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HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Introduction
This is the instruction manual for medium voltage direct inverter(HIVECTOL-E), <Part 1> Trouble shooting
guide.
<Part 1> describes how to investigate and repair any troubles. Since quick and appropriate
repairmen is required at a trouble occurrence, the composition of <Part 1> is centered on procedure flow
according to phenomena. Therefore not include operating principle, hardware specifications, etc., for which
please refer to relevant parts given hereunder.
Some trouble repairing works involve human safety items. Before the work, be sure to read through safety
precautions given on subsequent pages.

Readers intended for


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

Composition of HIVECTOL-HVI-E instruction manual


The composition of this manual is shown hereunder.
Part 1 Trouble shooting guide
The troubleshooting guide describes the procedure used to determine the seriousness of failure from various
situations, as well as how to reset the device or investigate failure causes.
So, when this product experiences problems, please refer to this part 1.
This first part also includes excerpts of the contents of parts 2 and 3. For details of maintenance and
maintenance tools, please refer to the second and third parts.
Part 2 Maintenance Tool (hereinafter referred to as M.TOOL)
M.TOOL refers to communication with the control board using the PC (M.TOOL). The part 2 describes the
procedures for control setting and collecting the trace back data, etc.
Part 3 Hardware Specifications and Maintenance
The part 3 describes the hardware specifications, appearance, and structure of the Direct Inverter. It also
describes maintenance methods, such as part replacement.

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Precautions for safety


For correct run, maintenance or checkup, carefully read the entire instruction manual and related literature
beforehand. Familiarize yourself with all device knowledge, safety information and precautions prior to
operation. Indications of danger, warning and caution underline dangerous and important information.

CAUTION

The main circuit voltage of 3000V11000V AC is applied in the panel. Do not get in nor
put any foreign matter in nor get a part of your body, rod or others near the panel when the main
circuit is energized.
In the panel, there are smoothing electrolytic capacitors and, even after turning off the main
circuit, a voltage may remain. Make it a rule to touch the electric circuitry only after checking
yourself whether any potential is present or not. Do the check by the galvanoscope after turning
off the LED display of the cell inverter.
Do not use the spare items other than our recommendation when replacing a part. Operation
when an equivalent function items other than recommendation are used is not guaranteed.
For avoiding electric shock, a protective cover is mounted on the high voltage section.
Do not remove the protective cover while the voltage is applied.
(There is no protective cover about the hanging door type. )
Before turning on, put in place the protective cover if removed for maintenance, etc.
(There is no protective cover about the hanging door type. )
Weight of cell inverter is 28kg. Be careful enough not to fall.
Be sure to use lifter of exclusive use for desertion of cell inverter.
Since it is dangerous, do not perform supporting directly by hands by any means.

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

CONTENTS
1. Outline of trouble shooting

1-1

2. Trouble code list

1-3

2.1 Graphic Panel Display Function

1-3

2.2 Failure display screen

1-4

2.3 Factor of major / Alarm display screen

1-4

2.4 Major fault factor codes

1-5

2.5 Alarm factor

1-7

2.6 Control circuit PCB abnormal factor

1-8

2.7 Cell inverter fault factor

1-9

2.8 Others

1-10

2.9 Interlock factor

1-11

3. LED display of each PCB

1-12

3.1 Control PCB (HVS026)

1-12

3.2 Driver interface PCB (HVS026)

1-13

4. Trouble shooting by fault factors

1-14

4.1 Major fault trouble shooting

1-15

4.2 Other faults

1-33

4.2.1 Light fault

1-33

4.2.2 Control PCB abnormal

1-34

4.2.3 Controller power source abnormal

1-35

4.3 Interlock factor

1-36

4.3.1 CONNECTOR NOT INSERTED

1-36

4.3.2 MAIN CIRCUIT BREAKER OFF

1-36

4.3.3 I/F ABNORMAL

1-36

4.3.4 MAJOR FAULT

1-36

4.3.5 HV CUB MAJOR FAULT

1-36

4.3.6 EMERGENCY STOP

1-36

4.3.7 MOTOR COOLING FAN STOP

1-36

4.3.8 MOTOR RUNNING

1-36

4.4 Supplemental documented procedures


4.4.1 Relay input and output identification procedure

1-37
1-37

HIVECTOL-HVI-E

5. How to get trace-back data

Part 1 Trouble shooting guide

1-39

5.1 Starting of maintenance tool

1-39

5.2 Invoking Trace-back Command

1-41

5.3 Sampling Trace-back Data

1-42

5.3.1 Trace-back data acquiring

1-42

5.3.2 Forced logging data acquiring

1-46

5.4 Numerical display

1-47

5.5 Trend Display

1-53

5.6 Fault Factor Display

1-56

5.7 Cell Inverter fault factor

1-59

6. DETAILS OF VARIOUS CHECK ITEMS


6.1 IGBT Soundness Check

1-62
1-62

6.1.1 Property of IGBT

1-62

6.1.2 Soundness check method

1-62

6.2 CT Output Check

1-63

6.3 Optical Cable Identification Train

1-64

6.3.1 Wiring Composition of Optical Cable

1-64

6.3.2 Composition of Optical Communication

1-65

6.3.3 Optical cable identification procedure

1-66

7. Cell inverter exchanging procedure

1-68

7.1 Detaching of hanging door

1-68

7.2 Detaching of cell inverter

1-68

7.3 Drawer of Cell Inverter

1-69

7.4 Repair work

1-69

8. Replacing the control PCB

1-70

8.1 Replacing the Control PCB

1-70

8.2 Loading method of software and control constant

1-71

8.3 Setup of VR and DIP SW

1-77

8.3.1 Setup of DIP SW

1-77

9. Parts replacing procedure

1-78

9.1 Fuse

1-78

9.2 Current detector

1-79

10. Other notes


10.1 Fault reset method

1-80
1-80

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

1. Outline of trouble shooting


If a trouble has occurred, it is important to locate and remedy it for preventing its recurrence.
However, device recovery and facility startup take precedence often.
There are different trouble circumstances.
(1) So fatal that parts must be replaced
(2) Resetting the trouble allows a recovery but, for locating it, measuring instrument, etc. must be
connected
(3) The cause is distinct and just resetting the trouble allows a recovery
(4) So slight that the run can be pursued without trouble reset
They are remedied by particular methods.
The present manual includes procedures of judging the seriousness from the circumstances of trouble
occurrence and restoring the devices or locating the trouble.
The procedure is outlined in Fig. 1.1.

1-1

HIVECTOL-HVI-E

<Symptom >

Part 1 Trouble shooting guide

<Remedy >

Trouble
occurrence

By display on HIVECTOLHVI-E panel, check the fault


factor indication

Judge the fault cause


Referring to trouble shooting of
corresponding code, investigate and
restore. Parts may have to be replaced.

YES

Major fault?
NO

(Light fault)

Judge whether caused by high


rank system or HIVECTOL

Check the operating


conditions and eliminate the
factor

YES

System factor?
NO

Acquire trace-back data and

If factor cannot be located,


check the condition of panel
inside parts by sequence.

record the run conditions and


notify them to us

Electrolytic capacitors are installed in main circuit


and potential may remain. After high voltage power
supply cutting, 10 minutes should pass, and work
after checking that the LED display in a Cell Inverter
has gone out.

After reset

You are requested to send us trouble


conditions and trace-back data

Fig. 1.1 Processing flow at trouble occurrence

1-2

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2. Trouble code list


The graphic panel on the control The graphic panel on the unit surface has a function that displays not
only commands and feedback but also factors for failure.
This section describes such failure factors.

2.1 Graphic Panel Display Function


As shown in Figure 2.1, the graphic panel (hereinafter referred to as the GP), mounted on the control
panel has a function to display not only the operation conditions, such as the motor speed, but also the
factors for failure and the causes for turning OFF the main circuit.
Action for failure begins with checking the displayed items on the GP. In order to take prompt action,
therefore, it is necessary to fully understand the display function of the GP. This section describes the GP
display function, particularly focusing on the displayed items to be checked when failure occurs and when
the operation restarts. (For details of the GP display function and operation method, please refer to Part2
Maintenance Tool.)
In case of failure, the screen will be automatically switched to the failure display screen, as shown in
Figure 2.1. (This automatic screen switching function is designed to display the factors for serious failures
taking precedence over those considered minor when they occur at the same time.) * Figure 2.1 shows the
structure of the 3.3 kV unit.

Reset switch

Number of factors

Switch for
turn a page
Display of
details of faults

Graphic Panel

Switch that displays details of faults

Emergency Stop(PBS)

Inverter Panel
Control Panel

Fig.2.1

Installation location of GP and the failure display

1-3

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.2 Failure display screen


Figure 2.2 is the failure screen. The change from the failure display screen to the failure display screen
has the following condition.
(1)Manual change by pushing FAULT" switch on watch display screen
(2)Automatic change due to a major fault
(3)Automatic change due to a Alarm fault(Note)
(Note) The setting of the control constant decides
whether to display the failure display screen
automatically at an Alarm occurrence.
The setting of an automatic change is the following constant.
Refer to the record of the trial run for a set value.
V/00C0038_#Bit2
1 : Automatic change ON 2: Automatic change OFF

Switch that displays details of faults


Figure2.2 Monitoring display screenSample

2.3 Factor of major / Alarm display screen


The factor of the major fault and the Alarm is displayed at the center of the screen.
The generated failure name is displayed on the screen.The failure name that the number attaches to the
head of the name is a major fault.
(For instance,(1)OVERCURRENT)
In similar the Alarm is attached (AL).
(For instance ,(AL)SPEED REF VALUE ERROR(2mA))
The number in () of a major fault shows the order of faults occurring. The displayed factor is different
according to facilities.
Refer to the completion drawing of the delivery equipment for details of the factor name.
Reset switch

Number of factors

Switch for
turn a page

Display of
details of faults

Switch that displays details of faults


Figure2.3 Factor of major / Alarm display screen

1-4

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.4 Major fault factor codes


Table 2.1 gives fault factor codes indicated at major trouble occurrences with details of troubles.
The trouble respectability refers to whether just resetting recovers from trouble or not.
For further details of respective troubles, refer to "4. Trouble shooting by fault factors".
Table 2.4 Major fault factor
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Fault message
START FAILURE
CTL POWER DROP
OVERCURRENT(SOFT)
OVERCURRENT(HARD)
OVERVOLTAGE
OVERLOAD
MAIN CIRCUIT POWER DROP
CONNECTOR NOT INSERTED
AC VOLTAGE ABNORMAL
AC CURRENT ABNORMAL
GROUND DETECTED
INV COOLING FAN STOP
TR COOLING FAN STOP TD

Contents
The start failed.
The AVR power supply for the control substrate has decreased.
The current that exceeded the maximum rating of the electric motor flowed.
The current that exceeded the maximum rating of the inverter device flowed.
The voltage of the motor exceeded the over voltage level.
The current that exceeded the rated load flowed to the motor for 1 minute or more.
The input voltage has decreased.
The connector of each PCB has the uninsertion connector.
The voltage detecting circuit did not function correctly.
The current detection circuit did not function correctly.
One phase of either of the three-phase circuit output did earth fault.
When the inverter board cooler fan drove, the inverter device stopped.
The transformer cooling fan stops when the VFD drives, and set time has passed.

CUBICLE OVERHEAT(>60)
TRANSFORMER OVERHEAT
U PHASE CELL FAULT
V PHASE CELL FAULT
W PHASE CELL FAULT
U PHASE SERIAL SIGNAL DOWN
V PHASE SERIAL SIGNAL DOWN
W PHASE SERIAL SIGNAL DOWN

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


The winding temperature of a multiple transformer exceeded the trip setting value.
The failure occurred by the U phase cell inverter.
The failure occurred by the V phase cell inverter.
The failure occurred by the W phase cell inverter.
Optical serial communications of U phase detected abnormality (disconnection) .
Optical serial communications of V phase detected abnormality (disconnection) .
Optical serial communications of W phase detected abnormality (disconnection) .
The driver interface substrate of U phase did not function correctly.
The driver interface substrate of V phase did not function correctly.
The driver interface substrate of W phase did not function correctly.

U PHASE DRV IF FAULT


V PHASE DRV IF FAULT
W PHASE DRV IF FAULT

1-5

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

When major faults have occurred, from the first to the third fault factors can chronologically be displayed.
Fault factors are sampled every 60ms and faults produced within 60ms are regarded as occurring
simultaneously. For example, if 2 faults have occurred within first 60ms, both of them are handled as the
first fault factors and if, within next 60ms, 2 faults have further occurred, the 2 constitutes the second fault
factors. The second and the third faults are separated only if they are at least 60ms apart. For example, if
a fault has occurred 1 second after the first fault, the former is handled as the second fault and all faults
which occur at least 60ms thereafter are handled as the third faults.
(See Fig. 2.4.1)
60ms
Trouble
occurrence

60ms

The first fault factor

60ms

The third fault factor

The second fault factor

1sec

Fig. 2.4.1 Time series of fault factors


The error code consists of number which indicates the time series and sequential number in the order of
occurrence within the same time zone.
For example, if a our put over current(soft detection) occurred first, U1 cell inverter fault occurred the
after (60 ms more) and, 60 ms further later, Out put Power abnormal occurred, the indication will be:
Reset switch

Number of factors

Switch for
turn a page

Display of
details of faults

Switch that displays details of faults


Figure2.4.2 Factor of major / Alarm display screen
The fault indication remains even after eliminating the cause.
For the method of clearing the major fault indication, refer to "10.1 How to clear the error display".

1-6

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.5 Alarm factor


Fig. 2.5 shows display screen at the time of alarm occurrence, and Table 2.5 shows fault factor and
contents of light fault. Trip does not carry out only by Alarm notifying fault.
However, "over load 1" and "motor cooling fan stop" serve as major fault by predetermined time
continuation. When you display fault factor display screen at the time of Alarm occurrencePush "fault"
switch under each screen.

Reset switch

Number of factors

Switch for
turn a page

Display of
details of faults

Switch that displays details of faults


Figure2.5 Factor of major / Alarm display screen
Fig. 2.5 Alarm factor display screen
No.
1
2
3
4
5
6
7
8

Fault message
(ALARM)OVERLOAD RUNNING
(ALARM)SPEED REF VALUE ERROR(<2mA)
(ALARM)TR COOLING FAN STOP

Contents
Load of motor exceeds rated one.
The speed command signal(4-20mA) became 2mA or less.
When driving, the transformer panel cooling fan stopped.

(ALARM)CUBICLE OVERHEAT(>55)
(ALARM)TRANSFORMER OVERHEAT
(ALARM)MOTOR OVERHEAT
(ALARM)INV COOLING FAN STOP

The contact at the temperature detection (55) in the cubicle operated.


The winding temperature of a transformer exceeded the warning setting value.
The winding temperature of a motor exceeded the warning setting value.
When driving, the inverter panels cooling fan stopped.

(Note 2.5)
It becomes abnormalities when motor primary current integral value(KII4t)exceeds predetermined level.
For example, if motors of 150% 1min are operated at 150% and 30 sec over when detection level is
50%,failure will occur.

1-7

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.6 Control circuit PCB abnormal factor


Figure 2.6 is a display screen of the control circuit PCB abnormal.
Control circuit PCB's abnormality has the case to happen by chance as various conditions come in
succession and the case which breaks down due to single defects of parts. It is necessary to exchange the
control circuit PCB when relapsing even if it is GR(General Reset).
Refer to "8.1 exchange procedure of control circuit PCB" for details.
Table 2.6 shows details of a control circuit PCB abnormal code.

Fig. 2.6 Control circuit PCB abnormal display screen


Table 2.6 Control circuit PCB abnormal code
No.

Fault code

Contents

0001

WDT (watch dock timer) occurred.

0002

General unjust (Invalid) command was executed.

0004

Slot unjust (slot error) command was executed.

0008

CPU address error occurred.

0010

DMAC/DT C address error occurred.

0020

Overflow occurred in the stack.

0040

CRC error occurred.

1-8

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.7 Cell inverter fault factor


Fig. 2.7 .3 is the screen which displays the contents of a fault factor of a cell inverter.
When cell inverter fault occurs, the contents of a fault factor generated within the cell inverter unit can be
displayed. The fault factor code displayed on Table 2.7.1 at the time of cell inverter fault generating and
its contents of fault are shown. This screen is displayed by choosing a cell inverter displaying a fault
factor from the cell inverter information screen of Fig. 2.7.2. The cell inverter fault factor display method
is shown below.
Push "cell information" switch in screen lower part of display of face of a board (as for "cell
information" switch, only fault factor display screen is displayed).
Display of face of a board changes to cell inverter information screen of Fig. 2.7.1 by operation of
If "cell inverter selection switch" is pushed, it will change to cell inverter fault factor screen of Fig.
2.7.3 automatically.

Phase select switch

Cell No. Select switch

Figure 2.7.1 Phase select screen (Detail of fault)

Figure 2.7.2 - Phase cell No. select screen

Switch for turn a page


Display of details of faults
Number of factors

Fig. 2.7.3 Cell inverter information screen

Switch for turn a page


(Cell inverters in the back and
forth is displayed.)

Table 2.7 Cell inverter fault factor


No.
1
2

Fault message
DC OVERVOLTAGE
CELL CONTROL POWER DOWN

Contents
The DC voltage exceeded the over voltage level.
The input voltage of the DRVIF PCB has decreased.

1-9

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.8 Others
When the control circuit PCB is an off-line
mode, Figure 2.8 is displayed.
It is displayed, when control software is nonloading or DIPSW of a control PCB is an offline mode setup.

Fig. 2.7 Off-line mode screen

1-10

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

2.9 Interlock factor


The motor might not be able to be driven though it is not a fault.
In this case, investigate the factor referring to the interlock display screen in Figure 2.9, because there is a
possibility that the interlock is not complete. Interlock factor is shown in Table 2.9.

Switch for turn a page

Display of details of faults


Number of factors

Fig. 2.9 Interlock display screen

Table2.9 Interlock factor


No.

Signal name

Contents

MAJOR FAULT

Major fault factor has not been removed.

EMERGENCY STOP

Emergency stop is operated.

ALARM

Alarm fault factor has not been removed.

CONNECTOR NOT INSERTED

Non-inserted connector exists in connector of control PCB

PROCESS INTERLOCK FAILURE

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

MOTOR INTERLOCK FAILURE


MOTOR RUNNING
AC415V POWER DOWN

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


Motor is not stopped.

7
8

Auxiliary power (AC415V) is not a normal

1-11

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

3. LED display of each PCB


On PCB, LED and check terminal for checking operating state are mounted.
LED, mounting location of check terminal, and the contents of display are explained below.

3.1 Control PCB (HVS026)


MPU and the peripheral circuitry of it are mounted so that the control PCB may variously control
the inverter. Refer to 3 part (Hardware Specifications and Maintenance)for details.
Figure 3.1 shows the installation position of control PCB from the component placement of control PCB
and the externals structure of the control panel. This figure is used to confirm the LED display on PCB.
Table 3.1 shows the meaning of the LED display.

LED
P48

Control panel
(Door open)

Control PCB (HVS026)


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

Table 3.1 Display on control circuit PCB


LED display
Device
LD1
LD2
LD3
LD4
LD5
LD6

T he contents of display

PLC interface normal


CT L PCB normal
WDT error
Initial normalcy
Pulse output state
DI pulse source normal

color
Green
Green
Red
Green
Green
Green

Check terminal
Device
T P1
T P2
T P3
T P4

1-12

Maker use
Maker use
Maker use
Maker use

Contents

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

3.2 Driver interface PCB (HVS750)


Driver interface PCB is PCB that consolidated the function of interface PCB, driver PCB, and power
supply stabilization PCB. Refer to 3 part (Hardware Specifications and Maintenance)for details. Figure
3.2.1 shows the part arrangement of the driver interface PCB. Figure 3.2.2 shows the installation position
of the driver interface PCB from externals.

Driver interface PCB

Figure 3.2.1 Part arrangement of the driver interface PCB


Table 3.2.2 Display on control circuit PCB
LED display
Device
LD1
LD2
LD3
LD4

T he contents of display

color

Pulse generating state


Main circuit capacitor charge condition
Error condition
Power source normal condition

Green
Red
Red
Green

1-13

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

4. Trouble shooting by fault factors


The following explains the investigating and restoring procedure by error codes.
At trouble shooting, be sure to observe the precautions stated below

Danger
Before investigating, checking or replacing the parts, turn off
power and check for presence of potential. Otherwise, there might be
an electric shock.
For any investigation, do not touch the panel interior with main
power ON.
Cell inverter unit has the following weight. When replacing the
unit, use the furnished lifter. Otherwise, you might get injured by tip
over or drop.

Caution
When locating a trouble, get trace-back data first, which contains an important
information for it. To cope with any necessity of replacing parts or circuit PCBs,
prepare required tools beforehand.
Some parts are mounted in locations where working space is hard to secure
and it is necessary to check beforehand whether the work is possible with
available tools or not.

1-14

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

4.1 Major fault trouble shooting


When major failure occurs, from table, check fault No. corresponding to fault factor displayed on display
panel, and eliminate fault factor according to correspondence chart.
Note: Failure analysis must be performed based on the trace back data. In case of major failure, therefore,
the trace back data must be collected first. (For collecting the trace back data, see Section 5.) After
collecting the data, eliminate the failure factors according to the failure number chart.
Table 4.1.1 Major fault factor
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Fault message
START FAILURE
CTL POWER DROP
OVERCURRENT(SOFT)
OVERCURRENT(HARD)
OVERVOLTAGE
OVERLOAD
MAIN CIRCUIT POWER DROP
CONNECTOR NOT INSERTED
AC VOLTAGE ABNORMAL
AC CURRENT ABNORMAL
GROUND DETECTED
INV COOLING FAN STOP
TR COOLING FAN STOP TD
CUBICLE OVERHEAT(>60)
TRANSFORMER OVERHEAT
U PHASE CELL FAULT
V PHASE CELL FAULT
W PHASE CELL FAULT
U PHASE SIRIAL SIGNAL DOWN
V PHASE SIRIAL SIGNAL DOWN
W PHASE SIRIAL SIGNAL DOWN
U PHASE DRVIF FAULT
V PHASE DRVIF FAULT
W PHASE DRVIF FAULT

Contents
Detail factor
The start failed
Note1
The AVR power supply for the control substrate has decreased.
Note2
The current that exceeded the maximum rating of the electric motor flowed.
H1
The current that exceeded the maximum rating of the inverter device flowed.
H1
The voltage of the motor exceeded the over voltage level.
H2
The current that exceeded the rated load flowed to the motor for 1 minute or more.
H3
The input voltage has decreased.
H4
The connector of each PCB has the uninsertion connector.
H5
The voltage detecting circuit did not function correctly.
H6
The current detection circuit did not function correctly.
H7
One phase of either of the three-phase circuit output did earth fault.
H8
When the inverter board cooler fan drove, the inverter device stopped.
H9
The transformer cooling fan stops when the VSD drives, and set time has passed.
H9
H10
The contact at the temperature detection (60) in the cubicle operated.
The winding temperature of a multiple transformer exceeded the trip setting value.
H11
The failure occurred by the U phase cell inverter.
Note3
The failure occurred by the V phase cell inverter.
Note3
The failure occurred by the W phase cell inverter.
Note3
Optical serial communications of U phase detected abnormality (disconnection) .
H12
Optical serial communications of V phase detected abnormality (disconnection) .
H12
Optical serial communications of W phase detected abnormality (disconnection) .
H12
The driver interface substrate of U phase did not function correctly.
H13
The driver interface substrate of V phase did not function correctly.
H13
The driver interface substrate of W phase did not function correctly.
H13
Note 1. Refer to table 4.1.2(Start fault factor).
Note 2. Refer to table 4.2.3(Light fault).
Note 3. Refer to table 4.1.3(Cell inverter Start fault factor).

Table 4.1.2 Start fault factor


No.
1
2
3
4
5
6
7
8

Fault message
U PHASE SIRIAL SIGNAL DOWN
V PHASE SIRIAL SIGNAL DOWN
W PHASE SIRIAL SIGNAL DOWN
U PHASE CELL NO. SETTING ERROR
V PHASE CELL NO. SETTING ERROR
W PHASE CELL NO. SETTING ERROR
PRECHARGING BUSY
MAIN CIRCUIT BREAKER ABNORMAL

Contents
It was in the state of the optical cable disconnection of U phase.
It was in the state of the optical cable disconnection of V phase.
It was in the state of the optical cable disconnection of W phase.
The U-phase cell number was not set correctly.
The V-phase cell number was not set correctly.
The W-phase cell number was not set correctly.
Optical transmission did not function correctly within a set time.
The circuit breaker was not closed by the close command.

Detail factor
H12
H12
H12
H16
H16
H16
H17
-

Table 4.1.3 Cell inverter Start fault factor


No.
1
2

Fault message
DC OVERVOLTAGE
CELL CONTROL POWER DOWN

Contents
The DC voltage exceeded the over voltage level.
The input voltage of the DRVIF PCB has decreased.

1-15

Detail factor
H14
H15

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H1

OVERCURRENT(HARD)
OVERCURRENT(SOFT)

GP
display

Display screen
Fault factor display

Detector composition
Over current detection detects output voltage of current detector connected between inverter and motor with
comparator of soft and hard circuit in control PCB as compared with over current level.
HCTU

HVS026

CTL

INV

AI

IM
HCTW

CMP

Soft detection
Major fault stop
Fault display

OC level

Hard detection
CP

DI

Hard current level

HCTU
HCTW
CTL

U phase current detector


W phase current detector
Control PCB

Major fault stop


Fault display

<< soft circuit >>


<< hard circuit >>

Main causality of fault


(1) IGBT fault of cell inverter
(2)

Fault of DC detector (HCTU, HCTW)

(3)

Incorrect setup of over current level

(4)

Fault of fault detector

(5)

Fault of works system


The contents of enquiry

!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage enquiry of current detector (Is it sine wave or isn't there any offset? )Refer to terms 6.2.
(3) Set point enquiry of over current Set point should check test run account. )
over current setup(hard)

V/00C00380 1mV

over current setup(hard)

V/00C00094 5%

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

1-16

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H2
GP
display

Display screen

OVERVOLTAGE(SOFT)

Fault factor display

Detector composition
Output over voltage carries out AI of the output voltage FB to control PCB, and compares and detects motor
primary voltage FB and output over voltage level which were calculated by soft circuit.

CTL

HVS026

PTUV

INV

CMP

IM

Major fault
stop
Fault display

PTVW
Detection level

AI
V1
arithmetic

FLT

AI
CTL
FLT
PTUV
PTVW

<< soft circuit >>

Control PCB
Filter
Voltage detector UV(PT)
Voltage detector VW(PT)

Main causality of fault


(1) Fluctuation of receiving voltage
(2) Direct current voltage upsurge by regeneration motion
(3) Fault of voltage detector
(4) Fault of cell inverter
(5) Incorrect setup of output over voltage level

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage identification of voltage detector
(3) Soundness check of IGBT Refer to 6.1 terms.
(4) Set point enquiry of output voltage abnormal detection level Set point should check test run report.
Soft circuit setup For setup VRAMV/C001FC1%+100%

1-17

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H3
GP
display

Display screen

OVERLOAD

Fault factor display

Detector composition
It carries out AI using the inverter AC detected by current detector into control PCB,
overload characteristic is calculated by I4t integral arithmetic of soft circuit, and overload is detected.
HVS026

CTL
t
HCTU

CMP
I4

INV

IM

Overload
detection level

HCTW

Major fault
stop
Fault display

AI
CMP

I1
arithmetic
AI
HCTU
HCTW
CTL

U phase current detector


W phase current detector
Control PCB

Integral starting
current level

<< soft circuit >>

Main causality of fault


(1) Increase of motor load
(2)

Abnormality in setting of detection level

(3)

Fault of exchange current detector

(4)

Fault of machine system

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage enquiry of current detector (Is it sine wave or isn't there any offset? )Refer to terms 6.2.
(3) Enquiry of set point of fault detection level (set point should check test run report.)
Integral stating level

V/C00120 (1%+100%)

Over load detection level

V/C00120 (1:125%,1 minute )

1-18

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H4
GP
display

Display screen

MAIN CIRCUIT POWER DROP

Fault factor display

Detector composition
Main circuit power failure is detected by comparator of hard circuit in control PCB in voltage of multiplex
transformer tertiary winding as compared with power failure detection level. Power return is comparing
with Power return detection level at soft circuit.
CTL

HVS026

Main TR

AI

<

CMP

Power return
disregard level

TR for moment
power failure detection

CP

DI

Power failure
level set
CTL
TR
TD

TD

Major fault
stop
Fault display

<< soft circuit >>

Control PCB
Transformer
Time Delay

<< hard circuit >>

Main causality of fault


(1) Power failure of power receiving power source
(2) Fault of transformer for omen power failure detection
(3) Fault of fault detection circuit
(4) Incorrect setup of power failure setting level

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) It is voltage enquiry of transformer for power failure detection at the moment.
(3) Set point enquiry of detection level of power failure / power return Check Set point by test run report.
power normal level setup For setup VRAMV/C000E0

1%

power failure level setup For setup VRAMV/C00384

1mV

1-19

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H5
GP
display

Display screen

CONNECTOR NOT INSERTED

Fault factor display

Detector composition
It carries out DI of the abnormalities in connector insertion in hard circuit in control PCB, and detects them
by soft circuit.
CTL

HVS026

CN3
CN8
CN9
CN10
CN1
CN12

DI

Major fault
stop
Fault display

<< hard circuit >>

<< soft circuit >>

CTL
Control PCB
CN3,812
Connector
Main causality of fault
(1) Un-inserting of connector .
(2) Fault of control PCB .

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) It investigates whether connector is inserted.
It exchanges control PCBs, when connector is inserted normally

1-20

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H6
GP
display

Display screen

AC VOLTAGE ABNORMAL

Fault factor display

Detector composition
It carries out AI of the output voltage FB to control PCB, and it compares output voltage unusual level from
difference of voltage reference and voltage FB, and detects by soft circuit. Detection level is proportional to
voltage directive.
CTL

HVS026

PTUV

INV

CMP

IM

Major fault
stop
Fault display

V*

PTVW

Disregard level

AI

V1
arithmetic

AI
CTL
Control PCB
PTUV Voltage detector UV(PT)
PTVW Voltage detector VW(PT)

Voltage
reference

<< soft circuit >>

Main causality of fault


(1) Voltage FB line and open circuit of output cable
(2) Looseness of connector or TB
(3) Fault of voltage detector
(4) Fault of cell inverter
(5) Incorrect setup of output voltage unusual level

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage identification of voltage detector
(3) It investigates looseness of connector and TB, and open circuit.
(4) Soundness check of IGBT Refer to 6.1 terms.
(5) Set point enquiry of output voltage abnormal detection level Set point should check test run report.
Soft circuit setup For setup VRAMV/C0006C
1-21

5%

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H7
GP
display

Display screen

AC CURRENT ABNORMAL

Fault factor display

Detector composition
It carries out AI of the current FB to control PCB, and current value detects under on abnormal level by soft
circuit as compared with output current abnormal level.

CTL

HCTU

INV

HVS026

CMP

IM
HCTW

Major fault
stop
Fault display

Detection level

AI
I1
arithmetic

AI
<< soft circuit >>

CTL
Control PCB
HCTU U phase current detector
HCTW W phase current detector
Main causality of fault
(1) Open circuit of current FB line, output cable, and motor
(2) Looseness of connector or TB
(3) Fault of current detector
(4) Fault of cell inverter
(5) Incorrect setup of output current abnormal level

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage identification of current detector Refer to 6.2 terms.
(3) It investigates looseness of connector and TB, and open circuit.
(4) Soundness check of IGBT Refer to 6.1 terms.
(5) Set point enquiry of output current abnormal detection level Set point should check test run report.
Soft circuit setup VRAMV/C0007C
1-22

1%

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H8
GP
display

Display screen

GROUND DETECTED

Fault factor display

Detector composition
Ground detection carries out AI of the ground voltage to control PCB, and detects it by soft circuit as
compared with ground detection level. Detection level is proportional to speed.
Neutral point
CTL
GDT

HVS026

HVS610
AI

CMP

Major fault
stop

speed

Fault display
detection level

<< hard circuit >>

<< soft circuit >>

EB

CTL
GDT
IF
FLT

Control PCB
Ground detection PCB
I/F PCB
Filter

FLT
<< hard circuit >>

Main causality of fault


(1) Wiring ground between inverter motors
(2) Ground of motor
(3) Fault of ground detector
(4) Incorrect setup of ground detection level

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Insulation to the earth situation enquiry of wiring between inverter motors
(3) Insulation to the earth situation enquiry of motor
(4) Set point enquiry of ground detection level (set point should check test run report.)
Soft circuit setup For setup VRAMV/C0011C

1-23

0.1V

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H9
GP
display

Display screen

INV CUB COOLING FAN ABNORMAL

Fault factor display

Detector composition
Abnormality in cooling fan are operation of thermal relay for taking care of cooling fan (ceiling fan) of
inverter board, or voltage reduction detection of cooling fan. Therefore, it carries out DI of electromagnetic
contactor for cooling fan motion, and the contact of power source normal detection relay, and detects by
soft circuit.
AC400/440V

FFB*

49F*

88F*

FAN
CTL

HVS026

88F*

52
DI5

NOT

Major fault
stop
Fault display

<< soft circuit >>


88F*
49F*
52
FFB
FAN

Electromagnetic contactor for cooling fan motion


Thermal relay
Answerback of power receiving breaker
Breaker
Cooling fan

Main causality of fault


(1) Cooling fan's motor breaks down.
(2) Cooling fan locked physically.
(3) Cooling fan power source lowered.
(4) Incorrect setup of thermal relay trip level
(5) Fault of DI circuit
(6) Thermal relay is turned on.

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) ON / OFF identification of breaker for cooling fans
(3) Identification of thermal relay trip and set point
(4) Soundness identification of DI circuit refer to 4.4.1 terms.
(5) Cooling fan's check of operation

1-24

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H10
GP
display

Display screen

CUBICLE OVERHEAT

Fault factor display

Detector composition
Temperature rise in cubicle carries out DI of the thermo switch (it turns on at 55) installed in inverter
cubicle to control PCB, and detects it by soft circuit.
CTL

26C

HVS026

Major fault
stop

DI6

Fault display
<< soft circuit >>

CTL
26C

Control PCB
Thermo switch for cubicles

Main causality of fault


(1) Upsurge of ambient temperature
(2) Prolonged motion in the over load condition
(3) Blinding of air filter
(4) Fault of cooling fan power source
(5) Fault of DI circuit
The contents of enquiry
!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Enquiry of ambient temperature
(3) Enquiry of air filter dirt
(4) Cooling fan's check of operation
(5) Soundness identification of DI circuit Refer to 4.4.1 terms.

1-25

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H11
GP
display

Display screen

TRANSFORMER OVERHEAT

Fault factor display

Detector composition
Multiplex transformer superheating carries out DI of the thermo switch installed in transformer board to
control PCB, and detects it by soft circuit.
CTL

TR

HVS026

T1
DI

H1

Fault display
<< soft circuit >>

<< hard circuit >>


CTL
TR
T1
H1

Major fault
stop

Control PCB
Transformer cubicle
Transformer attached thermometer
Transformer attached thermo switch

Main causality of fault


(1) Continuation of overload operation
(2) Upsurge of ambient temperature
(3) Abnormalities of thermometer
(4) Fault of DI circuit

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Enquiry of ambient temperature
(3) Soundness identification of DI circuit Refer to 4.4.1 terms.

1-26

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H12
GP
display

Display screen

OPTICAL COMMUNICATION ABNORMAL

Fault factor display

Detector composition
When light which is carrying out loop for every four cell inverters (see the 6.4th term for details) intercepts,
it causes abnormalities in transmission. It generated in fault of Optical cable broken and driver interface
PCB, and has detected in soft circuit of control PCB.
CTL

HVS026

DRVIF

<< soft circuit >>


E/O
HVS750
DRVIF

HVS750

O/E

DRVIF

DI

52
Major fault stop
Fault display

HVS750

Major fault stop

DRVIF

<< hard circuit >>


CTL
DRVIF
E/O
O/E

HVS750

Control PCB
Driver Interface PCB
Electricity / optical signal conversion device
Light / electrical signal converter

Main causality of fault


(1) Open circuit of optical cable
(2) Fault of driver interface PCB
(3) Receipt power supply abnormal or fuse breakdown
(4) Loosening or disconnection of connector

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Open circuit enquiry of optical cable Refer to 6.4 terms.
(3) Enquiry of interface PCB LED display identification (3.2 terms)

1-27

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H13
GP
display

Display screen

** CELL INV FAULT

Fault factor display

Detector composition
* When cell inverter breaks down (refer to fault factor table 4.1.2), it has notified * cell inverter fault to
control PCB by intercepting output of optical sign by driver interface PCB. It is carrying out loop of the
optical cable for every four cell inverters (see the 6.4th term for details).
"**" shows serial number of broken cell inverter.
CTL

HVS026

DRVIF

<< soft circuit >>


E/O
HVS750
DRVIF

HVS750

O/E

DRVIF

DI

52
Major fault stop
Fault display

HVS750

Major fault stop

DRVIF

<< hard circuit >>


CTL
DRVIF
E/O
O/E

HVS750

Control PCB
Driver Interface PCB
Electricity / optical signal conversion device
Light / electrical signal converter

Main causality of fault


(1) Fault of cell inverter
(2) Fault of driver PCB
(3) Fault of driver interface PCB
(4) Optical cable open circuit

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Identification of cell inverter fault factor Refer to 2.5 terms.
(3) Enquiry of driver interface PCB LED display, connector enquiry (refer to 3.2 terms)
(4) Open circuit enquiry of optical cable refer to 6.4 terms.

1-28

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H14
GP
display

Display screen

DC OVERVOLTAGE

Fault factor display

Detector composition
As compared with over voltage detection level, it detects direct current over voltage, and is carrying out DI
of the direct current voltage inputted into driver interface PCB to control PCB.
Cell INV
HVS750

CTL

E/O

O/E

HVS026
DI

52

Major fault stop


Fault display

HFC1

CNV

Voltage
reduction
detection

<< soft circuit >>

HFC2

Major fault stop


<< hard circuit >>

DRVIF
O/E
DRVIF
S/P
E/O

Light / electrical signal converter


Driver Interface PCB
Serial/parallel conversion
E/O Electricity / optical signal conversion device

CTL
Control PCB
HFC1,2 High rap Fuse

Main causality of fault


Over voltage
(1) Motion situation is regeneration condition.
Under voltage
(1) Secondary voltage depression of multiplex transformer
(2) Investigating looseness of connector and TB, and open circuit.
Common
(1) Fault of cell inverter
(2) Fault of voltage detector
(3) Fault of driver-interface PCB

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Heavy enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Electrolytic capacitor enquiry
(3) Enquiry of driver interface PCB LED display identification (Refer to 3.2 terms)
(4) Insertion identification of connector
1-29

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H15
GP
display

Display screen

DRIVER POWER DROP

Fault factor display

Detector composition
Driver power source depression detects voltage reduction of power source for driver PCBs of each cell
inverter within driver interface PCB, and is carrying out DI to control PCB.

Cell INV
HVS750

CTL

E/O

O/E

HVS026
DI

52

Major fault stop


Fault display

HFC1

OV
detection
CNV

<< soft circuit >>

HFC2

Major fault stop


<< hard circuit >>

DRVIF

CTL
DRV

Control PCB
Driver PCB

O/E
HFC1,2

Light / electrical signal converter


High rap Fuse

Main causality of fault


(1) Fault of driver power source
(2) Fault of driver PCB
(3) Fault of driver interface PCB
(4) Fault of IGBT, fuse broken
(5) Loosening or disconnection of connector
The contents of enquiry
!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Output voltage enquiry of driver power source
(3) Enquiry of driver PCB -> LED lighting enquiry (3.3 terms)
(4) Enquiry of interface PCB LED lighting enquiry (3.2 terms)
(5) Investigating looseness of connector and TB, and open circuit.
(6) Soundness identification of IGBT refer to 6.1 terms.
(7) Fusing identification of fuse
1-30

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H16
GP
display

Display screen

DIP SW SETTING ABNORMAL

Fault factor display

Detector composition
Abnormalities in DIP switch setting detect condition of DIP switch of driver interface PCB of each cell
inverter by driver interface PCB, and it is carrying out DI to control PCB. As compared with normal setting
condition, it has detected using the DI signal.
CTL

DRVIF

HVS026
52
Major fault stop
Fault display

DIP
Switch
Condition
detection

O/E

E/O

DI

CMP

Set value
<< soft circuit >>
HVS750

CTL
O/E
DRVIF
E/O

Control PCB
Light / electrical signal converter
Driver Interface PCB
Electricity / optical signal conversion device

Main causality of fault


(1) The mistake is found in a set number of the DIP switch.
(2) Fault of driver interface PCB
(3) Open circuit of optical cable
(4) Loosening or disconnection of connector

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) DIP switch setting identification (Setup should check commissioning report.)
(3) Optical cable open circuit identification Refer to 6.4 terms.
(4) Enquiry of driver interface PCB LED display identification (refer to 3.2 terms)
(5) Confirmation of loosening or disconnection of connector

1-31

HIVECTOL-HVI-E

Part 1 Trouble shooting guide

Fault No.H17
GP
display

Display screen

PRECHARGING BUSY

Fault factor display

Detector composition
Initial charge tie up carried out DI (optical transmission) of the voltage establishment by driver interface
PCB from main circuit voltage of each cell inverter during initial charge, and has detected it by soft circuit.
It generates also at the time of DIP switch un-setting of driver interface PCB up.

Cell-INV Unit
CTL
DRVIF

HVS026

HVS750
Under initial charge

CMP

E/O

DI

Major fault
stop
Fault display

<< soft circuit >>

Power source
establishment level

<< hard circuit >>

CTL
Control PCB
E/O
Electricity / optical signal conversion device
DRVIF Driver interface PCB
Main causality of fault
(1) Initial charge power source blockage
(2) Bad conditions of initial charge circuit
(3) Fault of driver interface PCB ,Un-setting of DIP switch up.
(4) Depression of driver and driver interface power source
(5) Open circuit of optical cable
(6) Fault of cell inverter

The contents of enquiry


!
DANGER

Be sure to make sure that the High voltage direct inverter unit is set to the following condition before
starting enquiry.
Make sure that High voltage direct inverter unit is stopped operatingCheck blockage of power
receive breaker.
Make sure that the master circuit DC voltage is0VLED putting out lights in cell inverter

Major enquiry items


(1) Enquiry of motion situation (trace back data, motion situation of high rank)
Trace back's details are referred to term 5.
(2) Initial charge power source FFB and voltage enquiry in control panel
(3) Enquiry of thermal relay trip of initial charge circuit, and set point
(4) Enquiry of driver interface LED display and DIP switch setting identification (refer to 3.2 terms)
(5) Supply voltage enquiry of driver interface, and connector CN1 insertion identification (refer to 3.2 terms)
(6) Open circuit enquiry of optical cable refer to 6.4 terms.

1-32

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Part 1 Trouble shooting guide

4.2 Other faults


4.2.1 Light fault
The Alarm may:
Cause no problem even if left unremedied
Transfer to major fault after certain lapse of time.
Tables 4.2.1 give their respective remedial procedures.
Table 4.2.1.1 List of Minor Failure Factors
No.
1
2
3
4
5

Fault message
(ALARM)OVERLOAD ALARM
(ALARM)SPEED COMMAND ERROR
(ALARM)TRANSFORMER UNIT

No.
1

Fault message
(ALARM) SPEED COMMAND ERROR

No.
1

Fault message
(ALARM)OVERLOAD ALARM
(ALARM) TRANSFORMER
UNIT COOLING FAN STOP

Action
The motor load exceeded the rated load.
Check whether the cooling fan of the transformer unit has stopped. (The serious
failure Transformer Unit Cooling Fan TD will occur within a set time while the
circuit breaker is ON.)

(ALARM) UNIT TEMPARETURE RISE


3

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


cooling fan operation, and DI circuit error. (The serious failure Unit Temperature
Rise will occur when the unit temperature exceeds 60 degrees.

(ALARM) MULTUPLEX TRANSFORMER Check the ambient temperature, operation conditions (overload), filter clogging,
OVERHEAT
cooling fan operation, and DI circuit error. (The serious failure Unit Temperature
Rise will occur when the unit temperature exceeds the preset temperature.

(ALARM)CUBICLE OVERHEAT(>55)
(ALARM)TRANSFORMER OVERHEAT

Action
The motor load exceeded the rated load.
The speed command signal (420 mA) dropped to 2 mA or less.
The cooling fan of the transformer unit stopped during the operation.
The unit temperature detection contact (55 degrees) was activated.
The winding temperature of the multiplex transformer exceeded the alarm set value.

Table 4.2.1.2 Action for minor failure that allows you to continue operation
Action
Check the speed command and set the speed within the set value.

Table 4.2.1.3 Action for minor failure that becomes a serious failure

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4.2.2 Control PCB abnormal


If abnormalities of control PCB occur at the time of online mode, "abnormalities in controller" screen is
shown. A trouble of the control circuit PCB is attributable to:
Malfunction of component part on circuit PCB
Power voltage fluctuation or other external factors.
The trouble is very hard to locate
When abnormalities display of control PCB occurs, Operate GR switch of control PCB. (Fig. 4.2.1)
Exchange control PCBs, when GR switch operation back and abnormalities recur.
GR switch

Enlargement

PUSH

Fig. 4.2.2 GR switch operation

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4.2.3 Controller power source abnormal


If the control power ( 15 V) drops while in online mode, Controller Power Failure occurs.
The possible causes are:
Defective components in the board;
External factors, including voltage fluctuations of the power supply; or
Failure of the control power AVR.
If the control power is not available, failure factors cannot be displayed. If the power of the graphic panel
on the unit surface is available, the Offline Mode Screen is displayed.
Check as follows:
Check whether the LEDs of the control board (HVS026) are turned ON.
Check whether the LED of the control power AVR is turned ON.
Check the voltage of the control power AVR.
If the control power AVR has no trouble and if all LEDs on the control board are turned OFF, replace the
control board.

Installation position of AVR for control source


(Sample)

Control PCB (HVS026)

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

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4.3 Interlock factor


Although fault has not occurred, when you cannot operate, investigate pending interlock by interlock
factor display screen of face of a board display.

4.3.1 CONNECTOR NOT INSERTED


Confirm whether the connector of control PCB (HVS020) is completely inserted.
There are some parts where connectors of the number of same poles are used. Confirm connector No.
described to the cable is corresponding to the printed circuit PCB.

4.3.2 MAIN CIRCUIT BREAKER OFF


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

4.3.3 I/F ABNORMAL


Check whether high rank I/F is operating normally.

4.3.4 MAJOR FAULT


Refer to the contents of major failure

4.3.5 HV CUB MAJOR FAULT


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

4.3.6 EMERGENCY STOP


Check whether emergency stop operation is carried out.

4.3.7 MOTOR COOLING FAN STOP


Check whether fan for motor cooling is operating.

4.3.8 MOTOR RUNNING


Check whether motor is rotating.

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4.4 Supplemental documented procedures


4.4.1 Relay input and output identification procedure
Contact signal inputted into control PCB is changed into signal (memory) which software finally
recognizes via photo coupler.
Moreover, digital signal outputted from control PCB is outputted by relay contact.
The contents of standard DI/DO signal are shown in Table 4.4.1.1-2 (Please refer to description of
operation, and schematic diagram for details) .
Turn on/off input
source contact
Confirm display (ON/OFF)
of the signal input on the
"DIO" screen of the display
unit.
Is data
Input ON: Lit
Input OFF: Not lit ?
Has it become?

NO

Confirm whether there


is not loosening in the
connector of the
control circuit PCB.

Abnormal

Normal
YES

Control PCB faulty

Connector insertion is defective

Replace control PCB

Restart available

Input is normal. Investigate whether other points are abnormal.


If trouble cannot be located notify us phenomenon and trace-back data.
Example of display
When D11, 5, 7, 8 and 9, and DO0 and 1 are ON

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Table 4.4.1.1 Contents of DI signal


Signal name
DI0

At normal
running

Contents of signal
Hard Suppression

OFF

Remarks
Emergency stop command signal

DI1
DI2
DI3

Main circuit breaker 52 turn on


answerback

ON

52 answerback signals

DI4

T ransformer overheat

OFF

T hermal relay for temperature rise


detection of multiplex transformer

DI5

Cooling fan normalcy in


Inverter panel

ON

with thermal relay for cooling fans in


inverter panel C.T .T

DI6

T emperature rise in board

OFF

T hermal relay for temperature rise


detection in inverter board

DI7

Inverter board door closed

ON

Door closed switch detection relay

DI8

DI9

DI10

OFF

DI11

DI12

DI13

DI14

DI15

(Note)

Inverter run command

Cooling fan normalcy in


transformer panel

ON

Inverter operation directive signal

with thermal relay for cooling fans in


inverter panelC.T .T

According to system, as for DI 1,2, 8, 9, 1114, the contents of signal and condition at the

time of normal operation are changed.


Table 4.4.1.2 Contents of DO signal
Signal name
DO0

(Note)

At normal
running

Contents of signal
Inverter heavy fault

ON

DO1

DO2

DO3

DO4

DO5

DO6

DO7

Remarks
Heavy fault accrual sign (turn off by
failure)

According to system, as for DO17, the contents of signal and condition at the time of

normal operation are changed.


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5. How to get trace-back data


The description here concerns how to get data necessitated for analyzing troubles.
The trace backing data is gathered with a maintenance tool.
For further details, refer to manual "Part 2 Maintenance tool".

5.1 Starting of maintenance tool


Turn ON the computer and start Windows.
If the M.TOOL for Windows has not yet been installed on the hard disk, copy the data
from the M.TOOL CD-R.

Click M.TOOL.exe to start.

The initial setting screen (Figure 5.1.1) appears when the M.TOOL for Windows starts.
Connect the serial interface connector (COM1) of PC, and the connector on the display unit
on the surface of a control panel (Fig. 5.1.2) by a RS-232C cable.
* Make connection of PC and a RS-232C cable first at the time of connection.

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

Startup completed

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Fig. 5.1.1 Initial setting screen

Graphic panel

VSD(VFD)

Control panel
Maintenance tool connector

Acrylic cover

Stop tool for acrylic cover

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

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5.2 Invoking Trace-back Command


Track command is invoked by pushing the [F5] key on the Figure 5.2.1 Start of Track command. Once it
is invoked, Figure 5.2.2 Trace back menu screen appears on the screen.

Please push F5 (Track) key.

Figure 5.2.1 Start of Track command

Please select
" 1. Collection of Logging data"

Figure 5.2.2 Trace back menu screen

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5.3 Sampling Trace-back Data


5.3.1 Trace-back data acquiring
Choose the menu option [1.Collection of Logging data] on the Figure 5.2.2 Trace back menu screen.
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)
The screen moves to Figure 5.3.1 Logging data collection menu screen. Choose either
[1. Normal collection of data] or [2. Compulsion collection of data] on this screen.
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)
[2. Compulsion collection of data] is chosen when the logging data currently in operation is acquired
forcedly. For forced acquiring, see "VOLUME II MAINTENANCE TOOLS.

Please select this menu option, if you


wish to acquire the logging data which is
stored in case of fault.
Please select this menu option, if you
wish to acquire the logging data currently
in operation.

Figure 5.3.1 Logging data collection menu screen

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If [1. Normal Data Collection] is selected, the screen for selecting the data to be collected (Figure
5.3.2) appears. Use either the [] or [] key to select the data to be collected, and press the [Enter] key.
The lowest number in the [No.] column on the screen shows the latest failure data.
The State column shows the following information:
[Uncollection]: There is uncollected data in the area.
[Collected]: The data in the area has been collected.
[No data]: There is no data in the area.
The [Logging stop time] column shows the time and date of when a failure occurs.
Press the [R] key. Then, the latest information in the control board will be read and the screen will be
updated.

Figure 5.3.2: Screen for Selecting Data to be Collected


<< cautions >>
The right time is not displayed unless time of PC suits it, since failure accrual time is computed from time
of PC (personal computer).

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When you choose the data, the screen moves to Output file name input screen (Figure 5.3.3), on
which you may enter up to Sixty-four half-size (one-byte) characters as the output file name.
If the same file name as you have just entered already exists, a message " The file already exists. Can I
overwrite? [Y/N] " appears on the screen. If you wish to overwrite, push the [Y]. If you change the name
to another, push the [N] and re-enter the file name.

Input the file name by 64 characters or less.

Figure 5.3.3 Output file name input screen


When you input the output file name, the screen moves to Comment input screen (Figure 5.3.4), on
which you may enter up to Fifty half-size (one-byte) characters as the comment.
Press the [Enter] key if you do not enter a comment.

Input the comment by 50 characters or less.

Figure 5.3.4 Comment input screen

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


If there is no space for storing the data in the HDD, the message, File making error(empty capacity of the
current drive) is displayed. In this case, make sure that the HDD has enough space, and collect the data
again.
During data acquiring, the screen as shown in Figure 5.3.5 is displayed, on which the data being acquired
and the amount of acquired data are displayed.
When all the logging data are acquired, the following message appears:
" The collection of data ended. Please push any key. "
Push the [SPACE] key.
(The screen returns to Figure 5.3.1 Logging data collection menu screen.)

File name is displayed.

These values are counted during data acquiring.

Displayed when all the data collecting is completed

Figure 5.3.5 Screen display gathering trace back data

Now you have finished data acquiring. The contents of the acquired data may be displayed by
choosing the menu option [2. Display of Logging data] on the Trace back menu screen.(Figure 5.2.2)

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5.3.2 Forced logging data acquiring


Forced logging data acquiring is used to acquire logging data while the inverter is normally running. To
acquire data, choose the menu option [3. Compulsion collection of data] on Figure 5.3.1 Trace back data
collection menu screen. Forced data acquiring cannot be made unless logging is performed. When you
choose forced acquiring while logging is stopped, a message
Because logging has stopped, data cannot be compulsorily gathered.appears.
Push the space key. To make sure that logging is working, you may find it by observing that the No. 8
display on the digital readout is counting. During logging, choose an item, and a message
May I compulsorily gather data? [Y/N]
appears. If you wish to acquire, push the [Y] and if not, push the [N] key. Once you push the [N] key, the
screen moves to Figure 5.3.1. If you press the [Y] key, the screen moves to Figure 5.3.3 Output file name
input screen. Remaining steps after the step of entering file name are the same as those for regular data
acquiring.

CAUTION

When you choose forced data acquiring, logging stops for about one to three seconds. In case that serious
fault occurs during logging stop, the fault data cannot be stored in the flash memory.

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5.4 Numerical display


<<Procedure>>
On Figure 5.4.1 Trace back menu screen,choose the menu option [2. Display of Logging data].
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)

Please select
2.Display of Logging data

Figure 5.4.1 Trace back menu screen


The screen moves to Figure 5.4.2 File selection screen , on which you may choose a
file. Use the [] or [] key to choose a file, and push the [Enter] key.

File information is displayed

Figure 5.4.2 File selection screen

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When you choose a file, the screen moves to Figure 5.4.3, on which you may use the
[] or [] key, and push the [Enter] key.

Please select
1.Numeric Display

Figure 5.4.3 Logging data display menu screen


When you choose the menu option [1 Numeric Display], the screen moves to Figure 5.4.4 Selection
screen at output point.. Use the [] or [] key to choose an
appropriate menu option, and push the [Enter] key .

Please select
1.Display

Figure 5.4.4 Selection screen at output point

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When you choose the menu option [1. Display] on Figure 5.4.4 Selection screen at output point, the
screen moves to Figure 5.4.5 Numeric display data selection screen . Use the [] or [] key to choose an
appropriate menu option, and push the [Enter] key.
If you choose the menu option [1. 0.3ms Cycle Logging], Figure 5.4.6 appears and
if you choose the menu option [2. 30ms Cycle Logging], then Figure 5.4.7 appears.

Figure 5.4.5 Numeric display data selection screen

Figure 5.4.6 Output item selection screen (0.3ms cycle)

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Figure 5.4.7 Output item selection screen (30ms cycle)


In order to choose the item to display, input the number on the left-hand side of an output item by
double figures.
The number of the items which can be chosen is a maximum of eight.
Press the [Enter] key, when you carry out selection closing of the item to output.
The screen moves to Figure 5.4.8 Numeric display screen .
[Example]
To let the numbers 1, 3, 10, 11, and 12 on Figure 5.4.6, push the [space][1], [space][3], [1][0], [1][1],
[1][2], and [Enter] keys in this order .
[space][1]

[space][3]

[1][0] [1][1] [1][2]

[Enter]
Select End

10

11

12

When the item number is one digit(19),


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

Explanation of a use key:


[ESC]

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

[]

Displays the next page.

[]

Displays the previous page.

[PrtSc]

Prints out the screen currently being displayed.

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Fig. 5.4.8 Numerical display of logging data


When you choose the menu option [2.File] on Figure 5.4.4 Selection screen at output point , the
screen moves to Figure 5.4.9 Output format choice display screen . Select the desired output format.
Next the screen moves to Figure 5.4.10 Output file name input screen , on which you may enter up to
Sixty-four half size characters as the output file name.
If there is a file with the same name as you entered, a message
" The file already exists. Can I overwrite? [Y/N] "
appears on the screen, prompting your confirmation.
If you wish to overwrite, push the [Y]. Or if you wish to enter another name, push the [N].
When you enter [N], re-enter the file name

Figure 5.4.9 Output format choice display screen

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Input the file name by 64 characters or less.

Figure 5.4.10 Output file name input screen


Once the output file name is entered, file output is started.
The file will be stored in the Trace Data folder in which the M.TOOL has been installed.

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5.5 Trend Display


<<Procedure>>
On Figure 5.5.1 Trace back menu screen, choose the menu option [2. Display of logging data].
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)

Please select
2.Display of Logging data

Figure 5.5.1 Trace back menu screen


The screen moves to Figure 5.5.2 File selection screen . Use the [] or [] key to choose an
appropriate file, and push the [Enter] key.

File information is displayed

Figure 5.5.2 File selection screen

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When you finish choosing the file, the screen moves to Figure 5.5.3 Logging data display menu
screen . Use the [] or [] key to choose the menu option [2. Trend display], and push the [Enter] key

Please select
2.Trend Display

Figure 5.5.3 Logging data display menu screen


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

Figure 5.5.4 Selection screen at output point

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To choose a menu option, enter the leftmost number of the output item in two digits. Up to eight items
may be chosen. When you finish choosing an item you wish to output, push the [Enter] key. Choosing an
item and pushing the [Enter] key allow you to move the screen to Figure 5.5.5 Trend display screen .
To exit, push the [ESC] key. (The screen returns to Figure 5.5.3 Logging data display menu screen .)
[Example]
A case that displays the numbers 1, 3, 10, 11, and 12 on Figure 5.5.4.
[space][1]

[space][3]

[1][0] [1][1] [1][2]

[Enter]
Select End

10

11

12

When the item number is one digit(19),


then press the [0] or space key first

Figure 5.5.5 Trend display screen

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5.6 Fault Factor Display


<<Procedure>>
Choose the menu option [2. Display of Logging data] on Figure 5.6.1. Trace back menu screen
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)

Please select
2.Display of Logging data

Figure 5.6.1 Trace back menu screen


The screen moves to Figure 5.6.2 File selection screen . Use the [] or [] key to choose an
appropriate file, and push the [Enter] key.

File information is displayed

Figure 5.6.2 File selection screen

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When you finish choosing the file, the screen moves to Figure 5.6.3 Logging data display menu
screen Use the [] or [] key to choose the menu option [3. Fault Factor Display], and push the [Enter]
key.

Please select
3.Fault Factor Display

Figure 5.6.3 Logging data display menu screen


On the Figure 5.6.3 Logging data display menu screen, choose the menu option [3. Fault Factor
Display]. And the screen moves to Figure 5.6.4 and 5.6.5 and 5.6.6 Fault factor display screen .
In the figure, all faults are displayed for an explanation.
Press the [ESC] key, the screen Fault factor display screen is closed.
(The screen returns to Figure 5.6.3 Logging data display menu screen.)
Press the [Putsch] key, if you would like to print the displayed screen.

: First fault factor


: Second fault factor
: Third fault factor

Figure 5.6.4 Fault factor display screen 1


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Figure 6.6.5 Fault factor display screen 2

Figure 6.6.6 Fault factor display screen 3

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5.7 Cell Inverter fault factor


<<Procedure>>
Choose the menu option [2. Display of Logging data] on Figure 5.7.1.
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.

Please select
2.Display of Logging data

Figure 5.7.1 Trace back menu screen


The screen moves to Figure 5.7.2 File selection screen. Use the [] or [] key to choose an
appropriate file, and push the [Enter] key.

File information is displayed

Figure 5.7.2 File selection screen

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When you finish choosing the file, the screen moves to Figure 5.7.3 Logging data display menu
screen Use the [] or [] key to choose the menu option [4. Cell Inverter Fault Factor Display], and push
the [Enter] key.

Please select
4.Cell INV Fault Factor Display

Figure 5.7.3 Logging data display menu screen


On the Figure 5.7.3 Logging data display menu screen, choose the menu option [4. Cell Inverter
Fault Factor Display]. And the screen moves to Figure 5.7.4 Cell Inverter Fault Factor Display screen .
Cell inverter which fault generated.

Fig. 5.7.4 Cell inverter fault factor display screen

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In the cell inverter fault factor display screen (Fig. 5.7.4), when a cell inverter is chosen using the
[], [], [] or [] key and a [Enter] key is pressed, the fault factor of the corresponding "cell inverter"
will be displayed.
Moreover, the cell inverter which fault generated is displayed as "(fault)" after a name.
In the figure, all cell inverter faults are displayed for explanation.

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6. DETAILS OF VARIOUS CHECK ITEMS


6.1 IGBT Soundness Check

CAUTION

Before conducting continuity check, be sure to shut off all the power supply

6.1.1 Property of IGBT


No continuity

As shown in Fig. 6.1.1, diode is built in IGBT.


If between gate and emitter is short-circuited and IGBT checks electrical

connection between C-E in the state of OFF, the property of this diode

will appear. It conducts diode, when flowing current toward collector


side from emitter side, as shown in figure. It judges that IGBT is

short
Continuity

damaged, when there is electrical connection or there is no electrical

connection at each polarity. In addition, since resistance between C-E

changes with voltage of measuring instrument to be used, normal value


does not exist. Judge by comparison with other IGBTs.

short

(Be careful not to impress more than voltage DC15V by gate at the time
6.1.1 Property of IGBT

of single article check)

6.1.2 Soundness check method


(1) Remove cell inverter. Refer to the 7th term for the removal method.
(2) Disassemble removed cell inverter.
(3) Carry out continuity check in IGBT single article.
Gate emitter terminal is short-circuited.
Measure resistance between collector emitters (notes 6.1).
Notes 6.1

Use 1000V mugger. Since normal value does not exist, judge resistance by comparison

with other IGBT(s).

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6.2 CT Output Check


As it is impossible to let the rated current flow to check the CT output, wrap an electric wire several times
to increase the magnification of detection.
As an example, connect a 10A current source to the 2000A/10V CT and wrap a wire so that it passes
through in the CT 20 times. Then the output voltage at CT
becomes
10A 20 times/2000A 10V = 1V
10A

Wind so that 20 turns will pass


Figure 6.2.1 Output Check of CT
Make sure that the output voltage (offset voltage) is 30mV or below when the current is zero. Confirm
that the output varies in proportion with the current value varying.

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6.3 Optical Cable Identification Train


6.3.1 Wiring Composition of Optical Cable
Communication of the pulse signal between driver interface PCBs and during a driver interface, a fault,
etc. is performed using an optical cable from a control PCB.
Wiring of an optical cable is shown in Fig. 6.3.1 and Table 6.3.1. As shown in a figure, the loop of the
optical cable is carried out for every four cell inverters. When the signal transmitted from the control PCB
has returned to the control PCB through four sets of cell inverters and a cell inverter breaks down, the
output of an optical signal was intercepted by the broken driver interface PCB of a cell inverter, and the
fault is notified to the control PCB.

HVS026
GUTA

GURA

GVTA

Gate
signal

HVS750
SIN

V6

HVS750
SIN

U2

V5

HVS750
SIN
SOUT

W6

V2

W5

HVS750
SIN
SOUT

HVS750
SIN

W2

SOUT

V1

HVS750
SIN
SOUT

SOUT

SOUT

U1

HVS750
SIN

HVS750
SIN

loopback
signal

SOUT

SOUT

HVS750
SIN

GWRA

Gate
signal

loopback
signal

SOUT

U5

GWTA

Gate
signal

loopback
signal

U6

GVRA

HVS750
SIN

SOUT

W1

SOUT

Fig. 6.3.1 Optical cable wiring diagram

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Table 6.3.1 Contents of optical connector


A system (Regular)
Device
Contents
GUTA
U phase gate signal
GVTA
V phase gate signal
GWTA
W phase gate signal

Transmitting side

GURA
GVRA
GWRA

Receiving side

B system (Back up)


Device
Contents
GUTB
U phase gate signal
GVTB
V phase gate signal
GWTB
W phase gate signal

U phase loop back signal GURB


V phase loop back signal GVRB
W phase loop back signal GWRB

U phase loop back signal


V phase loop back signal
W phase loop back signal

6.3.2 Composition of Optical Communication


Composition of optical transmission and reception is shown in Fig. 6.3.2.
From control PCB (HVS026), gate signal sent as an optical serial sign is changed into parallel sign by
driver interface PCB (HVS750) is supplied. Driver PCB inputs gate signal changed into parallel sign by
driver interface PCB, and has role changed into sign for drive of IGBT. In driver interface PCB, fault
detection is also performed and it has transmitted to control PCB by making fault factor into optical serial
sign.
HVS026

HVS750

GT
E/O

Optical serial
transmission

: U, V, W (phase is expressed)
: A(Regular)B (Back up)

SOUT
E/O

parallel Serial conversion

GR
O/E

SIN
O/E

Serial parallel conversion

Optical serial
transmission

Short circuit
pulse detection
Driver power
U-V24V source DC36V Rectifier circuit
detection
DC36
OV detection

Main circuit direct


current voltage

OC detection
R phase fuse broken detection
T phase fuse broken detection
DIP switch set point

Cell Inverter

Fig. 6.3.2 Optical transmission and reception composition

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6.3.3 Optical cable identification procedure


If optical cable is disconnected, intelligence of pulse, fault factor, etc. will become impossible, and it will
become cell inverter fault.
It is shown procedure of optical cable open circuit enquiry below

Remove CN1 of interface PCB


HVS750 of each cell inverter.

Connect external power source


(DC24V cable) to CN1 of interface
PCB HVS750 of all cell inverters.
YES

YES

Is light coming to optical cable


edge (Fig. 6.3.3.3) of CTL-PCB?

Has "abnormalities in
transmission" occurred?

NO

NO

Is light coming to SOUT


(Fig. 6.3.3.4) of the 1st
stage of driver interface?
NO
Is light coming to SIN
(Fig. 6.3.3.4) of driver
interface of the 1st stage?

Optical cable open


circuit between the 1st
stage of HVS026 and
HVS750

YES

YES

Fault of control
PCB HVS026

HVS750 breaks down to


the 1st stage.

NO
Investigate like following where
it has run out.

Optical cable is
normal.

Fig. 6.3.3.1 Optical cable open circuit enquiry procedure

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Remove optical cable and investigate whether leading edge of cable has
shone. Red light is observed when having not disconnected.

Fig. 6.3.3.2 Optical cable enquiry of HVS026

Investigate whether optical cable was


removed and leading edge of cable has
shown. Red light is observed when having
not disconnected.

Fig. 6.3.3.3 Optical cable enquiry of driver interface PCB (HVS750)

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7. Cell inverter exchanging procedure


When IGBT is damaged, it is necessary to exchange the whole cell inverter. Exchange should follow in
following order.

7.1 Detaching of hanging door


Detach screw (B) and loosen screw (A) without removing in order of AC.
Next, detach the hanging door gripping the knob in the hanging door in similar the order.
Screws(B)

Screws(A)

Screws(B)
Fig. 7.1.1 Close-up of inverter board

Fig. 7.1.2 Left : Inverter panel and control panel


(Door closed)
Right : Inverter panel and control panel
(Door opened)

7.2 Detaching of cell inverter


Remove parts of the cell inverter that shows in the following.
Secondary wiring : Bolts 3
Principal circuit : Bolt2
Optical cable : Connectors2
Note1 : Screws4
Detach it referring to Figure 7.2.

Optical cable

Note1 : Position in which plinth


and cell inverter are fixed.
Principal circuit
Secondary wiring
Note1
Fig. 7.2 Work of cell inverter front.
Be careful for strength with optical cable impossible for to be added, and not to

CAUTION

damage it. Moreover, work after identification that voltage of electrolytic


capacitor is discharging completely (about 10 minutes or more pass after high
voltage power supply blockage, and LED2 (red) of driver interface PCB puts out
the light).

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7.3 Drawer of Cell Inverter


Pull out cell inverter using lifter of exclusive use.
Move forward to unite arm of lifter with lower part of cell inverter.
It is oil, lifter will go up, if handle is shaken at right and left, and if reduced pressure bulb is turned, it will
descend.

Cell Inverter

Lifter's plinth

Pulling out of cell inverter(for reference)

Cell Inverter
Lifter's plinth
Lifter for maintenance
Cell inverter and lifter (for reference)
Fig. 7.3 Drawer of cell inverter (for reference)Note1
Note1 : The cell inverter of the photograph and figure is the references.

CAUTION

(1) Weight of cell inverter is as follows. Be careful enough not to fall.


Be sure to use lifter of exclusive use for description of cell inverter.
Since it is dangerous, do not perform supporting directly by hands by any means.
(2) Pull out slowly so that Optical cable does not collide with lifter.

7.4 Repair work


After new cell inverter is inserted, restore in procedure contrary to the above-mentioned.
If exchange work is completed, confirm again whether there is any failure of wiring
error, screw, and bolt to fasten.
Confirm the number of DIP switch on driver interface PCB after exchanging cell
inverter.

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8. Replacing the control PCB


8.1 Replacing the Control PCB
Exchange of control PCB (HVS026) is (1) exchange of PCB, (2) software, and loading of control constant.
(3) Carrying out in order of setup of VR and DIPSW.
Shutting off the main circuit and control power supplies
(1) Blockage of main circuit power source
Stop inverter and intercept high pressure breaker.
Check that main circuit direct current voltage is "0V."
(LED2 of driver interface PCB in cell inverter has turned light off.)
(2) Blockage of control power source
Intercept each FFB of control power source.
Removal of PCB
Remove all cables inserted in PCB and remove 4 attachment screws of PCB by Phillips screwdriver.
(Fig. 8.1)

Screw
Control PCB

Fig. 8.1 Removal of PCB


Attachment of PCB
Using phillips screwdriver, attach PCB in main part with 4 screws, and restore cable.
End
Exchange of PCB is finishing.
When you exchange PCBs, be sure to perform software, loading of control constant, and setup of
VR-DIP SW.
(Refer to the test run record for setup of VR-DIPSW.)

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8.2 Loading method of software and control constant


To load program (software and control parameters) and to check by comparison, the maintenance tool is
used. For program loading, follow the steps below.
DIPSW setting (offline switching)
In order to perform loading and comparison check of program, it is necessary to change to off-line mode.
Change in off-line mode opens 2-15 of DIPSW (DIPS1) of control PCB, and short-circuits 1-16. (Fig.
8.2.1)
a
DIPS1
8

10

11

12

13

14

15

16

DIPS1

HVS026

[Explanation of DIPSW1 ]
1-16 short offline mode
2-15 open online mode
3-14 open Not used
4-13 open Not used
5-12 open Not used
6-11 open Not used
7-10 short maker use
8- 9 short maker use

Figure 8.2.1 DIPSW switching (offline mode)

Starting up the maintenance tool


Connect the tool cable to CN1 on the Display unit, and turn on the power to the PC (personal computer)
for the maintenance tool. For details of starting up the maintenance tool, see 5.1 Starting Up the
Maintenance Tool
GR switch operation
Confirm that the DISPLAY UNIT changes the display to "OFFLINE MODE" screen when you operate
the GR switch( Figure 8.2.3) on the control PCB .( Figure 8.2.2)

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HITACHI , Ltd 2010

Figure 8.2.2 GR operation on the Control PCB

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Figure 8.2.3 OFFLINE MODE

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Starting up the file operation command


To load program and check by comparison, use the [F9] (File) command. The File command is executed
by pushing the [F9] key on the M.TOOL screen (Figure 8.2.4). When File command starts, file operation
menu panel of Fig. 8.2.5 is displayed.

Please push F9 (File) key.

Figure 8.2.4 M.TOOL initial screen

Please select
" 1. Loading (File to PCB)"

Figure 8.2.5 File operation menu screen

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Loading of MPU1 Program


(1) On Figure 8.2.5 File operation menu screen, choose the menu option [1. loading of File].
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)
(2) The screen moves to Figure 8.2.6 File selection screen. Choose a file you wish to load on this
screen. Carry out loading of the software of MPU1. (Choose file of MPU1 in mode.)
(Please press [Enter] key after choosing item by [] and [] key)

Figure 8.2.6 File confirmation screen


(3) The screen changes to Figure 8.2.7 File confirmation screen.
A message " May I load this file? [Y/N] " appears on the screen. Confirm the contents of the file
, and push [Y] for loading it, or [N] for not comparing. If you choose [N], the screen returns to
Figure 8.2.5.

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Figure 8.2.7 File confirmation screen

(4) When you finish choosing [Y] or [N] for loading or not loading, respectively,
the file loading is started.
During loading, the following messages are displayed on screen of Fig. 8.2.7 one by one.
0 clearing of the program area. Please wait for a while
(Zero-clearing done)
The file is being loaded. Please wait for a while.
(Loading)
Data is written in flash memory. Please wait for a while.
(Storing done)
Loading the file ended. Please push any key.
By pushing the space key, the screen returns to the menu screen Figure 8.2.5.
(5) Now the loading is finished.
After loading is finished, be sure to check the file by comparison.
Comparison check of MPU1 program
(1) On Figure 8.2.5 File operation menu screen , choose the menu option [2.Compare of File].
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)
(2) The screen moves to Figure 8.2.8 File selection screen. Choose a file you wish to compare
on this screen.
(Use the [] or [] key to choose an appropriate menu option, and push the [Enter] key.)

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Figure 8.2.8 File selection screen


(3) The screen changes to Figure 8.2.9 File confirmation screen.
A message " May I compare this file? [Y/N] " appears on the screen. Confirm the contents of the file, and
push [Y] for comparing it, or [N] for not comparing. If you choose [N], the screen returns to Figure 8.2.5

Figure 8.2.9 File confirmation screen

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(4) When you finish choosing [Y] or [N] for comparing or not comparing, respectively, the file
comparison is started. During comparison, the following messages are displayed on screen of Fig. 8.2.9
one by one.
Files are being compared. Please wait for a while.
(Comparing normally done)
The comparison of files ended. Please press some keys.
When comparison is finished, the screen returns to the menu screen Figure 8.2.5. by pushing the space
key. If the comparison failed, try to reload the program.
(5) Now the comparison is finished.

Confirmation
Confirm that face of a board display unit changes to "operation screen" display (Fig. 8.2.10).
When it does not change to "operation screen" display, please confirm whether LED 1, 3, and 5 of control
PCB (HVS026) is on.
When the light is not switched on, please perform loading again.

Fig. 8.2.10 Operation screen display


Closure
Now the program loading and file comparison have been done

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8.3 Setup of VR and DIP SW


8.3.1 Setup of DIP SW
Please make DIP SW the same setup as PCB before exchange. Setup of DIPSW is shown in Table 8.3.1.
Mounting location of DIP SW and VR is shown in Fig. 8.3.1.
Table 8.3.1 Function of DIP SW (HVS026)
DIPS1
1-16
2-15
3-14
4-13
5-12
6-11
7-10
8-9

offline mode
online mode
Not used
Not used
Not used
Not used
maker used
maker used

DIPS2
1-16
2-15
3-14
4-13
5-12
6-11
7-10
8-9

maker used
maker used
maker used
maker used
maker used
maker used
maker used
maker used

Function
ON:offline
ON:online

OFF:online
OFF:offline

Function

Standard
OFF
ON
OFF
OFF
OFF
OFF
ON
ON
Standard
ON
ON
ON
ON
ON
ON
ON
ON

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9. Parts replacing procedure


The following explains how to replace parts whose mounting is complicated only

9.1 Fuse
Fuse is attached in surface bus bar.
Bolt is bound tight by fuse directly. Fig. 9.1 is an example of the exchange method of fuse.
As for the structure of a bus bar, with equipment, a difference does not have measure in an exchange
procedure in things.

(a)

Detach the hanging doors of the inverter panel.

(b) Confirm the voltage of the principal circuit is 0V without fail before working next.
(c)

Remove the bolt for the fixation of the fuse. At this time, when power is added to the bolt too much,

the copper bar might be transformed and be damaged.


(d) Install a new fuse. Confirm to tighten the bolts firmly.
(e)

Inverter panel is closed by the hanging doors and completion.

Cell Inverter
Bolts (2/Fuse)

Fuse

Fig. 9.1 Fuse mounting structure

CAUTION

Reuse the existing micro switch for detecting a blown fuse.


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9.2 Current detector


From detection axiom, current detector is attached so that bus bar may penetrate.
At the time of exchange, as shown in figure, remove and extract a part for bus bar and connection of cable.
9.2 is an example of the exchange method of fuse.
As for the structure of a bus bar, with equipment, a difference does not have measure in an exchange
procedure in things.
(a)

Open the door of control panel and confirm the position of Fig9.2.

(b) Confirm the voltage of the principal circuit is 0V without fail before working next.
(c)

Remove bolts from in order referring to Fig9.2.

(d) Pull out CT from copper bar. ()


(e)

Confirm the direction of CT and tightening bolts.

Inverter panel


PULL
Copper bar

Current detector

Fig. 9.2 Exchange method of current detector

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10. Other notes


10.1 Fault reset method
At the time of major fault occurrence, a display unit on board face changes to "fault factor display" screen.
When reset lamp is on, major fault has occurred.
Fault reset method at the time of major fault occurrence is shown below.

Reset
switch

CELL
SELECT
Figure 10.1 LED mounting scheme on the digital readout
Perform fault reset operation according to the following procedures.
A reset lamp is completion of the fault reset by putting out lights.
However, since fault reset is possible also when parts are damaged by major fault, "4. Trouble shooting by
fault factors " Follow, and carry out resumption of operation after removing fault factor.

Reset
switch

"Reset switch" lighting which changes


to major fault occurrence "fault factor"
screen.

Record the fault factor of the display


unit

Push the "RESET" switch on the


display unit for about five seconds.

LED putting out lights


Was "reset" switch turned off?

CELL
SELECT

Under LED blink


The removal of the fault factor is not
completed.
Execute the fault reset operation again
after removing the fault factor.

Fault reset normal


completion

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