Site Comp End 02

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS
EQUIPMENT
:
LOAD COMMUTATED
INVERTER (VFD)
DOCUMENT
DOCUMENT NO.
COMPENDIUM OF
FAULTS/ALARMS
441/COMPEND/LCI REV.02 DTD.10/03/05
When referring to a solution for a problem, the particular category of

Fault /Alarm is to be seen. Further please also read General checks,
Checks for ground fault, Load Commutation Failure, Load PLL Fault and
SEM Earthing document at the end of this document.
REVISION HISTORY SHEET

REV.NO./ DATE
PREPARED BY
CHECKED BY
NATURE OF CHANGE
Page 1 of 66
FIRST ISSUE

00 /25.03.04
UPDATED UPTO 09.06.04
01 /09.06.04
UPDATED UPTO 10.03.05
02 /10.03.05
Page 2 of 66
Category
MISC
Sl.no.
Problem
Solution
1.
Small crack observed in base of 1 no. CT in Load

Break Switch Panel.
The primary connections on the CTs are such that load of

the Cu bars is coming on the CTs. Therefore necessary to
provide flexible connection on one side of the CT.
Failure of CTs.
Customer opined that failure may be due to thermal

stresses.
This point was taken care of when replacement of Load
Break Switch with Contactor was done.
Customer opined that replacement of gaskets necessary.
Gaskets replaced at places wherever required.
MISC
2.
Gaskets on doors have gaps at many places resulting

in air being sucked through these gaps also.
MMI FOR VFD
3.
MMI remains out of service due to Communication

Link failure.
Defective line driver replaced by a new one.

Demultiplexer channels at control room were not working.
Same repaired.
One wire of RS232 port was found disconnected, same
rectified.
One reed relay card to be replaced (failed during
troubleshooting). MMI system put on-line bypassing Drive
status and Reset command from PC.
Replaced reed relay card. Problem solved.
MMI s/w hanging problem.
Corrected version of software installed. Became OK.

1. LMARG changed from 25 to 30. No change
observed.
2. FLALEN and FLASEN changed to TRUE. No
change observed.
3. Changed parameters CRGAIN, FRGAIN, FRTC,
MISC
4.
6A Ch-2 tripped on electrical fault.

Current hunting was observed in Ch-1 and tripped on
R phase Overcurrent.
When Ch-2 of ID Fan 6A trips, current/voltage
hunting is observed in the Ch-1 and it also trips.
Page 3 of 66
Motor foundation vibration found higher compared

to other motors.
SHORTED
WINDING
MOTOR
5.
6A Ch-2 trips with message Shorted motor

winding. Ch1 stopped after current hunting
observed.
However, current drawn continues to be higher than
other fans due to poor p.f.
Tripping of channels due to Loose connections of
cards on SEM rack.
MISC
6.
MISC
7.
Frequent failure of NPPB card. Heat dissipated by

bleeder res. is high. Bleeder resistor installed on
PSFF just behind mother board NPPB.
MISC
8.
Self Test
healthy.
MISC
9.
UPS supply tripping on trf. inrush current.

120/120VAC, 1ph, trf. with 2P & 2S windings, 1 sec.
Winding found defective.
MISC
10.
6A Ch-1 tripped , Ch-2 not responding to speed

lower command from CRT. Current and speed of ID
fan stuck. 6A taken out of service manually and 6B
halts at No.23 even though channel is
PLLTOL, LIMARG. No change observed.

4. Finally by changing PLLMODE from 60 to 25, problem
was solved.
NLCB card in Ch-2 found defective. Card replaced and
problem solved.
Proposal for installing Anti-vibration pads on blower

support in panel. Concurrence given by BHEL for the
same.
Anti-vibration pads put and SEM lock bars installed.
Problem solved.
Proposal by customer to install bleeder resistor outside
PSFF module.
Customer asked to check VFD room temperature and clean
the mesh filter on C&EXE panel. Bleeder resistor can be
mounted outside only if above remedies do not work.
Temperature in VFD Room rectified. Problem solved.
BHEL requested customer to furnish a print-out of self
test program to study the problem.
Customer asked to adjust offset zero on NLIB load card
FAB, FBC & FCA with BAL1 and BAL2 pots on NLCB
Allowed tolerance is 30mV. Problem solved.
Spec. for trf. given by EDN to TEC with msg. to procure
trf. locally. Screen to be provided between primary and
Sec. of trf. and Screen to be earthed to panel frame.
Changed transformer. Problem solved.
Parameter SRCLSC changed to 1.0 as in scheme.
4-20mA speed signal is not being recd. by Ch-1 or Ch-2.
Problem in I&C system solved. 6A taken into service.
Page 4 of 66
MISC
11.
MISC
12.
MISC
13.
taken into service. SRCLSC found to be 0.7 instead

of 1.0 in other channels.
Erosion of cooling tubes at the tip of
the
tubeshoot at O/B side of ID Fan motors. Resulted
in passing of external air into motor body. Motor is
CACA cooled.
ID 6A Ch1 oscillating and load currents on
contactor not balanced. 1 phase current missing.
Source currents balanced.
0IA load NLIB
negative humps missing.
Repeated faults in drive due to loose connection on
SEM Rack.
Customer proposed to replace all cooling tubes (1980

tubes). Asked for advise.
Referred to contact BHEL/EMRP-Mumbai for further
action.
Told to change HPTF card in LTM1 or LTM4.
Pulse was missing in LTM4. Changed HPTF card. Problem
solved.
Recommended to install lock bars to secure control cards
in the racks. SEM Lock bar installed. Problem solved.
MMI FOR VFD
14.
MMI getting hung frequently. Line drivers OK.

After PC rebooting the MMI PC, communication
gets re-established.
If power goes OFF, sometimes MMI PC hangs as told by

customer. EDN suggested to put the MMI PC on UPS so
that this will not occur. MMI put on UPS. Problem solved.
MISC
15.
ID Fan 6A taking high current (400A), current of

both channels hunts in the range 320-400A.
Higher current is due to higher LMARG and LIMARG as

motor p.f is lower. Adjusted SRGAIN such that hunting of
speed and current stops. Problem solved.
LOAD PLL FAULT
16.
6C1 tripping on Load PLL fault. Gate test OK. Self

test OK upto 40. Channel goes back to service
every time after tripping.
Additional to Load PLL fault, MP alarm also coming.
IMOK of HMPG and NLCB missing. Missing Leds
come on after reset.
6C1 started as slave channel after swapping HMPG
with 6C2. Load current does not come immediately
but hunts a lot. Also LED 0 on HRDA card (for
MAMS) flickers. Firing of load thyristors also
HRDA, HROA, NLCB replaced. NLIB Source & Load

replaced.
Tripping freq. increased.
EDN Suggested
1. To install lock bar of SEM. HMPG/DMPB may be loose
in its slot.
2. Clean HMPG/DMPB and pins on mother board by air
blowing.
Load current hunting may be due to MTRFMIN and FLUXS
values being slightly different than actual requirement.
Page 5 of 66
LOAD PLL FAULT
17.
flickers. Flickering stops after sometime and

channel becomes OK. Channel trips after few days.
Suggested to lower the values of MTRFMIN and FLUXS in

steps of 0.01 and if not sufficient again in steps of 0.05.
Problem may be due to slight drift of NLIB load side flux
calibration over the years of service.
Also asked to check SEM earthing as per SEM Earthing
document. Problem solved by adjusting offset zero to less
than 30mV on NLIB using source volts and also earthing
SEM as per document.
6C1- Trips on Load PLL Fault on load.
Increased LMARG from 20 to 25.

Problem solved.
Page 6 of 66
Category
Sl.no.
Problem
Solution
LOAD
COMMUTATION
FAILURE
1.
Channel trips on Load Commutation failure
1. HPTF card in LTM3 found faulty when doing crowbar

test. HTPF card replaced. Problem solved.
2. BHEL has suggested to maintain control room
MISC
2.
LOAD
OVERCURRENT
3.
1 no. motor burnt out.

Replaced by spare motor available at site. All tests
while taking new motor into service done by
customer with telephone support from BHEL-EDN.
Channel tripping once a week with message Load
Overcurrent. 2 out of 3 flags in VFD Overcurrent
Relay have operated. Channel starts after resetting
and starting.
temperature at 25C.
Lead from stator was found melted out. Connections were
wrongly crimped. Connections Brazed and motor ready.
Kept ready for service.
Suggested to
1. Operate Overcurrent relay manually and check for
same message print-out on printer.
2. Short the relay contact which is in series with load
contactor aux. contact going to IOMA.
3. Change Load NSFC card.
NSFC load card was changed and problem solved.
LOAD
COMMUTATION
FAILURE
&
SHORTED MOTOR
WINDING
GROUND FAULT
4.
5.
Channel tripping
with fault message Load
Commutation failure and Shorted motor winding
Suggested to
1. Change NSFC load card
2. Checking of all connectors and RC filter circuits on
load side.
3. Check power bridge on load side.
Firing pulse LED on one card in source bridge

(HPTF) was not steady and was flickering.
HTPF card on source side changed and problem solved.
Ground fault in both channels of 4B.
In one channel one load side capacitor was faulty. In the

Page 7 of 66
MISC
6.
Chattering of MAMS relay in slave channel.
MISC
7.
HMPGDMPB in 4B1 giving Bushog after few hours

in service.
GROUND FAULT
8.
VFD Ground Fault problem in slave channel.
MISC
9.
Master and Slave both start and run individually. At

minimum speed, slave does not take load when
paralleled with Master channel.
MISC
10.
Ch-1 tripped but no annunciation on the door

mounted printer or at remote C&I.
MISC
11.
1. After overhauling, when ID Fan-B was started, it

became ON & OFF many times on its own. When fan
speed was increased, it became normal. Again when
other channel, the neutral grounding of R-C circuit was

not OK. Problem in both channels solved.
Adjusted offset zero in NLIB Load FAB,FBC,FCA by back
charging from Master. Problem solved.
HMPG/DMPB card replaced.
Problem solved.
See text on ground fault at the end of this document.
Cable insulation was found faulty on cable from contactor
to motor during hi-pot test to earth. Problem solved.
Back-charged slave with source breaker open and load
Contactor closed. Adjusted FAB, FBC, FCA on NLIB-load
on slave with that of Master.
Slave channel paralleled. OK. Problem solved.
Initially suspected that "Stop" command was being issued
from C&I system, but found this was not true. Channel
selector switch and Local/Remote switch on IOMA were
bypassed but trippings continued. Trippings were reported
at regular intervals.
Laptop PC was then connected to HMPG. Found that
Microprocessor was getting reset every time the drive
tripped. This was evident from the Laptop display.
This could happen only if LVSH from PSFF goes "High".
PSFF supply was cleaned by blowing air. Channel put into
service and no trippings observed.
PSFF changed as per customer requirement. No further
trippings observed.
Problem is that Ch-2 is not going to LMODE=3. The
reason is that the flux levels in the machine is lesser than
the values set for FLUXS and MTRFMIN.
Page 8 of 66
the channel was started after station tripping, same

problem occurred. 2. When Ch-2 was started,
Drive received ON command and took load also, but
OFF status did not go from the desk, while RUN
indication was appearing on the VFD panel. Then,
Ch-1 was started first and
Ch-2 started
thereafter. Now drive started normally.
Following suggested:
During the next shutdown, backcharge Ch-2 and adjust
NLIB Load Flux values to the same as in Ch-1. Also please
check the FLUXS, MTRFMIN and FRSTART values in Ch-2
are the same as in Ch-1.
Start motor from Ch-2 and please check motor goes to
LMODE=3.
SPD and SPM pots on NLCB do not matter for proper
starting of the drive.
Page 9 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
During Start-up operation, ID Fan has tripped on

Source Overcurrent on channel Ch-1 and Load
Overcurrent on channel Ch-2. Overcurrent relays
operated on load breaker switch.
Restarted the drive but again tripped on the same
fault. LMODE on HHT not changed from 0.
1. Conducted all tests-found OK. Run in Local mode and
Channel tripping several times due to various faults.
Customer feels that mother board is not giving proper

contact to SEM modules which causes frequent trips. Has
requested to change all mother boards or provide
alternative modified female connectors in mother board.
BHEL-EDN sent SEM lock bars to customer and the same
was installed on all SEM modules. Problem solved.
MISC
2.
motor in uncoupled condition. OK.

Motor coupled back and started drive with slightly
higher CRSTART & FRSTART. Motor start and run was
OK from both channels. Normalised CRSTART &
FRSTART to original values.
This phenomenon happens after long shut down, when
oil film under fan bearing not built-up or inlet damper,
inlet and outlet gates not properly closed during start.
Customer has been asked to check these points.
Page 10 of 66
LCI CHANNELS FOR VFD COMPENDIUM OF FAULTS
Category
Sl.no.
Problem
Solution
MISC
1.
ID Fan 6A suddenly got unloaded even though motor

contactors are ON. ID Fan 6A currents suddenly
dropped to zero.
FD Fan 6A did not trip on interlock ID Fan 6A
Speed<Min.
Both fans were hand tripped, restarted.
ID Fan 6A hand tripped and FD Fan 6A tripped on
ID Fan Speed <Min.
220 VDC supply from distribution board failed and

therefore contactor did not trip. Further STOP command
was issued from I&C to both channels as 220V DC supply
had failed.
Further customer asked to check in I&C system whether
MAMS has been taken for MFT1, MFT2, MFT3 in FSSS
for ID Fan OFF. Customer confirmed that same has been
done.
PLL FAULT
2.
Channel tripping frequently on PLL Fault. After

manual reset, channel comes into service.
SEM not earthed properly. SEM earthing done as per SEM

Earthing document. Problem solved.
GROUND FAULT
3.
Slave channel tripped on Ground Fault.
Flex leads at motor terminal box had got melted and

neutral point on bushing was burnt out. Motor stopped,
rectification done by putting HT Insulation tape.
MISC
4.
Fan started from standstill and did not start. Fan

did not pick up speed and was rotating very slowly in
the wrong direction..
LOAD
5.
5A2 channel tripped on Load Commutation failure
Suspected No flux build up possibly because of melting of

field lead connections inside motor rotor exciter.
STIM, FRSTART, CRSTART increased. Motor Started.
Parameters changed to old values and start trials taken
were successful. Old parameters retained.
Reason- High breakaway torque. Subsequent starts were
OK because oil film was formed between bearing metal &
shaft, causing lower breakaway torque.
Found thyristor in leg module LTM3 defective. Both
Page 11 of 66
COMMUTATION
FAILURE
FAILURE TO START
6.
6A Ch-1 started, LMODE did not increase from 1

many times in spite of changing parameters like
MTRFMIN, FLUXS, STIM, CRSTART, FRSTART
etc. Suspected motor winding may be faulty.
Connected Ch-2 winding of motor to Ch-1 of LCI.
Problem persists.
LOAD
COMMUTATION
FAILURE
MISC
7.
Channel tripping on Load Commutation Failure in

5B1 and PLL Fault in 6A1.
8.
MISC
9.
There was a heavy jerk on grid and due to that

almost all 210MW units tripped out. When starting
and taking ID Fans on load, found that Fan B was not
taking load, but Fan A was getting loaded. Currents
and voltages in both channels equal in Fan B. This
phenomenon was present even when Fan B was run at
700 rpm.
When Ch-2 is individually started, Load contactor
closes, Field contactor closes but no current in
motor. But Ch-2 (Slave) can be paralleled with Ch1(Master) and is OK.
If Ch-1 is tripped, then Ch-2
does not take the load and its current stays at zero.
thyristors were shorted out. Replaced leg module. Problem

solved.
Found that snubber in STM6 was faulty. Capacitor was
shorted. Replaced snubber. Problem solved.
Customer asked to check bearing alignment on Fan bearing
in next shutdown.
HPTF cards changed in both channels after doing crowbar.

SEM earthing done as per SEM Earthing document.
Problem solved.
Changed Slave to Master and vice versa. Problem persists.
This confirmed no problem in VFD. Found problem was in
Inlet damper to ID Fan. Damper was almost in closed
condition and would not open. Corrected damper problem.
Problem solved. OK.
FLDCN (Field Contactor close) was not true in Ch-2 when

running alone. Aux. contact of Field contactor was not OK.
Rectified. Problem solved.
Page 12 of 66
Page 13 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
1. Channel B2 tripped on Motor Isolator not

closed.
1. Breaker closing link was not latching and breaker was
2. Second time tripped.

LOAD
COMMUTATION
FAILURE
2.
Channel B1 tripped on Load Commutation Failure
MISC
3.
Bus hog error on HMPG card.
tripping immediately after closing (Mechanical

problem). Breaker truck replaced and channel started.
Found that latching mechanism was faulty. Faulty part
replaced and CB truck tested and kept ready for
service. Problem solved.
2. Fault resetted and started.
1.
Checked load bridge capacitances for
charging
currents with megger OK..
2. Checked MOVs of load bridge for Insulation
resistance.- OK.
3. Checked gate pulses on HPTK card in gate test mode.
One HPTK card pulse not OK. Replaced card. Problem
solved.
Inserted HMPG card properly.
Put lock bars on SEM rack.
Also checked whether EPROMS are inserted properly
HMPG/DMPB. Problem solved.
on
SOURCE
UNDERVOLTAGE
4.
Tripping on Source Undervoltage when BFP started

and during fast bus changeover from unit to station.
Source Undervoltage alarm appears immediately but
Source Low line fault appears after sometime.
It was observed that source voltage dips below u/v set

value whenever MDBFP starts. This is because of very high
Inrush current in MDBFP. Changed source u/v setting to a
lower value as per site requirement. Problem solved.
MISC
5.
Abnormal sound of blower in panel.
Due to damaged bearing of fan.

Page 14 of 66
MISC
6.
MISC
7.
COOLING
LOSS
MISC
BLOWER
2 nos. temp. scanners are malfunctioning. Hence

tripping removed. However, winding temp. and
bearing temp. tripping from I/C panel is in service.
Speed indicating at VFD panel and actual speed are
matching. Speed at PMS not matching.
Bearing changed and fan replaced. Problem solved.

BHEL agreed to repair the faulty scanners. Scanners sent
to BHEL-EDN for repair.
BHEL has requested to adjust the mA reading as per
procedure given in VFD O&M manual, Vol1-Book1-Chapter
Clause 6.15.4 & 5.
EDN reply-The speed signal o/p from VFD to Plant C&I is
only for Indication Purpose & not for regulation/control.
Speed feedback on all channels adjusted. Speed reading on
PMS and actual speed are matching.
Fault resetted and drive started.
Cooling blower contactor dropped. 415V UV has occurred
for a time greater than normal leading to this trip.
8.
Alarm Cooling blower loss on Ch-1 and tripped on

Loss of cooling fan. But blowers running normal.
9.
Fan tripped without any indication.

Tripped due to failure of SEM supply.
MCB of PSFF had tripped. MCB reset and made ON. PSFF
was malfunctioning in this channel.
Site concerned about momentary malfunctioning
of
electronic cards since on next starts, card behaves normal.
Sometimes, no alarm is annunciated.
EDN replies that tripping of VFD channel & becoming OK
after MP reset could be due to:
a. Dust accumulation on PCBs
b. Loose connection between card & backplane connector.
All cards, Power modules, Power supplies cleaned with
blower. Problem solved.
Failure of HRIA card. Failure due to RUNX relay failure.

HRIA replaced and channel restarted.
Processor found hanged.
Control supply made ON/OFF.

Page 15 of 66
Processor normalised and restarted.

GROUND FAULT
10.
Channel tripped on ground fault.
SOURCE
COMMUTATION
FAILURE
11.
Tripped with following indication on printouts:

a. Source O/C b. Load Commutation failure c. Load
O/C d. Source commutation failure.
b. Channel could not be restarted , tripping on
same faults and hunting in currents.
ID Fan B-1 speed was locked at in running condition.
MISC
12.
SHORTED MOTOR
WINDING & LOAD
COMMUTATION
FAILURE
13.
I/O PROBLEM
14.
I/O PROBLEM
15.
Fan B1 tripped once on a) Load commutation failure

b) Bridge filter fuse c) Shorted motor winding
Second time on a) Load Commutation Failure
Third time on a) Load Commutation Failure b)
Shorted motor winding
Tripped on indications:
a) Motor Isolator not closed. b) RUNP missing c)
Bridge filter fuse
C1 tripped on
a. Source PLL Fault
Fault resetted and channel started smoothly. Problem may

be due to :
a. Loose connection in load side connections (busbars,
connector, earthing lug on HPTK, SEM Earthing.)
b. Loose connection on star point of load side filter
capacitor circuit.
c. Check voltage setting.
Site says all connections above have been found normal.
Suspected transient ground fault as there were no failures
of components to detect the same.
1. UPS voltage at panel checked and found OK.
2. Source side thyristor STM4 found failed. Replaced
module STM4 and channel taken into service. OK.
HMPG found hanged. HMPG resetted and fan started.

Could be due to loose connection of HMPG.
Site advised to put lock bars on SEM. Problem solved.
1. HPTK card found faulty after checking waveforms in
gate test mode. Replaced card.
2. Y ph thyristor in field exciter module had failed.
Calibration of field current feedback was wrong. Same
corrected. (in A1)
Fault indications were false. Fault reset and drive
restarted. Suspected UPS feeder supply problem.
Fault resetted and channel restarted.
Suspected UPS feeder supply problem.
Page 16 of 66
16.
MISC
b. STARTP/RUNP missing.
Channel tripped. 11kV Source breaker tripped on
IDMT O/C protection relay. No indication on VFD
before tripping.
HD of 5th harmonic of VFD system is 30%. To be
confirmed.
MISC
17.
MISC
18.
Channel tripped on Circuit Breaker protection

indication.
LOAD PLL FAULT
19.
Channel tripped on Load PLL Fault
MISC
20.
21.
Channel tripped with Bushog Led on HMPG Same not

resetting.
Channel tripped on Shorted Motor winding.
I/O PROBLEM
22.
Channel tripping on blower loss.
MISC
23.
HMPG card did not pass Self Test. Hangs midway.
SHORTED
WINDING
MOTOR
Relay resetted and channel restarted.

Malfunctioning of IDMT relay suspected.
30% HD for 5th harmonic current is acceptable as it is in
the case of all thyristor bridges. Voltage distortion is <5%
on 11kV VFD bus due to VFD operation which satisfies
requirement as per IEEE 519.
Investigation reveals all the thyristors in one power
module failed. Cause of the failure was that stud got
sheared. Replaced studs in all power modules wherever
failure suspected. OK.
Balanced Voltages at NLIB(1D) by back charging from
master channel and made voltages at FAB,FBC and FCA
equal with offset zero below 30mV DC. Channel taken into
service. OK.
Replaced
HMPGDMPB. Checked that the 6 nos. of
EPROMs are installed correctly. Problem solved.
1. Check thyristor healthiness.-OK.
2. Reset and restarted - tripped.
3. Dry solder in voltage attenuator circuit on XPTN
card. Attended dry solder, Self test halted at 29 &
gate test also halted. LVSH on NPSJ card in PSFF
module was not present. NPSJ replaced and restarted.
Check to be done on Berg jumper position in XPTN during
card replacement. Channel taken into service. OK.
Blower selection contact Bottom blower selected not
wired to IOMA card. Same done. Problem solved.
Replace HMPG Put EPROMs U22, U23, U24, U25, U02, U03
and EEPROMs U04,U05 from old card in respective slots
Page 17 of 66
GATING
SUPPLY
UNDERVOLTAGE
24.
Tripped on Gate supply u/v.
in the new card. Lock bar to be put in SEM Rack. Problem

solved.
1. In gate test mode, HPTK card in LTM1, 1A fuse blown
Replaced and started. OK.
2. MCB CB2 feeding electronic modules found tripped.
NTRF card in PS7 module found faulty. Replaced.
Problem solved.
Page 18 of 66
Category
Sl.no.
Problem
Solution
SOURCE
OVERCURRENT &
LOAD
OVERCURRENT
1.
Speed
not
raising beyond 140rpm (Rated =
700rpm). Current hunting in 2 channels.
Channel tripped on Source and Load Suppression
Fault
1.
Source side attenuation voltage feedback not

available.
2.
3.
4.
5.
MISC
2.
Self test not going through. Each time test failed in

different steps.(2 racks)
MISC
3.
GROUND FAULT
4.
HMPG did not recognise status of running blowers

even when blowers were run. Hence Source breaker
close permissive was not available.
Tripping on ground fault whenever speed raised
beyond 500rpm and motor volts is 500V without
any fault in motor or cable.
1st channel Current hunting due to improper voltage

feedback from source bridge due to failure of
attenuator in HPTF card. Replaced HPTF. Problem
solved.
2nd channel Wrong polarity of current feedbacks
from motor side CTs.
Changed NLCB card. No change observed. Original
card put back in rack.
Checked ribbon cable from IOMA is properly seated
on the SEM header.
4-20mA not reaching SEM.
Pressed connector & became OK.
Conducted crowbar test. Crowbar test OK.
Motor with both channels taken into service. OK.

0PAR signal was pulled down by defective NLIB cards.
Replaced NLIB cards in the 2 racks. Problem solved.
HMPG found defective. Replaced the 6 EPROMs from the
defective card. Ensured that they are put in the correct
position with correct polarity. Channel started. OK.
1. Replaced HLCB card. No change observed. Original
card put back in SEM rack.
2. 3 MOVs MOV1, MOV2 and MOV4 failed at a much
less voltage than designed.
Checked wiring in panel. Found wrong wiring. Corrected
the same. Drive taken into service. OK.
Page 19 of 66
MISC
5.
MISC
6.
LOAD
COMMUTATION
FAILURE
7.
LOAD PLL FAULT
8.
Cleared crowbar test. But motor not starting

smoothly. Current going to inversion.
During crowbar test, one thyristor cell found not

conducting.
Unit tripped frequently on Load Commutation
failure causing Unit trip out.
Channel tripping on Load PLL Fault.
1. Check whether CT feedback polarity is reversed on the

load side. Corrected polarity of load side CT.
2. One leg of load thyristor bridge conducting. Changed
HPTF. OK.
Drive taken into service.
One thyristor found not conducting. Gate resistance found
abnormally high. Replaced thyristor cell. OK.
1. UPS voltage found low, changed transformer tap to
raise the input voltage.
2. Conducted crowbar test. OK. Drive taken into service.
1. Conducted crowbar test. Test was not OK.

2. Shorted DC buses on load side with DC Link Reactor in
3.
4.
5.
6.
7.
8.
MISC
9.
Channel tripped without any fault indication and
circuit. Conducted crowbar test. Test OK.

Changed NSFC load and conducted crowbar test. Test
not OK.
Checked all thyristors and snubbers on load side
bridge. All OK.
Checked pulses to gate of all load side thyristors, with
current probe. OK.
Removed individual thyristor module on load side. Found
that tightening studs on LTM1 was loose. Tightened
the same.
Conducted crowbar test after removing DC bus short
on load side. Crowbar test OK.
Channel taken into service. OK.
NOTE: When putting back power module, pulse ribbon

cable and attenuator connector must be put in the correct
direction.
Lock bar at SEM centre installed.
Page 20 of 66
Bushog LED on HMPG

MISOL.
MISOL found
Checked SEM fan direction of rotation. OK.

Channel taken into service.
Cleaned contact with sandpaper and CTC and drive taken
into service. OK.
MISC
10.
Sparking on contactor
damaged.
MISC
11.
VFD trips on u/v condition of control supply.
VFD trf. 110V/110V given for rectification sent to site.

Customer was told to check UPS feeder voltage. Changed
tap on trf. in VFD panel C & EXE cubicle feeding
electronics. OK.
MISC
12.
Reference voltage keeps varying even with constant

demand signal. Causes Drive hunting.
Motor speed and current changing at I&C, even
though steady at panel.
SPD test point gives 14V even when speed is zero.
Replaced NLCB. Problem solved.
Motor Speed and current indication at both local &

remote are erratic.
Printer works OK in test mode, but does not print
Status/Fault from SEM
HRDD does not give output LEDs and voltages
corresponding to existing status.
Motor crawling during starting and did not pick up
speed.
Replaced NLCB Problem solved.
Suspected due to dust accumulation on

Firing cards cleaned by air blowing. OK.
MISC
13.
I/O PROBLEM
14.
FAILURE TO START
15.
MISC
16.
Channels getting
conditions normal.
MISC
17.
Drives could not go to current limit and increase the
unloaded with all operating
Replaced NLCB. Problem solved.

Replaced DLCB. Problem solved.
Replaced Printer. Printer sent for repair to BHEL-EDN.

Replaced HRDD. Problem solved. Card sent for repair to
BHEL-EDN.
Changed parameters FRSTART, MTRFMIN and CRSTART
to slightly higher values.
Inlet and outlet gates on ID Fan duct not closed properly.
OK.
firing cards.
Investigation to be done by customer during shutdown at

Page 21 of 66
LOAD
COMMUTATION
FAILURE
18.
I/O PROBLEM
19.
fan speed due to clamp on speed reference from

I&C system (Auto clamping).
Channel tripping due to Load Commutation failure
Running normal after fault reset.
I&C system.
Channel tripping on Bridge Differential Pressure

fault when taken into service.
Channel started, after crossing min. speed, current
started hunting and tripped on Load Commutation
failure. Crowbar test was done for power ckt. check,
one hump missing in current waveform.
Current hunting when channel taken into service.
IOMA found faulty. Replaced IOMA.
To be checked in test jig of repair cell at BHEL-EDN.

Energise RUN relay in IOMA. Check if TP8 in HRIA(2A)
goes high, JJ pin 22 on SEM header goes high, flicker of
LED I15 on HISA 1B.
IOMA checked in repair cell but no fault found. Replaced
the two mother boards on IOMA. Retested and
despatched to site. Suspected tracking problem on mother
board.
Backcharge Slave with Master running and adjust FAB,
FBC, FCA on NLIB Load of Slave same as Master. Use the
same multimeter.
Found Slave adjustment was not OK. Adjusted. Problem
solved.
I/O PROBLEM
20.
When RUN relay energised, BDIFSW (IOMA TB608) goes high, HMPG senses this as Bridge
Differential Pressure Fault & drive trips.
MISC
21.
Slave channel and Master channel can individually

start and run. But Slave channel cannot be paralleled
with Master. If paralleling is done, current in slave
remains at zero.
Loose connections in the CT feedback.

Improper earthing of SEM Rack.
SEM Rack earthed as per SEM Earthing document. Drive
taken into service. OK.
HPTF card in source bridge found failed. Replaced and

became OK.
Load side cards not firing correctly or in sequence. One

HPTF card, both neons did not switch On/Off together.
HPTF card faulty. Replaced and Problem solved.
Page 22 of 66
SOURCE
UNDERVOLTAGE
22.
Source Undervoltage fault even though Source

voltage is OK.
Asked to check voltage feedback circuit from HPTF

attenuator to NSFC and also line voltages on NSFC
backplane. Found Y phase Source attenuator not OK.
Replaced. Problem solved.
Site was also asked to check whether the ground pillar on
HPTF is not loose (dry solder) before sending HPTF card
for repair.
MISC
23.
Ch-1 and Ch-2 speed meters not matching.
MISC
24.
Channel trips without any fault or alarm message.

RUN light is ON but channel gets unloaded
current=0.
Speed meter does not have pot.

Customer advised to adjust LCI door 10V DC speed meter
after seeing counts 1024=60Hz=900rpm. Told to adjust
SPM pot only.
Problem solved.
All SEM voltages O.K.
Gate test not O.K. Self test done. Failed in test 06:
NSFC-2C. Replaced NSFC 2C. Problem solved.
Page 23 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
FIELD
OVERCURRENT
LOAD PLL FAULT
2.
Channel starts but gives loss of speed reference

though 4mA reference is present.
VFD Field Overcurrent problem.
3.
During starting, VFD trips on Load PLL Fault.

Firing pulses not getting released in Gate Test
mode even though Self test passes.
FIELD
OVERCURRENT
4.
Channel tripping on Field Overcurrent.
I/O PROBLEM
5.
HROA found malfunctioning. MAMX and ALARMX

relays remain latched even if fan is in stopped
condition & there is no alarm in the system.
Customer asked to check I&C reference. Must be 4mA

minimum.
Adjusted Field current feedback at SEM card. Problem
solved.
1. Variable components on NLIB-1C and 1D not as per
scheme.
2. Pin-72 of HAIA had got dislodged. Not making proper
contact on the backplane.
3. Rectified sl.no.1&2 above. Problem solved.
Checked cable of AC Input Exciter, was getting heated.
Power termination inside the module found loose.
Tightened and became OK. Drive taken into service.
HROA replaced. Drive taken into service. OK. Card sent
for repair to BHEL-EDN.
I/O PROBLEM
6.
Self test Crowbar test excitation power test done

in Channel 1 & 2 of 3A.
MISC
7.
MISC
8.
Channel taking more time to start and come to

minimum speed.
This
behaviour
was
not
observed
during
commissioning.
FD Fan trips when MAMSX and ALAMX relays drop
1 no. HROA card found defective in 3A1. Replaced.

1 no. NSFC card replaced in 3A2.
Drive taken into service.
Cards sent for repair to BHEL-EDN.
BHEL stated this may happen due to additional loading of
the fan during starting.
This happens if inlet damper at ID Fan is not closed
properly.
Suggested to introduce time delay (off delay) of 1.5secs.
1.
2.
3.
4.
Page 24 of 66
MISC
9.
MISC
10.
due to momentary voltage dips or voltage jerk

condition.
Unbalanced field currents when channel is taken
into service.
When 220V DC fails, VFD motor contactor will not
trip even though power to motor is cut-off.
for FD Fan tripping when MAMSX drops. Problem solved.

Due to irregular firing of thyristors in NHVL card.
Replaced NHVL Problem solved.
No harm to VFD system due to 220V DC supply failure.
I&C system will issue STOP to both channels. Load side
contactor will trip when 220V DC is re-established. Hence
no modification required.
Page 25 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
Tripping on undervoltage.
1. Changed C17 on DLIB to 0.47F from 0.047F. Did not
MISC
2.
MISC
3.
MISC
4.
Problem of crowbar test.
solve the problem.

2. LT supply to Control panel changed to Unit LT Bus
instead of Station LT bus.(voltage will not be steady
because external grid disturbances will get reflected
to this).
3. Found that timers in Control Panel were ON delay
instead of OFF delay. Changed timers to OFF delay
type.
4. Problem solved.
Module replaced with healthy power module. Faulty module
sent to BHEL-EDN for repair.
1. Check if all EPROMs and EEPROMS on HMPG/DMPB
are properly seated. Found OK.
2. Check SEM Lock bar is put and all card top and bottom
locks are firm. Found OK.
3. Check if SEM frame is locked to the panel using the Langle provided. Found OK.
4. Found out that even though SEM locking bar is put,
there is clearance between lock bar foam and card.
5. EDN sent lock bars with thicker foam for all SEM
modules so that bars are in contact with all the cards.
Problem solved.
Malfunctioning of HAIA card.
Channel current is found hunting for a load beyond
1.
One no. thyristor module on load side failed in BFP

10C. All 3 nos. series thyristors got shorted.
System tripped without any annunciation.
HMPG hanged and test led is glowing.
C1-Exciter output found abnormal. One thyristor of

Page 26 of 66
350A.
FIELD LOSS
5.
Feedback of NHVL card is not coming.

Only 2 Leds on NHVL card are glowing.
MISC
6.
Field current saturates above certain load.
SOURCE PLL FAULT
7.
Channel tripped on Source PLL Fault.
MISC
8.
Channel tripping frequently on SEM power supply

(PSFF) failure.
MISC
9.
MISC
10.
Unequal field current in 10A & 10B. 10A taking 20A

more current than 10B.
Motors not attaining full speed of 740rpm for 100%
EVC was not conducting. Replaced & OK.

2.
C2-NHVL card of EVC found defective. Replaced and
No hunting observed.
3.
Replace NLIB Source card.
4.
NHVL only 2 lamps found glowing. Channel manually
tripped. HMPG thoroughly cleaned and restarted. No
hunting observed.
5 . FCLIM values increased. Speed meters for all 4
channels calibrated.
6. Speed regulator gain changed from 35 to 25.
EDN suggested checking of exciter feedbacks during
calibration.
Replaced NHVL card.
HMPG, HLCB & NSFE replaced. Cards sent for repair to
BHEL-EDN.
ID Fan was getting overloaded. Customer requested to
check whether the loading is as per the load points given in
Motor data sheet in O&M Manual. Also inlet damper
position to be checked. Problem solved.
1. Ribbon cables are tightened.
2. If trips again, recommended to replace HLCB card.
BHEL recommended to decrease AC temperature in VFD
Room for better cooling and provide internal fan for
channel. If not solved, Replace PSFF.
Recommended temperature in AC VFD room is 25C.
Replaced MCB in PSFF. Problem solved.
Load on 10A is more than 10B, at same speed. Hence
higher stator current and also field current.
Motor does not have sufficient reserve torque to
Page 27 of 66
demand.
accelerate beyond a certain speed and excitation current

limit is being reached.
Load side thyristor electrical connections tightened.
Loose connection of Load attenuator wire from Local AC
Busbar found. Problem solved.
Motor was in service earlier from both channels. Individual
channel running was also proved. Therefore suspected
motor.
Found that DC cable in motor from output of exciter
diode bridge to main field had melted at lug point.
BHEL-BHOPAL representatives called to site. Changed
cable. Problem solved.
LOAD PLL FAULT &

SHORTED MOTOR
WINDING
FAILURE TO START
11.
PLL Fault and Motor shorted winding Fault.
12.
Motor rotates in the correct direction very slowly,

when run either from Ch-1 or Ch-2.
MISC
13.
Adjusted cam that actuates the contacts for the coil

control circuit on the contactor. Channel taken into
service. OK. Problem solved.
LOAD
COMMUTATION
FAILURE
14.
Output Contactor was not holding after close

command was given. Contactor is M/s.
Telemachanique make Magnetic latch type
CR1BL33M21. Magnet face OK.
Slave channel of BFP trips on Load Commutation
failure randomly.
SHORTED MOTOR
WINDING
15.
Master channel tripping on Shorted Motor Winding.
Changed Slave to Master and vice versa. Backcharged

Slave from Master. Adjusted Slave NLIB load fluxes to
same as Master. Problem solved.
SEM grounding, panel grounding checked and found OK.

Changed HLCB card. Problem solved.
Page 28 of 66
Category
Sl.no.
Problem
MISC
1.
Flickering of LEDs on HPTK cards

rectifier and Inverter in Gate Test Mode.
BRIDGE
DIFFERENTIAL
PRESSURE
LOAD PLL FAULT
2.
Bridge Differential Pressure message appearing

in the printer in spite of blowers running.
1. Check cable connection from AFM to IO module. OK.

2. Replaced Air Flow monitor. Problem solved.
3.
At rated speed, fluctuations observed in main power

supply to motor, accompanied by unbalanced
excitation parameters.
Voltage sensed by VFD was higher.
Motor speed could not be increased beyond 400rpm
and VFD tripping on LOAD PLL FAULT.
1. Jumper setting in HPTK Voltage attenuator circuit
FAILURE TO START
4.
Solution
both in
Channel tripped on Microprocessor alarm.
Problem solved by changing HPTK cards.
corrected.
2. Exciter phase sequence wrong.

Problem solved.
EDN insisted that VFD room should be maintained dust

free.
Snubber bar assembly LTM2 and LTM5 were found open.
Replaced Snubber Bar Assembly & started.
Hunting observed. Crowbar and EVC test found OK.

CRSTART modified from 0.3 to 0.5 and started.
Hunting persists.
Load current CT feedback cable(10 pin) on SEM header

found reversed. Inserted in correct direction. Problem
solved.
MISC
5.
Run light always ON.
Backplane wire wrapping problem. Corrected. Problem

solved.
P105
UNDERVOLTAGE
6.
Channel tripping due to P105 u/v.
Changed DPSA card.

Changed DPSA power supply.
Mounting of power supply found loose(no screw). Also, AC
Page 29 of 66
7.
Self Test fails at 2001.
8.
Could not go to Gate Test mode.
MISC
9.
MISC
10.
MISC
11.
MISC
12.
MAMS relay not getting reset even after VFD is

stopped (Speed is zero).
Speed suddenly reached 500rpm and unit tripped on
furnace pressure very low.
ID Fan Auto control is not working properly. Hunting
in current when Furnace pressure controller is put in
Auto mode.
Controller very slow. May damage VFD/motor.
Clearance asked to make controller fast.
MISC
13.
MISC
14.
MISC
15.
MISC
MISC
VFD did not stop with Stop command from DCS,

Filed stop PB. Finally stopped with Emergency Stop
PB from 6.6kV.
Speed does not vary with input signal and
communication to HRDA card fails.
Drives reached rated currents at less than rated
speed.
Current drawn at 705 rpm (max.) is exceeding
rated current in 3 motors.
HMPG IMOK Led was going OFF resulting in tripping
of 6.6kV breaker.
input to the card has been reduced to 110V by adjusting

tap position to the input transformer. Problem solved.
EDN says problem is in Self test circuits only. Site asked
to go ahead with motor running. This circuit does not have
any function when drive is in service.
Corrected offset zero on NLIB Load and NLIB Source
FAB, FBC & FCA with test oscillator ON by slightly
adjusting BAL1 and BAL2 potentiometers on NLCB Then
changed MTRFMIN and FLUXS to 0.2 and 0.1 respectively.
Problem solved.
HRDA card found faulty. Replaced. Problem solved.
Due to sudden high set point from I&C 4-20mA signal.
Corrected problem at I&C. Problem solved.
Customer asked to change P & I values in PI furnace draft
controller in I&C system. Problem solved.
Customer asked to time furnace draft PI controller at I&C
system for optimum performance to suit system
requirement. Problem solved.
Due to Bushog problem in HMPG Suspected loose
connection between HMPG and mother board on SEM rack.
HMPG cleaned and inserted in rack. Lock bar put. Problem
solved.
Current limit to be raised by raising the value of SRCLSC
by 10% to increase the speed further. This can be done as
there is margin in motor and VFD. Problem solved.
Due to vibration of SEM Rack.
Source of vibration-SEM Rack cooling fan. Fan replaced.
Page 30 of 66
Problem temporarily removed after tightening of

SEM front bar plates. Problem persists & repeats
after 2 days.
Problem solved.
Due to higher time taken to achieve minimum speed of

145rpm from standstill. Timing in C&I increased from 30
secs to 60 secs. Problem solved.
Corresponding thyristor found failed. Replaced thyristor
module and sent faulty thyristor module to BHEL-EDN for
repair.
There will be difference in indication upto 25Hz. Over this
the
indications will be nearly same. This is due to
saturation in the metering core of CT at low frequency.
Indications in VFD panel to be taken as actual.
Since VFD is a current limited drive, speed can increase
only upto the current limit set. Customer asked to check
inlet damper position and verify whether it is as per
recommendation.
MISC
16.
During starting, Stop command was being given by

C&I system.
MISC
17.
One no. Neon lamp of XPTN card on load side

thyristor module is not glowing.
MISC
18.
Current and voltage at motor isolator switch is not

matching with the corresponding values at control
and excitation panel.
MISC
19.
MISC
20.
The maximum speed at 100% demand from control

room is below rated speed. i.e. 725rpm in all 3
motors.
Current drawn at 705rpm is exceeding the rated
current of all 3 motors.
Microprocessor alarm appears. IMOK of HMPG and
NLCB disappears and subsequent tripping of 6.6kV
breaker occurs.
Frequent tripping of Fan on various faults.
1. Observe whether the fault appears under the conditions:

a. Only Auxiliaries ON, HT supply OFF to VFD
b. With HT & auxiliaries ON, drive not running
c. With drive running.
2. Check voltage levels of P5, P15, N15 & P28 supplies.
3. Check the status of Alarm Word.
4. Replace all 6 EPROMS (4 on HMPG & 2 on DMPB).
5. Check if SEM earthing is as per SEM Earthing
document.
6. Since sl.1 to 5 did not lead to any definite reason,
SEM rack was changed. The original cards were
returned. Lock bar of SEM put.
Page 31 of 66
MISC
LOAD
COMMUTATION
FAILURE
21.
22.
Fan tripped with Motor Overtemperature Alarm and

Overtemperature Trip. Found MCBs CB1, CB2, CB4
and CB13 in control panel tripped without actual
temp. rise in motor.
7. Problem was solved.

1. Could have been only due to fault in the circuit
connected to CB1 breaker.

Checked all auxiliary
circuits including 110V contactors connected to CB1
breaker for healthiness.
Subsequently motor did not start and Rotor

position start alarm was observed.
2. Motor opened and inspected. Found exciter wiring had

soot covering at some spots.
Exciter stator winding round carbonised.
Motor
needs to be repaired/replaced with new one. Motor
sent to Bhopal for rectification of exciter rotor.
Received back at site.
Channel tripping intermittently on Load Commutation

failure.
Channel tripped again after few hours.
HMPG, 5 nos. of NTDA cards changed.
Self test conducted. Speed feedback circuit found

malfunctioning in NLCB/DLCB.
DLCB replaced.
Crowbar test conducted. Current feedbacks O/C

protection circuits checked, adjusted and started.
Channel tripped on Load Commutation failure again
after few hours.
Firing pulses and load side HPTK cards, NSFC, related

cables checked. 2 HPTK cards on load side, reference for
detection of UV of gating supply was 1.3VDC while in
others it was 1.8VDC. This reference adjusted to 1.8V in all
HPTK cards.
Gating power supply voltage was low. Corrected this to
required level. Self test and Gate test passed. Channel
taken into service.
Load side bridge thyristors, snubber ckt., CT circuit,

gating circuits checked. All terminations on HPTK and
NTDA cards checked for loose connections and
soldered/tightened/replaced wherever required.
Page 32 of 66
MISC
23.
HMPG and NLCB IMOK going OFF.
GATING
SUPPLY
UNDERVOLTAGE
FAULT
MISC
24.
UV chattering of relay in PS7 power supply.
25.
Drive tripping on Microprocessor Alarm and Stack

fault.
SEM cards to be thoroughly cleaned by blowing over SEM

with blower.
Check SEM lock bar is installed correctly and firmly. SEM
module is anchored properly. Drive taken into service.
NTRF card in PS7 changed. Problem solved.
Card sent for repair to BHEL-EDN.
This type of problem is due to spurious interrupts which is
normally attributable to grounding.
Found that earth bus at rear of panel was sheared off at
panel end and also earthing bus was not continuous.
Incorporated jumper cables on earth bus and tightened
connections. Incorporated extra connections between
2A/34, 2B/34, 2C/34 to DCOM. Drive taken into service.
Page 33 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
Unbalance motor Currents upto 1.5A in blowers.
MISC
2.
Failure of cards and intermittent failure of VFDs.
LOSS OF COLLING
FAN
3.
Channels tripped on Blower loss.
MISC
4.
MMI FOR VFD
5.
PSFF power supply MCB trips frequently even

though load is normal.
1 no. Line driver found defective.
On executing VFD MMI S/w, after 2 minutes,
program came out of main exe. File. Drive status
had also not got updated.
Vendor has informed that unbalanced current of the motor

cannot cause any damage or reduce overall life expectancy
of blowers.
Failure rate of cards could be high during commissioning
but extremely low after stabilisation.
Analysis-Most of the component failures attributed to
voltage mix-up and wrong cabling during pre-commissioning,
handling, dust accumulation during commissioning.
Due to tripping of blower supply to ID Fan because of
flashover in ESP LT switchgear.
Customer requested to provide individual channels blower
AC supply from 2 separate sources.
Customer was advised that the same is not required, as
such problem has not occurred at any other site. Reason
for flashover in ESP switchgears to be analysed and
corrective action to be taken.
Replaced MCB of PSFF. Problem solved.
1. Replaced. Defective line driver sent for repair to

BHEL-EDN.
2. Check if Serial intelligent card & Reed relay card are

available.
3. Check 24V DC Jyothi Relay in C&EXE panel is getting
energised on program execution. If OK, Connect 25 pin

connector to door mounted printer.
Check that
messages are printed on printer.
Page 34 of 66
4. Check MMI system connections as per scheme.

If all connections/hardware are OK, Pink window
Drive Status should appear on MMI screen, else Blue
window Link Failure appears on MMI screen.
MISC
6.
Com Port of one Laptop supplied for VFD is not

working.
1 computer of VFD-MMI not working.
Repaired by BHEL-site through laptop vendor.
Channel tripping on Load Commutation Failure.

Channel tripping intermittently on faults Load PLL
Fault Load Commutation Failure, Motor Winding
Shorted & Power Supply PSFF failure.
3 MOVs of 440V 1A,2A & 3A found burnt during
inspection and maintenance work. Found incorrect
connections,
SEM earthing found not proper. Same rectified.
LOAD
COMMUTATION
FAILURE & LOAD
PLL FAULT
MISC
7.
LOAD
COMMUTATION
FAILURE
9.
Slave Channel tripping on Load Commutation failure.
MISC
10.
Both Master and Slave channel of one ID Fan

tripped out. In Master channel, Source and Load
breaker tripped. In Slave channel, only Load breaker
tripped.
8.
Mother board replaced by computer vendor at site.
3 nos. HPTK modules and 1 no. PSFF changed.

Fuses feeding MOVs No failure observed. Found MOVs
burnt. Found wrong connection in panel.
Advised to change all 9 MOVs 1A to 1C, 2A to 2C, 3A to 3C.
MOVs changed. Problem solved.
Channel back-charged with Source breaker open and Load
breaker closed. FAB, FBC, FCA in NLIB load found with
large DC offset.
Changed NLIB card and adjusted DC offsets to less than
30mV and balanced AC voltages of FAB, FBC, FCA. Channel
taken into service. OK. Problem solved.
Flashover in Source side of Master channel. Master
channel isolated and Slave channel taken into service.
Found source side AC and DC filter fuses blown and also
cable tapping from busbar to filter fuses burnt. MOVs on
Source side OK. Fuses and wires replaced. All clearances
are more than adequate. Cause of flashover not known.
Channel taken into service. OK.
Page 35 of 66
MISC
11.
Fan-B Ch-2 tripped. Following were noticed: 1.

Source breaker tripped. 2. FT1 indication observed
at VFD end. 3. HMPG IMOK LED was not glowing.
4. There was huge current hunting only in this
channel before tripping.
Crowbar test done Found O.K.

Gate Test done - Found O.K.
Self Test done Found O.K.
Primary injection tests in all 4 CTs done. Found O.K.
Finally problem was traced to improper earthing in
electronic earth pit. Salt added. Drive started and found
O.K.
Page 36 of 66
Category
Sl.no.
Problem
MISC
1.
MISC
2.
Incoming MCCB to IOMA PSFF tripping due

inrush currents.
Channel did not start smoothly.
MISC
Solution
to
3.
Hunting observed in current & speed.
Breaker setting adjusted according to site conditions.

Problem Solved.
Found load C.T polarity reversed after examination of Load
current waveform w.r.t. load firing pulses. Corrected
polarity. Problem solved.
Parameter SRGAIN tuned.
Problem solved.
MISC
4.
MISC
5.
During exciter test on channel, resistors R70, R71

replaced from 56 Ohms to 46 Ohms to adjust
burden of CT
Self test not passing because offset value was not
within the range.
MISC
6.
HMPG IMOK not coming.
MISC
7.
MISC
8.
Pulses not getting distributed to thyristor stack

individually in gate test mode.
ID Fan ON check back derived from its speed
being above a certain value
(MAMS). During starting MAMS chatters as speed
hunts slightly resulting in ID Fan ON/OFF toggle.
This gives auto start to shutdown sequence.
Feedback as required adjusted with potentiometer on

NHVL.
Problem solved.
DC offset on source & load NLIB FAB,FBC and FCA could
not be adjusted within 30mV with test oscillator ON by
adjusting BAL1, BAL2 pots on NLCB. NLCB replaced.
Problem solved.
Replaced HMPG with EPROM sets of tested card (6
EPROMS). Card sent for repair.
Card XTFX in source side found defective. Replaced.
Problem solved.
Automatic initiation of shutdown sequence due to ID fan
OFF status will be delayed. Introduced time delay OFF
logic for MAMS input at I&C. Problem solved.
MISC
9.
VFD demand goes to max. when both ID Fans are

OFF. This prevents reducing the VFD demand to
This command is removed in I&C system as it is not

necessary.
Page 37 of 66
min, when taking the first ID Fan into service.

ID Fan VFD given a protection trip from Source
Breaker OFF condition but also source breaker is
given trip on VFD OFF condition, thus creating a
logical problem.
Channel tripping on Load Commutation failure
MISC
10.
LOAD
COMMUTATION
FAILURE
11.
MISC
12.
Any electrical supply system jerk causes drive to

trip.
MISC
13.
Customer expressed that Auto fault Reset facility

is not available.
MISC
14.
Coil for OEN make relay found burnt in IOMA

Reason unknown.
NLCB gives IMOK indication but fails
during self test of NCLB card.
MISC
15.
MISC
16.
NLIB gives IMOK indication but fails in Self Test.
SOURCE
COMMUTATION
FAILURE &
SOURCE
OVERCURRENT
17.
Drive tripped on Source Commutation Failure.

Drive restarted and motor tripped without picking
speed on Source Backup Overcurrent Operated
tripping Source breaker also.
Gate test and Crowbar tests passed.
Problem solved.
Source breaker trip due to VFD OFF condition will be
removed and instead will be given a trip command on its
Electrical protection acted input being true. This is
implemented at I & C. Problem solved.
LMARG was changed from 25 to 30.
Found P28 was 21.5Volts. Site asked to change this to
minimum 24V level during gate test mode. Problem solved.
Changed back to 25 after channel was normalised.
Presently UPS feeding VFD is not fully commissioned and
UPS is running on By-pass. Problem will not occur if UPS is
commissioned.
EDN informed that facility will not be given. It is
required that the maintenance engineer has to come to the
VFD panel to find out the fault and take corrective action
before re-setting.
Suspected quality problem. Relay changed. OK.
DLCB card components R1 & C1 not
matching as per
scheme. Changed from other card. Problem solved.
Daughter board components R22, R31, R40, R23, R32, R41,
R60, R68, R72 not matching as per scheme.
Changed the components as required and also adjusted the
gains of FAB, FBC, FCA as per commissioning procedure.
Problem solved.
Advised to conduct EVC test and crow bar test. Also
inspection of output contactor contacts advised.
Found that
one of the thyristor cells in the load side

Page 38 of 66
I/O PROBLEM
18.
Both channels commissioned but not able to take

both into service simultaneously because of a
missing feedback due to HROA card.
Current hunting after that.
Current sharing problem between channels.
MISC
19.
FAILURE TO START
20.
VFD failed to start and Rotor failed to start (Bit 1

of ALARM WORD) displayed on printer.
MISC
21.
Laptop battery back up not working.
MISC
22.
Unit tripped on received AUTO OFF commands.

WSPOSE relevant alarm display was Auxiliary
Supply failure
Customer requires that 24V DC and 220V DC
supply failure be separated.
MISC
23.
High vibration noticed in fans at speed above

650rpm (Speed at unit F.L.condition is <600rpm)
bridge had got shorted. Replaced thyristor module & sent

the faulty module for repair to BHEL-EDN.
Problem solved.
HROA card replaced. Simultaneous operation possible.
Problem solved.
HROA card sent for repair to BHEL-EDN.
Actual currents were balanced. Meter on LCI channel not
showing correctly. Meter adjusted OK with pot. IM on
NLIB.
Problem in DC field and exciter on synchronous motor.
Motor changed in presence of BHEL-Bhopal person and it
is running OK.
Customer has asked to send 2 battery back ups.
EDN says that Laptop PC can be fed from UPS supply
available in VFD panel. As such battery back up is not
required in laptop PC for VFD maintenance.
Site : Logic built in VFD such that a time-delayed timer 035secs. (set to 3secs.) drops when either of 24V or
220V DC supply fails. Contacts of this timer used for
Source drive breaker Start Perm. and its inverted status
used for generating AUTO OFF commands to source
breaker cards simultaneously.
EDN does not recommend separate logics for 24V & 220V
DC monitoring, as both 24V DC and 220V DC failures
should trip the drive.
Resonance is being observed
from foundation at
speed>650rpm. However, vibration is in good zone.
BHEL-Ranipet recommends that status of spring
compression can be checked during annual maintenance
Page 39 of 66
shut down.
Time delay of 2 secs. already incorporated to tide over
the problem. Customer has been asked to look into the
source of the swing/jerk and take appropriate action.
MISC
24.
VFD trips when small system jerks occurrence.
Category
Sl.no.
Problem
Solution
MISC
1.
When individually run, both channels run OK. When

both channels put on parallel for equal sharing of
current, it could not work. Current in Ch-2 became
0.
Ch-1 Tripped due to MP module power supply failure.
Ch-2 tripped due to Stack failure.
Only once, channels could run in parallel operation,
but local stop PB did not respond, tripping could be
done by operating local/remote selector switch.
Problem seems to be due to 240V supply fed to electronics

or malfunctioning of circuit breaker in PSFF module. EDN
has asked site to carry our the following & give feedback.:
a. Put both channels in Gate Test mode at the same time
by changing MTRFMIN to 0.2 and FLUXS to 0.1 &
putting NLCB switch up. DO NOT SAVE. It may take
about 5 minutes for pulses to be released.
b. Check input supply at sheet 1BB of scheme. Change tap
of trf. to get 110V on sec. of T1.
Check 28, +5, +15, -15 volts on SEM
rack OK.
Check 70V DC from gating power supply OK. Should be
atleast 75V DC during gate test.
c. Quit gate test by putting NLCB switch down and
resetting MP.
d. Check 220V DC supply to VCBs OK.
e. Run up Ch-1(master) to minimum speed. Check
LMODE=3.
f. Run Ch-2(slave). Check LMODE goes to 3 in slave. If it
does not, slightly lower MTRFMIN and FLUXS in Ch-2.
g. Power supply tripping problem in Ch-1 sorted out.
Page 40 of 66
MISC
2.
Following problems during parallel running of 2

channels:
a. Individual load breakers do not trip with remote
trip command/local stop PB. Only Run relay
drops & MP does not issue a trip command via
RUN relay.
However process trip commands trip load side
breakers at a time for both channels as
expected.
a. Monitor 105V DC level on IOMA TB3-9,10 when RUN1
b. During loading, fan speed rises upto 35% speed

ref. Command. And beyond that speed does not
rise. Stator current hunts from min. to max.,
but speed does not rise.
b. Observe INVLIM during normal running and when
& RUN2 relays in control panel drop. Check operation

of load breakers, independently by removing plug-in
type RUN relay in IOMA and simulate Load Breaker
operation. Source breakers must be OFF when doing
this test.
Mistake in wiring chart of Ch-2. This was the cause of
Ch-2 not switching OFF when STOP command given
from C&I. Problem solved.
hunting happens by continuous display of INVLIM.

The value of INVLIM displayed will tell the type of
fault. Please do the following:
1. Increase LMARG to 0.3 from present 0.16. Run
drive and see if hunting persists. Hunting
persisted.
2. If it persists, Change LMARG back to 0.16. Change
resistor R60,R68, R76 in NLIB to 100K from 180K.
Run & see if hunting persists, Changed resistors.
Hunting persisted.
3. If it persists, change above resistors from 100K to
56K. While changing resistors, NLIB to DLIB
Ribbon cable connection is to be removed.
Hunting remains.
Inadequate excitation caused dip in Armature voltage
leading to hunting of speed and armature current.
ALPHFLD was reaching 255. Exciter current was
reaching 63A LRMS-too high for the load. Reversed
exciter stator cable thereby changing the phase
Page 41 of 66
sequence. Problem solved.

MISC
3.
Motor current calibration on VFD C&EXE panel.
Run both channels at min. speed. Check LMODE=3 in both

channels. Measure trf. sec. winding current with clip-on
meter. Since trf. current = motor current, adjust
NLIB/DLIB pot. IM so that panel meter reads correctly.
Note that at minimum speed current will be minimum &
steady.
MISC
4.
Running VFD when ID Fan handles air instead of flue

gas. Speed does not go to Maximum.
Since density of air is much higher than flue gas, it will not
be possible to run the drive to 540rpm as current will
reach the limit values before this speed.
LOAD
COMMUTATION
FAILURE
5.
Channel tripped giving Commutation failure.

Both channels tripped due to fan vibration very
high-process trip.
1. Changed XL compensation resistors in NLIB load R60,

2.
3.
MISC
6.
Channel does not start. On excitation board, only 2

LEDs glowing on Start command.
Power supply unit failed.
Printer not receiving data from the MP.
R68, R76 from 180K to 67K. Tripping continues.

Resistors changed back to original value.
P70 Volts output changed to 80 Volts during gate test
mode. Problem solved.
Vibration problem
attended by mechanical
maintenance group.
1. NHVL excitation board

2.
3.
failed in Field Exciter.

Replaced. OK. Failed board sent for repair.
PSFF module replaced. OK. Failed PSFF sent for repair.
Printer replaced.
Page 42 of 66
I/O PROBLEM
7.
Motor decoupled smooth in both channels. While

starting the fan on Ch-1, ammeter reading does not
go beyond 400A whereas in running it goes upto
600A and comes back for any speed increase
command.
When fan started through ch1, fan did not start,
rotor oscillating and stator current hunting. Ch-1
stopped and ch-2 started. Ch-1 paralleled. Found
OK. Ch-1 OK even ch-2 stopped. Ch-1 started
independently before rotor came to rest. Ch-1 does
not start from rest position.
11 nos. Modules found defective. Replaced.

Ch-1-Polarity of CT inside excitation board was changed as
IFB waveform not found OK. During power-up, before
restarting, MAMX in picked-up condition though HROA-R2
LED not glowing. Load breaker closed without any
command. Self test failed in 230D.
HRDD, NLCB
suspected defective, Replaced & power On. MAMX picking
up. HROA in 1B failed. Spark observed in K3 relay body.
FU-6 blown in HROA. In MAMX, suppressor block (R-C
net) changed as lugging was not OK. IOMA changed. HROA
connector found burnt. HRDD found defective.
All replaced. Self test passed. Fan started.
4-20mA for remote indication was not there.
NLCB
changed. OSP and SPM setting was done. Fan run and
paralleled.
Ch-1 fault and not starting. All LEDs on HRDD glowing.
HRDD replaced. Remote speed indication and local speed
indication became zero. NLCB changed and ID fan started.
Problem repeated again.
Problem maybe in exciter module or NSFF card. Check
waveform during field exciter test at TP IFBK in NSFE.
Compared with healthy channel. Also, checked exciter
pulses SIG1 to SIG6 at NSFE.
One of the thyristor pulses was missing, Pulse trf. on
NHVL exciter board failed.
When motor started through VFD Ch-2, did not start and
tripped on Source & load OverCurrent & ground faults.
During meggering on motor insulation , IR value found very
low. Problem related to Motor insulation, BHEL-Bhopal
Page 43 of 66
MISC
8.
Ch-2 self test not passing. DC Offset not getting

adjusted to zero volts.
During trial run, Ch-1 Commutation failure fault
appeared.
9.
Failure of IOMA modules.
10.
Ch-1 of ID fan-starting and running

OK.
Ch-2 (slave) of ID fan- Does not start. But runs OK
after paralleling with Ch-1.
Tune-up parameters are same in Ch-1 & Ch-2.
LOAD
COMMUTATION
FAILURE &
SOURCE
COMMUTATION
FAILURE
I/O PROBLEM
FAILURE TO START
contacted. Motor end covers opened & 1 conductor was

observed to have turned black. This was due to insulation
failure which resulted in high earth fault.
Motor
replaced. Same problems observed. Also spurious
trippings/startings observed in Ch-1.
IOMA modules replaced in Ch-1 & 2. PSFF replaced in Ch-2.
Fan Run OK.
Additional earthing provided. NLIB card replaced. Offset
voltage made zero in NLIB Source & NLIB Load FAB, FBC,
FCA by adjusting BAL1, BAL2 pots in NLCB. Self test
passed OK.
NTDA card on thyristor modules resoldered wherever it
was suspected dry solder present. Fans run OK.
Seems to be a chance of voltage mix-up in P105 and IOMA

output contactor circuit. Mix-up could be from inside the
panel or from outside IOMA.
Found that there was no voltage mix-up in panel side.
IOMA modules suspected.
Sent to BHEL-EDN for repair. Found problem of open PCB
tracks on IOMA module backplane and also tracking
between PCB tracks. Backplane PCBs on I/O module
changed. Vender de-listed. Quality problem. Problem
solved.
Found in Ch-2 that the load side CT polarity is reversed
after observing the waveforms of load side firing pulses
w.r.t. Load side CTs. Corrected CT polarity.
Problem solved.
Page 44 of 66
LOAD PLL FAULT
11.
On starting, Load breaker trips. Load PLL Fault or

Load Overcurrent or Shorted Motor Winding
message appears. SUPP Led not glowing.
GROUND FAULT
12.
Ch-2 tripping on ground fault intermittently and

thereafter as soon as channel was paralleled to Ch1.
Found that NSFC load card was loose and not properly
inserted in rack.
Inserted card in rack and put SEM lock bar. Drive started
and found OK.
Action taken:
Checked tightness of all power connections including earth
bus. Found OK.
Checked SEM earthing. Found OK.
Checked gate pulses and any loose connections etc. Found
OK. Backcharged Ch-2 and checked load fluxes on NLIB
load. Found OK.
Crowbar was conducted with all doors and backcovers
open with CRSTART=0.
Found sparking on one of the load side capacitors in Fan &
filter panel. It was seen that the discharge resistor
connected across capacitor terminals was very close to
capacitor body leading to the sparking and hence ground
fault.
Corrected position of resistor and its leads for adequate
clearance from capacitor body.
Problem solved.
Page 45 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
Door mounted printer not

printing messages.
Found one wire wrap wire carrying printer signal was cut on
SEM. Re-wrapped wire. Problem solved.
FAILURE TO START
2.
Drive not picking up speed. Runs at a speed below

minimum speed continuously.
FIELD
OVERCURRENT
3.
Drive trips on Field Overcurrent or Field loss

during start.
One load side thyristor module not firing properly.

Problem traced to loose connection on wire lug carrying
firing pulses. Re-crimped wire. Problem solved.
415V auxiliary supply for VFD was fed from DG set. The
main 11KV supply was fed from Electricity board feeder.
Since the Source Thyristor bridge and Excitation
Thyristor bridge work on the some PLL (Phase Locked
Loop), both bridges must be fed with electrical power
derived from the same power source.
Changed auxiliary power 415V source feeder. Problem
solved.
FAILURE TO
START
4.
Motor not starting in uncoupled

condition.
MISC
5.
Motor starts and heavy vibration observed in Motor

and fan.
Found that parameters in software were parameters for

coupled condition. Changed to uncoupled condition
parameters. Motor Run. OK.
Found that no firing pulses to STM3. Also source 11kV
current unbalanced.
Changed HPTK card on STM3. Problem solved.
Page 46 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
Channel tripped. Found that DMPB IMOK was not

ON. LVSH from PSFF power supply was giving high.
Also HMPG was not communicating properly with
Laptop PC.
See DMPB IMOKP15, N15 at PSFF. IMOK LED of DMPB lit

up. Channel taken into service. OK. Problem solved.
MISC
2.
Frequent tripping of VFD transformers on process

trippings.
MMI FOR VFD
3.
VFD MMI:
1. While carrying additional tests for Line drivers
mounted in C&EXE panel, R+ and T+ led are glowing
but key pressed in not getting printed on VT100
screen.
EDN
did not recommend introduction of any extra
breaker/contactor/switch giving the following explanation:
1. LCI decides to open the Load or Source breaker or
both depending on the type of fault.
2. Emergency stop conditions are rare as this represents
emergency conditions.
3. Once unit starts generating, the no. of operations of
the source breaker becomes extremely low.
4. Similar interlocks for source breaker existing in
earlier drives already supplied and in service. No
transformer failures encountered to date.
Check all cabling is as per document.
1. Check that cable connection that has been made
between the VT100 terminal and the line drivers is a
one-to-one connection, i.e. Connect the wires to the
respective as follows: 2-2, 3-3, 7-7 (and connect 7
to ground) , check that individual line drivers are OK
and then conduct Loop-Back test.
2. Check if the software is reading the MPCC card and
the Reed-relay card. For this, take out the above
cards from their respective slots inside the PC. Run
2. Link fail is coming in window during Integrated

test for MMI system.
Page 47 of 66
3. Error no. 13 is also appearing in editor mode.

4. In O&M panel, while switching on PON and TL
both LEDs glow, whereas in C&EXE panel, R+

and PON LEDs glow and when wire is looped by
shorting T+ to R+ and T- to R- then TL LED
glows.
3.
4.
the MMI.exe file. The following should happen:

a. A message will be printed out: MPCC/Reed-relay
card not in place.
b. The MMI window will not appear.
If the message dos not appear and MMI window
appears-contact BHEL-EDN.
If the above is OK, put back the 2 cards and reexecute the MMI.exe file and then perform the
Integrated test. While conducting the test, start
with conducting it only on a single C&EXE panel i.e.
switch off all the other line-drivers in the O&M panel
and the other C&EXE panels. Switch on only the linedriver in one C&EXE panel and the line driver
corresponding to this channel in the O&M panel. It is
very important that the other line-drivers be
switched off since the open connection at the Dconnectors can give rise to link failure.
After the above tests have passed, check whether
this error message still appears.
Do this test first on the O&M panel Line-driver:
While switching on this line driver, switch off &
remove the connection between the C&EXE panel line
driver & the O&M panel. i.e. do this check with this
line driver totally isolated. Remove the shorting
between T+ & R+,T- & R- if present. The TL Led
should not glow. Then short T+ & R+,T- & R-. Now the
TL Led should glow.
Perform the same test on C&EXE panel line driver and
check that the same is OK. Of problem persists, swap
the line drivers and check. If the above is not
happening, the individual Line Driver buffer may have
Page 48 of 66
got spoilt and the same needs to be replaced.

RS232 interface adaptor found defective. Replaced.
Problem solved.
MISC
4.
Current hunting problem during loading of drive

motor accompanied by voltage collapse.
MISC
5.
Loading of RPM meter and current meter.
LOAD
COMMUTATION
FAILURE
6.
Ch-2 tripped on Load Commutation Failure.
GATING SUPPLY DIP
7.
1. Ch-2 tripping on Gating Supply dip.

1. HPTK card of STM3 found defective. Card replaced.
OK.
2. After 12 hours running, irregular firing and no
LED indication on leg STM3 reported by 2. One HPTK card of STM3 & one NSFC card found
BRIDGE
DIFFERENTIAL
PRESSURE
8.
customer. Machine did not start after stopping.

3. During starting current going to 580A then
coming to zero and then going to 500Amps, then
stabilizes around 100-150 Amps.
Channel Tripping on Bridge Differential Pressure.
Phase sequence at motor exciter terminal box changed.

Problem solved.
BHEL-EDN suggested to put a resistance of 200 Ohms
across the respective IOMA TBs after disconnecting
external cables. EDN to revert back after receiving the
reading on the door module meters and the mA current
through the 200 Ohms resistance.
Problem traced to higher loading in C&I. Problem at C&I
sorted out. OK.
NSFC Load card found defective. Replaced. Problem
solved.
defective. Replaced and Machine started.
Lowered the differential pressure setting in Air Flow

monitor. Problem solved.
Page 49 of 66
SOURCE
COMMUTATION
FAILURE
9.
Channel tripped on Source Commutation failure

when running on no-load.
One no. SCR in STM2, all three SCRs in LTM1 and 2 SCRs
in LTM3 showing zero resistance. Problem cause is the
loose connection of T2 control trf. in LCI panel.
Connection tightened. Problem solved.
MISC
10.
Current hunting problem in channels.
One no. thyristor leg found defective. Replaced and

problem solved.
LOAD
COMMUTATION
FAILURE
11.
Channel tripped on Load Commutation Failure.
GATING SUPPLY DIP
12.
Problem of Gating supply dip & LED not glowing in

STM3 NTDA card.
Following tests were carried out:

1. Resistance across all the thyristors checked. Found
satisfactory.
2. Fuses in all HPTK cards checked. Found OK.
3. Self test failed in 2901 during testing of HRDA(1A),
HISA(1B) & I/O module.
Replaced HRIA (I/O 2A), HROA (I/O 2B), HISA (1B).
Fuse & 105V supply checked. Continuity of ribbon cables
from I/O module to SEM checked.
Problem persists.
Dust ingress on SEM Electronic rack cards & HPTK
thyristor pulse trf. card found to be the problem. Dust
removed by air blowing.
Problem solved. Channel taken into service.
One thyristor of STM3 found short. Replaced. Gating
supply UV problem persists.
MISC
13.
Failure of as many as six thyristor legs in one unit

and 2 thyristors in another unit.
Customer asked for an expert thorough analysis at site.

Dust level on the cards in the electronic rack & in the
thyristor power modules found high. This found to be the
possible cause of failure after thyristor failure analysis
done at BHEL-EDN.
Page 50 of 66
LOAD
COMMUTATION
FAILURE,
SOURCE
OVERCURRENT &
FIELD LOSS
MISC
14.
MISC
16.
MISC
17.
MMI FOR VFD
18.
15.
1. Load commutation failure leading to tripping Excitation

of the fan.
2. Source Overcurrent fault
leading to tripping of the fan.
3. Field loss fault on start-up and unable to start
the fan.
2x500MW plant not able to generate more than
480MW when only 3 channels of ID Fan are
available.
Motor currents in 2 channels of ID FAN A suddenly

shot-up
from
476.95A/466.8A
to
741.02A/749.22A, whereas speed varied from
462.89/488.89 to 470.95/504.64 rpm. Sudden
increase in speed and current lasted only for a few
seconds and the values came back to their original
level.
Ch-2 not taking over when ch-1 tripped due to any
fault. Ch-2 not starting individually.
MMI of ch-2 not working.
circuit thoroughly checked up. Found

terminations in C phase and the current feedback CTs
were loose. Terminations tightened and EVC Power test
conducted.
Problem solved.
Damper position increased to 85% as per BHEL-Trichy
recommendation. Problem solved.
BHEL-EDN rep. Has explained to customer that this

problem is related to reference from I&C. Not a VFD
problem.
Problem traced to failure of fuse in HROA-1B card. Same

replaced.
Ch-2 started individually and in dual mode and operation
found normal.
Changeover and taking over of either channel in case the
other trips has also been found in order.
Circuits of door mounted printer port of VFD, line drivers
(VFD), line drivers (O&M), Multiplexer, Demultiplexer,
Junction base, MPCC card checked and found in order.
Data transfer and communication from SEM suspected.
Door mounted printer of VFD replaced. Problem solved.
Page 51 of 66
FIELD LOSS
19.
Tripping of ID Fan on field loss.
Self test failed.

MISC
20.
Vibration of motor current on ID Fan (sometimes in

the order of 80A). Output voltage waveform was
found distorted.
MISC
21.
Unbalance of 50A in the motor current between the

two channels of VFD.
GROUND FAULT
22.
When ID Fan started after cleaning for annual

maintenance, Ch-1 & ch-2 tripping on Ground fault at
a motor voltage of about 800VAC (300rpm). This
was observed on trials in single channel operation or
in dual channel mode.
Excitation system thoroughly checked. Found that in ch-2

the exciter output current was less due to non-conduction
of one thyristor. NHVL card changed. Channel cleared for
service after EVC power test and calibration.
One of the zener diode in IOMA Mother Board had
failed. Replaced and self test was passed.
Output feedback CTs were found loose at the mounting.
Same tightened. NHVL card replaced.
Motor current vibrations still present.
Adjustment of speed regulator gain did not reduce the
variations. SFE of ch-1 to be replaced when shutdown
available.
Ch-2 configured as Master and ch-1 as Slave and Fan put
into service. Variations not observed.
Defective card brought to BHEL-EDN for repair.
Ch-1 current indication at the remote(UCB) was showing
less where as in the local, the current was showing
balanced because of problem with the V/I converter in
NLCB card. Same replaced.
Problem solved. Current for both channels were balanced
at the remote. Defective card brought to BHEL-EDN for
repair.
During cleaning of the panels, customer has broken
connection at the lug points of the HV cables connecting to
the load side filter ckts. Cables recrimped. Problem solved.
Page 52 of 66
LOAD
COMMUTATION
FAILURE
23.
Channel tripped on Load Commutation Failure.
Check SEM earthing as per SEM Earthing document.

Change X(reactance) compensation resistors in
NLIB(1D) i.e. change R60, R68, R76 from 180K to
100K Ohms & check the 3 flux reconstructed
waveforms on NLIB(1D). Change resistors to lower
values (upto 33K Ohms) till the reconstructed
waveforms are sinusoidal.
3. Change LIMARG.
All the above done but problem not solved.
Intermittent tripping of channel between period of 4 hrs
to 48hrs observed.
1. The load side thyristors, snubber ckt, CT ckt, gating
ckts thoroughly checked. All terminations on HPTK
and NTDA cards checked for loose connections and
soldered/tightened/replaced wherever required.
2. Self test & gate test conducted. Speed feedback
ckt found malfunctioning in NLCB /DLCB. DLCB
changed. Speed fdbk ckt calibrated.
3. Gating power supply changed from 89V to 91V.
4. Crowbar test s conducted. Current feedbacks O/C
protection ckt checked and adjusted wherever
required.
5. Channel put into service, Voltage and checked
waveforms checked and found normal.
Channel tripped again on Load Commutation Failure.
1. Firing pulses and the associated ckts of HPTK , XTFU
and the related ribbon cables checked.
2. In 2 of the HPTK cards on the load side, the
reference for detection of undervoltage of gating
supply was 1.3V DC while in others it was 1.8V DC.
Reference adjusted to 1.8V DC in all HPTK cards.
1.
2.
Page 53 of 66
Self test
and gating tests conducted and all
parameters found normal.
Problem solved.
MISC
24.
Ch-2 tripped.
SEM Power supply

Problem solved.
PSFF found OFF. PSFF replaced.
MISC
25.
Ch-2 tripped. HMPG not getting reset.
HMPG Bushog problem. HMPG replaced. Problem solved.
BRIDGE
DIFFERENTIAL
PRESSURE
26.
Ch-1 tripped on Bridge Differential Pressure.

RSFM resistance found dry soldered.
And
disconnected from Tag board resistance card.
Dry solder problem in Tag board. Soldering done properly.

Problem solved.
MISC
27.
Ch-2 Current suddenly reduced to 220A.
Berg Jumper J2 on DMPB defective. Replaced. OK.
GATING SUPPLY DIP

& LOAD
COMMUTATION
FAILURE
28.
Ch-2 tripped on gating supply dip, load commutation

failure, gating power supply loss.
HPTK card of LTM4 burnt. HPTK card replaced.

HLCB card found failed. Replaced.
Problem solved.
SOURCE PLL FAULT
29.
Ch-2 tripped on Source PLL Fault
Loose attenuation card connection in STM1.
LOAD
COMMUTATION
FAILURE
30.
Ch-2 tripped on Load Commutation failure .
Dry solder problem in NTDA card. Card replaced.

2 nos. HPTK card changed. HMPG found failed. HMPG
replaced. Problem solved.
Page 54 of 66
GATING SUPPLY
UNDERVOLTAGE
31.
Ch-1 alarm Gating supply undervoltage.
NTRF card changed & channel started and channel tripped

on Field loss problem.
Field exciter board NHVL changed. Problem solved.
Channel taken into service.
GATING SUPPLY DIP
32.
Ch-2 tripped on Gating supply dip.
NTRF card failure on 70V power supply. NTRF changed.

Problem solved.
LOAD
COMMUTATION
FAILURE
33.
Ch-2 tripped on Load Commutation Failure.
24V DC in PSFF found dipped. HROA(1B) having Motor

above minimum speed changed. Problem solved.
MISC
34.
Advised to change HROA relay card in IOMA module

which energises SWGR relay. This module will have
SWGRX relay on it.
MISC
35.
Source Breaker trips but no Alarm or Fault lamp or

any message on printer. Channel taken into service
after taking out the wires on IOMA Elmex TB
connecting to SWGR relay aux. contact.
Gating tests and Exciter Power tests not passing in
Fan-B Ch-1.
HMPG card found to be the problem. U10 IC on the HMPG

cards found of Harris make.
HMPG cards replaced and Problem solved.
Page 55 of 66
Category
Sl.no.
Problem
Solution
MISC
1.
Ch-1 had problem of not starting.
Gate pulses for Source and Load were checked and found
OK.
SEM cards were removed, cleaned and inserted in its
position.
2 lug connections were found to be loose and were
corrected.
Customer requested BHEL-EDN to supply spare lugs and
snubber mounting screws for fixing.
Trial run of Ch-1 was taken from Local control and
starting of fan was smooth. This was checked again for
repeatability and found OK.
MISC
2.
Ch-2 not taking load when paralleled with Ch-1.
Checked 12P11P and 12P11N conections on sheet 2BF. Found

OK.
Changed NLCB in Ch-2.
Paralleled OK and took load.
Cleaned original NLCB and replaced. Load taken.
Problem was due to dust on NLCB/DLCB.
Page 56 of 66
GENERAL CHECKS:
Check thyristor gate pulses in Gate test mode.
Check thyristor and snubber healthiness.
Check healthiness of load, source and DC circuit capacitors, MOVs.
Check passing of Self test .
Conduct crowbar test and get OK results. During crowbar the voltmeter on C&EXE panel should show zero volts and must be
steady at that value. Also Source phase currents must be clean without any spikes.
6. Conduct Megger test on complete power circuits from transformer upto motor.
7. Remove motor inspection cover. Check healthiness of windings w.r.t. earth, between windings.
8. Check CT /PT feedback circuits.
9. Ensure proper earthing of SEM Rack by removing paint at various points.
10. All connections including busbars, connectors, wires, crimped terminals are to be checked for tightness.
Ensure SEM Lock bar is firmly in place.
11. All electronic cards, thyristor power modules, air filters are to be blown with clean air to remove dust.
1.
2.
3.
4.
5.
Page 57 of 66
CHECKS FOR GROUND FAULT , LOAD
COMMUTATION FAILURE, LOAD PLL FAULT :
1.
Check SEM earthing OK.
2. Back charge Ch-1 from Ch-2 by tripping Ch-1 source breaker and locking it out. Then close output contactor by shorting IOMA
3.
4.
5.
6.
TB8 after removing RUN relay from IOMA plug-in base. Check the waveform of attenuated voltages at NSFC Load and Flux
waveforms at NLIB-load. Check the waveform at NTL on NLCB . Ground fault occurs if NTL > 0.55V DC.
Check capacitors on load side by meggering with 1000V or 500V megger across its terminals & also w.r.t ground. Discharge
capacitors by using the 20M, 2W resistor on the DC capacitors or any suitable rheostat. Check capacitance values of Load side
capacitors by LCR bridge.
Remove end covers on the panels and check that the earth bus is continuous from C & EXE. Panel to ACOP panel. If earth bus is
broken in between the panels, bridge this connection with 25sq.mm Cu cable. Also check the JL solder stud on XTFL-Load is
firmly soldered and the wire from this point firmly connected to the earth bus running on the rear of the panels. Ensure that
SEM ground gives proper continuity with this stud.
Hi-pot to earth cables from motor to Output Contactor /Breaker after removing both ends of cable. Hipot voltage can be
restricted to the voltage, at which ground fault occurs.
Check load connection in load side MOV and load side RC filter circuit. Check healthiness of fuses on this circuit.
Page 58 of 66
EARTHING FOR SEM RACK
S
S
CARD
SLOTS
N
N
Aluminium
Extrusion
Aluminium
Extrusion
N
CARDS
SLOTS
Z
GND
SEM FRONT
VIEW
Y
Cu. Braid
Remove only one Nut/Bolt at a time. Check Spring/Plate washer present

1.Remove paint on both sides of Nut/Bolts marked N.
2.Remove paint on Nut side of S and lacquer on PCB board track(if lacquered) on Head side of S.
Test with mulimeter if in doubt. Generally this mother board will not be lacquered.
3.GND is tinned copper ground bus in C & Exe Panel (Regulation panel in high current rectifier) .
Make connection Y at site(if not already present) with 25-sq. mm. Aluminium or copper cable with lugs on
both sides. Check if Z cable copper/PVC already exists. If not make connection Z. Cable Z is 16 sq.mm.
Copper braid/PVC cable, connection may already done at BHEL/EDN in Panel.
C
C C
B
B
B
A
Front
Back
Front
Back
CCC
Page 59 of 66
SEM SIDE
VIEW
SEM SIDE
VIEW
SEM BACK
COVER
4.Scrape paint on both sides on plate of nut/bolt A and B. Exercise caution as the motherboard
pins may get bent accidentally when doing this.
5 Scrape paint on back cover on head side of screwsC.
6.The objective of these points 1 to 5 is to ensure that PCB(mother board) ground track mentioned in
point 2 is perfectly connected to tinned copper earth bus in C & Exe, panel(Regulation
Panel in high current rectifier).
7. All Nut Bolts to have spring and plate washers. Only plated washers to be in contact with paint
scraped surfaces only. Replace if biting/toothed washers are present. Replace one at a time.
8. Check that the PCB motherboard pins have not been bent.
9. Re-check all points 1 to 8 above have been done. Check for continuity between S and ground
copper flat.
Page 60 of 66
10.Install SEM back cover carefully.
Details of Fault and Alarm Messages in the LCI Drive
FAULT MESSAGES: 1. LOSS OF COOLING FAN : Please refer ladder logic sheet no 1FK
LOGIC = NOT (NBLF)
2. SOURCE LOW LINE
Please refer ladder logic sheet no 1FK
LOGIC = SUVFLT
3. FIELD LOSS
LOGIC = FLD_LOSS_FLT
4. SOURCE BACKUP OVERCURRENT FAULT
LOGIC = SRC_SUPP
INPUT = PORT 900C BIT 2
5.LOAD BACKUP OVERCURRENT FAULT
LOGIC = LD_SUPP
6.SOURCE OVERVOLTAGE FAULT
LOGIC = SRC_OV
7.GATING SUPPLY UNDERVOLTAGE FAULT
LOGIC = GSUV
8.P105 SUPPLY UNDERVOLTAGE
LOGIC = NOT (NPSUV)
9.LOAD OVERVOLTAGE FAULT
LOGIC = LD_OV
10. OVERSPEED
Page 61 of 66

LOGIC = OS
11.GROUND FAULT
LOGIC = GNDF
INPUT = PORT 8010 BIT 0
12. FAN COMPARTMENT DOOR OPEN
LOGIC = NOT(BFNDR)
13 .BRIDGE DIFF PRESSURE
LOGIC = BFDIFSW
14. FIELD CURRENT IMBALANCE: - FLTWD BIT 0
Field current imbalance check is for AC exciter only.
If a field current imbalance is detected by the NSFE card and persists for more than 0.5 sec then a fault is declared.
15. FIELD OVERCURRENT :-
FLTWD BIT 1
If field current exceeds FCLIM for the no of attempts given by FCFTIME then the fault is declared. A penalty
function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows recovery from
non repetitive faults.
16. SHORTED MOTOR WINDING :-
FLTWD BIT 2
During a start up from standstill, when the motor speed has exceeded the value set by TRSPD and the Load PLL is
locked. Then the peak flux reading taken at every 60 deg electrical from the machine (obtained from integration of load
voltages from NLIB Load card) exceeds its previous value set by SWINDTOL(approx 10%). Then a Shorted Motor
Winding Fault is declared. The shorted phase can be obtained from the variable Shorted winding in ENGG mode.
17.SOURCE OVERCURRENT: -
FLTWD BIT 3
If source current exceeds LKLIMS for the no of attempts set by LKOCTIM then the fault is declared. A penalty
function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows recovery from
non-repetitive faults.
18.LOAD OVERCURRENT : -
FLTWD BIT 4
If source current exceeds the limit set by LKLIML for the no of attempts given by LKOCTIM then the fault is
declared. A penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This
allows recovery from non-repetitive faults.
19. SOURCE COMMUTATION FAILURE : -
FLTWD BIT 5
Page 62 of 66
During normal running of the drive, if the difference between the source and load current (read in synchronous with load
frequency cycle) exceeds the limit set by LKLIMD for the no of times set by STHRUTIM then a fault is declared. A
penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This allows recovery
from non-repetitive faults.
20.LOAD COMMUTATION FAILURE :-
FLTWD BIT 6
During normal running of the drive, if the difference between the source and load current (read in synchronous with
Source frequency cycle) exceeds the limit set by LKLIMD for the no of times set by STHRUTIM then a fault is
declared. A penalty function is implemented such that 6 good firings following a failure will cancel a fault firing. This
allows recovery from non-repetitive faults.
21.SOURCE PLL FAULT:FLTWD BIT 8
The Source voltages are attenuated thro attenuator boards , conditioned in the firing card NSFC and then integrated in the
NLIB boards. These integrated signals are used for synchronization to fire the source bridge thyristors. Software/Hardware
Phase Locked Loop (PLL) does the synchronization.
If this synchronization is lost and remains as such for a period set by SPLLTIM then a fault is declared.
22.LOAD PLL FAULT:-
FLTWD BIT 9
The Load voltages are attenuated thro attenuator boards , conditioned in the firing card NSFC and then integrated in the
NLIB boards. These integrated signals are used for synchronization to fire the source bridge thyristors. Software/Hardware
Phase Locked Loop (PLL) does the synchronization.
If this synchronization is lost and remains as such for a period set by LPLLTIM then a fault is declared.
26. FIELD OVERVOLTAGE FAULT:-
FLTWD BIT 10
In Case The Exciter is DC. The field DC voltage is obtained through attenuators and the NSFF circuit. The NSFF circuit
has a over voltage detector (OOV) with fixed set point. When the field DC Voltage exceeds the limit the OOV sends a
signal and the Fault is annunciated.
23. STACK FAULT :-
FLTWD BIT 11
The processor because of extraneous reasons may run away and may do unintended tasks very frequently In such cases the
STACK builds up. It is necessary to declare a fault in such cases.
24. FAILURE TO START :-
FLTWD BIT 12
During start the speed regulator is open looped and the current command is fixed. The current command is ramped from
minimum current to a value required until motion is detected. Current reference ramps until the drive position has changed
120 electrical degrees to maximum value of CUR_REG_REG_STRT_E. Motion is detected by looking for a two cell
pair change in the load side firings. If motion is not detected even after 5 secs then a fault is declared.
25. EEPROM TRANSFER FAILURE:- FLTWD BIT 13
The tunes up constants are stored in the EPROM of HMPG the Processor Board, during running of the drive these
constants are loaded in to the EEPROM for operation. If there is a problem in this operation during initialization then this
fault is declared.
Page 63 of 66
26. MOTOR ISOLATOR NOT CLOSED

LOGIC = MISOL_STATUS_FLT
27. TACH FEEDBACK OR HTCA PROBLEM
This fault is only in Drives using Tacho feedback with HTCA card. When the HTCA card or the tacho malfunctions then
this fault is declared.
28.SOURCE MASTER/SLAVE CURRENT UNBALANCE
29. SLAVE HARDWARE OVERCURRENT
The above two faults are declared in case of series 12 Pulse.
ALARM MESSAGES: 1.MOTOR OVERTEMPERATURE

LOGIC = NOT(MOVTEMP)
2.TRANSFORMER ALARM
LOGIC = NOT(TTRBLE)
3.LINK REACTOR OVERTEMPERATURE
LOGIC = NOT(LTRBLE)
4.PCR OVERTEMPERATURE
LOGIC = NOT(PCROT)
5.USER DEFINED ALARM
LOGIC = NOT(USERA)
6.COOLING BLOWER LOSS
LOGIC = NOT(NBLA)
7.BRIDGE FILTER FUSE BLOWN
LOGIC = NOT(BFILF)
8.RUN PERM OR START PERM MISSING
Page 64 of 66
LOGIC = RUNPM, STRTPM

9.GATING SUPPLY DIP
Please refer ladder logic sheet no 1FE
LOGIC = GSUV_ALM
10.FIELD EXCITER VOLTAGE LOSS:-
ALA BIT 0
01H
During start when the field is energized and the field voltage is built and present but its value is lower than required then
this alarm is declared.
11.ROTOR POSITION START ALARM
ALA BIT 1
02H
During run If the motor fails to start within 1 sec from start, then this alarm is declared. The rotor position is determined
from relative flux amplitudes.
12.I/O ADDRESSING PROBLEM
ALA BIT 2
04H
The Processor is sending and receiving data from various boards within the SEM Rack. If the response of the Board
exceeds a given time then this alarm is activated.
13.MICROPROCESSOR ALARM
ALA BIT 3,4, 5,6,7.8.9.10
The Processor switches tasks by means of interrupts. This alarm is activated when the processor receives unintended
interrupts.
14.SOURCE UNDERVOLTS
ALA BIT 12
02H
If the Source breaker is energized, and the source NLIB indicates a Source under voltage condition then this alarm is
declared.
15.FIELD THERMAL OVERLOAD
ALA BIT 13
02H
The field thermal model when enabled, checks the field current with time and declares an alarm if the current has
exceeded its time limit.
16.LOSS OF SPEED REFERENCE
ALA BIT 14
02H
The drive remote reference will have value between 4 to 20 mA. If the reference falls below a value of 4 mA then this
alarm is activated.
17.LOSS OF SPEED CONTROL
During the drive operation in Self-commutation mode, if the difference between the Speed reference and the Speed
feedback to the Speed regulator exceeds the set parameter SRETOL for a time settable by SQTMR5 then an alarm is
declared.
18.FIELD GROUND ALARM
DC Exciter only.
A ground fault detector circuit is part of the NSFF Card on the SEM rack. This circuit detects grounds, which may occur at
the output of the Excitation module. This alarm is annunciated whenever this circuit is activated.
Page 65 of 66
19. TACH FEEDBACK/HTCA PROBLEM

This Alarm is only in Drives using Tacho-feedback with HTCA card. When the HTCA card or the tacho malfunctions then
this alarm is declared.
STATUS MESSAGES: To accommodate drives which run multiple motors of different ratings a tune up variable MOTSEL is available.
(a set of drive constants for every motor is stored separately ).
1. MOTOR TABLE 0 SELECTED

This Message is annunciated when the first motor is selected.
2. MOTOR TABLE 1 SELECTED

This Message is annunciated when the Second motor is selected.
Page 66 of 66

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LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

441/COMPEND/LCI REV.02 DTD.10/03/05

When referring to a solution for a problem, the particular category of

REVISION HISTORY SHEET

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

UPDATED UPTO 09.06.04

UPDATED UPTO 10.03.05

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

Small crack observed in base of 1 no. CT in Load

The primary connections on the CTs are such that load of

Customer opined that failure may be due to thermal

Gaskets on doors have gaps at many places resulting

MMI FOR VFD

MMI remains out of service due to Communication

Defective line driver replaced by a new one.

MMI s/w hanging problem.

Corrected version of software installed. Became OK.

6A Ch-2 tripped on electrical fault.

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

Motor foundation vibration found higher compared

6A Ch-2 trips with message Shorted motor

Frequent failure of NPPB card. Heat dissipated by

UPS supply tripping on trf. inrush current.

6A Ch-1 tripped , Ch-2 not responding to speed

halts at No.23 even though channel is

PLLTOL, LIMARG. No change observed.

Proposal for installing Anti-vibration pads on blower

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

taken into service. SRCLSC found to be 0.7 instead

Customer proposed to replace all cooling tubes (1980

MMI FOR VFD

MMI getting hung frequently. Line drivers OK.

If power goes OFF, sometimes MMI PC hangs as told by

ID Fan 6A taking high current (400A), current of

Higher current is due to higher LMARG and LIMARG as

LOAD PLL FAULT

6C1 tripping on Load PLL fault. Gate test OK. Self

HRDA, HROA, NLCB replaced. NLIB Source & Load

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

LOAD PLL FAULT

flickers. Flickering stops after sometime and

Suggested to lower the values of MTRFMIN and FLUXS in

6C1- Trips on Load PLL Fault on load.

Increased LMARG from 20 to 25.

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

Channel trips on Load Commutation failure

1. HPTF card in LTM3 found faulty when doing crowbar

2. BHEL has suggested to maintain control room

1 no. motor burnt out.

Firing pulse LED on one card in source bridge

HTPF card on source side changed and problem solved.

Ground fault in both channels of 4B.

In one channel one load side capacitor was faulty. In the

LCI CHANNELS FOR VFD - COMPENDIUM OF FAULTS

Chattering of MAMS relay in slave channel.

HMPGDMPB in 4B1 giving Bushog after few hours

VFD Ground Fault problem in slave channel.

Master and Slave both start and run individually. At

Ch-1 tripped but no annunciation on the door