VAASAN AMMATTIKORKEAKOULU
Contents
1. Figure 2 The main components of an AC drive 1 3 The Need for the Fault Analysis Manual The purpose of the thesis is to produce a template for analyzing and reporting failures of the frequency converters and their root causes for Vacon service organ ization In principle the device itself is simple However the electronics to protect to measure and to control the device makes it more complicated and more prone to component failures Semiconductors in device are controlled in very high speed with switching frequencies up to 16 kHz Because of many measurements and self protecting functions even a little malfunction in controlling software or hard ware can produce a failure that trips the device In case of a failure the customers who use the drives are forced to call to the nearest service partner to solve the problem If under warranty the device is usu ally replaced with the new one The service partners send the failed devices to Vaasa factory for further analysis 11 The final decisions in warranty issues are often dependent on the results of analysis The analyst solves a payer of the warranty costs At Vaasa factory the service organization acts also as a technical support and fault analysis team Partners and offices around the world strain the service de partment with a root cause analysis requests If most failures under warranty pe riod and their root causes could be anal2. VAASAN AMMATTIKORKEAKOULU 0042 VASA YRKESH GSKOLA d UNIVERSITY OF APPLIED SCIENCES Ilkka Laaksonen A FAULT ANALYSIS TEMPLATE FOR THE FREQUENCY CONVERTER Tekniikka ja liikenne 2012 This thesis has been written at Vaasan Ammattikorkeakoulu University of plied Sciences Degree Program in Electrical Engineering for Vacon Plc After Market Services department in Vaasa Finland I would like to thank Dr Mikko Hankaniemi Manager Reliability and Field Quality from Vacon Plc for help and support during the work I would also thank my supervisor Olli Tuovinen Senior Lecturer MEng for stretching the limits for me to keep in In addition special thanks belong to Pauliina and the rest of my family for pa tience and support during the studies Vilja my beloved daughter you kept the smile on my face Thank you Mustasaari 16 5 2012 Ilkka Laaksonen VAASAN AMMATTIKORKEAKOULU S hk tekniikka TIIVISTELM Tekij Ilkka Laaksonen Opinn ytety n nimi Fault Analysis Template for the Frequency Converter Vuosi 2012 Kieli Englanti Sivum r 40 4 liitett Ohjaaja Olli Tuovinen Opinn yte tehtiin taajuusmuuttajia suunnittelevan ja valmistavan Vacon Oyj n toimeksiannosta yrityksen huolto organisaation tarpeisiin Vikaantuneiden laittei den analyysiohjeistuksella pyrit n yhdenmukaistamaan analyysist saatavaa da taa tilastokelpoiseksi sek v hent m n logistiikan
3. 3 a 0 50 vas hs jom jo e UI DelayAfterKEx b 5 En enr ii 1385 emt cc Lisci Hz gt _ ol un 3 5 500 APPENDIX 4 List of Needed E EVACUATION PARAMETERS speed elerationtva edCtri 2 2 100
4. Top 10 Faults Unit OTHER BOARD 32 96 Others 36 96 OPTION BOARD 32 96 Figure 15 Top 10 Faults by the Unit 35 TopiOFaults sanos 3296 7820 Code 3230 Measurement 3230 3210 26 23 3111 Watchdog 7831 Y 7 i 7833 Brake Gate Driver 7810 Varistor W 7830 Brake Main Circuit lt v 15 7831 Brake Main Circuit Rectifier 276 3210 Main PSU 180 3296 Gate Driver PSU 13 14 7820 PSU Figure 16 Top 10 Failures by Fault Code Coils in the contactor and in the mechanical brake circuits can generate high over voltage If the voltage suppressor components are not rated properly or there are some deviations in the component quality the surge can break to the circuit board Failures Outside the TOP 10 Faults Part of Device 1 Input Part 6 96 2 Inverter Bridge 4 96 7 Board 2 3 Board 4 Wiring 1 6 Other reason 5 Mechanics 10 96 0 Figure 17 Distribution of Failures by Part of the Unit Until the end of the year 2011 the most common conclusion of the analysis ac cording to the statistics was a shorted diode or the capacitor 36 5 FAULT ANALYSIS 5 1 Case Example 1 F7 Saturation The customer s description of the failure was 7 Saturation Saturation is a crit ical fault that can appear if the IGBT transistor or the saturation detection circuit fails A shorted brake resistor c
5. and product families Key Words Fault Analysis Manual Frequency Converter CONTENTS FOREWORD TIIVISTELM ABSTRACT LIST OF FIGURES AND TABLES I e a ataca TEN EINE SSTP 8 Macon PICK ANTTI SSR E 8 1 2 Variable Speed AC Drive aka Frequency 9 1 3 The Need for the Fault Analysis Manual 10 2 DRIVE AND THE CURRENT FAULT ANALYSIS 12 2 1 Quality Control in the Production Line and the Warranty Policy 12 2 2 Service Organization ise sese tie eiat M VE Lr cda 13 2 3 Procedure an Case or a Failure 14 2 4 Tools for Analyzing the 1 15 3 FUTURE MODEL FOR ANALYZING THE FAILURE 21 21 3 2 Specifications of Template teh xs 22 3 3 the ESITUres 12 e io ei eit 30 4 ELEVATOR DRIVE Ubi ave 32 4 1 Drive and Application in General 32 4 2 Typical Faults of the Elevator Drive 34 5 PAUET ANALYSIS ounce pop apum e VIE 36 5 1 Case Example 1 F7 Sattar ion se uel oett boe p ee ebbe 36 6 E ONG TI SION xara ener adi eu OR RO AR at ceat A tp CM I 40 REFERENCES APPENDICES LIST OF Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 F
6. sovellusta esitell n ty ss my s lyhyesti Yksi analysoitu tapaus kuvaillaan esimerkiksi Opinn ytteen lopputuloksena saatiin luotua perusversio s hk isest analysointi dokumentointi ja raportointiohjeesta jonka t ydent minen ja laajentaminen mui ta laitteita ja tuoteperheit koskevaksi on mahdollista Avainsanat Vika analyysi Ohjeistus Taajuusmuuttaja VAASAN AMMATTIKORKEAKOULU UNIVERSITY OF APPLIED SCIENCES S hk tekniikka ABSTRACT Author Ilkka Laaksonen Title A Fault Analysis Template for the Freguency Converter Year 2012 Language English Pages 40 4 Appendices Name of Supervisor Tuovinen This thesis was ordered by Vacon Plc a company designing and manufacturing frequency converters and is aimed for the needs of the company s service organi zation The intention was to standardize the data received from analysis so that it can be used for statistics by the means of the analysis instructions of the damaged devices In addition the aim was to reduce the logistics expenses and the work load of the analysts in the factory in Vaasa In standard cases the analysis could even be done by a service partner if they are provided with necessary instructions Due to the extensive product range this thesis only concentrates on one device which belongs to the OEM product family and is supplied to an elevator manufac turer The extra eguipment installed and the tailor made option board and applica tio
7. that service personnel cannot test or disconnect the drive without disturbing the customer s process Under these cir cumstances the drives are always analyzed in the regional service centers 16 Vacon offers required official service training for service personnel The basic service training is offered for all service and maintenance personnel and the ad vanced service training is offered to service partners only The service training is held in Vacon training centers The 21 training centers network are located worldwide The locations of the Training centers are presented in Figure 6 Vacon has made recommendations for equipment in the service facilities The service partners and regional service centers have their own recommended equip ment Tools for the service engineer and for the service partner are mainly tools for disconnecting inspecting and repairing the device at the site or at the work shop In addition to engineer s tools the workshop tools include measuring equipment and special equipment Figure 7 produced by Vacon for analyzing the devices Each Vacon product family has its own type specific service manual The service manuals contain a lot of information about the specific device The mechanical construction power unit testing removing and replacing parts and the needed technical specifications are described in the document The service manuals are available for service personnel via the Internet A traine
8. with the visual in spection and with getting familiar with the information available from the device In most cases the passive measurements of the power unit and voltage measure ments from the control board will be performed The flow of the analysis depends on the failure descriptions and on the experience of the engineers In each case the process can proceed with different ways Engineers in the Vaasa factory have ac cess to the circuit diagram files and therefore their routes to the root causes can vary to the intuition and to the experience The tacit knowledge is the most im portant factor in the current analysis process The conclusions of the analysis are reported to several targets There are many parties who need information from the results of the analysis The customer in ad dition to many of the Vacon departments receives the data To limit the data to allowed and needed there is few different software and several files to save and describe the data from the analysis The quality team R amp D and after market ser vices team besides the analysis team itself is the customers in reporting of the analyst The current practice of reporting is laborious to the analyst It is also hard to get comparable and usable data because of the non standard reporting practice 2 4 Tools for Analyzing the Device The ways to analyze failed drive at the field are limited The device is usually a vital part of a specific process It is obvious
9. 27 Figure 11 The Map of the Top Side of the Power Board Analysis Passive Measurements The reader will be informed to disconnect the device from the mains and to ensure that the life threatening potential is not present The chapter is divided to chapters on the basis of the main units of the device 26 Power Unit The preparatory disassembling needed to measure the power unit components is guided step by step in this section The main terminals of the device and the diode measuring techniques are advised with the pictures presented in Figure 12 L1 en o v w Infinite Forward biased PN junction Reverse biased P N junction Figure 12 The Main Terminals and the Diode Measuring Techniques 27 The points to measure rectifier IGBT bridge and brake chopper and desired results of the measurements are tabulated as presented in Table 1 Table 1 The Main Circuit Measurements for the Rectifier Rectifier forward 0 45 V Rectifier reverse Infinite L1 L2 L3 to to L1 L2 L3 Rectifier forward 0 45 V Rectifier reverse Infinite B to L1 L2 L3 L1 L2 L3 to B Control Unit Option Boards The chapter advises the reader to the specific document about the diagnostics of the option board The most common damaged components are presented in the photograph and measuring the rectifier on the board is guided with the figures Enclosures The passive measurements of the enclosur
10. FAN c T1 1213 Figure 13 Measuring the FET 30 Diodes in the Power Board The chapter contains an illustrated instruction to measure and detect the failed di odes from the power board Charging Resistor Illustrated instruction for inspecting the condition of the charging resistor s are located in this chapter Control Board Analysis The chapter contains instructions for inspecting the control board There are sev eral test points to measure the voltages from the board In the chapter there is an enlarged photograph to find the test points and to locate the LEDs which indicate the functioning of the software The proper testing point voltages are tabulated For more accurate testing of the control board and the option boards the chapter guides the reader to the instructions of the special test equipment Documents Needed The chapter contains a tabulated list of the source files and the supporting docu ments of the template 3 3 Reporting the Failures The reporting of the failure is an important part of the analyzing process Without specific data from the case the information cannot be used for statistics to improve the quality of the product or the process The format of the received data must be standardized In the template there are several instructions how to document the analyzing process of the device There is guidance how to photograph the excep tional findings and record the measured values Due t
11. Workshop Reliability amp Field Expertise amp Quality Analysis Service Centers Figure 4 The Service Organization 14 2 3 Procedure in Case of a Failure When device fails under the warranty period the service partner receives a request to solve the problem The physical actions after the analysis vary to the case The flow of the entire process as it is related to device under the warranty period is presented in Figure 5 of Broken Unit Service center evaluation and retuming unit to Vaasa factory Details to Vacon Warranty of Repaired Unit Issue as a case Warranty of New reference number with Vacon Service Reporting tool vSRT Repait Possible Repait Figure 5 The shortest possible route of the device in case of warranty Vacon service organization uses tailored software called the Service Re porting Tool Every failed device gets the VSRT number to identify and follow the device during the service and analysis process 15 Shipping the device between workshops around world wastes time and money in the current procedure Also the stand by time in Vaasa factory workshop can delay the conclusions and the stream of money The analysis process depends on the case The device will be stored for the analy sis when it arrives to Vaasa factory workshop The standby period depends on the length of the queue The analysis engineer starts the analysis
12. XP device in the Appendix 2 The special components are linked to the safety functions of the elevator and regu lations or to the filtering the harmonics to the feeding network The THD reactor or choke coil acts as a filter between the device and feeding network Contactors are connected in series to ensure the stopping of the motor in case of one contac tor fails An external brake resistor consumes the energy generated by the engine functioning as a generator The illustration of the Vacon delivery is presented in the Appendix 3 The frequency converter in the elevator drive combination is a standard Vacon NXP device with a tailored application and an option board for the I O The eleva tor application in the device 15 tailored for the customer The elevator controlling software is running in the upper level programmable logic controller PLC The elevator controller collects the calls from the button panels and the software algo rithm in the PLC transfers the commands to the drive via CAN bus Mainly the 33 drive takes care of smooth and safe operation of elevator The elevator is driven by closed loop speed control with an internal position correction For the safe and comfortable functioning of the elevator the drive has to be pa rameterized Besides the motor parameters the elevator mechanics the safety functions and the speed control needs their parameters The list of needed parame ters is presented in t
13. an also cause the saturation trip The saturation trip is not a resettable from the panel of the device Components related to saturation fault are located in the power board and the measurements started there The saturation detection circuit is located both top and bottom sides of the circuit board The main functionality of the detection cir cuit is in the gate drive optocoupler The optocoupler has integrated desaturation detection and fault status feedback circuits When the gate signal is high and po tential difference between the and the IGBT output exceed the internal refer ence of 7V the fault signal is activated Fault protected IGBT gate drive in princi ple is presented in Figure 18 The circuit diagram of the HCPL 316J optocoupler is presented in Figure 19 Fault Protected IGBT Gate Drive HV ISOLATION T ISOLATION T ISOLATION BOUNDARY BOUNDARY BOUNDARY 1 H 51 1 1 peser 316J a dg 316 316 i i i 3 PHASE INPUT 1 2 N N ISOLATION ISOLATION BOUNDARY N BOUNDARY FAULT MICRO CONTROLLER Figure 18 Fault Protected IGBT Gate Drive 8 37 Viepi VLED1 Y Figure 19 HCPL 316J Gate Drive Optocoupler 8 Step 1 From the top side of the board the rectifier diodes of the supply transformer t
14. ation transformer 3 2 5 Checking the fan and the starting capacitor 4 SERVICE TOOLS 4 1 Information 4 2 NC Load 1 0 17 4 3 NC Drive 4 3 1 NC Drive 2 0 7 4 3 2 NC Drive 2 0 8 4 3 3 NC Drive 2 0 11 4 4 NC Service 4 4 1 Software version 1 09 4 4 2 Software version 1 10 443 Software Vermun LEE 4 4 4 Software version 1 12 4 4 5 Software version 1 13 4 5 Device Properties Service 4 5 1 Version 2 0 2 4 5 2 Version 2 0 3 4 5 3 Version 2 0 4 Figure 8 Vacon NX Service Manual Overview Table of Contents Page 1 6 19 Table of contents 5 FAULTCODES AND SOFTWARE 2 5 2 Fault codes possible reasons and checking to done 5 2 1 mese 222 5 3 Software version information 5 4 NXL software information 5 5 NXS software information 5 6 NXP software information 5 7 Information regarding fault tracing 5 8 FAULT CODES 5 8 1 Fault code flowcharts 5 8 2 Defect code 6 SERVICE INSTRUCTIONS FOR OPTION BOARDS 6 1 Basic tests 6 1 1 Control board interface diagram 6 1 2 Test equipment VB300 and 3BOXTEST 6 1 2 1 VB300 6 1 2 2 3 BoxTest 6 1 3 Testing the Eprom by panel 6 1 4 Testing the Eprom by Device Properties program 6 2 NX option boards 6 2 1 Basic I O boards NX OPT A 6 2 2 1 0 Expander boards NX OPT B 6 2 3 Fi
15. d person can perform maintenance troubleshooting and repairs with the help of the service manuals The tables of contents of the Vacon NX family service manual are presented in Figures 8 and 9 Different frame size specialties are described in the appendices of the service manual An example of the table of contents of a service manual ap pendix is presented in Figure 10 The manuals are good source of information for troubleshooting and for repairing the device but the root cause analysis is more or less depending on the compe tence of the analyst The analyst can notice the burned or melted components easi ly but in which functional circuit they are located is harder to find out without cir cuit diagrams If the component failure is not visible finding it can be very hard The deep going root cause analysis is not possible without the specific circuit dia 17 grams Because of concern of the information leaks circuit diagrams are not published in the service manuals Due to new updates of the devices several supplementary documents are pub lished These documents are mainly short notifications directives or informative attachments to manuals The documents deal with improvements changes in components identified quality issues guide to inspect and measure the drive or other important information about the device The manufacturer continually de velops the devices so the number of the supplementary documents increa
16. d start and the flow of the chapters was designed as presented in the thesis There are contents in every chapter of the document For the company the thesis is in our opinion at a good starting point for further de velopment In the future the template can be updated for other device models and drive families APPENDIX 1 Electronic Report Path 1 1 REFERENCES 1 2 3 4 5 6 TI 8 Vacon in Brief 2012 Vacon Company web pages http www vacon com Default aspx id 46 1829 What is an AC Drive 2012 Vacon Company webpages http www vacon com Default aspx id 464743 Products 2012 Vacon Company web pages http www vacon com Default aspx id 481764 Vacon Training Develop your in house expertice Vacon Company web pages Brochure http www vacon com Default aspx id2450403 amp File View 485015 User s Manual 3 PUT2 Service Tool Vacon 2008 Vacon NX Service Manual Overwiew Vacon 2011 Vacon NX Service Manual Appendix FR4 Vacon 2009 Data Sheet HCPL 316J 2 5 Amp Gate Drive Optocoupler with Integrated Desaturation Detection and Fault Status Feedback Avago Technologies 2011 APPENDIX 1 CUSTOMER Customer DRIVE Frame size Choose Frame Size Type Code Op Days Electronic Report Path VSRT Date received SERVICE Service Organization Serial Number Power unit type Powerboard model 1 1 Author Analysis started Case closed Failure d
17. eldbus boards NX OPT C 6 2 4 Adapter boards NX OPT D_ 6 3 Star coupler board 60VB00336 6 3 1 Frame 12 6 3 2 Frame 14 6 3 3 Control connections from NFE units to the inverter 6 3 4 FR12 and FR14 fibre cable connections 6 3 5 Star coupler description 6 4 Fibre adapter board 60VB00228 7 START UP AFTER REPAIR 7 1 An external DC power without the motor for FR4 to FR13 7 2 Testing with a DC supply without the motor connection 7 3 Load test with motor Figure 9 Vacon NX Service Manual Overview Table of Contents Page 2 6 20 1 SERVICE MANUAL VERSION HISTORY 2 MAIN CIRCUIT DIAGRAMS 3 MECHANICAL CONSTRUCTION 3 1 Spare part sets for the FR4 unit 3 2 Control boards in the FR4 unit 3 3 Power boards in the FR4 unit 4 THE FR4 POWER UNIT 3 12 A 4 1 Safety notice 4 2 Visual checkings and measurements before powering up the unit 12 1 Checking the cooling tunnel 12 4 2 2 Checking the power board 3 Checking the power module 4 Power unit checking testing and measurements 5 Testing with the power unit tester PUT 1 6 Checking the current measurement circuit 7 Checking the voltage measurement circuit 2 8 Checking the temperature measurement circuit 4 2 9 Checking the fan 4 2 10 Testing the pre charging circuit 5 TEST REMOVAL AND REPLACEMENT INSTRUCTIONS 2 ma 2 s 2 a 2 lt 5 4 Capacitors 5 5 Power module 5 5 1 Skiip power module measurements 5 5 2 Replacing the ski
18. es of the elevator drive are presented in this chapter within the informative table The tabulated introductions are presented in Table 2 28 Table 2 The Enclosures Braking resistor BRK Resistor Between R Between Contactor leads Contactor windings 0 6 each 111 11 112 12 13 Electrical Tests After the accepted passive tests of the power unit the electrical testing can be car ried out The chapter is divided into two sections Power Unit Tester PUT The chapter guides the reader to the service manual where the introductions to use the Power Unit Tester PUT can be found General Functionality The tabulated step by step introduction to testing the devices functionality is lo cated into this chapter The table guides the analyst through the test Every step contains the value or action to pass the step If the step cannot be accepted the further actions are advised 29 Power Board Analysis The chapter contains more specific introductions to detect and to measure failed components on the power board Main Power FET Measuring the main power supply circuit is guided in this chapter with the illus trations Mainly the main power FET and its feeder capacitor are components to inspect The introduction to measure the FET is presented in Figure 13 Drain Source 13 Diode mesuring Forward 5V Resistance MOhms B R U V W
19. escription MEASUREMENTS Powerboard model Checkings Charge circuit Details Measured values notes rootcause Capasitors Rect Diodes IGBT Gate drive Brake IGBT Brake drive PCB Main PSU Gate PSU DC link meas 2 Attached photos etc Liitetiedosto Make an document doc pdf and copy all photos etc to it Attach the document here REPAIR ACTIONS 1 1 APPENDIX 2 Circuit Diagram of Vacon NXP device 1 an K lene lomaan lommowsossa keon soano 11 11 11 as sin m ol aes ne APPENDIX 3 The illustration of the Vacon delivery 1 1 a o a 6 Bac 1 lt 4 lt 4 11 4 i E CA un 4 1 Bva 91 Bvacl lt lt Peg d E I 1 Vac l 1 2 Lo SF Contactor monita signals 1 418 switches 85232 xB u 2 3 Board rev OPTAG VB00363K _ APPENDIX 4 List of Needed Parameters 1 2 N N V 3 neeg N ase Sequence M 2 msmmmwr A EN TSS CONTROL 939 rennes s E E
20. from where the type codes can be found and how they should be decoded The type code key tables for the Vacon NX power unit and for the OEM elevator drives were located to this chapter Variants and Differences The version history of Vacon NXP 4 drives in a table 23 Pre Analysis Procedures The chapter contains instructions for preparatory actions e g making the needed file to attach pictures of the device to analyze Customer Failure Description The chapter guides to collect and record all available information of the case from the customer The process conditions external conditions malfunction descrip tions fault code from the device are mentioned as examples Documentation The information and guidance to document the analysis process and the findings are located in this chapter Serial Numbers and Batch ID The information how to photograph and record the serials is located in this chap ter Photographing the Device The chapter contains more accurate instructions for photographing and pointing out the components or other significant findings from the device request to in spect the conductivity of possible foreign materials is located here too Recording the Findings The chapter presents the electronic form that should be used for recording report ing and submitting the conclusions of the analysis Known Failures and Their Identification The section is divided into two parts top 10 failures and
21. he Appendix 4 Figure 14 The Standard Vacon NXP Device and the OEM Elevator Drive For the safety functions there are a few hardwired analog and digital inputs in the option board e DINI and DIN for the status of the motor contactors DING for the requests of the evacuation drive DIN4 for the on the floor contact e DIN5 and DING for the surveillance of the position of the electro mechan ical brake for thermostat of braking resistor e AD for the motor thermistor 34 Outputs are used for monitoring state of the device e ROI for FC Ready signal RO2 for Brake Close signal for Motor Fan Off signal 4 2 Typical Faults of the Elevator Drive 70 of all failures are in the Top 10 Failures of the analyzed Top 10 are mostly known and repaired 7 out of 10 quality issues caused by supplied components on the circuit boards or the board layout based problems The 5 most common failure was Reported Fault Found with the 6 share Failures with low count and share are considered as individual and random In most analyzed cases the root cause of the component failure was the overvoltage from the external circuits Top 10 faults by the unit of a drive are presented in Figure 15 Top 10 failures by the fault code without the No Fault are presented in Figure 16 The distribution of the failures outside the Top 10 by the part of the device is presented in Figure 17
22. hrough the transformer windings and gate supply voltages over capacitors were measured The threshold voltage of diodes was around 0 5V and the supply volt ages 10 17V D2 MURS120TJ3 MURS120T3 Figure 20 Step 1 Measurements 38 Step 2 To ensure there is no leaking current through the gate of the IGBT the capaci tance between the gate and the emitter of the IGBT was measured The measured value in this model should be and was around 20nF The power board was disas sembled to perform these measurements Step 3 The power module was tested to ensure the proper functioning by driving the de vice with accurate test board Step 4 The power board was fastened to accurate MiniSkiip module to test the board DC link voltage 540V was simulated with an auxiliary voltage source The gate signal from the control unit was simulated with an external source and the func tioning of the optocouplers was ensured with measuring the potential between pins 14 and 16 Figure 21 The difference was at the correct rate with 15mV HCPL 316J ViN 1 GND1 RESET FAULT VLED1 VLED1 RPULL DOWN THESE COMPONENTS ARE ONLY REQUIRED WHEN NEGATIVE GATE DRIVE IS IMPLEMENTED Figure 21 Gate Driver Circuit Example 8 39 Step 5 The control unit was connected to the power board and the drive was driven with 50Hz The saturation trip occ
23. igure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 FIGURES AND TABLES Key Figures 1 The main components of an AC drive Different Drive families of the Vacon 3 The Service Organization The shortest possible route of the device in case of warranty Vacon training centers 4 Special testing equipment Illustration of the Power Unit Tester Vacon NX Service Manual Overview Table of Contents Page 1 Vacon NX Service Manual Overview Table of Contents Page 2 Vacon NX service manual Appendix 4 Table of Contents The Map of the Top Side of the Power Board The Main Terminals and the Diode Measuring Techniques Measuring the FET The Standard Vacon NXP Device and the OEM Elevator Drive Top 10 Faults by the Unit Top 10 Failures by Fault Code Distribution of the Failures by Part of the Unit Fault Protected IGBT Gate Drive HCPL 316J Gate Drive Optocoupler Step 1 Measurements Gate Driver Circuit Example Components that caused the F7 Saturation Trip Table 1 The Main Circuit Measurements for the Rectifier Table 2 The Enclosures 10 12 13 14 17 17 18 20 25 26 29 33 34 35 35 36 37 37 38 39 27 28 LIST OF APPENDICES APPENDIX 1 Electronic Report Path APPENDIX 2 Main Circuit Diagram of the Vacon NXP device APPENDIX 3 The illustration
24. ip power module 5 6 Power board 5 7 The process of modifying a board 5 7 1 Tools 5 7 2 Working process 5 7 3 Checkup instructions 5 7 4 The tailored power boards 5 8 EMC level modification from H to T 6 SPECIFICATIONS 6 1 Torgue specifications 6 2 Temperature tables 6 3 Drive version history Figure 10 Vacon NX service manual Appendix FR4 Table of Contents 7 21 3 FUTURE MODEL FOR ANALYZING THE FAILURE In the future the main responsibility of the analysis is meant to be at the regional service centers Only exceptional cases will be analyzed at the Vaasa factory The fault analysis manual is meant to be exact enough to any trained engineer to use The reporting procedure should be standardized as well The future model of the analyzing process is meant to be more effective than the present one The time and costs of the logistics should decrease significantly Be cause of the division of the mass of devices to analyze between the service cen ters should the process time been shorter The standardized analyzing and report ing process gives the accurate data to make decisions without shipping the device around the world 3 1 Template The template for analyzing the device was the purpose of the thesis It was known that the work was comprehensive with limited experience and knowledge about Vacon AC drives The Vacon service organization has a need for the template and they had already started the mind work for i
25. kustannuksia ja kuormaa Vaa san tehtaan analysoijilta Ohjeistuksen avulla perustapauksissa analysointi voitai siin suorittaa huoltopartnerin toimesta Tuotevalikoiman laajuuden vuoksi opinn ytteess keskityttiin yhteen hissivalmis tajalle toimitettavan OEM tuoteperheen laitteeseen Hissik yt ss laitteeseen asennetut lis laitteet sek r t l idyt optiokortti ja sovellus toivat mielenkiintoi sen lis mausteen ty h n Laitevalmistajan kirjallista materiaalia k ytettiin hyv ksi tutustuttaessa laitteeseen sek manuaalin kuvituksen t ydent miseen Materiaalia oli saatavilla paljon joten sen karsiminen oleelliseen oli haastavaa Henkil haastatteluilla hankittiin tietoa analysointiprosessista Varsinkin mittauksien suorittamisesta ns hiljaista tietoa oli olemassa enemm n kuin dokumentoituja ohjeita Ty n edetess sen laajuus ja haastavuus paljastui tekij lle Yksityiskohtaisen analysointiohjeen muotoileminen ilman salaiseksi luokiteltujen piirikaavioiden julkaisemista on l hes mahdoton teht v Opinn ytteess esitell n tilaajayritys lyhyesti huolto organisaation rakennetta niilt osin kun se liittyy vikaantuneiden laitteiden logistiikkaan ja analysointiin sek nykyist analysointiprosessia kursorisesti Ty n luottamuksellisen luonteen vuoksi se esitell n otsikkotasolla Kunkin otsikon sis lt m materiaalia kuvail laan yleisell tasolla Hissik ytt n r t l idyn taajuusmuuttajan komponentteja sek
26. less common failures 24 10 10 failures their possible fault codes from device possible customer descriptions of malfunction and the identification code to the failure for Vacon database are tabulated in this chapter Other Analyzed Faults Some of less commonly known and analyzed faults are tabulated in this chapter The information about the unit of the drive the fault in it possible sub faults and failure codes for the treated sub faults can be seen from the table Short written descriptions of failed components are included Fault Codes to Cause The part of the document contains quick guide From Fault Code to Part to Check and map for the functions on the circuit boards Quick Guide The chapter contains a tabulated quick guide The user can follow the fault code of the device to the function or and components that may have failed Mentioned faults are based on analyzed NXP FRA failures Fault codes which do not guide to a fault unambiguous in this specific frame size are left empty Functional Map of the Device The fault code the customer s description of the failure or an observed malfunc tion can reveal a circuit where the failures are possibly located The chapter con tains pictures of the circuit boards with drawn map of the functions on boards The map of the top side of the power board is presented in Figure 10 as an example 25 He
27. n gave an interesting additional flavour to the work The written material provided by the manufacturer was used when getting to know the device and adding figures into the manual There was plenty of material available so it was demanding to cut it down into the essential Information on the process of the analysis was received by personal interviews Especially concern ing measuring procedures there was more so called tacit knowledge than there were documented instructions As the work proceeded it became obvious how extensive and challenging it was It is almost impossible to produce a detailed analysis instruction without publishing circuit diagrams that are classified as con fidential In this study the ordering company is introduced briefly The structure of the ser vice organization is demonstrated in those respects as it concerns the logistics and analysis of damaged devices The current process of the analysis is described only cursorily Due to the confidential nature of this work only headings are presented and the material under each heading is described only on a general level The tai lor made freguency converter components and application used in elevators are also briefly described One analyzed case is described as an example The result of this thesis is a basic version of an electrical analysis documentation and reporting instruction which can be complemented and expanded so that it is possible to use it for other devices
28. o human factor there can be variation in the quality and accuracy of the received data To eliminate the inaccu racy one possible way of reporting the analysis was designed in this thesis 31 The electronic report form was designed with Microsoft InfoPath software The data fields were chosen to collect and send forward the minimum information needed The form was designed for a model and it is not yet compatible with the company database To develop the form further is out of the focus of the thesis With the carefully designed and programmed form the received data can be se lected and standardized The form is presented in the Appendix 1 as an example 32 4 ELEVATOR DRIVE The focus during the thesis work was on the elevator drive Vacon has an OEM contract with a certain elevator manufacturer This customer is a very important business partner to Vacon and therefore the pilot manual was produced for the particular drive The fault analysis manual focuses on the one specific device model The extension of the template to the different frame sizes and power clas ses can be done easily 4 1 Drive and Application in General The drive modules consist of a Vacon NXP frequency converter an external brake chopper resistor module THD reactor and two contactors mounted on a chassis The differences in appearances to the standard Vacon NXP and the elevator drive are presented in the Figure 14 and the main circuit diagram of the N
29. of the Vacon delivery APPENDIX 4 List of Parameters Needed in Elevator Drive 1 INTRODUCTION 1 1 Vacon Plc Vacon Plc is a Finnish frequency converter manufacturer founded in 1993 The company s objective is to design manufacture and sell the best AC drives in the world From the staff of 13 the company has expanded to be an employer of over 1400 people The revenues in 2011 were 380 9 with the operating profit of 24 7 Key figures are presented in Figure 1 Vacon has R amp D and production facilities in Finland the United States China India and Italy 2007 2008 2009 2010 2011 Personnel at the end of the period 1 600 1468 1 400 1197 1228 1 200 2007 2008 2009 2010 2011 Sales by channel 2011 W H Direct sales 9 70 Distributors 15 20 H oem 25 70 96 Brand label customers 18 90 W System integrators 30 50 Figure 1 Key Figures Operating profit MEUR 34 6 292 286 247 25 225 20 15 10 5 0 2007 2008 2009 2010 2011 Return on investment 50 412 40 37 27 289 30 231 20 10 0 2007 2008 2009 2010 2011 Sales by region 2011 e Europe Middle East and Africa 66 30 North amp South America 17 80 96 Asia 5 Oceania 15 90 1 1 2 Variable Speed AC Drive aka Frequency Converter Pulse Width Modulated PWM Frequency Converter is an electronic device for mainly controlling speed and torque of AC Motor or Generator M
30. ost AC motors in industrial use need speed adjustment for process based on economical or functional demands Energy efficiency and adjustability makes fre quency converters more and more common in all kinds of industrial applications The rotor thus the axel of the AC motor rotates accompanied by a magnetic field generated by the mains The speed of the motor is controlled by changing the fre quency of the electrical supply to the motor The main components of an AC drive are presented in Figure 2 Rectifier unit The AC drive is supplied by the electrical network via a rectifier The rectifier unit can be uni or bidirectional When unidirectional the AC drive can accelerate and run the motor by taking energy from the network If bidirectional the AC drive can also take the mechanical rotation energy from the motor and process and feed it back to the electrical network 2 DC circuit The DC circuit will store the electrical energy from the rectifier for the inverter to use In most cases the energy is stored in high power capacitors 2 Inverter unit The inverter unit takes the electrical energy from the DC circuit and supplies it to the motor The inverter uses modulation techniques to create the needed 3 phase AC voltage output for the motor The frequency and voltage can be adjusted to match the need of the process 2 10 Rectifier Circuit Inverter Circuit O NE 2 cx c DC Link AC Motor
31. rm If needed the simple electrical measurements are made to ensure e g cor rect value of the shunt resistors Every component of the device is traced to facto ry SAP system with bar codes or serial numbers for future needs 13 The functional tests are made with specific automated testing equipment The high voltage test the warming and the other critical measurements and values are inspected during the test run The manufacturing defects are covered by the warranty The Manufacturer s time of warranty is 18 months from the delivery or 12 months from the commissioning whichever expires first 2 2 Service Organization The service organization of Vacon is based on service partner contracts The com pany has service partners all over the world The service partners are selected in dividual companies who are trained to perform installations maintenance and re pairs to the Vacon devices Often the service partner is a local company that has years of experience in maintenance and repairs of electrical devices in industrial environment The structure of the service organization as far as it relates to the analyzing process is presented in Figure 4 The service department at the Vacon Vaasa factory acts as a final analyst as well as technical support team After Market Services Service Product Field Services amp Management amp Network Support Repair Workshop Product Product Network support Field Services Repair
32. ses Training centers Figure 6 Vacon training centers 4 UH UL VH VL WL x X5 To ASIC Board A Selected Signal DC W Measurement Select Power on P q N KZ ERANI Ky lofrset CAUTION Read and understand instructions before use DRIVEN BY DRIVES To Driver Board H WH VH UH VL UL U Figure 7 Special testing equipment Illustration of the Power Unit Tester 5 18 Table of contents 1 SERVICE MANUAL VERSION HISTORY 2 AFTER MARKET SERVICE INFORMATION 2 1 Foreword 2 2 An overview of the manual information 2 3 Appendix manual information 2 4 Important instructions for various service situation 2 4 1 Personal requirements 2 4 2 Personal safety notice 2 4 3 Material requirements 2 4 4 Tool safety notice Service policy Warranty terms ReplacementT units and spare parts Maintenance 2 8 1 Recommended maintenance 2 8 2 Recharging the capacitors in stored units 2 8 3 Recharging individual capacitors that have been stored 2 8 4 DC link capacitor tests and replacement NNN Ov Un 2 8 4 2 Replacement 3 TROUBLESHOOTING OF THE AC FAN 3 1 Troubleshooting of the main fan 3 2 Troubleshooting steps 3 2 1 Fan control and LED status 3 2 2 Checking the fuses 3 2 3 Checking the output of the fan driver board 3 2 4 Checking the output of the fan insol
33. t The preliminary titles of the manual were collected and the flow of the template was thought The template is meant to be a digital document In digital format the updating of the document and the distribution to the organization is effective For a reasonable scope to the thesis only one specific device from NXP family was treated The template should be easily modified to other drives and the drive families The information to the template was collected by interviewing Vacon personnel and from the Vacon internal material 22 3 2 Specifications of the Template From the preliminary titles the template was modified into following structure Introduction The section explains the focus of the material and informs the user that the docu ment is based on the existing documents Safety The safety requirements of the electrical workshops based on the standards IEC 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use and EN 50110 1 Operation of electrical installations are mentioned in this section Some phrases to warn the reader and to protect the company will be added later Needed Tools The electrical tools hand tools electrical measurement equipment and other mis cellaneous items needed are presented in this section Specific descriptions were ignored but Vacon recommendations for equipment were highlighted Type Code Identification This chapter gives information
34. urred Step 6 The power board was disassembled and bottom side components were inspected A shorted diode and burned resistor was found The failed components are pointed out from the figure 22 Ve 16 VLEp2 15 14 Figure 22 Components that caused F7 Saturation Trip 8 Step 7 The root cause of the component failure was recorded as a possible component problem or reverse breakdown 40 6 CONCLUSION In this thesis we established the company confidential template or manual for ana lyzing and reporting the root cause of the frequency converters failure The work was known to be a big challenge Collecting the available data and doc uments getting familiar with the drive and analyzing processes needs was a big ger challenge than we realized Because of the electronics there are hundreds of possible ways how the device can fail There are going to be enormous job to document all possible failures and procedure to analyze them By the help of Vacon personnel studies in Vaasa University of Applied Sciences and couple of summers experience in assembling AC drives at Vacon the work could be per formed to the present point For a thesis worker the assignment was interesting Besides getting to know nice and helpful people a load of knowledge in the measuring techniques Vacon drives in general elevator drives in particular and company processes was adopt ed The template was set to a goo
35. yzed without sending devices to Vaasa factory the analyzing process would be more efficient More effective the analysis processes are the higher is customer satisfactory in warranty issues Also the quality improvement and R amp D organizations receive the information about the quality issues more quickly For compensating the billing between different busi ness units the information obtained from fault analysis is also necessary 12 2 DRIVE AND THE CURRENT FAULT ANALYSIS Frequency converters of each type types or families are presented in Figure 3 and size are made at the different production lines in the factory Devices are tai lored for different mains voltages different maximum power and if needed with the customized software Each device is tested with the programmed test cycle before packing and shipping to the customer to ensure the quality of the device E E E Vacon 10 X Series NXS amp NXS Standalone Vacon 20 NXL Vacon 8000 Wind amp Solar v amp Motor Mountable 5 NXP Air Cooled Vacon 100 HVAC NXP Liquid Cooled Figure 3 Different Drive families of the Vacon 3 2 1 Quality Control in the Production Line and the Warranty Policy The quality of all materials is inspected continuously during the assembly phase with the visual inspections Assemble workers control the quality of each other s work The assembling instructions are available in every working cell in electron ic fo
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