) An essential fourth stage is omitted in LOAD ASSIGNMENT THE NECESSARY CONDITIONS (in Section 4) for simplification but is covered separately in THROTTLE SWITCHING (in Section 4). The throttle must be "assigned" to the SCR being used. Each symptom of malfunction can be related directly to a stage but the actual problem may exist in a preceding stage that did not complete all of its functions. Much time can be saved by identifying, on the diagrams, the switching or other control action that advances the logic process from stage to stage. Absence of proper input for a stage blocks its action, but the problem lies somewhere in the operations that must precede. Systematic backtracking of circuits from the point of apparent malfunction will quickly lead to the true source of trouble.
TROUBLESHOOTING
10399-75 Rev. A
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9-11
EXAMPLE
The case covered briefly in COMPLETE SHUTDOWN OF SCR SYSTEM (in this section), "No Response to Throttle" can be used as an example of troubleshooting procedure. There are a number of things that could cause the response disability; the challenge is to identify, in the most direct manner, the one item at fault. 1. If throttle signal is not reaching the SCR control Module, there can be no response. A reading of throttle signal at the cubicle (Position 1 on Test Switch) is a logical first step. 2. If proper signal is present, there is no problem in the entire throttle circuit. The next step is to check the items in COMPLETE SHUTDOWN OF SCR SYSTEM (in this section). Note that one measurement has greatly narrowed the area for further checking. 3. If throttle signal is not present at the SCR cubicle, the next check should be made at the operator's Control Console. Disconnect the outgoing throttle connection at the TB and measure, at the TB terminals, the signal from the Console Throttle circuitry. If no signal is present, the problem lies in the console, the throttle itself, the Reference Voltage source or other element. In systems that use a Safety Relay, this device may be responsible.
4. If throttle signal is present in item 3, the problem must lie in the cable to the SCR cubicle or in the throttle assignment switching at the cubicle or in its wiring. Cable checking is a routine type undertaking. 5. With a two step procedure, the problem has been reduced to tracing the throttle signal paths through switches in the SCR cubicle. Auxiliary switches involved respond to contactor closing or opening so the contactors must be located and checked for proper operation. The throttle switching function stage cannot be completed if the preceding stage functions are incomplete. Possible failure of an auxiliary switch must not be overlooked. The Logic diagrams provide guidance in this tracing process but the required sequence of operations is an inseparable factor.
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10399-75 Rev. A
9-12
TROUBLESHOOTING
10399-75 Rev. A
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