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Draft 11 January 4, 2010
1
Variable Frequency Drive (VFD)
For
Permanent Magnet Motors (PMM)
Operation Manual
Variable Frequency DriveOperation Manual
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Table of Contents
1
Description and Operation ................................................................................................................. 9
1.1 Function ..................................................................................................................................... 10
1.2 Technical Specifications ........................................................................................................... 10
1.3 VFD Functions Performed ........................................................................................................ 11
1.4 VFD Physical Structure Description ......................................................................................... 12
1.4.1 Components Exposed by Large Front Door Opening........................................................ 13
1.4.2 Components Exposed by Small Front Door Opening........................................................ 14
1.4.3 Components Mounted Internal of Large Front Door and Left Side of Cabinet................. 16
1.4.4
Components mounted on inside at rear of cabinet ............................................................. 17
1.5 VFD Component Operations ..................................................................................................... 18
1.5.1 Power Circuit ..................................................................................................................... 20
1.5.2 Control Circuits .................................................................................................................. 20
1.5.3 External Power Transformer .............................................................................................. 21
1.5.4 Telemetry System .............................................................................................................. 21
1.5.5 Starting the VFD ................................................................................................................ 22
1.5.6 Shut down of VFD ............................................................................................................. 22
1.6 Marking And Packing of VFD .................................................................................................. 23
2 Description and Operation of VFD .................................................................................................. 24
2.1 VFD Controller (VFD C) .......................................................................................................... 24
2.2
Functions of Variable Frequency Controller (VFD C) ............................................................. 25
2.3 Operator’s Communication with VFD C .................................................................................. 26
2.4 Power Module ........................................................................................................................... 27
2.4.1 Rectifier Module Section ................................................................................................... 27
2.4.2 Pulse Wave Modulation Section ........................................................................................ 27
2.4.3 IGBT Module Section ........................................................................................................ 28
2.5 Power and Control Module ....................................................................................................... 28
2.5.1 Frequency Converter Controller (FCC) ............................................................................. 28
2.5.2 Control and Secondary Power Board ................................................................................. 29
2.5.3 Universal Power Packs ...................................................................................................... 29
2.6
LED Indicators .......................................................................................................................... 29
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2.7 VFD Protective Devices ............................................................................................................ 29
2.8 Analog Unit ............................................................................................................................... 30
2.9 Telemetry System ...................................................................................................................... 30
2.10 Information Read-Out Unit (IRU) ......................................................................................... 30
2.10.1
IRU Preparation for Operation ........................................................................................... 30
2.10.2 IRU Operation .................................................................................................................... 31
2.10.3 Testing................................................................................................................................ 32
3
Installation and Wiring .................................................................................................................... 33
3.1
Safety measures during drive preparation ................................................................................. 33
3.2 Preparation for Operation .......................................................................................................... 34
3.2.1 External Inspection ............................................................................................................ 34
3.2.2 Connection of VSD ............................................................................................................ 34
4
VFD Control Menu .......................................................................................................................... 37
4.1 Function of keys ........................................................................................................................ 37
4.2 Drive Controller Menu Description .......................................................................................... 38
4.2.1 Parameters .......................................................................................................................... 38
4.2.2 Menu Windows .................................................................................................................. 39
4.2.3 Settings ............................................................................................................................... 42
5 Start Up of Drive .............................................................................................................................. 48
5.1
Insertion of Setting and Tuning Values .................................................................................... 49
5.1.1
EDIT Mode ........................................................................................................................ 49
5.1.2 Setting Protections ............................................................................................................. 50
5.2 Samples of Protections and Settings ......................................................................................... 51
5.2.1 Example of Overload Protection ........................................................................................ 51
5.2.2 Example of Under Load Protection ................................................................................... 51
5.2.3 Protection for Insulation Resistance Reduction ................................................................. 52
5.2.4 Protection Against Wedge Complicated by Mechanical Mixtures .................................... 52
5.2.5 Protection Against Minimum Pump Intake Pressure ......................................................... 53
5.3
Automatic Adaptation ............................................................................................................... 53
5.3.1 Pavg Calculation .................................................................................................................. 54
5.3.2 Automatic Adaptation Settings and Example .................................................................... 55
5.4 Drive hardware protections not accessible to operator ............................................................. 56
5.5 Calibration Without TMS ......................................................................................................... 56
5.6 Motor Stop................................................................................................................................. 57
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5.7 VFD Disconnect ........................................................................................................................ 57
5.8 VFD Modification and Identification ........................................................................................ 57
5.9 VFD Operating Modes and Modification ................................................................................. 58
6 VFD Faults and Corrective Actions ................................................................................................. 59
6.1
VFD Disassembling Procedure ................................................................................................. 59
6.1.1 General Procedure .............................................................................................................. 59
6.1.2 Safety Measure During Disassembly ................................................................................. 59
6.1.3
Specific Component Replacement ..................................................................................... 59
6.2
Checking VFD Operational Capability ..................................................................................... 60
7 Appendices ....................................................................................................................................... 61
7.1 Appendix A – Fault List and Meaning ...................................................................................... 62
7.2 Appendix B – Parameters, Settings and Adjustments ............................................................... 64
7.3
Appendix C – Type Settings By ID .......................................................................................... 73
7.4 Appendix D – Probable Faults and Troubleshooting ................................................................ 75
7.5 Appendix E - External Signal Connections............................................................................... 79
7.6 Appendix F – PMM and ESP Motor TMPN Transformer Selection ........................................ 80
7.7 Appendix G – Board Light Indicators ....................................................................................... 83
7.8 Appendix H - Schematics .......................................................................................................... 90
7.8.1 VD80 Electrical Schematic – Page 1 ................................................................................. 91
7.8.2
VD80 Electrical Schematic – Page 2 ................................................................................. 92
7.8.3
VD40 Electrical Schematic – Page 1 ................................................................................. 93
7.8.4 VD40 Electrical Schematic – Page 2 ................................................................................. 94
7.8.5 VD250 Electrical Schematic – Page 1 ............................................................................... 95
7.8.6 VD250 Electrical schematic – page 2 ................................................................................ 96
7.9 Appendix I – Menu Samples ..................................................................................................... 97
7.10 Appendix J - GOST Standard References ............................................................................. 99
7.11 Appendix K - Modification Log .......................................................................................... 100
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Forward
This manual is written expressly for the Borets-Weatherford Variable Frequency Drive operation. It
covers, in general, all models of the Borets-Weatherford VFD line, their design, operating procedures,
service, repair, storage and transportation.
All VFD operating personnel will have specialized training for installation and operation of electrical
devices up to 1000 volts, and will have knowledge of this manual.
Some of the Borets-Weatherford VFD models are described in Table 1 of the technical specifications
per TU 3431-009-55280707-2007 (Technical Requirements for VFDs for Permanent Magnet Motors).
For example, a 40KW VFD, equipped with TMS, a manual mode selector, an analog input, and
designed for a PMM would be identified as:
Borets-VD 40.2 MPA TU 3431-009-55280707-2007 PMM VFD
where –
40.2 – 40KW maximum capacity, 480V input
M – VFD is designed for a motor equipped with TMS
P – VFD includes manual mode switch - - -
A – VFD includes input to connect to external analog signals
PMM – permanent magnet motor
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Abbreviations
The following abbreviations are used within this manual:
FCC - Frequency Converter Controller
FLB - Filter Limit Board
IRU - Information Read-Out Unit
PEN - Protective Earth Neutral
PMM - Permanent Magnet Motor
PWM - Pulse Wave Modulator
TMC - Telemetry Controller
TMS - Telemetry System
VFD - Variable Frequency Drive
VFD C - VFD Controller
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Safety
Solid state equipment has operational characteristics differing from those of electromechanical
equipment. Because of this difference, and also because of the wide variety of uses for solid state
equipment, all persons responsible for applying this equipment must satisfy themselves that each
intended application of this equipment is acceptable.
In no event will Borets-Weatherford be responsible or liable for indirect or consequential damages
resulting from the use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the
many variables and requirements associated with any particular installation, Borets-Weatherford cannotassume responsibility or liability for actual use based on the examples and diagrams.
Throughout this manual, when necessary, notes are used to make the operator aware of safety
considerations.
WARNING: Identifies information about practices or circumstances that can cause an
explosion in a hazardous environment, or which may lead to personal injury or death, property damage,
or economic loss.
Important: Identifies information that is critical for successful application and understanding of the
product.
ATTENTION: Identifies information about practices or circumstances that can lead to
personal injury or death, property damage, or economic loss. Attentions help the operator identify a
hazard, avoid a hazard, and recognize the consequences.
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Shock Hazard labels may be located on or inside the equipment (e.g., drive or motor) to
alert operators or maintenance personnel that dangerous voltage may be present.
Burn Hazard labels may be located on or inside the equipment (e.g., drive or motor) to
alert operators or maintenance personnel that some surfaces may be at dangerous temperatures.
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1 Description and Operation
General Precautions
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required when installing, testing, servicing or repairing this
assembly. Component damage may result if ESD control procedures are not followed.
ATTENTION: An incorrectly applied or installed drive can result in component damageor a reduction in product life. Wiring or application errors, such as, under sizing the motor, incorrect or
inadequate AC supply, or excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives andassociated machinery should plan or implement the installation, start-up and subsequent maintenance of
the system. Failure to comply may result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the buscapacitors has discharged before performing any work on the drive. Measure the DC bus voltage at the
+DC & – DC terminals of the Power Terminal Block. The voltage must be zero.
ATTENTION: To avoid an electric shock hazard, be aware that AC voltages are presentwithin the Drive with the primary power circuit breaker, QF5, turned OFF.
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1.1 Function
The Borets VD VFD is designed for use with version 1 and 2 VEDB permanent magnet motors.
The Borets VD VFD with the telemetry system is designed for use with version 3 and 4 permanent
magnet motors. Both series are for use as oil field equipment and provides the following general
functions:
- Protects the motor and VFD in emergency situations
- Displays main operating parameters of the motor and VFD
- Executes operator commands from the control panel
- Logs and processes data from the telemetry system (TMS)
- Logs data for subsequent processing
-
Transfers current and logged data to the upper level system (ULS)
- Software can be updated as required
1.2 Technical Specifications
Operating Modes
- Set by duration for long term
- Set by control and protection – manual, automatic, and automatic cycleSupply Voltage
- 3 phase, 4 wire, earth neutral
-
480 volt, +/- 120 voltsSupply Frequency
- 60 HZ, +/- 3 HZ
Operating Temperature
- -600C (-76
0F) to +50
0C (+122
0F)
Note
Operating Humidity
- 100% at +250C (+77
0F)
Enclosure- Second degree industrial atmosphere (GOST 15150 – Machines, instruments and other
industrial products. Modification for different climatic regions, operating, storage and
transportation conditions.)
-
Mechanical impact (GOST 17516.1 M1 – General requirements for environment mechanicalstability for electrical articles.)
- Protection in compliance with IP43 (GOST 14254 (Degrees of protection provided by
enclosure (IP Code)) or NEMA 3R)
Note – Operating temperature refers to the ambient operating exterior temperature. Heaters and
protective sensors limit the interior operating temperature to -400C (-40
0F).
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1.3 VFD Functions Performed
PMM Management functions
- Soft start and shutdown
- Variable speed within range of the PMM
-
Soft increase or decrease as set by the operator- Automatic adaptation of rotation speed based on intake pressure (for M versions)
- Rotation direction can be clockwise or counter clockwise
Fixed software and device protection (non-operator accessible)- Maximum current setting
- Motor overload
- Loss of output phase- Voltage change of more than +/-25% of nominal
- Overheating greater than +850C (+185
0F)
- Attempt to activate at temperatures below -400C (-40
0F)
- Operator set point protection
-
Pass word protected to prevent unauthorized setting changes- Current overload and under load (absolute values)
- Current overload and under load (percentage of nominal value)- Input voltage unbalance by more than 25%
- Output voltage unbalance by more than 25%
- Output current unbalance by more than 25%
- Electrical shut down delay on opening front door- Resistance reduction in motor cable and transformer secondary for values less than 30K
ohms to 500K ohms
- Ride through for short term gas discharge- Ride through for pressure at wellhead (contact pressure gage)
-
Change in power supply voltage greater than 15%Drive M with TMS additional protection
- Motor vibration in excess of 10g (PMM) at winding temperature of 1600C (320
0F)
- Pressure reduction at pump intake up to 300 atmospheres
Other functions
- Control value range of input settings- Logging and control of parameters
- Ambient temperature control
- Controller’s LCD heating activation control - Radiator temperature control
- Radiator cooling fan activation
-
Logging of all events during operation-
Review of logged data on LCD- Parameter logging with set step
- Logged data transfer to external computer for analysis
- Transmit current and logged data to ULS via external interface
- Update software from PC or IRU
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1.4 VFD Physical Structure Description
The VFD is contained in a metal cabinet and shown in Photo 1, and is described in the following:
Photo 1 – VFD External View
The cabinet of the VFD (1) is composed of two compartments, upper and lower, and has three doors.
Two of the doors are on the front of the cabinet (2 and 3), while the third is on the rear of the cabinet
(4). There are also two maintenance panels (5 and 6). All doors and maintenance panels have a rubber
seal, and are fastened either by 1800 twist locks (7) or screws. The twist locks require a special tool,
which is included with the drive.
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- Front door (2) accommodates access to VFD indicators and controls
- Front door (3) provides access to the VFD power circuits inside the cabinet
- Rear door (4) provides access to the VFD power connections
- Front panel (5) provides access to the lower compartment
- Rear panel (6) provides access to the cooling radiator and lower compartment
- External communications (8) are accommodated through side panel
- Hazard symbol (9) notes electrical shock hazard within cabinet
Overall dimensions and weights of the various VFD versions are listed in the Technical Specification
TU 3431-009-55280707-2007 (Technical Requirements for VFDs for Permanent Magnet Motors.
1.4.1 Components Exposed by Large Front Door Opening
Components for the VFD are installed inside the cabinet. A view of the internal structure is shown inPhoto 2, with the large front door open. Some device location codes may be repeated, depending n
their physical location (side wall, rear wall, etc.). Some of the items inside the cabinet are described in
the following:
- Power module (11), TsRKF.435782.001 The Power module consists of power
thyristor and transistor modules; IGBT, PWM, thyristors driver boards; snubber boards;heatsink heaters and temperature sensor. All are described in the specification and can be
found on a VSD schematic diagram marked .
- 2 capacitors banks (12), with discharge resistor boards TsRKF.435782.001 ,
TsRKF.435782.001 .- Filter-limiter board located under cover (13). Used as part of the insulation resistance
measuring.
- Output current sensors (14), < in the VD40 these are identified as A9, A10, and A11, whilein the VD80 they are identified as P2, P3, and P4>
- Excess voltage limiter (15)
- VFD power circuit breaker (16),
- High voltage terminal for TMS (17), , option M- Current sensor (18),
- Door opening limiting switch (19),
- Secondary power and control board (20)
-
Grounding terminals (21)- Light (22),
- Snubbers (23),
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1.4.2 Components Exposed by Small Front Door Opening
The components, indicators, and switches covered within the small front door opening are shown in
Photo 3. The description of each is given in the following:
- Indicator lamps of control station (24),
o GREEN light indicates operation, motor rotating (HL1)
o YELLOW light indicates unit in standby, waiting for START (HL2)
o RED light indicates stop, operator needed for re-start (HL3)
o YELLOW pilot indicates heating is ON (HL4)
o RED pilot indicates heating ON at the VFD controller front panel
Photo 2 – Internal View of VFD
- Borets-VD controller VFD C, display and keyboard (25)- Motor START button (26),
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- Motor STOP button (27), (may have P or may not)
- Operation mode selector (28 – option not shown), (will have on P models)
- Receptacle for 120V, 60HZ (29), - Breaker for receptacle (30),
- Breaker for cabinet light (31),
-
Breaker for control wiring (32), - Breaker for internal heating (33), - Main Power breaker (16),
- Thyristors (42),
- Pulse Wave Modulator (PWM) which can be reached through removable screen (43)- Rectifier thyristor control board (46),
- Temperature sensor boards (not visible from front),
- Heating element and blower (are not shown, but are located at lower right of cabinet). Note
– heating elements EK1, EK2, and EK3 have been replaced with heating element EK1 and amotor and fan, M2.
Photo 3 – Internal View of Small Front Door Opening
24
25 16
29, 30, 31, 32, 33
2627
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1.4.3 Components Mounted Internal of Large Front Door and Left Side of Cabinet
Photo 4 shows the internal side of the large front door with components mounted to it. It also showssome of the internal components mounted onto the left side of the cabinet. The description of each
follows:
- Reverse side of station controller (34),
- External analog input unit, (option, not shown, for version A VFD)
- Controller for telemetry unit (TMC) (36), (for version M VFD)- Mounting plate for Control and Secondary Power Board Assembly (70),
- Universal power pack (51),
- Control and Secondary Power board (52),
- Resistor divider board (53), - Measuring resistor board (54),
- Frequency converter controller board (55),
Photo 4 – Internal View of VFD Large Door and Left Side
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1.4.4 Components mounted on inside at rear of cabinet
The following components are mounted in the rear of the cabinet and are shown in Photo 5. A brief
description of each is as follows:
- Terminal for neutral main of transformer secondary (39),
- Input power connections (40),
- Output power connections (41), - Output power connection,
Photo 5 – Internal View With Rear Door Open
The lower compartment contains the smoothing chokes and the cooling fan. These are illustrated in
Photo 6.
- Smoothing chokes for version 40 and version 80
- Cooling fan
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Photo 6 – Lower Compartment
1.5 VFD Component Operations
The operation of the VFD is described in the following paragraphs. Figure 1 provides a block diagramof the internal connections and units found in the VFD. Primary elements within the VFD are the
primary power (A, B, C), the primary power circuit breaker, a three phase rectifier, filter elements, a
pulse-wave modulator, the commutation switch, and a number of control units. In addition, there will be a step-up transformer connected between the VFD and the submersible motor, as well as the
interfacing power cable and the PMM submersible motor.
L1
M1
L2
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Figure 1 – Schematic diagram for VFD
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1.5.1 Power Circuit
ATTENTION: To avoid an electric shock hazard, be aware that AC voltages are present within the Drive with the primary power circuit breaker, QF5, turned OFF.
Primary power to the VFD is supplied as 480 V, 60 Hz, 3 phase. When the primary circuit
breaker is energized, the power will be supplied to a full-wave rectifier. The output of the
rectifier is smoothed by a filter network, and results in a DC voltage of approximately 690V(LV+). The DC voltage is fed through a pulse wave modulation circuit, and then to a
commutation switch to convert the DC voltage to AC. The AC voltage is fed from the unit as
phases U, V, and W into a step-up transformer. The transformer is not a physical part of theVFD, it is an external device. The output of the transformer will be suitable to power the
selected submersible PMM motor in the downhole environment.
If the VFD has the telemetry system (TMS), the TMS ground will connect to the transformersecondary neutral. This connection will allow the downhole unit to send data signals to the
surface. If the VFD does not have the telemetry system, the main input neutral will be connected
to the VFD controller to enable insulation resistance measurements.
1.5.2 Control Circuits
The frequency converter controller (FCC) controls the operation of the various power circuitelements via drivers located on the various boards within the cabinet. These include:
- Thyristor control board- PWM driver board
- IGBT driver board
- Resistor divider board- Measuring resistors board
These boards provide error signals to the Frequency Converter Controller (FCC), and receive
control commands from it. The resistor divider board provides sensing signals to the FCC formonitoring purposes. The signals include; primary phase voltage signals from A, B, and C
phases, voltage sensing lines LK+ and L- from the DC current control, and output phase sensors
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of the U, V, and W outputs. The Measuring Resistors Board provides monitoring signals of
output current.
If normal operation is taking place, the Frequency Converter Controller (FCC) is connected to
the VFD controller (VFD C) through an RS485 communication interface. The VFD C sends
system settings to the FCC, as provided by the operator from the control panel of the VFD C.The VFD C receives current operational parameters from the VFD.
The VFD C may also be linked to the telemetry controller (TMS) via an RS232 interface,
receiving the motor sensor information.
The VFD C receives sensor signals from the START button, STOP button, and the door
interlock switch. The VFD C will also control the RUN, STANDBY, and STOP indicators. The
VFD C is also connected to the upper level system (ULS) via a separate RS-485 interface, protected through the lightning guard unit. The VFD C also processes discrete time signals (DS)
control gauge and operation inhibit, as well as analog signals which will be converted by the
analog input module, both of which will be transferred to the frequency converter controller.
Depending on the operational mode – normal operation or data removal – the VFD C will be
connected to either the upper level system (ULS) or the information read-out unit (IRU) as the
source for data transfer.
Heating and cooling control is also handled by the VFD C via the Control and Secondary Power
board.
1.5.3 External Power Transformer
The external power transformer provides the required voltage adjustment to accommodate thePMM motor needs, as well as the voltage drop of the power cable connecting the surface units
with the downhole devices. The secondary neutral point also provides the connection for the
system insulation resistance measurement.
1.5.4 Telemetry System
The telemetry system (TMS) provides the interface for a number of downhole measurements,
including:
- Motor winding temperature
- Pump intake pressure
- Pump intake temperature- Equipment string vibrations (accelerations) in X and Y axis
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- Insulation resistance of external transformer’s secondary
The TMS consists of three parts; the high voltage unit, the interface connection, and thesubmersible connection. Detailed information can be found in the TMS operating manual,
UVFK.134 RE (Operation Manual for Borets Downhole Monitoring System).
1.5.5 Starting the VFD
The VFD is started by turning on the main circuit breaker. If the temperature of the VFD is
lower than -400C (-40
0F), the system will automatically turn internal heaters in order to move
the unit into normal operating conditions. If the automatic circuit does not function correctly, the
heaters can be turned on manually by turning on the HEATING switch. Forced heating must beactivated to dry the inside of the cabinet, and ensure various components are within their
operating envelope. After start-up, the heating should be turned OFF.
If the temperature inside the VFD is greater than -400C (-40
0F), main power unit power will be
applied, followed by the various control circuits. When the temperature reaches -300C (-22
0F)
heating will be removed, and the VFD will enter a self check mode. When the VFD self check iscomplete, the operator should enter the operating parameters, set the mode to automatic start, and
press the START contact. Upon receiving the START, the VFD will start the preliminary charge
of the charging capacitor C1, and begin the rectifier thyristor switching. The pulse wavemodulator will also be activated, and the motor will begin to rotate to the commanded frequency
set by the operator.
In the OPERATION mode, the VFD C will monitor the internal radiator temperature throughtwo sensors built into the radiator. When the radiator temperature exceeds +40
0C (+104
0F) a
fan will be turned on. The fan will automatically shut off when the temperature falls below
+350C (+95
0F).
1.5.6 Shut down of VFD
The VFD can be shut down for the following reasons:
- By pressing the STOP button
-
Detection of an equipment failure- Limit exception exceeded on control parameter
In the case of an emergency stop, the VFD has automatic restart capability. The number of
restarts permitted depends on the type of stoppage:
- When control parameter limits are exceeded, the number of permitted restarts is set
by the operator.
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- When an equipment failure is detected, the number of restarts is limited to three.
The last fault and failures will be displayed on the LCD display. For a full list of possible faultsand their displays, see Appendix A. While at the stoppage, other faults may be present, and can
be viewed through menu selection. Failure data may also be saved for later viewing as part of
the VFD history.
1.6 Marking And Packing of VFD
The marking of the VFD is in compliance with GOST 18620 (Marking of Electrotechnical
articles) requirements.
- Name of VFD version (Borets – VD...Drive UXL1
- Technical Specification – TU 3431-009-55280707-2007 (Technical Requirements for
VFDs for Permanent Magnet Motors)- Plant Manufacturer’s trade mark
- Production Number
- Circuit voltage, nominal current
- Weight- Manufacturing date
Packing will be in accordance to GOST 23216 (General Requirements and Test Methods forElectrotechnical Products, Storage, Transportation, Temporary Corrosion) requirements.
Cargo marking will be in accordance to GOST 14192 (Marking of Cargos) requirements.
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2 Description and Operation of VFD
2.1 VFD Controller (VFD C)
The drive controller (VFD C) provides the main control algorithm for the operation of the VFDand the downhole equipment (PMM, TMS, and pump). The VFD C is shown in Photo 7, and
consists of:
- Keypad with six buttons- Four line LCD readout
- LED indicator for heater activation
-
Controller board with power connector and communication connectors
The schematic diagram for the VFD C is shown in Figure 2.
Photo 7 – VFD Controller
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Figure 2 – VFD Controller Structural Diagram
2.2 Functions of Variable Frequency Controller (VFD C)
The VFD C functions include the interface with the operator, and provide the following
operations:
- Setting and adjusting input parameters
-
Provides configuration information to the operator- Executes commands as entered by the operator
- Provides a VFD operation mode display
- Provides a device current operational parameters- Provides a VFD operating history including:
o Transfer of VFD C settings and commands by the operator
o Receipt, processing, and registration of parameter data
o Status of device operating mode
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o Work during fault or parameter limit checks, including:
Motor stop Motor failure and indication Motor restart in automatic mode, including:
Link with external control devices
Discrete signal processing, contact pressure gage Link with VFD ventilation system
Link with LCD heating system
Smoothly adjust motor speed as set by operator
Monitor interlock switch and power off if it is opened
Monitor communication between VFD C and FCC and power offif no communication for 10 minutes
Recognize various operating modes of the VFD
Perform resistance insulation check without TMS
Process TMS data if available
Process motor speed changes based on pump intake pressure
Process analog signals and commands as appropriate
Process saved data from the IRU to the upper level interface
Provide software updates to VFD C during operation
2.3 Operator’s Communication with VFD C
For operator’s communication with the VFD C controller, the operator panel is used. The panel
consists of an LCD display and six keys. Four lines of information are displayed on the LCDwindow. The operation of the VFD is controlled by the various commands and parameters that
can be set by the operator through the various screen menus. Movement between menus iscontrolled by the keys. A more detailed description of the controller menu and keyboard
functions is provided in Section 3.11.
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2.4 Power Module
The power module consists of several functional items. The power module is controlled by the
VFD C controller signals, and converts the input primary, 3 phase, 480V, 60 Hz into a DC
voltage, then into a pulse-wave modulated output, and finally into an AC signal at the desired
operating frequency, which is supplied to the PMM. The functional assemblies are:
- Thyristor driver board
- Three phase rectifier thyristors
- Pulse-wave modulation driver board- PWM and current control
- IGBT driver board
-
IGBT commutator
2.4.1 Rectifier Module Section
The thyristor driver board and thyristor rectifiers convert the incoming 3 phase, 480V, 60 Hz
power into a DC voltage level. That voltage, LV+, for this unit is a nominal 690V. The level of
output voltage is determined by commands from the VFD C to the thyristor driver board to
determine the turn-on point, or gate, to the thyristors. The thyristor is essentially an SCR (siliconcontrol rectifier), which is turned on by a gate signal and continues to conduct until the source
voltage goes away or goes negative (such as in an AC signal source). The output of this section
is fed to the Pulse Wave Modulation (PWM) section.
2.4.2 Pulse Wave Modulation Section
The DC voltage, LV+, out of the thyristor section is applied to the PWM part of the DC Current
Control unit. The PWM will determine, based on control signals from the Frequency Controller,the duty cycle of the PWM switch. The output of the PWM switch will vary from the nominal
690V (100% duty cycle) to some lesser value. For example, if the desired voltage were to be
345V, then the PWM would be set for a 50% duty cycle (on one-half of the time). The outputvoltage, LK+, is sensed through the resistor divider board and that signal passed to the
Frequency Controller.
Another function of the PWM section is to monitor the output current being delivered by the power section. This is accomplished through the current sensor, the measurement of which is
passed to the Frequency Controller to be acted upon (cause the output voltage to increase or
decrease as the load demands).
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2.4.3 IGBT Module Section
The IGBT driver board provides the controlling gate signals to the IGBTs used to transform theincoming DC voltage, LK+, to the desired output frequency to drive the downhole permanent
magnet motor (PMM). The IGBT driver board receives commands from the Frequency
Controller, and provides feedback to that unit. The output voltage and phase signals are passedto the Frequency Controller via the divider resistor board, and the output current, for phases U,
V, and W are passed via the measuring resistor board.
2.5 Power and Control Module
The power and control module consists of several assemblies, among them being:
- Variable frequency controller board
- Resistor divider board
-
Measuring resistor board- Control and Secondary Power board
- Universal power packs
2.5.1 Frequency Converter Controller (FCC)
The Frequency Converter Controller board accommodates analog and digital signal processing.The analog section receives and transforms normalized analog voltage and current signals. The
normalization is done via the resistor divider board and the measuring resistor board. The digital
signal processing is accomplished measuring devices and microprocessors to process the
measurement results.
The analog signals processed include:
- Primary power phases A, B, and C
- Commuting switch voltages LK+ and L-
- Output power phases U, V, and W
- Current through current detector- Output current in phases U, V, and W
- PWM voltage regulator
The digital signals processed include:
- RS485 control drivers
- RS485 timers (loss of signal detection)- Control device error signals
- START motor
- STOP motor- Power module radiator temperature sensor
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2.5.2 Control and Secondary Power Board
The control and secondary power board contains the internal temperature sensor. The boardenables control signals for the VFD to power on, sensing that the internal temperature is within
the proper operating range. It will also turn on the internal fans as required.
2.5.3 Universal Power Packs
There are five types of power pack boards. Each is designed to convert the input AC (220 V+/-55V, 60 Hz) to DC for the various controllers, sensors, drivers, and external interfaces. The
power packs are located at A5, A6, A7, A8, and A9. All 5 are supplied with Phase A AC input,
and have the following output voltages (and associated grounds where appropriate):
-
A5 – V5 (+15V) and V6 (-15V)- A6 – V7 (+15V), V8 (+5V), and V9 (-15V)
- A7 – +V10 (+100V), -V10 (-100V), V11 (+7V), and V12 (+15V)- A8 – V1 (-15V), V2 (+5V), and V3 (+15V)
- A9 – V4 (+12V)
2.6 LED Indicators
There are LED indicators on almost all boards. They are used to indicate power applied
conditions for the VFD C, drivers, displays, and status of the primary parts of the drive. The
location, purpose, and function of the various LEDs are given in Appendix G.
2.7 VFD Protective Devices
The Limit Filter board is designed to limit voltage excesses in the insulation measurement circuit
when the insulation resistance is reduced.
The Over Voltage Limiter is designed to protect the drive from lightning and commutation
overloads.
The Discharge Resistor boards are designed as protective devices for personnel through thedischarge of the power capacitors when the drive is turned off .
The Lightning Guard Board is designed to protect the external interface of the RS485communications line.
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2.8 Analog Unit
The analog unit is designed to process various analog signals, passing the measurements to the
VFD C via an RS-485 communications interface. The VFD C will use the signals for
operational considerations, i.e. motor stop, power off, etc. The parameter settings are set by the
operator or as permanent settings.
Two analog sensors may be connected to the drive, providing an analog signal range of -10 V to
+10V.
2.9 Telemetry System
The telemetry system is designed to monitor a variety of downhole signals, including:
- Motor winding temperature
- Pump intake pressure-
Pump intake temperature
- Equipment string vibrations (accelerations) in X, Y, and Z axis (Note – only X and Y
vibration are displayed)- Insulation resistance of external transformer’s secondary
The telemetry system consists of two parts; 1) the surface portion that receives, decodes, and
processes the various signals from the submersible equipment, and then passes the information tothe VFD C via the RS232 interface, and 2) the submersible portion where the sensor information
is translated to a frequency manipulated signal and passed to the surface unit via the motor stator
windings, power cable, and transformer secondary.
2.10 Information Read-Out Unit (IRU)
The information read-out unit (IRU) consists of hardware and software to perform the followingfunctions:
- Read and store data logged by the VFD controller. The data is stored in a flash-cardwith up to 1 G byte of storage. The data can be uploaded for analysis using a special
software package – Communicator.
- Provides the ability to load new versions of the controller software while the systemis operational.
-
Provides a test function of the VFD.
2.10.1 IRU Preparation for Operation
To prepare for operation of the IRU with the drive, the IRU must be connected to the RS485 port
on the VFD C front panel. The IRU must also have a flash-card inserted into it. For re-
programming or testing, the flash card must have the service data pre-recorded (this is
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accomplished by a special service program). Without the service data, the IRU will only
perform the data logging read function.
2.10.2 IRU Operation
As noted in 2.10.1, the IRU must be connected to the drive via the RS485 port on the front panel
of the VFD C. Once successful communication is established between the IRU and the VFD C,the IRU will be checked for a flash card containing service information. If there is service
information, the LCD submenu will appear; otherwise the IRU will be switched to data loggingread function. If there is service data, the LCD submenu may have any of the following items
displayed:
- Download history
- VFD C program
- VFD program- Testing
The availability of the last three items depends on the flash card service data content.
If within the first ten seconds the drive does not begin to communicate with the IRU, it is
possible that the drive is communicating with one of the assembly controllers. To force the driveto communicate with the IRU, press and hold the DOWN ARROW and the CANCEL buttons on
the VFD C front panel. An alternative method would be to select the submenu and change the
Upper Level System setting to NO Upper Level System. After all IRU operations have beencompleted, resume communication with the assembly controllers by removing and re-plugging
the RS-485 connector on the VFD C front panel.
After the IRU and drive have communicated, the display may display NO CARD. Disconnectthe IRU and check the flash memory card for being inserted and properly seated, and then
reconnect.
After the IRU and drive have communicated, the display may display INSUFFICIENT SPACE.
Disconnect the IRU and replace the flash memory card with one that has available memory, and
then reconnect.
2.10.2.1
History Download
During history download, the IRU will automatically determine that the data file available is
from this drive. If the data file is available, the LCD screen will display FILE
REPLACEMENT? Press the ENTER key to continue (and a new file will be opened for datalogging). The display will show the file being down loaded, along with the warning DO NOT
REMOVE IRU. When the transfer is complete, the LCD will display EXCHANGE OVER, and
IRU CAN BE REMOVED.
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After the IRU disconnect, the VFD C will switch to the indicated mode. At the completion of
the data transfer, the flash card file will be preserved and named in the format of assembly, wellnumber, and the file type of .pr. For example, for assembly 666 and well 13, the file name would
appear as 666_13.pr.
2.10.2.2 VFD C and FCC Programs
During the programming load process, the LCD will display REPLACE v.X.XX or v.Y.YY,indicating which program is being replaced. Press the ENTER button on the operator’s panel to
continue the re-programming, or CANCEL to stop the process and terminate communicationwith the IRU.
After beginning the re-programming process the LCD will display VFD PROGRAM. The
process will take 3 to 5 minutes to complete. Once the process is complete, the VFD C willswitch to normal mode and the IRU can be turned off.
Note – Do not disconnect the IRU or turn off the drive before re-programming is complete.
Either action can result in a severe error. If the action cannot be avoided, reconnect the
IRU to the drive and wait 10 minutes. When this time has elapsed, the LCD should flash 2
of the 4 display lines. If this does not occur and the VFD C does not return to normal mode
indications, the VFD C will require replacement and returned to the factory for
reprogramming.
If the drive programming must be completed without stopping the motor, the drive must be in
AUTOMATIC mode.
2.10.3 Testing
For testing the drive, the LCD display will provide a display listing of the tests available.
Choose the required test and press ENTER to start the test. During the test, the operator will
perform the instructions displayed on the LCD screen. The test may be stopped by pressing theCANCEL button. Upon test mode exit, the LCD will show the main window.
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3 Installation and Wiring
3.1 Safety measures during drive preparation
All installation, dismantling, and operational works should be completed incompliance with current regulations; “Technical Operation Regulations of User’s Electric
Devices” and inter -branch regulations of safety measures for personnel protection during the use
of user’s electric devices operation RM-016-2001 and RD 153-34.0-0-03.150-00.
Grounding and protective measures should be carried out in compliance with therequirements of the current “Regulations on Electric Devices Design”.
The station housing should be properly grounded. Station power should be suppliedfrom a 3-wire circuit with a dead-ground neutral. The zero wire should be properly connected
with the metallic body of the station at the terminal.
ATTENTION: To avoid an electric shock hazard, be aware that AC voltages are
present within the Drive with the primary power circuit breaker, QF5, turned OFF.
Before working inside of the drive, the following activities must be completed toensure electrical safety:
- Remove drive voltage and check for absence at input connection
- Place ground strap on all three input phases (A, B, and C)- Install warning placards showing workers in cabinet
- Allow at least 5 minutes for all circuits to discharge completely before beginning
work
- All voltage checks should be made by trained personnel only, as required by currentsafety practices
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3.2 Preparation for Operation
3.2.1 External Inspection
Carry out an external inspection, making specific checks for the following:
- All of the equipment is available
- All pertinent documentation is available- There is no evidence of equipment damage
- DB type connections are good, specifically:
FCC (4 places) IGBY driver board (1 place) PWM driver board (1 place)
Rectifier thyristor control board (1 place) Drive controller (4 places)
-
Ensure all electrical connections are properly tightened
Thyristors (5Nm +/- 0.5 Nm)
Power block transistors (4 Nm +/- 0.5 Nm) Power circuit switch (22 Nm +/- 1.5 Nm) Note: Nm is equivalent to lbs-in
3.2.2 Connection of VSD
- Connect drive with power circuits as illustrated in Figure 3.- Check proper connection of power to motor rotation.
- Check connections between drive and zero bus on transformer.
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Figure 3 – VFD Connection Diagram
- Install reference voltage at transformer Tr 1, as determined by the type of PMM
motor and ESP pump (reference Appendix F).
- Connect contacts XT7 and XT8 (socket heads in drive left side compartment) to theexternal circuits.
- Connect the RS485 connections (reference Appendix E).
- Set all circuit breakers on the drive control panel to OFF.- For drives with the 480V conversion kit, the kit must be installed as illustrated in
Figure 4.
ATTENTION: To avoid an electric shock hazard, be aware that AC voltages are present within the Drive with the primary power circuit breaker, QF5, turned OFF.
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Figure 4 – 480V Conversion Kit
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4 VFD Control Menu
For a complete Control Menu structure, refer to Appendix I. The operator uses the menu to
view, edit, execute commands, and measure insulation resistance.
4.1 Function of keys
Key function will change, depending on the type of menu operation. There are four types ofwork the operator be involved with, they are:
- View lists of parameters, settings, adjustments, and drive operational history
- Edit settings and adjustments- Execute commands
- Measure insulation resistance channel calibration
The various functions of the keys are given in Table 1.
Table 1 - Key board functions
Key board
Type of work
View EditCommand
ExecutionCalibration
Cursor transferone line up
Increase digit for unit Cursor transferone line up
No function
Cursor transfer
one line down
Decrease digit for unit Cursor transfer
one line down
No function
Transfer to next
window
Transfer one symbol
place to right
Transfer to next
window
No function
Transfer to
previous window
Transfer one symbol
place to left
Transfer to
previous window
No function
ENTERTransfer to next
menu level
Exit from edit with
input symbols saved
Execute
Command
Transfer to next
calibration step
CANCEL
Return to
previous menu
level
Exit from edit with
input symbols saved
Return to
previous menu
level
Exit from
calibration
without savingresults
In the VIEW mode, the operator can view lists of parameters, settings, and adjustments. The
viewed lists can be changed, depending on the composition of the drive equipment. The changes
are entered by the operator. Some submenu lists are automatically updated by the system afteran operator input. For example, if the operator input , CP control elements will be
included automatically into the submenu lists associated with the TMS operation.
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The operator can switch from the VIEW mode to EDIT mode, however a pass word must be
entered before any editing can be accomplished. Edit mode enables changes to settings and
tuning values within a set of permitted ranges. If the value inserted for a setting, tuning value, orother adjustment is not within the probable range for the drive, the VFD C controller will,
without leaving the Edit mode, suggest limiting values for the input from the operator.
The Edit mode password can be bypassed through COMMAND mode cancelling therequirement of a password by setting the password to 0000 (see COMMAND sub-menu for more
information).
4.2 Drive Controller Menu Description
The drive controller menu has three main groups. They are:
- Parameters (a list of parameters for drive operation)
- Menu (names of sub-menus)
-
Submenus (settings, tunings, or lower level sub-menus)
4.2.1 Parameters
The main menu, which contains the parameters list, will be displayed after the drive has
completed all of the controller checks and processes. There will be four lines on the display,where the lines will contain:
- (motor revolutions)
- (motor current)- (insulation resistance)
-
Status (current date and time, or last error causing motor stop)
The main menu window has an additional viewing area not found in the other menu windows.
This area is used to provide information to the operator for conditions sensed in the drive that
could be adjusted for a more optimal operation.
For example, on the line, an up arrow, down arrow, or tilde (~) could be displayed.
The up arrow is indicative that the voltage being applied to the motor is too high and will bedriving more current into the motor than required. The down arrow is indicative that the voltage
being applied is too low, and the drive may not be able to bring the motor to the required
rotational speed. The tilde is indicative that the motor is either accelerating or braking.
On the display line of , a down arrow may appear, meaning that the current being
delivered to the motor is not sufficient. Two things may cause this effect; 1) the transformer
secondary voltage, TMPN, is higher than required, or 2) the selected station driver power is not
sufficient to reach the set motor speed.
On the display line of , a down arrow may appear, meaning that the insulationresistance is lower than the value determined to be optimum for motor protection.
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Other symbols that may be displayed in the additional viewing area are:
- (drive has telemetry system installed)
- (drive main door is open)
-
, , (drive operating mode)- (independent automatic disconnect QF5 enabled)- < >>> > , < !> > (drive waiting on automatic start)
- , (motor speed increase or decrease, rotation speed, sharp reduction indynamic level of reservoir level, in automatic adaptation mode)
All parameters accessible for viewing can be selected by the operator using the key board via the
arrow keys as noted in Table 1. A full list of the parameters and their meaning are given inAppendix B. Parameter settings will change according to the requirements and equipment on the
drive.
4.2.2 Menu Windows
To move from the parameter window into the Menu Window, press ENTER on the keyboard.
The drive operation mode will be set in the Menu Window. The following are the sub-menu and
lower menu options:
- Settings – values used for drive and motor protection and control. Sub-menus
include items required for submersible equipment. Sub-menus include , , , and (for drives equipped withTMS).
- History – permits review of drive events including starts, stops, protective actions,
etc. Viewing starts with the latest event. A message will bedisplayed at the beginning of the record, and at the completion of the
file.
- Adjustments – contains the following items required for proper processing of record
file; 1) Well Number, 2) Cluster Number, 3) Oil deposit Number, and 4) Service data.Also included will be:
L descend, m – motor depth U transformer – transformer secondary voltage
Step of Record – parameters registration step Unit N – motor speed in Hz or revolutions/minute
- cable insulation leakage current (Zenith TMS only)
- Intensity – by using the up arrow and down arrow keys, the intensity of the LCDdisplay can be set for best view.
- Date and Time – by using the keyboard, the current date and time can be set.
- CP Composition – this menu has a number of sub-menus, including: Drive type (Borets VDXXXX), and is selected from a stored list
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PMM type, and is selected from a stored list
ESP m3/day, is the ESP capacity in cubic meters per day Head, m, is the ESP head TMS type, and is selected from a stored list
Note – VFD TYPE, PMM TYPE, and TMS TYPE must be set for drive
composition.- Passport (Calibration certificate) – submenu contains the following: - VFD Controller manufacturing number
- type of VFD controller - Controller manufacturing code - Controller manufacturing date
- drive serial number - drive type according to manufacturer classification - drive manufacturer code - drive manufacturing date
- feeder number
- Commands – enables service commands to be executed for drive operation.
Commands found in this menu include the following: Delete History – history data will be deleted from the drive Password Change – allows the password to be edited. If the password is set to
, the password is not required for access. Two levels are
recommended, factory set for use by the operator, and factoryset for the supervisor. If either password is lost, enter the alternate and
execute the command FACTORY SETTINGS. This will restore the factory
passwords, however, all current settings and adjustments will have to be re-
entered.
Test – will set VFD C into light and fan operational test. The LCD will
display TEST UNDERWAY, the fan will turn on, and the OPERATION,
STANDBY, and STOP indicators will flash. The test will run for one minuteand then stop automatically. If the operator wishes to stop the test, it can be
done by pressing CANCEL. The air flow can be measured for proper flow
rate at the upper cover at the rear side of the drive. Factory Settings – will set all settings to factory defaults. VFD Type, PMM
Type, and TMS type will not be changed.
Reset PMM Runtime – will change the motor runtime, number of start ups
permitted, and count of protected stops. Reset VFD Runtime – will reset drive runtime and power consumption
System Reset – will reset system after system loss
Unlocking VFD – removes lock of manual motor start after restart count has
been reached
- Calibration – performs calibration of insulation resistance measurements after repair,
preventive maintenance, and as a pre-measurement to the VFD C reading.
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- SVU – this menu is used to fine tune data exchanged between the drive and upper
level devices. Typical data includes: - select type from presented list - drive address in cluster net
- communication interface speed
- communication protocol number - Upper level interface permission to setting change
At the present time, two exchange protocols are defined. They are Surgut NG 3
and Region 2000. The appropriate address tables are contained in informationfrom the customer.
- Language – select the language to be used on the display.
- Service – provides parameters, settings, and adjustments for such devices as theVFD C, motor, VFD, and TMS. Access to these items requires a password.
The VFD parameters and status are:
RPM – motor revolutions per minute
, , - output phase to phase voltage
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The VFD settings and status are:
- rotary switch which may be turned ON or OFF
- test shutdown for EMF normalize
- test shutdown for backspin rotation
- current sensor protection. Can be turned off for
emergency motor start. - drive has analog inputs
- input voltage (380V/480V)
- over control range
- number of over controls permitted
- reset time of over control counter
Status – display of status bits forming VFD protection and setting fault list
During motor operation, motor speed may oscillate for a period of time. If
the oscillation exceeds motorinstability will be logged. If, within the time period given by , the number of oscillations exceeds the number set by ,
the motor will be shut down – if that protection has been set active.
The TMS settings and status are:
- rpm increase percentage from TMS
- pressure ramp rate to start over control
- over control step minimum
- pressure ramp rate in unstable operation mode, atm perminute
- pressure deviations
- temperature deviations
- vibration deviations Status – display of status bits forming TMS protection and setting fault list
4.2.3 Settings
- Other Settings
- motor rotation speed. Unit settings are displayed inrevolutions per minute or Hz, depending on the operator selection.
- sets the time between motor speed changes to maintain asmooth change. During motor start, the time starts when the motor
reaches the value given in .
- sets the motor rotation direction. If the motor phase iscorrectly connected, reference Figure 1, then the arrow direction to theright < >>> > corresponds to clockwise rotation, and the arrow to the left
<
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- sets the drive operating mode. It is either MANUAL orAUTOMATIC. A drive with the letter P in the designation does not have
this setting, and operating mode is set via a manual switch.
- protection switch for minimum insulation resistance check.It is either ON or OFF.
- sets the minimum insulation resistance value. If the valuedetected is lower than this, the motor will turn off (and restart is inhibited).
- protection switch for the contact gauge. It is either ON or
OFF.
- sets the contact gauge delay time in seconds.
- sets the contact gauge protection OFF immediately aftermotor start. Automatic motor restart cannot take place with the contact
gauge active.
Note – The number of automatic restarts after activation on is limited by the setting of .
- restart number for other protection occurrences.
- disconnect delay according to other protection after drivestart.
- counters zero setting time for Auto Restart numberlimitation.
- program set operating mode. It is either ON or OFF.
- sets time limit for drive to operate in Programmode.
- sets pause time for drive to operate in Program mode.
- sets the delay time for motor start after power is applied.
- sets the door interlock protection. It is either ON or OFF.
Note – If the door switch is OFF, a message will appear . If
protection is ON, QF5 automatic disconnect will turn the motor OFF, and
a message will appear , a red indicator will flash on the
operating panel, and the event will be registered in the log.
- sets the analog protection for analog 1 or 2 (the value ofn). It is either ON or OFF.
- sets the delay time for activation of the analog protectionfor analog 1 or 2 (the value of n).
- delay time of protection for Auto Restart according to
analog 1 or analog 2 (the value of n).
- the number of restarts permitted according to analog 1 or
analog 2 (the value of n). - delay time for protection according to analog 1 or
analog 2 (the value of n).
- sets all switches to OFF to protect against automatic
restart with old settings in place
Note – Restart time and number are set in and .
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- speed at which smooth start acceleration begins, see.
- U Settings
- low voltage protection, blocks even restart. - low voltage as percentage of nominal voltage, will provide
low voltage protection.
- low voltage protection delay in seconds.
- high voltage protection, blocks even restart.
- high voltage as percentage of nominal voltage, will providelow voltage protection.
- high voltage protection delay in seconds.
Note – Automatic restart after protection from or will take place once voltage has normalized, with a start delay as set by . At that time, the yellow indicator on the operator panel
should be flashing. - inhibits protection for input voltage imbalance, blocks
even motor restart.
- provides protection if the input voltage imbalance exceeds
the percentage given.
- provides the delay, in seconds, before the input voltageimbalance protection activates.
- provides the delay, in minutes, after the input
voltage imbalance occurs that restart will be inhibited.
- inhibits protection for output voltage imbalance, blockseven motor restart.
- provides protection if the output voltage imbalanceexceeds the percentage given.
- provides the delay, in seconds, before the outputvoltage imbalance protection activates.
- provides the delay, in minutes, after the output
voltage imbalance occurs that restart will be inhibited.
Note – The number of permitted restarts after protection has beenactivated by either or is given in .
- activation delay time for all U protections immediately
after drive start.
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- I Settings
- overload setting protection. It has 3 conditions, OFF
disconnects protection, BLOCK prohibits auto-restarts, and RESTARTwhich permits auto-restarts.
- provides absolute current limit. Current exceeding this value
will trip overload condition.
- provides an overload percentage from a nominal currentvalue. Current exceeding this value will trip overload condition.
Note - and are equal. Changing the value in will change the value in .
- provides shutdown delay after overload, in seconds.
- provides automatic restart delay, in minutes.
- provides the number of permitted restarts after overload
activation. - under load setting protection. It has 3 conditions, OFF
disconnects protection, BLOCK inhibits auto-restarts, and RESTART permits auto-restarts.
- provides absolute under load current limit. Current lowerthan this value will trip under load condition.
- provides an under load percentage from a nominal current
value. Current lower than this value will trip under load condition.
Note - and are equal. Changing the value in will change the value in .
- provides shutdown delay after under load, in seconds.
- provides automatic restart delay, in minutes.
- provides the number of permitted restarts after under load
activation.
Note – Under load protection becomes active when the motor speedreaches the value set by .
- load setting protection for motor current imbalance. It has 3conditions, OFF disconnects protection, BLOCK resets blocking
protection, and RESTART which resets protection.
- provides a current imbalance percentage from a nominalcurrent value. Current exceeding this value will trip imbalance condition.
- provides shutdown delay after current imbalance inseconds.
- provides automatic restart delay, in minutes, aftercurrent imbalance.
- provides the delay time of all current activation after drivestart.
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Note – Current protection is activated only after motor current exceeds avalue of 50% of nominal. The number of permitted restarts,
which is set in item .
-
TMS Settings
- disconnects and switches pressure regulation at pump intake
during automatic adaptation.
- setting provides pressure required for maintainingoperation during automatic adaptation.
- disconnects vibration protection, switches restart blocking protection, and switches restart protection.
- setting provides vibration level in g’s, which, if exceeded,will result in motor stop.
- setting provides vibration activation in seconds.
- setting provides restart delay, in minutes, aftervibration protection activation.
- setting disconnects over heating protection, switchesrestart blocking protection, and switches restart protection.
- setting provides maximum PMM winding temperature in
degrees C, if exceeded will cause motor to STOP.
- provides shut down delay in case of high PMM winding
temperature condition. Time is in seconds.
- provides restart delay, in minutes, after PMM windingtemperature protection activation.
Note – If after the time specified in , the PMM
temperature has not dropped below 120 oC, automatic start will bedeferred. The yellow indicator will be ON at the operator panel.
Automatic restart will activate once the PMM temperature drops below
120oC.
- setting will disconnect low pump intake pressure protection, including restart blocking protection, and switches restart
protection.
- setting provides pressure in atmospheres when low pumpintake protection will activate.
- setting provides pressure in atmospheres when pumpintake pressure will allow automatic restart.
- provides shutdown delay, in seconds, for low pump intake protection.
- provides restart delay, in minutes, after low pumpintake pressure protection.
Note – If after the time specified in has expired and the pump intake pressure has still not reached the value given in , the PMM restart will be delayed, the yellow indicator will come on
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steady. Automatic restart will take place only when has
been satisfied.
- setting provides blocking time to protect TMS afterPMM start.
Note – The number of automatic restarts after any activation of , , or is given in .
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5 Start Up of Drive
In the following descriptions, the symbol → represents pressing the ENTER button on the
operator keyboard. For example:
PARAMETERS →
Menu →
Menu →
→
(value required) →
Setting Editing, value required
The PASSWORD should only be entered once for the current session. The password is entered
using the same operator keyboard used for the setting edits. If an improper password is entered,an error message will be displayed and it will be necessary to repeat the
entry or press CANCEL to exit edit mode. If a data entry is attempted which is protected by passwords, a message will be displayed . Enter the password, or pressCANCEL to exit edit mode.
Prior to drive start up, if the drive has been turned off and exposed to high humidity conditions, it
is necessary to ensure the interior of the drive cabinet is dry. Make sure the CIRCUITCONTROL is in the OFF position, and turn on the HEATER switch. The yellow indicator
HEATING should come on. Leave HEATING on until the system radiator reaches +5oC (+41
oF). This process should also be followed if the exterior temperature is below -40
oC (-40
oF)
and the normal HEATING on indicator did not illuminate (force heating on).
On the operator control panel, place the circuit breaker CIRCUIT CONTROL into the ON position. A yellow indicator should be illuminated with a few seconds, and current drive parameters should appear on the LCD display screen.
If the interior temperature of the drive is less than -40oC (-40
oF), a yellow indicator HEATING
should illuminate. If the interior temperature is above -40oC, but the interior temperature of a
controller is less than 0oC (+32
oF), LCD heating will be illuminated and the front control panel
will have a red signal HEATING turn on. This signal will go off when the temperature of thecontroller reaches +10
oC (+50
oF). If the temperature of a controller is lower than -20
oC (+4
oF), VFD C will switch off the screen brightness, and will turn it on when the temperature
reaches -10oC (+14
oF).
After drive power on, the following should be set:
- Settings
- Tunings
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- Protection
- Composition (if drive is an M version)
For some foreign supplies, the input voltage must be changed to 480V. To do this, insert 480 V( → → → → ). After all changes
have been entered, switch on the power feed circuit breaker. Press the START button and the
motor should begin to rotate. The red light should go OFF and the green light should go ON at
the control panel. The motor rotation indication should show (<
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type>, , , , , , and blocking
protection settings should use the up and down arrow keys to select from the presented list.
Some settings depend on the status of motor rotation or position. Attempting to input to these
settings will result in an error message when EDIT mode is entered.
5.1.2 Setting Protections
Protection settings are generally items selected from a list. The particular item being protectedwill normally start with an entry such as , with the asterisk denoting the first item
in that particular set. This parameter will typically have the following items to select from for itsentry:
- - protection is not active
- - protection is active (not for automatic restart systems)
- - protection is active, but automatic restarts are not permitted- - protection is active and automatic restarts are permitted
Typical protect entries include the following:
- Limiting value, after which the motor will be stopped
- Delay time prior to motor stop- Number of permitted restarts
- Delay time prior to automatic motor restart
- Protect disconnect immediately after motor start- Limit of clearing of restart counters
Note – When the STOP button is pressed, the automatic restart counter is cleared, as the
restart count is calculated from zero after STOP.
If the protection key entry, i.e. , has the setting of , if a limit is reached in
one of the controlling protection parameters, the drive operation will not change –
PROTECTION IS OFF.
If the protection key entry, i.e. , has a setting of , , or and a limit is reached in one of the controlling protection parameters, the green light on
the panel will begin to blink. After the shut down delay, , setting is reached, themotor will stop. The motor stop will be recorded in the operating history file, and the LCD will
display the protection that caused the motor stop.
If the protection key entry has a setting of or , the red indicator will begin to blink and the motor will stop after the shut down delay has been reached. The motor cannot be
restarted without operator intervention.
If the protection key entry has a setting of , the yellow indicator will blink
and the motor will stop after the shut down delay has been reached. The LCD display will have
displayed. After the time has expired, the motor will attempt toautomatically restart. The motor start event will be recorded in the drive log.
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The automatic protection cycle will be repeated as many times as set by . When the
maximum number of restarts has been reached, the red indicator will be turned ON, and themotor cannot be restarted without operator intervention.
Protection is delayed by seconds on motor start.
5.2 Samples of Protections and Settings
5.2.1 Example of Overload Protection
The protection adjustments have had the following values set (reference ):
= Automatic Restart
= 12.5 A (50% of nominal motor current) = 50%
The motor was selected from the motor list, with a nominal motor current of 25 A.
= s = 5 seconds = m = 20 minutes
= rst = 3
Overload protection will become active when the motor current reaches 12.5A, or 50% of load.The system will begin the shut down timer and the green indicator will blink. After 5 seconds, if
the motor current has not decreased to a value less than 12.5A the motor will stop, an errormessage will be displayed on the LCD screen, the green indicator will go OFF and the yellowindicator will start to blink. On the LCD screen, in the normal motor rotation position, will be
displayed . Within 20 minutes the automatic restart should occur. The motor stop cause and
motor restart will be logged on the drive history log.
The automatic restarts will continue until the number would exceed the quantity of resets in
. If this occurs, the red light will be turned ON, the rotation position on the LCDscreen the will disappear, and the motor cannot be restarted without operator intervention.
5.2.2 Example of Under Load Protection
The protection adjustments have had the following values set (reference ):
= Automatic Restart = 5 A (20% of nominal motor current)
= 20%
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The motor was selected from the motor list, with a nominal motor current of 25 A.
= s = 5 seconds
= m = 1 minute
= rst = 2
Under load protection will become active when the motor current decreases to 5A or lower, or
20% of load. The system will begin the shut down timer and the green indicator will blink.
After 5 seconds, if the motor current has not increased to a value more than 5A the motor willstop, an error message will be displayed on the LCD screen, the green indicator will go OFF and
the yellow indicator will start to blink. On the LCD screen, in the normal motor rotation
position, will be displayed . Within 1 minute the automatic restart should occur. The motor
stop cause and motor restart will be logged on the drive history log.
The automatic restarts will continue until the number would exceed the quantity of resets in
. If this occurs, the red light will be turned
