Presentation on theme: "Troubleshooting Training Course. Visual and General Test Perform System Test (Mode Perform System Test) Identify The Error If you need Technical."— Presentation transcript:
Troubleshooting Training Course
Visual and General Test Perform System Test (Mode Perform System Test) Identify The Error If you need Technical support write down the results of this test before you contact technical support
Automatic Error Detection Automatic and manual self test that test all errors and can locate the exact phase and group of the fault.
E3– Unable to Connect Capacitor Group E5- Misfiring E6- Network Synchronization E7- Over Temperature E10-Resonance
Errors that do not disable the system completely will be indicated in the upper section of the controller screen and will indicate to which group the error is associated.
Errors that disable all of the system operation will be displayed on the main section of the controller screen.
Unable to connect Error Monitored Signals: X (reactance) of the connected capacitor(s), on all three phases. Averaging/Delay: 8 consecutive network cycles of exceeding the limit. Limits: 10% from nominal value. What action is taken: The particular group is disconnected and disabled. Error Reset: Automatically (see below) or manually by activating self test. Automatic Reset Delay: The system repeats the self test on defective groups only, after 1 minute. If the same groups are detected faulty again, the test repeats after 2 minutes and the interval is doubled each test until maximum 10 repeats (with delay of 512 minutes = 8.5 hours). If the result of each test is not identical to the previous one – the repeat interval is set back to 1 minute.
Find Errors and Locate the source of the fault (group and phase ) Mode Perform System Test Mode of Operation Menu Measuring Screen
Group Test Report Screen Group Details Screen - Group OK Group Details Screen - Group with Error 3 Background Readings
controller Switching Module Firing Fuse Bus bars Fuse Power Supply
Led Tester Firing signals are the signals that the controller sends to the Switching modules in order to open the Thyristors
Misfiring Monitored Signals: THD of capacitor current in the first two phases. Averaging/Delay: 2 consecutive network cycles of exceeding the limit. Limits: 300%. What action is taken: The particular group is disconnected and disabled. If detected during normal operation – self test is activated. Error Reset: Automatically (see below) or manually by activating self test. Automatic Reset Delay: The system repeats the self test on defective groups only after 1 minute. If the same groups are detected faulty again, the test repeats after 2 minutes and the interval is doubled each test until maximum 10 repeats (with delay of 512 minutes = 8.5 hours). If the result of each test is not identical to the previous one – the repeat interval is set to 1 minute.
Test all the relevant firing cables and connectors disconnect and reconnect the connectors and test the system again. Disable E5 and test if the system works properly now, test the Thd of the network if it is very high maybe the E5 should be disabled. If this is not the case the controller firing card or the SWM firing card are the next suspects. Sometimes because of E3 in one phase E5 can be detected but the cause is E3, reactors shortcut can also cause E5.
Network synchronization Monitored Signals: L1-L2 Voltage (in three phase system). Averaging/Delay: 500 consecutive network cycles of internal PLL synchronization error. Limits: Internal PLL failed to synchronize to signal. What action is taken: System disconnects. Error Reset: Automatically. Automatic Reset Delay: 250 consecutive network cycles of error-free PLL operation.
Test the voltage in L1- L2 terminals of the controller (with a multimeter) a valid voltage signal Should be detected. If a valid voltage is not detected make sure that the controller will receive the signal. If there is a valid voltage in the terminals the controller should be checked.
Over Temperature Monitored Signals: External Thermostats. Averaging/Delay: Immediate. Limits: Depends on external thermostats. What action is taken: System disconnects. Error Reset: Automatically. Automatic Reset Delay: Immediate.
55° Thermostat Activates an Deactivate the SWM Fan 85°C and 120°C Thermostats Deactivate the whole System controller Switching Module 55°C Thermostat 85°C N.O Thermostat 120°C N.C Thermostats Reactors
Resonance Monitored Signals: Mains and Load current, on all three phases and 63 harmonics. Averaging/Delay: 10 consecutive network cycles of exceeding the limit, counted for each phase and harmony separately. Limits: I MAIN -I LOAD >X%*I CAP(NOMINAL). X% is 50% for normal limit and 30% for sensitive limit. What action is taken: System disconnects. Error Reset: Automatically. Automatic Reset Delay: The system disconnects for 10 seconds for first occurrence and doubles the time for each occurrence happened within 20 seconds from the end of previous disconnection, until a maximum of 3000 seconds.
Measurements must be performed and analyzed to understand the source of resonance.
Menu System Setup Site Installation Modify The Above Next few times in Error Detection screen chose Customize disable the needed Errors
L C M – Load Caps Mains What is it used for? To see if the system is connected and measuring correctly. Menu L C M Combined Total KVAr Meters Mode Manual insert one group manually Expected results after inserting the group: Load should not change Caps should show the expected KVAr from this group Mains should show the former value minus the Caps Value
Test that the measured currents match the expected currents
Menu System Information Events The Events log, saves all system events, Errors, changes in status changes in setup, power losses, etc… And the time and date of these events. The Events log can help us understand the source of a problem The Events log can be downloaded into a computer
The controller needs to have a communication Card, if there is no communication card use the Service Card The communication protocol is RS-485 Com to RS485 AdapterPCMCI to RS485 AdapterService Card
Tools Led tester Service card Laptop Computer Communication Adapter for the Laptop Multimeter Current clamp Fuse for the Switching module Fuse for control module Power Fuse Optional: firing cards, switching module, Capacitors