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India 180 kVA Operation & Maintenance Computer Aided Diagnostics

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5.2 Requirements to the computer system

5.2.1 WinDiag needs to run:

WinDiag runs on any PC, laptop or notebook fulfilling the following requirements:

one free serial port

Pentium II processor with 300 MHz and 32 MB RAM

standard VGA video card

one of the following Microsoft Windows operating systems: 95, 98/1, 98/2, 2000, NT4.0

approx. 1 MB free hard disk space

5.2.2 What ports can be used?

After startup, the program checks the serial port used and configures it automatically. Any port from COM1 toCOM4 is accepted.

5.2.3 Connection between the converter control system and the computer

The numbers in the following section refer to Figure 16.-

For computer-aided diagnostics, the serial port of the computer (1) must be connected to the serial port X3 (4)on the converter control unit (5), using a null-modem cable (2) with two 9-pin Sub-D female connectors (3). Ifyour computer is fitted with a 25-pin serial connector, you can use a standard 25-to-9 adaptor. The plug

connection used as a serial port is brought out of the converter (converter diagnosis interface on the aircondition unit).

Figure 16: Connecting the computer to the interface of the converter control unit A710

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5.2.3.1 CONNECTING THE INTERFACE CABLE

(see Figure 16):

1 Switch off the computer!

To avoid damage to the serial port of the computer, you should only connect/disconnect cablesfrom the serial port with the computer switched off.

2

Connect one of the 9-pin connectors of the interface cable to the converter diagnosis interface on

the air condition unit.

3 Connect the second 9-pin connector of the interface cable to the computers serial port, switch onthe computer and run WinDiag.

5.2.3.2 DISCONNECTING THE INTERFACE CABLE

1 Switch off the computer:To avoid damage to the serial port of the computer, you should only connect/disconnect cablesfrom the serial port with the computer switched off.

2 Disconnect the interface cable from the converter diagnosis interface on the air condition unit.

3Disconnect the 9-pin connector at the other end of the interface cable from the serial port of the

computer.

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5.2.4 Null-modem cable and interfaces

The converter diagnosis interface on the air condition unit is directly connected to the computer via a standardcommercially available null-modem cable with two 9-pin Sub-D female connectors.

Data is transmitted at a connection rate of 28 800 baud. As this is a rather high rate, compared to the RS232standard, cable length should not exceed 22 ft. The quality of the cables shielding and the interface driverscan also affect maximum cable length.

Figure 17: Pin assignment of the nullmodem cable

connecting the converter control unit A710via the diagnosis interface to the computer

Figure 18: 9-pole Sub-D connectors

5.2.5 Transmission protocol

Transmission rate: 28 800 bit/s (baud)

Protocol: asynchronous without handshake (TX, RX, GND), 8 databits, even parity, 1 stop bit, with checksum in last byte(sum of all bytes)

Hardware Status Lines: None. The communication will work if only the lines TX,RX, GND are connected as shown above.

(DTR was used in previous versions of the diagnosticsoftware running under MS-DOS. However, this isobsolete for this project).

Special Software Protocol: The status byte indicating a new protocol frame (datapackage) is transmitted with odd parity.

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5.3 How does WinDiag work?

The converter control unit A710 is equipped with a status memory providing 80 memory locations. In the eventof a malfunction, all relevant data including time and date are saved to one of these locations. For someerrors, two entries are required (beginning and end of the error condition). When the status memory is full, thenext new entry overwrites the oldest one (first in - first out). With computer-aided diagnostics, the contents ofthe status memory are transmitted to the computer, where the data is processed, displayed and a preliminarydiagnosis is given.

5.3.1 Operating modes of the converter control unit

The converter control unit can be switched between two different operating modes which are used by theWinDiag program.

5.3.1.1 ONLINE MODE

At predefined intervals (specified in the project settings), relevant operational data of the converter aremeasured and instantly transmitted to the computer (real time monitoring). If a malfunction occurs, datarelevant to the error is stored in the status memory.

5.3.1.2 DATA MODE

Data monitoring and storage in the event of a converter malfunction, do not differ compared to ONLINE mode.However, no data is instantly transmitted to the computer. DATA mode must be activated first for thecomputer to load the current contents of the status memory and to display the latest entry.

Auxiliary voltage errors are not stored in memory:

As a general rule, only errors are stored in the status memory, i.e. those events that are indicated by redLEDs. However, the error "UHerr" (auxiliary voltage error) is an exception to this rule. This error means thatthe voltage supply of the AC/DC regulation is defective. This leads to the reporting of further errors which havenot occurred in reality. In order to screen out these ghost errors, the status of UHerr is checked every timean error is reported. The error is stored in the status memory only if UHerr is not set. As a consequence of this

screening, the error UHerr itself is only reported in ONLINE mode, not in DATA mode (which means thatauxiliary voltage errors do not appear in the error history)!

5.3.1.3 MENU BAR

After connecting the converter to the computer via the serial port and starting WinDiag, a menu bar isdisplayed at the bottom of the program window. These menu buttons allow you to switch between differentviews and operating modes. The status line below the menu bar gives explanations on the individual buttons.

Figure 19: Menu bar

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5.4 Screen Views

5.4.1 Diag view: overview of all converter signals

When you start the WinDiagprogram, the Diag view is automatically opened. This contains a completeoverview of all converter signals arranged in individual info boxes. This allows you to determine the operatingstatus of the converter as a whole.

The signal descriptions in the info boxes are assigned symbolic LEDs. When an LED is lit, the associatedentry provides a general indication of what this means. Grayed-out LEDs can be ignored. Each LED isdisplayed with one of the following colours:

LED colours Meaning Description

Red Error Threshold value exceeded

Yellow Warning Threshold value reached

Green OK Threshold value not reached

Grayed-out Inactive

When operating in data mode, the info boxes provide information on errors that have occurred at some pointin the past. Any LEDs set are lit permanently.

When operating in online mode, errors are displayed as they occur and are reported by means of an audiblesignal. The LEDs remain lit only for the duration of the error or warning. Since errors always trigger an entry inthe status memory, an error that occurs after the converter has returned to data mode can be displayedpermanently for analysis.

Figure 20: Diagnostic view (data mode) in WinDiag

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5.4.1.1 INFO BOX 1: TIME, SERIAL NUMBER, MODE, INTERFACE

This info box indicates the date and time, serial number, and current operating mode of the converter, as wellas the interface used on the computer. The LED may be lit either green or red to indicate whether or not datatransmission is possible:Cabling between the converter control board and the computer correct?Converter control board connected to the right supply voltage?

Figure 21: Info box 1

5.4.1.2 INFO BOX 2: IVPS

This info box provides information onselected events concerning thethyristor bridge A201 of the IVPSsection.

The LED symbols of info box 2

correspond with the hardware LEDson the SCR control board A702 (seesection 4.1.2.2 and see column"Corresp." in the table below).


Field LED Colour Corresp. Meaning

RUN green Betrieb SCR control board A702 and SCR module A201 operating

READY yellow Bereit SCR control board A702 and SCR module A201 ready for operation

ERROR red Stoer Composite error in SCR module A201

STOP yellow - Pulse output to power module stopped. Short-time stop, restartsautomatically

ENABLE green External enable signal applied

VIMAX red UEH Input voltage VIhas exceeded maximum permitted value.

VIMIN yellow UEL Input voltage VIhas fallen below minimum permitted value.

VZMAX yellow UAH Intermediate circuit voltage VZhas exceeded maximum permittedvalue.

VZMIN yellow UAL Intermediate circuit voltage VZhas dropped below minimum permittedvalue.

IDYN red IDYN Dynamic current limitation has responded four times within oneminute.

ILIM yellow ILIM Intermediate circuit current limitation is active

TWARN yellow Temperature warning:Heat sink temperature of SCR module A201 has exceeded 75 C.(temperature switch closes at 68 C)

TMAX red T-MAX Overtemperature:Heat sink temperature of SCR module A201 has exceeded 85 C.(temperature switch closes at 77 C)

VCC red 15V 15 V electronics supply voltage fault

ST RUN green Self test of board A702 running

ST WARN orange Warning after self test of board A702 (i. e. buffer battery low)ST FAIL red Failure after self test of board A702

ST SUCC green Selftest of board A702 successful

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5.4.1.3 INFO BOX 3: OUTPUT (INVERTER, LVPS)

This info box provides informationon selected events concerning theinverters A301.1-3 (left column)and the LVPS module A401 (rightcolumn).

The LED symbols of the leftcolumn correspond with thehardware LEDs on the invertercontrol board A703 (see section4.1.3.2 and see column "Corresp."in the table below).

The LED symbols of the rightcolumn correspond with thehardware LEDs on the LVPScontrol board A704 (see section4.1.4.2 and see column "Corresp."in the table next page).


INVERTER


RUN green BETRIEB Inverter module A301 and inverter control board A703operating

READY yellow BEREIT Inverter module A301 and inverter control board A703 readyfor operation

ERROR red STOER Composite error in inverter A301

ENABLE green External enable signal for inverter A301

VZMAX red UZ MAX. Inverter input voltage (= intermediate circuit) VZhas exceededmaximum permitted value.

VZMIN yellow UZ MIN. Inverter input voltage (= intermediate circuit) VZhas droppedbelow minimum permitted value.

PHASE yellow PHASE Load unsymmetry at the AC oputput phases

LOCKED red AUSG. 4 UCEerrors or start attempts in current limitation within oneminute

T80 yellow T80 * Temperature prewarning:Heat sink temperature of inverter A301.1-3 exceeds 85 C

T100 red T100* Overtemperature:Heat sink temperature of inverter A301.1-3 exceeds 95 C

ILIM red I-BEGR. Output current at upper limit (current limitation)

DRIVER R red TREIB-R IGBT error (e.g. saturation voltage VCEtoo high) on phase L1.DRIVER S red TREIB-S IGBT error (e.g. saturation voltage VCEtoo high) on phase L2.

DRIVER T red TREIB-T IGBT error (e.g. saturation voltage VCEtoo high) on phase L3.

VH red 5 V electronics supply voltage fault

TTR red Maximum coil temperature (150 C) of autotransformer T302exceeded

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LVPS


RUN green Betrieb LVPS chopper module A401 and LVPS control board A704operating

READY yellow Bereit LVPS chopper module A401 and LVPS control board A704

ready for operationERROR red Strung Composite error in LVPS chopper module A401

SWAB red AB The current through double IGBT moduleV01.1 V01.2 (= switches A and B) in LVPS chopper module

A401 has exceeded maximum permitted value.

SWCD red CD The current through double IGBT moduleV01.2 (= switches C and D) in LVPS chopper module A401has exceeded maximum permitted value.

ILIM yellow SLIM Total current limitation is active

IPR red Ipr The primary current on transformer T1 of LVPS choppermodule A401 has exceeded maximum permitted values.

UZH red UEH LVPS input voltage UZ(= intermediate circuit voltage)has exceeded maximum permitted value.

UZL yellow UEL LVPS input voltage UZUZ(= intermediate circuit voltage)has dropped below minimum permitted value.

UBH red UBH Output voltage UDChas exceeded maximum permitted value.

UBL yellow UBL Output voltage UDChas dropped below minimum permittedvalue.

T100 red Tmax1 Overtemperature:Heat sink temperature of LVPS module A401exceeds 100 C

ERR15V red 15V ok 15 V electronics supply voltage fault

VH 5 V electronics supply voltage fault

LVPS LOCKED

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5.4.1.4 INFO BOX 4: CCU

This info box provides informationon the converter interface, as wellas selected CAN bus events.

There are no corresponding LEDson the converter control board.


Field LED Colour Meaning

Disable Converter disabled (external signal)Fault K5 red General fault of converter

F01 red Input fuse F101 tripped

Q901 red Fan protection switch 1 tripped (no function of fan M901)

Q902 red Fan protection switch 2 tripped (no function of fan M902)

Q301 red Single phase transformer (T301) protection switch tripped

GND-Fault red Ground fault detection has detected ground fault

Vbat, ccu red Buffer battery on converter control board has to be changed(voltage at lowest permissible level)

5.5 see section 6.3"Maintenance Tasks

Replacing Buffer Battery of Converter Control Unit"

CAN IVPS red Error in CAN bus connection of IVPS thyristor bridge A201

CAN INV red Error in CAN bus connection of inverters A301.1-3

CAN LVPS red Error in CAN bus connection of LVPS chopper A401

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5.5.1.1 INFO BOX 5: ERROR MEMORY

When operating in data mode, all location numbers (1 to 100) of theerror memory can be called up in the right-hand margin of the Diagview.

Any error memories marked coloured are already occupied. The lastlocation is marked in red colour and contains the latest error entry. Allpreceding error entries are then listed in reverse chronological order

above this.The error memory has been designed as a ring buffer. Once alllocations have been occupied, any new incoming error data willoverwrite the oldest (top) entry.

To select a specific memory location, use the arrow keys on yourkeyboard.

After the selection of a memory location, the different info boxes resp.views display the selected memory location data:

The different info boxes of Diag view display the specific errormemory informations like:

LEDs lit (Info boxes 2, 3 and 4)

Display of specific measured values andtheir detailed analysis in plaintext format (Info 6)

Also the Osci view and the List view displays the associatederror entries immediately.For instance, if location 2 is chosen and you then switch to anotherview, this view will also display the data in memory location 2. Figure 25: Info box 5

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5.5.1.2 INFO BOX 6: IMPORTANT MEASURED VALUES

General

Up to four electrical values can be monitored by the control boards, depending on the equipment ofmeasurement devices in the converter. The control system of the India 180 kVA converter monitors followingvalues:

input voltage VI

AC output voltage VAC

AC output current IACbattery voltage VB

These four values are continuously measured and displayed. If an error occurs all four values of the errorinstant will be picked up and stored in the event log memory in order to allow in-depth error analysis.

WinDiag allows to display the monitored values in different ways:

Info box 6 shows the values as plain figures, see Figure 26

the oscilloscope view shows the values versus time, see next page

the list view shows the list of saved error events whereby all four values at every error instant are listed(see next page)


Left: Right:

Display of the monitoredelectrical values

Datamode: Values valid atthe time at which the errorentry was made.

Onlinemode: Arithmetic

mean values averaged outover a number ofmeasured values, whichwere updated in eachdefined period (project-specific).

Detailed analysis of serious errors in plaintext format.

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