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Variable Frequency Drive

Operation Manual

Variable Frequency Drive (VFD)


For
Permanent Magnet Motors (PMM)
Operation Manual

Draft 11 January 4, 2010


1

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

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
2

VFD Component Operations..................................................................................................... 18

Marking And Packing of VFD .................................................................................................. 23

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

Operators 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


2

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

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

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
3

5.7

VFD Disconnect ........................................................................................................................ 57

5.8

VFD Modification and Identification ........................................................................................ 57

5.9

VFD Operating Modes and Modification ................................................................................. 58

VFD Faults and Corrective Actions ................................................................................................. 59


6.1

6.1.1

General Procedure .............................................................................................................. 59

6.1.2

Safety Measure During Disassembly ................................................................................. 59

6.1.3

Specific Component Replacement ..................................................................................... 59

6.2
7

VFD Disassembling Procedure ................................................................................................. 59

Checking VFD Operational Capability ..................................................................................... 60

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

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 - <STOP> - <MANUAL> - <AUTOMATIC>
A VFD includes input to connect to external analog signals
PMM permanent magnet motor

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

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 cannot
assume 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.
7

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.

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 damage


or 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 and
associated 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 bus
capacitors 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 present
within the Drive with the primary power circuit breaker, QF5, turned OFF.

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 cycle
Supply Voltage
- 3 phase, 4 wire, earth neutral
- 480 volt, +/- 120 volts
Supply Frequency
- 60 HZ, +/- 3 HZ
Operating Temperature
- -60 0C (-76 0F) to +50 0C (+122 0F) Note
Operating Humidity
- 100% at +25 0C (+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 mechanical
stability 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 -40 0C (-40 0F).
10

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 +85 0C (+185 0F)
- Attempt to activate at temperatures below -40 0C (-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 160 0C (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
- Controllers 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

11

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.

12

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 in
Photo 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 <+2> 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>.
2 capacitors banks (12), with discharge resistor boards <A2, A3> TsRKF.435782.001 <+4>,
TsRKF.435782.001 <+5>.
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, while
in the VD80 they are identified as P2, P3, and P4>
Excess voltage limiter (15)
VFD power circuit breaker (16), <QF5>
High voltage terminal for TMS (17), <A5>, option M
Current sensor (18), <P1>
Door opening limiting switch (19), <SA1>
Secondary power and control board (20)
Grounding terminals (21)
Light (22), <EL1>
Snubbers (23), <A4, A5, A6>

13

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), <HL1, HL2, HL3, HL4>


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), <SB2>
14

Motor STOP button (27), <SB1> (may have P or may not)


Operation mode selector (28 option not shown), <SA5> (will have on P models)
Receptacle for 120V, 60HZ (29), <XS1>
Breaker for receptacle (30), <QF1>
Breaker for cabinet light (31), <QF3>
Breaker for control wiring (32), <QF2>
Breaker for internal heating (33), <QF4>
Main Power breaker (16), <QF5>
Thyristors (42), <MVD1, MVD2, and MVD3>
Pulse Wave Modulator (PWM) which can be reached through removable screen (43)
Rectifier thyristor control board (46), <A1>
Temperature sensor boards (not visible from front), <BK1, BK2>
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 a
motor and fan, M2.

25

16

24

27

26

29, 30, 31, 32, 33

Photo 3 Internal View of Small Front Door Opening

15

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 shows
some of the internal components mounted onto the left side of the cabinet. The description of each
follows:
-

Reverse side of station controller (34), <A4>


External analog input unit, <A12> (option, not shown, for version A VFD)
Controller for telemetry unit (TMC) (36), <A6> (for version M VFD)
Mounting plate for Control and Secondary Power Board Assembly (70),
Universal power pack (51), <A5 to A9>
Control and Secondary Power board (52), <A4>
Resistor divider board (53), <A2>
Measuring resistor board (54), <A3>
Frequency converter controller board (55), <A1>

Photo 4 Internal View of VFD Large Door and Left Side


16

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), <XT6>


Input power connections (40), <A, B, C and XT1, XT2, XT3>
Output power connections (41), <U, V, W and XT9, XT10, XT11>
Output power connection, <Ground, XT4>

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 <L1> and version 80 <L1 and L2>
Cooling fan <M1>

17

L2

L1

M1

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 diagram
of 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.

18

Figure 1 Schematic diagram for VFD

Draft 11 January 4, 2010


19

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 the
VFD, 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 transformer
secondary 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 circuit
elements 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 for
monitoring 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

Draft 11 January 4, 2010


20

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 the
PMM 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
21

Insulation resistance of external transformers secondary

The TMS consists of three parts; the high voltage unit, the interface connection, and the
submersible 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 -40 0C (-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 be
activated 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 -40 0C (-40 0F), main power unit power will be
applied, followed by the various control circuits. When the temperature reaches -30 0C (-22 0F)
heating will be removed, and the VFD will enter a self check mode. When the VFD self check is
complete, 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 wave
modulator 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 through
two 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
+35 0C (+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.
22

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 faults
and 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 Manufacturers trade mark
Production Number
Circuit voltage, nominal current
Weight
Manufacturing date

Packing will be in accordance to GOST 23216 (General Requirements and Test Methods for
Electrotechnical Products, Storage, Transportation, Temporary Corrosion) requirements.
Cargo marking will be in accordance to GOST 14192 (Marking of Cargos) requirements.

23

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 VFD
and 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

24

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
25

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 off
if 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 Operators Communication with VFD C


For operators 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 LCD
window. 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 is
controlled by the keys. A more detailed description of the controller menu and keyboard
functions is provided in Section 3.11.

26

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 (silicon
control 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 output
voltage, 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).

27

2.4.3 IGBT Module Section


The IGBT driver board provides the controlling gate signals to the IGBTs used to transform the
incoming 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 passed
to 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 LOutput 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
28

2.5.2 Control and Secondary Power Board


The control and secondary power board contains the internal temperature sensor. The board
enables 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 the
discharge of the power capacitors when the drive is turned off .
The Lightning Guard Board is designed to protect the external interface of the RS485
communications line.

29

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 transformers 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 to
the 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 following
functions:
-

Read and store data logged by the VFD controller. The data is stored in a flash-card
with 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 system
is 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 reprogramming or testing, the flash card must have the service data pre-recorded (this is
30

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 logging
read 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 drive
to 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 been
completed, 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. Disconnect
the 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 data
logging). 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.
31

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, well
number, 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 operators panel to
continue the re-programming, or CANCEL to stop the process and terminate communication
with 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 will
switch 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 the
CANCEL button. Upon test mode exit, the LCD will show the main window.

32

3 Installation and Wiring


3.1 Safety measures during drive preparation

All installation, dismantling, and operational works should be completed in


compliance with current regulations; Technical Operation Regulations of Users Electric
Devices and inter-branch regulations of safety measures for personnel protection during the use
of users 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 the
requirements of the current Regulations on Electric Devices Design.

The station housing should be properly grounded. Station power should be supplied
from 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 <PEN> 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 to
ensure 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 current
safety practices
33

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.

34

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 the
external 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.

35

Figure 4 480V Conversion Kit

36

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 of
work 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
Type of work
Key board

ENTER

CANCEL

View
Cursor transfer
one line up
Cursor transfer
one line down
Transfer to next
window
Transfer to
previous window
Transfer to next
menu level
Return to
previous menu
level

Edit
Increase digit for unit
Decrease digit for unit
Transfer one symbol
place to right
Transfer one symbol
place to left
Exit from edit with
input symbols saved
Exit from edit with
input symbols saved

Command
Execution
Cursor transfer
one line up
Cursor transfer
one line down
Transfer to next
window
Transfer to
previous window
Execute
Command
Return to
previous menu
level

Calibration
No function
No function
No function
No function
Transfer to next
calibration step
Exit from
calibration
without saving
results

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 after
an operator input. For example, if the operator input <TMS type>, CP control elements will be
included automatically into the submenu lists associated with the TMS operation.
37

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, or
other 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 the
requirement 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:
-

<RPM, r/m> (motor revolutions)


<I motor, A> (motor current)
<Rins, kOm> (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 <RPM, r/m> 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 be
driving 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 <I motor, A>, 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 <Rins, kOm>, a down arrow may appear, meaning that the insulation
resistance is lower than the value determined to be optimum for motor protection.
38

Other symbols that may be displayed in the additional viewing area are:
-

<TMS> (drive has telemetry system installed)


<VFD dr o> (drive main door is open)
<MAN>, <AUT>, <PRG> (drive operating mode)
<DISC> (independent automatic disconnect QF5 enabled)
< >>> > , < <<< > (indicates motor rotation direction)
< <!< >, < >!> > (drive waiting on automatic start)
<<n,u>>, <!!> (motor speed increase or decrease, rotation speed, sharp reduction in
dynamic 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 in
Appendix 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 <Settings
DR>, <Settings U>, <Settings I>, and <Settings TMS> (for drives equipped with
TMS).
History permits review of drive events including starts, stops, protective actions,
etc. Viewing starts with the latest event. A message <History beginning> will be
displayed at the beginning of the record, and <History end> 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
<I cons TMS, mA> - cable insulation leakage current (Zenith TMS only)
Intensity by using the up arrow and down arrow keys, the intensity of the LCD
display 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
39

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:
<Cont No.> - VFD Controller manufacturing number
<Type of VFD C> - type of VFD controller
<Cont m/code> - Controller manufacturing code
<Cont m/date> - Controller manufacturing date
<VFD No.> - drive serial number
<VFD Type> - drive type according to manufacturer classification
<VFD m/code> - drive manufacturer code
<VFD m/date> - drive manufacturing date
<Feeder No.> - 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
<0000>, the password is not required for access. Two levels are
recommended, <4321> factory set for use by the operator, and <8991> factory
set 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 reentered.
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 minute
and 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.

40

SVU this menu is used to fine tune data exchanged between the drive and upper
level devices. Typical data includes:
<Cls cont type> - select type from presented list
<VFD address> - drive address in cluster net
<Com speed> - communication interface speed
<Prot No.> - communication protocol number
<Record from ULS> - 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 information
from the customer.

Language select the language to be used on the display.


Service provides parameters, settings, and adjustments for such devices as the
VFD C, motor, VFD, and TMS. Access to these items requires a password.

The VFD parameters and status are:

RPM motor revolutions per minute


<Uab, V>, <Ubc, V>, <Uca, V> - output phase to phase voltage
<T1,0C T2, 0C) radiator temperatures
<Uuv,B>, <Uvw,B>,<Uwu,B> - drive output voltage.
<Iab,A>,<Ibc,A>,<Ica,A> - phase currents
<I motor,A> - motor current
VFD version VFD software version
VFD No. VFD factory number
Date of VFD VFD software setting date
Status display of status bits forming drive status

The motor parameters are:


Package of supplied package of settings required for motor operation
<Rated Im, A> - motor ampere rating
<Rated Pm, KWt> - motor rated brake power
<Rated Um, V> - motor voltage rating
<Q pole pairs> - number of motor pole pairs
<I1 break, A> - ampere-second characteristic current 1
<T1 break, s> - ampere-second characteristic motor 1 disconnect time
<I2 break, A> - ampere-second characteristic current 2
<T2 break, s> - ampere-second characteristic motor 2 disconnect time
<I3 break, A> - ampere-second characteristic current 3
<T3 break, s> - ampere-second characteristic motor 3 disconnect time
<Rot min, rpm> - minimum motor rpm
<Rot max, rpm> - maximum motor rpm
<I form-factor> - motor current form factor

41

The VFD settings and status are:


<Rot/sw> - rotary switch which may be turned ON or OFF
<NEMF test> - test shutdown for EMF normalize
<B/S rot test> - test shutdown for backspin rotation
<Prt sen I PWM> - current sensor protection. Can be turned off for
emergency motor start.
<An input> - drive has analog inputs
<Uin> - input voltage (380V/480V)
<O/C range, rpm> - over control range
<Num O/Cs> - number of over controls permitted
<Res O/C cr,m> - 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 <(Rot max, rpm) (Rot min, rpm)> motor
instability will be logged. If, within the time period given by <Res O/C cr,
m>, the number of oscillations exceeds the number set by <Num O/Cs>,
the motor will be shut down if that protection has been set active.

The TMS settings and status are:


<% RPM rrTMS> - rpm increase percentage from TMS
<P rr O/C, atm> - pressure ramp rate to start over control
<O/C step,m> - over control step minimum
<P rr,atm> - pressure ramp rate in unstable operation mode, atm per
minute
<Log Pdev, atm> - pressure deviations
<Log Pdev, C> - temperature deviations
<Log Pdev, g> - vibration deviations
Status display of status bits forming TMS protection and setting fault list

4.2.3 Settings

Other Settings

<Rot speed, rpm> - motor rotation speed. Unit settings are displayed in
revolutions per minute or Hz, depending on the operator selection.
<Acc time> - sets the time between motor speed changes to maintain a
smooth change. During motor start, the time starts when the motor
reaches the value given in <Int spd, rpm>.
<Rot direct> - sets the motor rotation direction. If the motor phase is
correctly connected, reference Figure 1, then the arrow direction to the
right < >>> > corresponds to clockwise rotation, and the arrow to the left
< <<< > corresponds to counter clockwise rotation. Setting is accessible
only in STOP mode, when the red lamp is flashing on the indicator panel.
42

<VFD mode> - sets the drive operating mode. It is either MANUAL or


AUTOMATIC. A drive with the letter P in the designation does not have
this setting, and operating mode is set via a manual switch.
<*Rins prtn> - protection switch for minimum insulation resistance check.
It is either ON or OFF.
<Rins|KoOm> - sets the minimum insulation resistance value. If the value
detected is lower than this, the motor will turn off (and restart is inhibited).
<*CPG prtn> - protection switch for the contact gauge. It is either ON or
OFF.
<CPG sd dl, s> - sets the contact gauge delay time in seconds.
<CPG prt dl, s> - sets the contact gauge protection OFF immediately after
motor start. Automatic motor restart cannot take place with the contact
gauge active.
Note The number of automatic restarts after activation on <*CPG prtn>
is limited by the setting of <Othr num rst>.
<Othr num rst> - restart number for other protection occurrences.
<*Othr prt dl> - disconnect delay according to other protection after drive
start.
<Res ntrk, m> - counters zero setting time for Auto Restart number
limitation.
<*Prog mode> - program set operating mode. It is either ON or OFF.
<Operation time, m> - sets time limit for drive to operate in Program
mode.
<Break time, m> - sets pause time for drive to operate in Program mode.
<Start dl, m> - sets the delay time for motor start after power is applied.
<*Door prtn> - sets the door interlock protection. It is either ON or OFF.
Note If the door switch is OFF, a message will appear <DOOR>. If
protection is ON, QF5 automatic disconnect will turn the motor OFF, and
a message will appear <Door prtn>, a red indicator will flash on the
operating panel, and the event will be registered in the log.
<*A/I n prtn> - sets the analog protection for analog 1 or 2 (the value of
n). It is either ON or OFF.
<A/I n sd dl> - sets the delay time for activation of the analog protection
for analog 1 or 2 (the value of n).
<A/I n AR dl> - delay time of protection for Auto Restart according to
analog 1 or analog 2 (the value of n).
<A/I n num> - the number of restarts permitted according to analog 1 or
analog 2 (the value of n).
<A/I n prt dl, s> - delay time for protection according to analog 1 or
analog 2 (the value of n).
<*Unst wk prtn> - sets all switches to OFF to protect against automatic
restart with old settings in place
Note Restart time and number are set in <U/L AR dl, m> and <U/L num
rst>.

43

<Int spd, rpm> - speed at which smooth start acceleration begins, see
<Acc time>.

U Settings

<*Uin prtn> - low voltage protection, blocks even restart.


<Uin , %> - low voltage as percentage of nominal voltage, will provide
low voltage protection.
<Uin sd dl, s> - low voltage protection delay in seconds.
<*Uin prtn> - high voltage protection, blocks even restart.
<Uin , %> - high voltage as percentage of nominal voltage, will provide
low voltage protection.
<Uin sd dl, s> - high voltage protection delay in seconds.
Note Automatic restart after protection from <*Uin prtn> or <Uin ,
%> will take place once voltage has normalized, with a start delay as set
by <Start dl, M>. At that time, the yellow indicator on the operator panel
should be flashing.
<Uin db prtn> - inhibits protection for input voltage imbalance, blocks
even motor restart.
<Uin db, %> - provides protection if the input voltage imbalance exceeds
the percentage given.
<Uin db sd dl, s> - provides the delay, in seconds, before the input voltage
imbalance protection activates.
<Uin db AR dl, M> - provides the delay, in minutes, after the input
voltage imbalance occurs that restart will be inhibited.
<*Uout db prtn> - inhibits protection for output voltage imbalance, blocks
even motor restart.
<Uout db, %> - provides protection if the output voltage imbalance
exceeds the percentage given.
<Uout db sd dl, s> - provides the delay, in seconds, before the output
voltage imbalance protection activates.
<Uout db AR dl, M> - 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 been
activated by either <*Uin db prtn> or <*Uout db prtn> is given in <Othr
num rst>.
<U prtn dl, s> - activation delay time for all U protections immediately
after drive start.

44

I Settings

<*O/L prtn> - overload setting protection. It has 3 conditions, OFF


disconnects protection, BLOCK prohibits auto-restarts, and RESTART
which permits auto-restarts.
<O/L I, A> - provides absolute current limit. Current exceeding this value
will trip overload condition.
<O/L I, %> - provides an overload percentage from a nominal current
value. Current exceeding this value will trip overload condition.
Note - <O/L I, A> and <O/L I, %> are equal. Changing the value in <O/L
I, A> will change the value in <O/L I, %>.
<O/L sd dl, s> - provides shutdown delay after overload, in seconds.
<O/L AR dl, m> - provides automatic restart delay, in minutes.
<O/L num rst> - provides the number of permitted restarts after overload
activation.
<*U/L prtn> - under load setting protection. It has 3 conditions, OFF
disconnects protection, BLOCK inhibits auto-restarts, and RESTART
permits auto-restarts.
<U/L I, A> - provides absolute under load current limit. Current lower
than this value will trip under load condition.
<U/L I, %> - provides an under load percentage from a nominal current
value. Current lower than this value will trip under load condition.
Note - <U/L I, A> and <U/L I, %> are equal. Changing the value in <U/L
I, A> will change the value in <U/L I, %>.
<U/L sd dl, s> - provides shutdown delay after under load, in seconds.
<U/L AR dl, m> - provides automatic restart delay, in minutes.
<U/L num rst> - provides the number of permitted restarts after under load
activation.
Note Under load protection becomes active when the motor speed
reaches the value set by <Rot Spd, rpm>.
<*I db prt> - load setting protection for motor current imbalance. It has 3
conditions, OFF disconnects protection, BLOCK resets blocking
protection, and RESTART which resets protection.
<I db, %> - provides a current imbalance percentage from a nominal
current value. Current exceeding this value will trip imbalance condition.
<I db sd dl, s> - provides shutdown delay after current imbalance in
seconds.
<I db AR dl, m> - provides automatic restart delay, in minutes, after
current imbalance.
<I prtn dl, s> - provides the delay time of all current activation after drive
start.

45

Note Current protection is activated only after motor current exceeds a


value of 50% of nominal. The number of permitted restarts, <*I db prt>
which is set in item <Othr num rstr>.

TMS Settings

<Pint Reg> - disconnects and switches pressure regulation at pump intake


during automatic adaptation.
<Pint Reg, atm> - setting provides pressure required for maintaining
operation during automatic adaptation.
<*Vibr prtn> - disconnects vibration protection, switches restart blocking
protection, and switches restart protection.
<Vibr off,g> - setting provides vibration level in gs, which, if exceeded,
will result in motor stop.
<Vibr sd dl, s> - setting provides vibration activation in seconds.
<Vibr AR dl, m> - setting provides restart delay, in minutes, after
vibration protection activation.
<*Tm win prtn> - setting disconnects over heating protection, switches
restart blocking protection, and switches restart protection.
<Tm max, oC> - setting provides maximum PMM winding temperature in
degrees C, if exceeded will cause motor to STOP.
<Tm sd dl w, s> - provides shut down delay in case of high PMM winding
temperature condition. Time is in seconds.
<Tm AR dl, m> - provides restart delay, in minutes, after PMM winding
temperature protection activation.
Note If after the time specified in <Tm AR dl, m>, the PMM
temperature has not dropped below 120 oC, automatic start will be
deferred. The yellow indicator will be ON at the operator panel.
Automatic restart will activate once the PMM temperature drops below
120 oC.
<*Pint prtn> - setting will disconnect low pump intake pressure
protection, including restart blocking protection, and switches restart
protection.
<Pint , atm> - setting provides pressure in atmospheres when low pump
intake protection will activate.
<Pint , atm> - setting provides pressure in atmospheres when pump
intake pressure will allow automatic restart.
<Pint sd dl,s> - provides shutdown delay, in seconds, for low pump intake
protection.
<Pint AR dl, m> - provides restart delay, in minutes, after low pump
intake pressure protection.
Note If after the time specified in <Pint AR dl, m> has expired and the
pump intake pressure has still not reached the value given in <Pint ,
atm>, the PMM restart will be delayed, the yellow indicator will come on
46

steady. Automatic restart will take place only when <Pint , atm> has
been satisfied.
<TMS prt dl, s> - setting provides blocking time to protect TMS after
PMM start.
Note The number of automatic restarts after any activation of <*Vibr
off,g>, <*Tm max,oC>, or <*Pint prtn> is given in <Othr num rst>.

47

5 Start Up of Drive
In the following descriptions, the symbol represents pressing the ENTER button on the
operator keyboard. For example:
PARAMETERS
Menu <SETTINGS>
Menu <Other Settings>
<Rot speed, rpm>
<Password> (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 <enter error, repeat> 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 <access denied, repeat>. Enter the password, or press
CANCEL 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 CIRCUIT
CONTROL 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 +5 oC (+41
o
F). 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 -40 oC (-40 oF), a yellow indicator HEATING
should illuminate. If the interior temperature is above -40 oC, but the interior temperature of a
controller is less than 0 oC (+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 the
controller reaches +10 oC (+50 oF). If the temperature of a controller is lower than -20 oC (+4
o
F), VFD C will switch off the screen brightness, and will turn it on when the temperature
reaches -10 oC (+14 oF).
After drive power on, the following should be set:
- Settings
<Mode>
<Rot speed, rpm>
<Rot direction>
- Tunings
<Trans Sec U,V>
48

<Well No.>
<Cluster No.>
<Field No.>
<Pint depth, m>
Protection
<R insulation>
<Underload>
<Overload>
<Current imbalance>
<Voltage imbalance>
<Door interlock>
Composition
<VFD type>
<Motor type>
<TMS type> (if drive is an M version)

For some foreign supplies, the input voltage must be changed to 480V. To do this, insert 480 V
(<Service> <VFD> <SETTINGS> <SETTINGS> <Supl U,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 (< <<< >), as well as the measured
parameters should be displayed. In case of a motor fault, the red lamp will illuminate and the
yellow lamp will be blinking, indicating the system is waiting for an automatic restart. The
cause of the fault will be displayed on the VFD C display (reference Appendix A for a complete
list of faults).

5.1 Insertion of Setting and Tuning Values


Select the desired menu through the use of the up arrow and down arrow keys on the keypad.
When you reach the desired menu, press ENTER to enter the particular menu in VIEW mode. In
view mode, again using the arrow keys, move through the displayed entries until the one you
wish to set, or tune, is positioned. Then again press ENTER to enter EDIT mode.
5.1.1 EDIT Mode
In EDIT mode, the display will show the cursor under the symbol in place for editing. Use the
up and down arrow keys to move to the value specified for that position. Use the right and left
arrow keys to move to the next desired position to be modified. When all positions have been set
to the proper value, press the ENTER key to save the modified values. If you do not wish to
save the entered values, press the CANCEL key.
Some of the entries have a slightly different manner of adjusting. For example, the <Brightness>
and <Contrast> entries can be adjusted by using the up and down arrows to cause the change.
The arrows must be pressed and held to cause the adjustment to take place. Similarly, <VFD

49

type>, <Motor type>, <TMS type>, <V comm, baud>, <Mode>, <Rotation direct>, 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 protected
will normally start with an entry such as <*O/L prtn...>, with the asterisk denoting the first item
in that particular set. This parameter will typically have the following items to select from for its
entry:
- <OFF> - protection is not active
- <ON> - protection is active (not for automatic restart systems)
- <BLOCK> - protection is active, but automatic restarts are not permitted
- <Automatic Restart> - 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. <*I prtn dl,s>, has the setting of <OFF>, 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. <*I prtn dl, s>, has a setting of <ON>, <BLOCK>, or <Automatic
Restart> 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, <shtd dl, s>, setting is reached, the
motor 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 <ON> or <BLOCK>, 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 <Automatic Restart>, 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 <restart delay, m> time has expired, the motor will attempt to
automatically restart. The motor start event will be recorded in the drive log.
50

The automatic protection cycle will be repeated as many times as set by <A/L rst>. When the
maximum number of restarts has been reached, the red indicator will be turned ON, and the
motor cannot be restarted without operator intervention.
Protection is delayed by <dl, s> 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 <Settings I>):
<* O/L prtn> = Automatic Restart
<I O/L prtn, A> = 12.5 A (50% of nominal motor current)
<IO/L prtn, %> = 50%
The motor was selected from the motor list, with a nominal motor current of 25 A.
<O/L sd dl, s> = s = 5 seconds
<O/L AR dl,m> = m = 20 minutes
<O/L num rst> = 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 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 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
<U/L num 3>. If this occurs, the red light will be turned ON, the rotation position on the LCD
screen 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 <Settings I>):
<* U/L prtn> = Automatic Restart
<I U/L prtn, A> = 5 A (20% of nominal motor current)
<IU/L prtn, %> = 20%
51

The motor was selected from the motor list, with a nominal motor current of 25 A.
<U/L sd dl, s> = s = 5 seconds
<U/L AR dl,m> = m = 1 minute
<U/L num rst> = 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 will
stop, 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
<U/L num 2>. If this occurs, the red light will be turned ON, the rotation position on the LCD
screen the <!> will disappear, and the motor cannot be restarted without operator intervention.
Note Under Load protection will begin to operate when the motor revolutions reach the value
given by <Rot Speed/rpm> setting.
5.2.3 Protection for Insulation Resistance Reduction
Settings are set to the following:
<3R ins> = ON (protection is turned on)
<Rins min> = 30K ohms (minimum resistance)
If the measured insulation resistance drops below the value given in <Rins min>, in this case the
30K ohms, resistance protection will activate. The red indicator will be illuminated, and the
motor cannot be restarted without operator intervention.
5.2.4 Protection Against Wedge Complicated by Mechanical Mixtures
Settings are set to the following:
<Intl spd, rpm> = 1200 rpm
<Acc time, m> = 20 minutes
<Rot speed, rpm> = 2700 rpm
During motor start, the motor will obtain the speed of 1200 rpm, or more, within 20 minutes.
After that, it will continue to smoothly accelerate to the desired 2700 rpm. If <Acc time, m> is
set to zero, this protection is turned OFF.

52

5.2.5 Protection Against Minimum Pump Intake Pressure


Settings are set to the following:
<* Pint, min> = Automatic Reset
<Pint> = 40 atmospheres
<Pint sd dl,s> = 10 seconds
<Pint AR dl,m> = 40 minutes
<Pint,m> = 70 atmospheres
<Othr num rst> = 2
<Res cntr,m> = 180 minutes
If the pump intake pressure drops lower than 40 atmospheres, the minimum pump intake
pressure protection will be activated within 10 seconds. The green indicator will be blinking at
this time. The motor will shut off if the pump intake pressure does not rise above 40
atmospheres, and the yellow indicator will blink. Automatic restart will take place in 40
minutes. If the pressure fails to reach the 70 atmosphere pump intake pressure, the motor
shutdown will once again take place. Two restarts are permitted. If the two restarts occur in a
time period exceeding 180 minutes, the automatic restart counter will be zeroed. If the two
restarts occur within a time period of less than 180 minutes, the device will be blocked and the
motor cannot be restarted without operator intervention.

5.3 Automatic Adaptation


Automatic Adaptation is an operating mode for the drive where the motor rotational speed is set
by the pump intake pressure desired. Decision to accelerate or decelerate the motor speed is
made on an average measured pressure, Pavg, which is calculated from 50 samples over a 5
minutes period.

53

5.3.1 Pavg Calculation


The difference between the average pressure, Pavg, and the adjusted pressure is given as:
P = Pavg P regulated
A positive difference will result in a motor speed increase, while a negative difference will result
in a motor speed decrease.
Pressure change velocity is calculated as:
P = P3 / T3,

Where P3 = P1 P2 and T3 = T1 T2

Adjustment examples are given in Table 2.

No.

Condition for
regulation and
Non-regulation

P > 10 atm,
P' calc > P'reg

P <10 atm,
P' calc > P'reg

P' calc < P'reg

Regulation
No

1. Revolution change is
calculated for regulation:
N=N d N/ 100, where
P rr O/C - revolution increase
New rotation speed N new
=N-N
2. Speed change will be in
every d reg minuteMinimal time of rotation
speed change.
1.Relative error can be
calculated: = P / dPreg,
where dPreg- permissible
given pressure deviation.
2.Revolution change for
regulation can be calculated:
N=N d Nreg/ 100
3.New rotation speed will be
calculated
New =N N ( - depending
54

FCC
indication
in line
N rev/m
!!

!!

Note
Regulation is not
taking place, since
liquid pumping speed
is higher than the set
one and pressure
difference is high.
Regulation is carried
out in dynamic mode,
speed will decrease at
N within every
dreg.

Regulation is carried
out in dynamic mode
under conditions, if
> 8 and less is
dynamic, but under
< 8 condition.

No.

Condition for
regulation and
Non-regulation

Regulation

FCC
indication
in line
N rev/m

Note

on regulation direction, if P
value is positive, then it will
be +, if value is negative,
then it will be -).
4.If > 8, than speed change
will be via d time.
5.If < 8, then speed
change will occur within a
time calculated according to a
formula T= ( 9 - ) dreg.
Table 2 Auto Adaptation Adjustments
Note Revolution adjustment limited to the range of Nmax > N > Nmin.

5.3.2 Automatic Adaptation Settings and Example


Automatic Adaptation settings are as follows:
<* Pint Reg> = disconnects and switches regulation based on pump intake pressure
<Pint Reg, atm> = provides pressure required at pump intake
<RPM Max> = motor maximum rpm during auto adaptation operation
<RPM Min> = motor minimum rpm
<P rr,atm/min> = pressure change speed setting
<% RPM rr TMS> = rpm increase percentage during adjustment
<P rr O/C, atm> = permissible deviation from setting pressure at pump intake
<O/C step, m> = time, in minutes, through which rotation speed will change
For example:
<* Pint Reg> = ON
<Pint reg, atm> = 50 atmospheres
<Prr, atm/min> = 0.03 atmospheres
<Rot min, rpm> = 2700 rpm
<% RPM rr TMS> = 5%
<P rr, atm> = 2 atmospheres
<dTper, m> = 20 minutes
<RPM max> = 2790 rpm
<RPM min> = 2300 rpm
The motor will reach the 2700 rpm. If the difference between the measured pressure and the set
point pressure is large, approximately every 20 minutes, the motor rotational speed will change
55

by 5%, up or down. If the difference is less than 2 atmospheres, regulation will cease. If the
motor speed exceeds 2790 rpm or becomes less than 2300 rpm, regulation will also cease.

5.4 Drive hardware protections not accessible to operator


These protections are set during manufacture of the drive and cannot be changed by the operator.
Each protection will provide an output message to the LCD display for operator information.
<Fail sen I PWM> - PWM driver fault, or power thyristor failure
<THYR prnt> - +12 V problem or power thyristor failure
<COMM prtn> - Drive short circuit or module fault
<PWM prtn> - PWM module fault or module power fault
<GND I prnt> - short circuit in any output phase or fault in sensor output current
<Max I prtn> - maximum output current for drive
<Usup prtn> - circuit voltage exceeds 25% of nominal value
<Uout prnt> - maximum voltage for drive
<I overload> - motor protection for maximum amperes or other protections
Activation of any of the above protections, the motor will shut down. After approximately 40
seconds, a restart will be attempted. After the third restart attempt, the motor will remain OFF
and operator intervention is required. The restart count will be set to zero when the motor
reaches the designated rpm.
<U net>, <U net> - high and low voltages, set to within 25% of nominal value
<Overheating> - drive radiator exceeding 85 oC (185 oF)
The drive will restart when the protective conditions are removed.
A complete list of hardware is provided in Appendix F.

5.5 Calibration Without TMS


The insulation resistance measurement, Rins, will be accomplished in this step. This is normally
performed after any controller change.
Select the <Calibration> menu. The LCD display will provide a message <Prepare R change>.
Disconnect the driver from terminal XT6 (see photo 3), which comes from the mid-point of the
output transformer secondary. Press ENTER.
The LCD display will provide a message <Create Rins K3>. Close XT6 and press ENTER.
The LCD display will provide a message <Save>. If the measurement was carried out correctly,
the displayed value should be in the range of 110K ohms and 130K ohms. If correct, press
ENTER to save the measurement. If not, calibration must be re-run.
56

5.6 Motor Stop


Press the STOP button. The motor should stop.
The green indicator should go OFF on the operator panel, and the red indicator should go ON.
The running indicator should show < >>> >.

5.7 VFD Disconnect


After the motor has been stopped, turn the primary power breaker <QF5> to the OFF position.
Place the CONTROL CIRCUITS breaker into the OFF position.
Turn OFF all associated switches.

5.8 VFD Modification and Identification


The drive has a number of modifications, based on power output and equipment additions. The
drive power output, normally expressed in KW, is designated in the VFD name. For example,
Borets-VD40 and Borets-VD80. In the case of the 480V conversion model, it would be
Borets-VD40.2.
Equipment designators are also included in the equipment identifier as follows:
<P> - VFD equipped with gang switch
<A> - VFD equipped with analog input
<M> - VFD equipped with TMS system
Older systems, prior to the VFD C, drive equipment identifiers were as follows:
<G> - Drive equipped with <Rot/gang sw> (rotary gang switch)
<A> - Drive equipped with <An inputs> (analog inputs)
<M> - Drive equipped with <TMS type> (TMS and type)
A drive equipped with TMS can be used for operation without TMS if required based on
operating conditions or TMS failure. In the event this is necessary, the following changes should
be made for the insulation resistance measurements:
-

Remove insulation tube from wires <A1-X1:1>, <A1-X2:1>, and <A1:X2:2>


Connect wire <A1-X1:1> to contact X1:1 on board A1
Connect wire <A1-X2:1> to contact X2:1 on board A1
Connect wire <A1-X2:2> to contact X2:2 on board A1
Disconnect wire from XT6 terminal coming from FU1:1, block A5
Connect wire just disconnected to frame at QF5.

For the cable connections on Board A1, use the WAGO 236-332 terminals.
57

5.9 VFD Operating Modes and Modification


The VFD can operate in one of three modes. The three modes are:
-

Hand mode
Automatic mode
Programmed mode

Hand mode implies an operator managed station operation. Automatic motor restarts are not
permitted in this operating mode.
Automatic mode implies that automatic motor restarts may take place after protection activation,
and the restart count will permit the restart (restart count set by the operator).
During programmed mode operation, VFD automatic motor stops are added, along with
automatic motor restarts. The stops and starts are input by the operator as part of an operational
timing diagram.
For drives equipped with the gang switch, the drive mode change is accomplished by moving the
switch from STOP into the position of HAND or AUTOMATIC as appropriate.
For drives not equipped with the gang switch, the drive mode change is made by changing the
<Mode> parameter change.
Program mode changes are entered via input to <*PRG Setting>, with stops and starts as set in
the parameters <PRG operation,m> and <PRG pause,m>, where the operations and stops are
measured in minutes.

58

6 VFD Faults and Corrective Actions


A list of VFD faults and possible corrective actions are given in Appendix D.
Some repairs, as noted in the Appendix, can only be accomplished at an approved Repair Center.

6.1 VFD Disassembling Procedure


6.1.1 General Procedure
During drive component replacement, assembly instructions should be followed.
6.1.2 Safety Measure During Disassembly
Disconnect power cables from power input A, B, and C, and output power U, V, and W.
Make sure all capacitors have completed discharge, using a ground strap (normal on-board
indicators will not being working).
6.1.3 Specific Component Replacement
-

During installation and removal of WAGO type connectors, special tools must be
used. When disconnecting the D-SAB type connectors, it is necessary to use the
TsRKF 745265.001 connect/disconnect tool, which is part of the drive parts.
During the installation of the driver board of the PWM driver and IGBT driver board
in the Borets VD80 drive, it is necessary to make sure the bridge is installed on the
reverse side of the board (reference Appendix G).
In order to replace power modules it is necessary to replace the rectifier thyristor
control board, the pulse-length modulation convertor, and the switching unit driver
board and screen.
During power thyristor and transistor module replacement, it is required that:
Elastic glue layer must be removed without damaging board
Remove any grease from module seat with mineral spirit and gas mix
Apply thin, smooth coat of heat conducting paste on the module seat (Fischer
elektronik)
Place module in slot and ensure uniform positioning. Tighten the hold-down
bolt using a calibrated screwdriver, to 5 +/- 0.5 Nm.
Remove any excess paste from around the module.
Tighten transistor screws with a force of 4 +/- 0.5 Nm.
Tighten thyristor screws with a force of 5 +/- 0.5 Nm.
59

Reconnect all control circuits to the module.


During power circuit replacement for parts like the power circuit breaker, a condenser
in the condenser block, current sensors, chokes, power cables, etc., it is necessary to
tighten all connections to the diagram specifications (<4 +/- 0.5 Nm> for all but the
thyristors, which are <5 +/- 0.5 Nm>).

6.2 Checking VFD Operational Capability


Drive operational capability is checked in compliance with the publication TsRKF.656437.001
PM1 (Instruction for Acceptance Test).
FCC and VFD C controller program loading is completed in accordance with the software
instruction TsRKF.656437.001 (Instruction for Controller Programming. Loading of the FCC
and VFD C software can be performed from the IRU as noted in Section 2.10.2 of this manual.

60

7 Appendices
7.1 Appendix A Fault List and Meaning
7.2 Appendix B Parameters, Settings, and Adjustments
7.3 Appendix C Type Settings By ID
7.4 Appendix D Probable Faults and Troubleshooting
7.5 Appendix E External Signal Connections
7.6 Appendix F PMM and ESP TMPN Transformer Selection
7.7 Appendix G Board Light Indicators
7.8 Appendix H VFD Schematics
7.9 Appendix I Menu Samples
7.10 Appendix J GOST Document References
7.11 Appendix K Modification Log

61

7.1 Appendix A Fault List and Meaning


Display at a screen
Fail sen I PWM
THYR prnt
COMM prtn
PWM prtn
GND I prtn
Max I prnt
Usup prtn
Uout prnt
I overload
Not accelerate
Fail EMFN
Fail DU FRC
Fail AU FRC
Fail half-br
Fail Throttle
Fail sen T FRC
Overheating
Usup
Usup
Turbine rot
Fail FRC chip
Tout COM FRC
No sets DC
Fail Phase
Overload
Underload
Fail R sensor
OPG prtn
Oper prohibit
Fail COM FRC
Fail COM Cls
Fail EEPROMmenu
Fail EEPROM 1
Fail EEPROM 2
Fail EEPROM 3
Fail EEPROM 4
Fail EEPROM 5

Meaning
PWM current sensor failure
Thyristor protector
Commutator protection
PWM protection
GND current protection
Max current protection
Power supply voltage protection when over permit
Output voltage protection when over permit
Current overload (protection as per ampere and second
specifications)
Motor hadnt run
EMF normalizer failure during its start up.
Failure of digital unit of frequency reformer controller
Failure of analog unit of frequency reformer controller
half-bridge failure
Throttle failure
Failure of temperature sensor of frequency reformer
controller
Motor over heating
Power supply voltage over permit.
Power supply voltage under permit
Turbine rotation
Program failure of frequency reformer control chip
Timeout at charging of frequency reformer control chip
No sets for this drive complex
Phase failure
Overload protection
Under load protection
Rinds sensor failure
Contact pressure gage protection
Operation prohibition
Failure of frequency reformer controller connection line
Failure connection line with outer devices
EEPROM menu failure
Failure of EEPROM of protocol 1
Failure of EEPROM of protocol 2
Failure of EEPROM of protocol 3
Failure of EEPROM of protocol 4
Failure of EEPROM of protocol 5
62

Display at a screen
Fail EEPROM 6
Fail EEPROM 7
Fail LCD
Fail 12 Cpot
Fail timer
Fail sen T LCD
Fail poten.
Rins
Door prtn
Not calibr Rins
Power on
BOR restart
Fail prog
Fail memory
Fail EEPROM
Uin prtn
Uin prtn
I db prtn
Uin db prtn
Uoout db prtn
A/I1 prtn
A/I2 prtn
Fail COM A/I
Fail TMS
Tm win prnt
Pint prnt
Vibr prnt
Unst wk prtn

Meaning
Failure of EEPROM of protocol 6
Failure of EEPROM of protocol 7
Indicator failure
I2C potentiometer failure
Timer failure
Indicator temperature sensor failure
Potentiometers failure
Rins protection is under permit
High voltage opening door protection
Rins sensor is not calibrated
Power on
BOR restart
Program failure
Memory failure
EEPROM VFD controller failure
Power supply voltage protection is under permit
Power supply voltage protection is over permit
Current misbalance protection
Power supply voltage misbalance protection
Exit voltage misbalance protection
Analog input 1 protection
Analog input 2 protection
Analog unit communication failure
Telemetry failure
Motor winding heating protection
Pump input pressure protection is higher of tolerance
Vibration protection is higher of tolerance
Motor unstable work protection

63

7.2 Appendix B Parameters, Settings and Adjustments


Indication at SVD

RPM, r\m Hz
I motor, A
Rins, kOm
Date Time
Supply voltage,
V
U sup disb, %

Parameter
settings and
adjustments

Factory
settings

Full name

List of parameters of installation operation


Motor revolution number
Motor current
Cable insulation resistance
Current date, time
Supply voltage;
Current value of non symmetric ratio of
phase voltage;
Current value of non symmetric ratio of
phase voltage;
Current value of non symmetric ratio of
phase voltage;
Current values of actual loading;
Time of mode end (pause of work);
Consumed power, kWt
Energy consumption, MWt*hrs
Number of restarts;
Motor run time, hours
Switchboard runtime, hours
LCD temperature, deg C;
Software version;
Number of shutdowns in case of under load;
Number of shutdowns in case of overload
Number of shutdowns in case of other
alarms;
Motor run time since last start, hours
Analog input 1;
Analog input 2;
Pump intake temperature, deg C
PMM winding temperature deg C;
Vibration X, g;
Vibration Y, g
Pump intake pressure, atm.

U out disb, %
U sup disb, %
Load, %
Time to end%
P, kWt
W, Vt *h
Num rst, hrs
Motor r\t, hrs
VFD r\t, hrs
LCD Temp, C
SW version
Num Stdn U/N
Num Stdn O/L
Num Stdn O/A
Last mot r/t
An imp. 1
An imp. 2
T intake
T m wim, C
Vibr X, g
Vibr Y, g
P intake
Menu

Submenu of setting, which is opened in


submenu of other level, containing items:

<Settings>

64

Indication at SVD

Parameter
settings and
adjustments

<History>
<Settings>
<LCD>
<Date Time>
<Drive conf>
<Commands>
<Calibration>
<ULS>
<Language>
<Service>

Factory
settings

Full name

Other settings, U settings, I settings,


S settings;
Submenu of viewing of scrolling of
installation work history;
Submenu, which opened in a list of setting
adjustment;
Submenu, which opened in a list of LCD
settings;
Submenu, which opened in a list of date and
time settings;
Submenu, which opened in a list of drive
configuration;
Submenu, which opened in a list of
commands;
Submenu, which opens calibration service
mode;
Submenu, which opened in a list of upper
level of settings;
Submenu, which opens list of languages of
data image;
Submenu of service usage.
Submenu Settings
1
Well No;

Well No.

1-65535

Cluster No.

1-65535

Cluster No;

Field No.

1-65535

Field No;

Pint depth, m

0-9999

Pump intake depth, m;

Tran Sec U,V

300-3500

983

Transformer secondary voltage, V;

0-9999

120

Parameter registration step, min

Par reg step, m


Mtr rot,

rpm

Hz - rev/min
8 12

Disp bright
Disp con
Date
Time

rev/min
10

Motor revolution speed unit;


Leakage Measurement

Submenu LCD
70
Display brightness of LCD ;
100
Display contrast of LCD.
Submenu Date and time
01.01.06
Current date;
00.00.00
Current time.
Submenu of DS (composition of drive set)

0-255
0-255

65

Indication at SVD

Parameter
settings and
adjustments

Factory
settings

Full name

VFD type

1 - 255***

VFD type selected in compliance with


composition of device from presented list;

Motor type

1 - 255***

ESP capacity

0 2000

PMM type selected in compliance with


composition of device from presented list
ESP capacity, m3/day

ESP head

0 5000

ESP head, m;

TMS type

1 - 255***

No TMS

S type, which is selected in compliance


with set of settings from presented list.

Delete history
Password
change
Testing

Submenu Commands
Command deletes VFD operation history;
4321,
8991

Manufacturer
sets
Reset PPM
runtime
Reset VFD
runtime
System reset
Unlocking
CWB
Cls cont type
VFD address
Com speed
Prot No
CBY
RPM.r\m hrz

Command enables password change of


installation access;
Command permits to test light indication and
fan operation; while performing it at the
controllers screen indication symbols
selection will start, including fan and at door
in a turn green, red and yellow indicators will
be switched; test will finish within a minute
after start or with Cancel button pressure.
Command sets all settings into initial
position;
Reset Motor Counters
Reset Drive Counters
Total Reset
Remove Manual Start Block

Submenu ULS (Upper level systems)


1 - 255***
No Cls
Cluster controller type;
1 - 255
5
VFD address in cluster net;
1 - 255***
9600
Communication speed;
1 - 255
0
Number of cluster communication protocol
On/Off
Off
Drive Remote Control
Submenu Other settings
500-3500**
1500**
Revolution per minute /frequency (it can be
in Hz );
66

Indication at SVD

Acc time

Parameter
settings and
adjustments
0 1000

Factory
settings

Rins prtn
Rins!
CPG prtn
CPG sd dl, s

<<</>>>
HAND
MODE/AUTO
MODE
On/Off
30-500
On/Off
0-999

CPG prtn dl, s

0-999

CPG prtn dl st,


s
CPG num rst
Res cntr, m
Prog mode
Operat time, m
Break time, m
Start dl, m
Door Prtn
A/I1 prtn
A/I1 op level
A/I1 sd dl, s
A/I1 AR dl, m
A/I1 num rst
A/I1 pn dl, s

0-60

15

0-9999
0-9999
On/Off
1-9999
1-9999
1-60
On/Off
Off/block/resetting
0 10
0 120
1 300
0 - 9999
0 60

5
5
Off
1
1
1
On
Off
0
5
1
5
15

A/I2 prt
A/I2 op level
A/I12sd dl, s
A/I2 AR dl, m
A/I2num rst
A/I1 pn dl, s

Off/block/resetting
0 10
0 120
1 300
0 - 9999
0 60

Off
0
5
1
5
15

Unst wk prtn
Inst spd, rpm

Off/block/resetting
5003500**

Off
500

Rot direct
Auto mode

>>>
HAND
MODE
Off
50
Off
5

Full name

Time of acceleration to set speed on the


program of rotation during managed
acceleration;
VD rotation direction;
Activation of automatic operation;

Law insulation resistance protection;


Minimal R ins value;
Contact gage protection;
Shutdown delay in case of contact pressure
gage protection response, s;
Contact pressure gage protection delay after
PMM start up, sec
Other protection delay after PMM startup,
sec;
Number of contact pressure gage restart
Time to reset of restart counters;
Activation of programmed operation;
Programmed operation time, min
Break time on programmed operation, min
Start up delay after power switched on, min;
Open door protection;
Analog input 1 protection;
Operation level of analog input 1 protection;
Analog input 1 shutdown delay, sec;
Analog input 1 automatic restart delay, min;
Number of restarts for analog input 1;
Analog input 1 protection delay after
PMM start up, sec
Analog input 2 protection;
Operation level of analog input 2 protection;
Analog input 2 shutdown delay, sec;
Analog input 2 automatic restart delay, min;
Number of restarts for analog input 2;
Analog input 2 protection delay after PMM
start up, sec;
Unstable work protection;
Initial speed on programmed acceleration,
rpm.
67

Indication at SVD

Uin ! prtn
Uin !, %
Uin ! sd dl, s
Uin |
Uin | %
Uin | sd dl, s
Uin db prtn
Uin db, %
Uin db sd dl, s
Uin db AR dl,s
U out db prtn
U out db, %
Uo db sd dl, s
Uo db
U prtn dl, s

O/L Prtn
O/L I, A
O/L I
O/L sd dl, s
O/L AR dl, m
O/L num rst
U/L Prtn
U/L I, A
U/L I, %
U/L sd dl, s
U/L AR dl, m
U/L num rst
I db prtn

Parameter
settings and
adjustments

Factory
settings

Full name

Submenu Voltage settings


On
Low input voltage protection;
80
Low input voltage;
5
Shutdown delay in case of low input voltage,
sec
On/Off
On
High input voltage protection;
100-125
110
High input voltage;
0-60
5
Shutdown delay in case of high input
voltage, sec;
Off/block/resetting Resetting
Input voltage imbalance protection;
0-20
20
Output voltage imbalance, %
0-60
5
Shutdown delay in case of input voltage
imbalance, sec;
0-300
5
Automatic restart delay in case of input
voltage imbalance, min;
Off/block/resetting Resetting
Output voltage imbalance protection;
0-20
20
Input voltage imbalance; %
0-60
5
Shutdown delay in case of output voltage
imbalance;
0-300
5
Automatic restart delay in case of output
voltage imbalance, min;
0-60
15
Voltage protection delay after PMM startup,
sec .
Submenu Settings I (Current settings)
Off/block/resetting Resetting
Overload protection;
0-25**
0
Overload PMM current, A
100-400
110
Overload PMM current, %;
0-120
20
Shout down delay in case of overload;
1-3000
5
Automatic restart delay in case of overload,
min;
1-10
1
Number of restarts in case of overload;
Off/block/resetting Resetting
Underload protection;
0-25**
0
Underload PMM current, A;
1-100
50
Underload PMM current, %;
1-600
40
Shutdown delay in case of underload, sec;
1-3000
60
Automatic restart delay in case of underload,
min;
0-21
3
Number of restarts in case of underload;
Off/block/resetting Resetting
Current imbalance protection;
On/Off
70-100
0-60

68

Indication at SVD

Parameter
settings and
adjustments

Factory
settings

I db, %

0-25

25

I db sd dl, s

0-60

0 60

1 300

60

I db AR dl, m
I prtn dl, s
Pint reg
Pint Req, atm
RPM max
RPM mix
Vbr P/L
Vbr off, g
Vbr sd dl, s
Vbr AR dl, s
Tm min, P/L
Tm max, C
Tm sd dl w,s
Pint|, P/L
Pint|, atm
Pint|, atm
Pint|, atm
Pint sd d,s
Pint AR dl, m
TMS prt dl,s

VFD s/n
VFD type
VFD m/code

Full name

Current imbalance, %;

Shutdown delay in case of current


imbalance, sec;
0-300
5
Automatic restart delay in case of current
imbalance, min;
0-60
15
Current protection delay after PMM start up.
Submenu TMS settings
On/Off
Off
Lockout of adjustment based on Pint signals;
0 300
90
Required pump intake pressure, atm;
500-3500**
1500**
Maximum PMM speed on adjustment (may
be in Hz);
500-3500**
1500**
Minimum PMM speed on adjustment (may
be in Hz);
Off/block/resetting Off
Vibration protection lockout;
0.1 10.0
0.1
Vibration level when motor off, atm;
0 60
5
Shutdown delay in case of vibration excess,
min
1 300
60
Automatic restart delay in case of vibration
excess, min
Off/block/resetting Off
PMM winding temperature protection;
0 160
115
Maximum PMM winding temperature deg C;
Shutdown delay in case of high PMM
winding temperature, sec;
Low pump intake pressure protection lockout

Off/block/resetting Off
0 300
40
0 300
0 60

Minimum pump intake pressure;


Maximum pump intake pressure;

80
5

Maximum pump intake pressure;


Shutdown delay in case of high PMM
winding temperature, sec;
1 3000
60
Automatic restart delay in case of low pump
intake pressure protection work;
0 999
15
TMS protection delay after PMM startup, sec
;
Submenu Passport
0 99999999
0
Switchboard serial number;
0 9999
0
Switchboard type according to manufacturer
classification;
0 9999
0
Switchboard manufacture code;
69

Indication at SVD

Parameter
settings and
adjustments

VFD m/date
VFD s/n
VFD type

0 99999999
0 9999

VFD m/date

0 9999

VFD m/date
Feeder No.
FCC revs
AB l/v, V
BC l/v, V
CA, l/v, V
T 1 rad, o C
T 2 rad, o C

Factory
settings
01.01.06
0
0
0

Full name

Switchboard manufacture date;


Switchboard serial number;
Switchboard type according to manufacturer
classification;
Switchboard manufacture code;

01.01.06
Switchboard manufacture date;
0 999999
0
Feeder No.
Submenu Parameters (Service=> FCC)
Revolutions from FCC
Line voltage AB, V
Line voltage , V
Line voltage , V
Radiator temperature 1, deg C
Radiator temperature 2, deg C

UWm l/v,V

Line voltage on motor UW, V

VWm l/v,V

Line voltage on motor VW, V

WWm l/v,V

Line voltage on motorWU, V

I phase A,A
I phase B,A
I phase C,A

Phase A current, A
Phase B current, A

I motor, A

Motor current, A

FCC SW ver
FCC s/n
FCC S/V date
Sets pack No.
Rated I m, A
Rated Pm,
kWt

Phase C current, A

FCC software version


FCC serial number
Date of last SFC weaving
Submenu Motor (Service)
Setting pack number
Motor ampere rating
Motor rated break power

Rated Um, V

Motor voltage rating

Q pole pairs

Quantity pole pair

I1 break, A

Ampere-second characteristic current 1

1 break, s

Ampere-second characteristic motor 1


disconnection time
70

Indication at SVD

Parameter
settings and
adjustments

Factory
settings

Full name

I2 break, A

Ampere-second characteristic current 2

2 break, s

Ampere-second characteristic motor 2


disconnection time

I3 break, A

Ampere-second characteristic current 3

2 break, s

Ampere-second characteristic motor 3


disconnection time

Rot min,rpm

Minimal motor revolutions

Rot max,rpm

Maximum motor revolutions

I form -factor

Current-form-factor
Submenu settings (Service VFD)

Rot/sw

Yes/No

No

Availability of rotary switch

NEMF test

On/Off

On

Test shutdown for EMF normalizer

B/S rot test

On/Off

On

Test shutdown for backspin rotation

PWM prnt

On/Off

On

PWM protection

An inputs

Yes/No

No

Availability of analog inputs in switchboard

Sup Voltage, V
Over control
range
Num O/Cs

380V/480V

380V

100-1000

400

3-100

Number of over controls

Res O/C cr, m

1-15

Reset time of over control counter.

% RPM rr
TMS
P rr, O/C, atm
O/C step, m
P rr, atm/ min
Log Pdev, atm
Log Tdev, C

Supply voltage 380/480V


Over control range

Submenu Registration settings (Service S)


RPM ramp rate on adjustment based on TMS
0.0-99.99
1.00
signals, %
0-9999

Pressure ramp rate to start over control, atm

1-9999

20

Over control step

0.0-99.00

0.03

Pressure ramp rate when designation of


unstable operation mode, atm/min

0-9999

Logged value of pressure deviation, atm

0-9999

Logged value of temperature deviation, deg

71

Indication at SVD

Parameter
settings and
adjustments

Factory
settings

Full name

C
Log Vdev, g

0.0-10.0

0.1

Logged value of vibration deviation, g

* - protection can be switched off by an operator;


** - setting range depends on motor type.
*** - setting has list format. Lists may be changed with modification of setting equipment
composition that is reflected in software versions.

72

7.3 Appendix C Type Settings By ID


Line
No.
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37

Setting ID
VD type setting
VD type
2VEDBT 0-117/1V5
x2 VEDBT 12-117/1 V 5
x2 VEDBT 14-117/1 V 5
x2 VEDBT 24-117/1 V 5
x2 VEDBT 21-117/1 V 5
x2 VEDBT 28-117/1 V 5
x2 VEDBT 42-117/1 V 5
x2 VEDBT 35-117/1 V 5
x2 VEDBT 49-117/1 V 5
x2 VEDBT 56-117/1 V 5
x1 VEDBT 32-117/3 V 5
x2 VEDBT 70-117/1 V 5
x1 VEDBT 72-117/3 V 5
x1 VEDBT 18-117/3 V 5
x1 VEDBT 26-117/3 V 5
x1 VEDBT 36-117/3 V 5
x1 VEDBT 45-117/3 V 5
x1 VEDBT 54-117/3 V 5
x1 VEDBT 63-117/3 V 5
x1 VEDBT 110-117/3 V 5
x1 VEDBT 128-117/3 V 5
x1 VEDBT 180-117/3 V 5
x1 VEDBT 200-117/3 V 5
x5 VEDBT 30-117/3 V 5
x5 VEDBT 40-117/3 V 5
x5 VEDBT 50-117/3 V 5
x5 VEDBT 70-117/3 V 5
x5 VEDBT 100-117/3 V 5
x5 VEDBT 125-117/3 V 5
x5 VEDBT 150-117/3 V 5
x5 VEDBT 175-117/3 V 5
x5 VEDBT 80-117/6 V 5
x5 VEDBT 110-117/6 V 5
x5 VEDBT 160-117/6 V 5
x5 VEDBT 200-117/6 V 5
x5 VEDBT 250-117/6 V 5
x5 VEDBT 300-117/6 V 5
73

Note

Line
No.
38
39
0
1
2
3
1
2
3
1
2
3
1
2
3
4
5
6
7
8

Setting ID
x5 VEDBT 350-117/6 V 5
x1 VEDBT 140-117/3 V 5
VFD type setting
SU Type
BORETS -VD80
BORETS -VD40
BORETS -VD250
TMS type setting
S not available
S SPT -1
S Zenith
VFD type setting
VFD not available
VFD SurgutNG N3
VFD Region-2000
V exchange, baud setting
V exchange,baud 1200
V exchange, baud 2400
V exchange, baud 4800
V exchange, baud 9600
V exchange, baud 19200
V exchange, baud 38400
V exchange, baud 57600
V exchange, baud 115200

74

Note

7.4 Appendix D Probable Faults and Troubleshooting

No

Indication

Fault
PWM current
sensor failure

1 Current sensor P1
failure
2 Power module 5
failure
3. 2 drivers board of
pulse-length modulation
convertor failure

Thyristor control
board protection
was activated

1 Failure of one of the


convertor modules
MVD1MVD3
2 Thyristor control board
(1)
3 9 power module
failure
1 Failure of one of switch
board modules
MV2MV4
(drivers board of pulselength modulation convertor)
2
(3) board failure
3 Short circuit in
switchboard load circuit
1 Short circuit at
switchboard output contacts
2 Short circuit in pulsewave modulation transistor
circuit
3 MV1 module pulsewave modulation convertor
failure
4 drivers board of pulsewave modulation convertor
(2) board failure

Fail sen I
PWM

THYR prnt

COMM prnt

Inverter thyristor
control board
protection was
activated

Thyristor control
board protection of
PWD convertor was
activated
4

PWD prnt

Possible causes

75

Troubleshooting
1 Replace current
sensor 1
2 Replace power
module 5
3 Replace board 2
(drivers board of
pulse-length modulation
convertor)
1 Replace defective
module
2 Replace 1
Thyristor control board
3 Replace 9 power
module

1 Replace (3)
defected module board
2 Remove short
circuit in station load
circuit

1 Rectify short circuit


in a circuit of external
transformer connection
2 Rectify short circuit
Replace defected
transistor PDM
3 Replace 2 (pulsewave modulation)
board
4 Rectify short circuit
with defected transistor
pulse-wave modulation

No

Indication

Fault
Input currents
misbalance

GND I prnt

Maximum current
protection
6

Max I prnt

Current overload
7

I overload

Troubleshooting

1 Ground short-circuiting
of phase at VSD output
2 Switch boards one
sensor failure
3 5 power feeding
module failure

1. 1 Rectify VSD
ground shortcircuiting of
phase
2. Replace
defected current
sensor
3. Replace 5
power feeding
module failure
1 Device wedging
1 Remove device
2 External PN
wedging
matching transformer failure 2 Replace external
3 5 power module
matching transformer
failure
3 Replace 5 power
module
1 Device overload
1 Rectify overload
2 Incorrectly entered
cause
voltage setting of matching
2 Enter correct U
transformer secondary
str setting

Motor has not


accelerated

1 Device wedging
2 Violation of integrity of
circuit connection of engine
transformer switchboard
3 Motor type was
incorrectly entered in
paragraph Drive config

Voltage normalizer
failure at FCC board

Not
accelerated

Fail EMFN

Possible causes

Loading is disconnected

2 Matching Trans second


U is defected
3 FCC board failure
4 Resistor divider board
failure
5 Break-down or absence
of contact in
CIRCUIT 380V-PRDFCC circuit
6 Inadmissible circuit
interferences

76

1.Remove device
wedging
2. Check integrity of
circuit connection of
engine transformer
VSD
3. Enter required motor
type
1 Connect load
2 Replace transformer
3 Replace FCC board
4 Rectify rupture

No

Indication

Fault

Possible causes

Troubleshooting

FCC digital part


failure

FCC failure

Replace FCC

10 Fail DU FRC
11 Fail AU FRC

FCC analogue part


failure

FCC failure

Replace FCC

Pulse-length
modulation
convertor
inductivity is lower
than standard one

1 Short circuit of PDM


converter throttle coil;
2 Considerable feeding
power circuit distortions

Replace throttle

Check circuit

Failure of two
temperature sensors

Failure of two temperature


sensors

Replace temperature
sensors

Converter
temperature is more
than 85

1 Fan failure
2 Control and secondary
board (4) failure
3 VFD A1 failure
4 Communication breakdown in fan control circuit
VFD - CONTROL AND
SECONDARY BOARD FAN
1 FCC (1) failure
2 Feeding power module
(8) failure

1 Replace fan
2 Replace control and
secondary board (4)
3 Replace VFD (1)
4 Remove breakdown

12 Fail Throttle

13

Fail sen T
FRC

14 Overheating

FCC failure
15 Fail FRC

Fail COM
16
FRC

17 Turbine rot

FCC (1) failure

Communication line
failure between VFD
and FCC

Turbine rotation

1 Installation turbine
rotation
2 Circuit neutral is
connected to WSD case
3 Matching transformer
case is not connected with
VSD case
4 Circuit interferences

2 Feeding power module


(8) failure
3 Communication
breakdown

77

1 Replace FCC (1)


2 Replace feeding
power 8 module
1 Replace FCC (1)
2 Replace feeding
power 8 module
3 Replace VFD C
(4).
4 Check connectors
contacts
1 It is necessary to
wait for turbine rotation
end and start device
2 Replace power
feeding 8 module
3 Replace VFD
(4)
4 Disconnect
Resting Turbine rot

No

Indication

18 No sets DC

19 Fail R sensor

Fail EPROM
20
menu

Fault

Drive engineering
Drive engineering package
package composition composition is not entered
is not available
to drive engineering
package.
Failure of R sensor
1 Power feeding module
7 failure.
2 Failure of VFD (4)

Enter correct
composition of drive
engineering package

Installation
permanent memory
failure

Failure of VFD (4)

Door protection

1 Front door with


disconnected blocking
during door opening is open
2 Limit switch SA1 is
defective

1 Close VSD front


door. Switch off door
opening blocking
2 Replace limit
switch SA1

No calibration
according to R
insulation

calibration not carried out


during first switching or
after VFD controller
replacement

Carry out calibration

Telemetry system
failure

1 Installed TMS type not


correctly entered
2 TMS failure

1 Enter correct
installed TMS type
2 Replace TMS

No controller
indication

1 Supply voltage at
switchboard
2 Replace controller
3 Replace switching
of Control circuits
toggle switch
4 Replace control and
secondary board or
replace safety device at
the control and
secondary power board
1 Rectify short circuit
2 Replace varistors

23 Fail TMS

VSD is not connected

2 Controller indicator is
not operational
3 Toggle switch
Control circuits is not
operational

24

Power automat fails


25

Troubleshooting

1 Replace power
feeding module 7
2 Replace VFD
(4)
Replace VFD (4)

21 Door prtn

22 Not calibr Ris

Possible causes

4 Control and secondary


power board is not
operational
1 Input circuit short
circuit
2 One of input circuit
varistors has burned off

78

7.5 Appendix E - External Signal Connections


7
Circuit

Contact

Common pressure
gage

Contact pressure gage

General external
inhibition

External inhibition

motor switch

General motor switch

Motor switch

8
Circuit

Contact

U input 1+

U input 1-

U input 2+

U input 2-

U input 3+

U input 3-

10

79

7.6 Appendix F PMM and ESP Motor TMPN Transformer Selection


Calculated value of secondary voltage of step-up transformer taking into consideration
voltage drop in a cable for required frequency of electric motor rotation frequency, which is
calculated according to the formula:

U U0 U L
where: U [V] - calculated voltage of transformer regulation degree,
U [V/km] - specific voltage drop in a cable with nominal electric motor current in
compliance with table,
U0 [V] - transformer voltage regulation degree without accounting for cable
voltage drop,
L [] - cable length.
Transformer voltage stage is selected as nearest from calculated value.

80

Table 7.6.1 - For permanent magnet motor (PMM)

No.
1
2
3
4
5
6
7
8
9

Rotation frequency
[rev/min]
Electric motor type
2VEDBT 10-117/1 V 5
2 VEDBT 14-117/1 V 5
2 VEDBT 21-117/1 V 5
2 VEDBT 28-117/1 V 5
2 VEDBT 35-117/1 V 5
2 VEDBT 42-117/1 V 5
2 VEDBT 49-117/1 V 5
2 VEDBT 56-117/1 V 5
2 VEDBT 70-117/1 V 5

250

500

750

1000

1250

1500

Transformer regulation voltage stage not taking into account


voltage drop consideration with cable U0 [V]
95
195
290
385
480
575
130
260
385
515
640
770
195
390
585
775
970
1165
260
515
770
1025
1280
1535
325
645
965
1285
1610
1930
390
770
1155
1535
1920
2305
450
900
1350
1800
2250
2700
515
1025
1540
2050
2560
3075
640
1280
1920
2560
3200
3840

Draft 11 January 4, 2010


81

Nominal
current
I [A]
27
27
27
27
27
27
27
27
27

U cable
[V/km]
55
55
55
55
55
55
55
55
55

Table 7.6.2 - For ESP electric motor

No.
1
2
3
4
5
6
7
8
9
10
11
12

Rotation frequency
[rev/min]
Electric motor type
1 VEDBT 18-117/3 V 5
1 VEDBT 26-117/3 V 5
1 VEDBT 36-117/35 V 5
1 VEDBT 45-117/3 V 5
1 VEDBT 54-117/3 V 5
1 VEDBT 63-117/3 V 5
1 VEDBT 72-117/3 V 5
1 VEDBT 110-117/3 V 5
1 VEDBT 128-117/3 V 5
1 VEDBT 140-117/3 V 5
1 VEDBT 180-117/3 V 5
1 VEDBT 200-117/35

2000

2250

2500

2750

3000

3250

3500

Transformer regulation voltage degree not taking into account


voltage drop consideration with cable U0 [V]
450
505
560
617
670
730
785
670
750
835
920
1000
1085
1170
890
1005
1115
1225
1335
1450
1560
1115 1255
1395
1530
1670
1810
1950
1335 1500
1670
1835
2000
2170
2335
1560 1755
1950
2140
2335
2530
2725
1420 1600
1775
1955
2130
2310
2485
1590 1785
1835
2185
2380
2580
2780
1910 2145
2385
2625
2860
3100
3340
1520 1710
1900
2090
2280
2470
2260
1645 1850
2055
2260
2465
2670
2880
1830 2055
2285
2515
2740
2970
3200

82

Nominal
current
[A]
23
23
23.5
23.5
23.5
23,5
29.5
40
40
54
65.5
65.5

U cable
[V/m]
45
45
45
45
45
45
60
80
80
108
125
125

7.7 Appendix G Board Light Indicators


Figure 7.7.1 FCC Board

HL1, red ON during activation of protection according to maximum values of: input
voltage, commutator voltage, output current, phase current unbalance, faults in
sensor circuits;
HL2, green flickering if communication via the RS485 interface is established between
VFD C and FCC;
HL3, red ON during exceeding permissible motor rotation speed;
6HL1, 6HL2, 6HL3, green - ON if power 15 V, +15 V and +5 V are provided.

83

Figure 7.7.2 IGBT driver board (Commutators driver)

HL1, green ON if +5 V power is provided;


HL2, green ON if +12V power is provided;
1HL16HL1, red ON when fault (short circuit) of input circuit of the
corresponding module MVT2MVT4, or fault of output
circuits of IGBT driver board.
1HL26HL2, red - ON when there is fault of the corresponding module
MVT2MVT4, or short circuit in load circuit.

84

Figure 7.7.3 PWM driver board

HL1, green ON if +5 V power exists;


HL2, green ON if +12V power exists.
1HL1, red ON when it is fault (short circuit) of input circuit of MVT1 module
is defective;
1HL2, red - ON when it is fault of MVT1 module or short circuit in switch
board circuit.

85

Figure 7.7.4 Discharge resistors board

HL1, red weak light when bus voltage is 70 V;


fully ON when bus voltage is 400

86

Figure 7.7.5 Control and secondary power board and universal power modules

At control and secondary power board:


HL1, red ON when drive heating is ON.
HL2, red ON when main power circuit breaker trips due to emergency
conditions.
At universal power modules
HL1, HL2, HL3, green ON if there is voltage at corresponding
outputs of universal power modules.

87

Figure 7.7.6 Thyristors driver module

HL1, red - ON when the transistor, responsible for preliminary rectifier filter charge, cannot
be switched ON
HL2HL4, red ON if corresponding thyristor module MVD1MVD3 cannot be
switched ON
HL5, green ON if +12 V power is present

88

Figure 7.7.7 Setting of jumpers on PWM driver board and on IGBT driver board

1XP2
1XP1

1R27

PWM
driver
board

Jumper

1R28

1XP3
1XP4

IGBT
driver
board

Jumper

1R29
1R30

89

7.8 Appendix H - Schematics

Draft 11 January 4, 2010


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

Draft 11 January 4, 2010


97

Service

Submenu

Submenu FCC

VSD submenu

Submenu
TMS

<FCC>

FCC

Parameters

Condition

Adjustment sets

<Motor>
<VSD>

<Parameters >
<Condition >

<S>

Motor

Rot speed , rpmm


Ab I/I, v

Power activation *

BC I/v,V

Settings

% RPM rr TMS
P rr O / C , atm
O/C step , m

Sets packs No.

Uca,B

Rot/ sw

P rr, atm/ atm

Rated Im, A
Rated Pm, kWt,
Rated Um , V

1, rad ,
2, rad
UVm I , v,V

NEMF test
B/S rot test
Prt sen I PWP

Log Pdev,atm
Log Tdev, C
Log Vdev,g

Q pole pairs

VW I/v,V

An . inputs

I1 break ,
1 break, s

UVm I/ v,V
I phase ,A, A

Uin
O/C range , rpm

I2 break,
2 break,

I phase ,B, A
I phase ,C, A

Numb. O/Cs
Res O/C cr, m

I3 break ,

Rot min, rpm

Iout,A
Option software
Software
No. FCC

Rot max, rpm

Date of software of FCC

T3 break ,s

I Form ratio
SVD

Condition
No active *

Condition
No active *

< Condition >


<Settings>

S
< Adjustment sets
>
< Condition >

*Submenu <Condition> contains list of active


protections and faults of devices, if they are available

98

7.10 Appendix J - GOST Standard References


GOST #

Title

Equivalent Documents

14192

Cargo Marking

14254

Degrees of protection provided by enclosure

15150

Machines, instruments, and other industrial


products, modification for different climatic
regions (operating, storage, and transportation)

17516

General requirements for environment


mechanical stability in electrical articles

18620

Marking of electrotechnical articles

23216

General requirements and testing methods for


electrotechnical products storage,
transportation, and temporary corrosion

51317.6.2

External EMC protection

IEC 61000-6-2
EN 50082-2-95

51317.6.4

EMC emissions from drives

IEC 61000-6-4
EN 50081-2-94

51321.1

General safety requirements electrical


equipment

Draft 11 January 4, 2010


99

IEC 60439-1-92

7.11 Appendix K - Modification Log


Number of sheets (pages)
Mod
number

modified

replaced

new

Number of
modification
annulled notification

100

Signature

Date of
Date of
record modification
inserting
inserting