Issue Date: 08-May-2007 Rev.

Date: 10-Sep-2007 Revision: 02

Author: Beth Nollenberger Page 1 of 16 Content ID: 4323677

Schlumberger Private
UniConn/SWD/SS2K+ Troubleshooting Companion
ERROR CODE EXPLANATION FOR UNICONN CONTROLLER IN VSD MODE

Revision History
Rev.
No. Effective Date Description
01 08-May-2007 First release
02 10-Sep-2007 Updated version, with additions and corrections

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 Page 2 of 16

Section 1: Introduction .................................................................................................................................3

Section 2: VSD Parts and Nomenclature ..................................................................................................4
Section 3: GX Errors ......................................................................................................................................6
Notes on “GX” and what it means .............................................................................................................6
GX CPU ERR: CPU Error ................................................................................................................. 6
GX DC OC R*: DC Overcurrent (Run) ............................................................................................ 7
GX DC OC A: DC Overcurrent (Acceleration)............................................................................... 7
GX E HARD: Earth Fault (Hard)...................................................................................................... 7
GX INV OL: Inverter Overload ....................................................................................................... 8
GX OH ERR or GX OC (ACC): Overheat Trip - The VSD has exceeded 83C (181F) ..................... 8
GX OPT ERR: Option ROM Error .................................................................................................... 9
GX ROM ERR:.................................................................................................................................. 9
GX TF ERR: Inverter Typeform Error ............................................................................................. 9
GX PH U Sht: U-phase short circuit.............................................................................................. 9
GX PH V Sht: V-phase short circuit .............................................................................................10
GX PH W Sht: W-phase short circuit ..........................................................................................10
Section 4: VSD Errors..................................................................................................................................10
VSD SYNC: UniConn and VSD run status are not “Synchronized” ..........................................10
U_BAT: Internal battery needs to be replaced in UniConn. .....................................................10
VSD_COMM: Communication Error VSD and UniConn are not communicating......................10
VSD_OLOAD: Overcurrent............................................................................................................11
VSD_ULOAD: Low Current Trip Motor amperage is below set point. ......................................11
StarView: .......................................................................................................................................12
Section 5: Non-error generating problems.............................................................................................12
Section 6: Appendix ....................................................................................................................................14

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 Page 3 of 16

SECTION 1: INTRODUCTION

NOTE - This guide is to be used in conjunction with the UniConn and VSD Manuals.
Please refer to the QHSE section in each of those guides before proceeding.

NOTE - For the following guide the VSD Errors are in bold, the wellview downloaded
follows in small type and the description is in normal type. Please follow the steps
until the problem is solved. If the problem persists beyond the steps of this guide
contact InTouch for further support and report the steps that have been performed.

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and Trade Secret and not to be disclosed, used, or reproduced without written approval from
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 Page 4 of 16

SECTION 2: VSD PARTS AND NOMENCLATURE

Figure – 1 - Typical layout of the Internal Parts Inside of the VSDs

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 Page 5 of 16

External
Fan Heat Sink

Heat Sink
Cooling Fan
Capacitor

Capacitor
Bank
Phase W
Snubber
Board (PCB21)

Snubber
Board (PCB20) Phase V

IGBTs
(Under Snubber Phase U
Boards)

Internal
Contactor Fans

Figure – 2 - Typical layout of the Internal Parts Inside of the VSDs and
Equipment located behind the metal plate

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 Page 6 of 16

The following VSD parts have several common names:

VSD Manual Name Commonly Used Terms

Main Circuit Breaker Main Disconnect, MCB
Terminal Board PCB6 Board
Controller Board Inverter Board, PCB1 Board
Gate Driver Board Base Board, Mother Board, PCB3 Board
Option Rom Control Board Chip, Opt ROM, REDA ROM
IGBTs Transistors
Snubber Board PCB20, PCB21
External Fan Heat exchanger
Communication Cable Telephone cord
Phase U, V, W Phase A, B, C

SECTION 3: GX ERRORS

Any alarm that starts with a GX represents a trip code from the VSD hardware; this is not a
UniConn generated alarm.

NOTES ON “GX” AND WHAT IT MEANS

The “G” refers to the first letter of the drive “Series”, for example “G” series Toshiba VSD
NOTE – This is currently the only series of VSD that SLB uses in the low voltage KVA range of 66-
1500 KVA from Toshiba.

The “X” refers to the “Type” of the VSD, for example SLB currently uses the type “3” and “7”
VSDs. Typically referred to as the “G3” and “G7” VSDs.

NOTE - There are currently no plans to segregate the errors reported by each of the
different control systems.

GX CPU ERR: CPU ERROR

1. Is the option ROM (chip) securely in place?

2. Is there a ground connected to CC on terminal board?
3. Remove ground.
4. Is there an external source connected to PP on terminal board?
5. Remove external source.

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 Page 7 of 16

6. Change out control board and option ROM.

GX DC OC R*: DC OVERCURRENT (RUN)

1. For 518-1500KVA drives Toshiba published a document stating that this may be caused by
an incorrect wire routing in the VSD. On the MS2 discharge contactor near the top of the
drive look for the wire marked PA. Follow that wire and double check that it runs along
the outside of the DC bar at the bottom of the drive. If it runs along the inside of the bar it
needs to be moved as it may be creating noise. Refer to InTouch 4288313. See
attachment for more details.
2. Are CPTs tapped for the correct incoming voltage (output of CPTs should be ~240V.)?
3. Are control voltages present on the terminal board (+/-5V, +/-12V), test terminal board as
outlined in SWD manual section 11.4.1.4 Control Power Supply Checks. If necessary
change out the control and gate driver boards.
4. Are all fans functioning properly? This error can be due to the fans drawing undue
amount of power from wear or bad bearings.
5. Does incoming power have loading problems upon startup?

GX DC OC A: DC OVERCURRENT (ACCELERATION)

1. See steps above for GX DC OC R*.

GX E HARD: EARTH FAULT (HARD)

NOTE – Indication that you have a current unbalance on the three phases that enter the VSD
through the ZCT (Zero Current Transformer.)

1. Are the three phases unbalanced?

a. Make all attempts to balance the three phases.

b. If the incoming power is irrevocably unbalanced over the three phases, you can
disable the ZCTs (only in Oilfield applications, check local standards.) Make sure the
VSD is off and the power is disconnected. At the circuit board disconnect terminals
CN5-1 and CN5-3 on PCB-3. This was described in InTouch 4258066; diagram is below.

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 Page 8 of 16

2. Is the resistance of the ZCTs 13.9 ohm singularly and 70 ohms in combination?

1. Replace ZCTs.

GX INV OL: INVERTER OVERLOAD

1. Is input voltage in the nominal range (380V or 460V +/- 10 %.)

2. This problem is often due to poor configuration. Is the size of the VSD ample for the
project? Also, is the surface voltage correct for downhole equipment and voltage
loss?

GX OH ERR OR GX OC (ACC): OVERHEAT TRIP - THE VSD HAS EXCEEDED 83C (181F)

1. Are all fans operational?

a. Is 240VAC control voltage functional? Check CPT2.
2. Is the heat sink blocked?
3. Is the heat sink functioning?
a. Is there 240V power to it?

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 Page 9 of 16

b. Is the capacitor mal-functioning? Check this by disconnecting the two wires

leading to the capacitor on the terminal block and replacing them with a jumper
(Do NOT run drive like this, make sure to replace capacitor.)

GX OPT ERR: OPTION ROM ERROR

NOTE – There is a problem with the OPTION ROM chip (the small chip attached to the inverter
board)

1. Is chip properly secured to the inverter board?

2. Change chip.
3. Change inverter board.

GX ROM ERR:

1. Is there a ground connected to CC on terminal board?

a. Remove ground.
2. Is there an external source connected to PP on terminal board?
a. Remove external source.
3. Change control board

GX TF ERR: INVERTER TYPEFORM ERROR

NOTE - The control board is not configured to the drive’s rating

1. Is the UniConn software and Firmware up to date?

a. In the VSD section, go to the advanced area. Then set VSD Reset to Initialize Type
Form and Accept.
2. A G3 keypad is needed to do a type 7 reset to clear. Please see SWD Manual. If that is
not available in the field, the control board should be replaced.

GX PH U SHT: U-PHASE SHORT CIRCUIT

NOTE – Drive detects a short-circuit in IGBT on phase U

1. Are IGBTs bad? These (3) can be checked by using the process outlined in the SWD
Manual section 11.4.1.3 Checking Single-Transistor IGBTs.
a. Change out all 3 IGBTs in the phase plus both snubber boards (these must be
changed out any time IGBTs are replaced.)
2. Change out snubber boards.

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and Trade Secret and not to be disclosed, used, or reproduced without written approval from
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 Page 10 of 16

GX PH V SHT: V-PHASE SHORT CIRCUIT

NOTE – Drive detects a short-circuit in IGBT on phase V

1. See GX U Sht

GX PH W SHT: W-PHASE SHORT CIRCUIT

NOTE – Drive detects a short-circuit in IGBT on phase W

1. See GX U Sht

SECTION 4: VSD ERRORS

VSD SYNC: UNICONN AND VSD RUN STATUS ARE NOT “SYNCHRONIZED”
NOTE – Low voltage into the Precharge Contactor causes the VSD to shutdown automatically.
When the UniConn discovers the VSD has shut down without being told to it displays this
message Synchronized

1. Are the CPTs tapped to reflect the incoming power (460V or 380V)? They should have an
output of 240V and 120V respectively.
2. Does the incoming power sag significantly during start up?
3. Does the communication cable between VSD and UniConn get interference from any
other source in the VSD?
4. Change out Gate Driver and Inverter boards.

U_BAT: INTERNAL BATTERY NEEDS TO BE REPLACED IN UNICONN.

1. It is normal to see this during start up.

2. UniConn should be replaced and returned to the factory. Do not attempt to replace
battery in field.

VSD_COMM: COMMUNICATION ERROR VSD AND UNICONN ARE NOT COMMUNICATING

1. Is the main circuit breaker closed?

2. Normal upon closing main circuit breaker in VSD. Does it go away within a minute?
3. Is the communication cable connected to UniConn control card and Controller board as
per UniConn Manual section 7.2.4.3 UniConn Parameter Configuration?

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 Page 11 of 16

4. Has the Port with the VSD control card been set up as per UniConn Manual section 6.1.9
Expansion Cards?
5. Is the communication cable tie wrapped to other cables or near other boards? This can
cause noise in the cable.
6. Replace communication cable.
7. Replace inverter board.

VSD_OLOAD: OVERCURRENT

1. Is error due to normal run conditions? That is, does the drive usually run very close to
over load settings?
a. Work with AE to see if motor can be saturated to decrease run amperage.
2. Are overload settings (value and trip time) correct?
3. Is downhole equipment electrically sound? Test Continuity and Insulation.
4. Does this error occur with no load?
a. Does it occur if step up transformer is removed?
b. Test Insulation of cables out of VSD and test transformer.
5. Does this error occur on start up?
a. Does the drive shut down immediately? If so, is the transformer ratio set up
correctly? (Default is 1 and needs to be changed to reflect step up transformer tap
setting)
b. Is acceleration time appropriate?
6. Are there sags in the incoming power?
7. Is the pump likely to be stuck downhole?
a. With AE consent… try rocking starts.

VSD_ULOAD: LOW CURRENT TRIP MOTOR AMPERAGE IS BELOW SET POINT.

1. Upon start up does amperage increase above idle amps (~60% of name plate)?
a. Does pump have enough lift to produce fluid to surface?
b. There is most likely a mechanical problem downhole (i.e. broken shaft, plugged
intake)
2. Is VSD shutting down due to motor running at amperage only slightly below underload
value?
a. Discuss with AE the possibility of lowering underload.
3. Is there ample fluid above the pump when error occurs (ie is the well pumping off)?
4. Is the pump gas locking?

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 Page 12 of 16

STARVIEW:
1. Has Wellview been used to start or stop drive with a laptop?
a. Shutdown power to drive and restart. Use “Start” and “Stop” buttons on UniConn.

SECTION 5: NON-ERROR GENERATING PROBLEMS.

VSD accelerates to minimum frequency but does not increase to target speed.
1. Open the VSD section in Wellview. Is the Extended Ramp Setup in the VSD section
selected to OFF?
2. Is the VSD reaching Thermal Stall (the percentage of drive load the VSD allows itself to
power up to)? This setting can be checked in Wellview in VSD > Advanced.

VSD runs at 0Hz, 0V, ~0A.

1. Jumper CC and ST together on the terminal block below the inverter board. If the drive
runs normally after this then most likely one of the capacitor fuses in the filter has opened.
(Warning - Do Not allow the drive to run with this jumper as it bypasses the filter
shutdown.)
a. Pull off the cover over the capacitors. Make sure the contacts on top of the
capacitors are intact and not touching the cover.
b. Inspect blown fuse indicators on the capacitors. Determine cause failure.

VSD shuts down on overload after accelerating to a low frequency

1. Is downhole integrity (continuity and insulation test) acceptable?
2. Shaft is likely stuck. Try reversing drive direction to see if the shaft can turn the other
way. If so, retry in original direction.
3. If VSD does not ramp up a rocking start or Boost may be necessary; this should be
discussed with AE before attempting.

Power Factor decreases as motor load increases

1. Are the PTs connected correctly? Phasing must be ABC for power factor to be correctly
interpreted.

VSD is running at normal speed and amperage but fluid is not being produced
at surface.
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 Page 13 of 16

1. Most likely there is a hole in the tubing.

VSD is running at idle amperage and fluid is not being produced at surface.

1. Is well likely to be gaseous?

a. Wait until reservoir has replenished to try to push gas out of stages.
b. Try rocking starts to see if gas is freed.
2. Most likely a pump shaft is broken or intake is plugged.

Control voltage (240V) fuse blows constantly

1. Is UniConn connected to 240V?

a. Connect to 120V to eliminate it as a cause of the problem.
2. Most likely one of the fans, heat sink or heat exchanger is shorted out. Check for
grounding and or problems with the one if these devices.
3. Disconnect fans, heat sink and heat exchanger. Reconnect one at a time until fuse blows
again. Replace component.

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and Trade Secret and not to be disclosed, used, or reproduced without written approval from
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 Page 14 of 16

SECTION 6: APPENDIX

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 Page 15 of 16

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and Trade Secret and not to be disclosed, used, or reproduced without written approval from
Schlumberger.
 Page 16 of 16

© Copyright Statement: This document remains the property of Schlumberger. It is Confidential

and Trade Secret and not to be disclosed, used, or reproduced without written approval from
Schlumberger.