Rectifier O and M Manual - Nuberg - Fluoder

Users Manual
RECTIFIER
Maintenance and Troubleshooting
ABB INDIA Ltd

Dept. DM PC
NEELAMANGAL/BANGALORE
Title
Pre.
Appr.
Plant Description
SMD
DM-PC
CVP DM-PC
Project
NUBERG_FLUODER, South America
Document identity
3AYN122174-MAD
ABB INDIA Ltd
Lang.
Rev. ind.
Contents
Page
1
Safety Instructions
1.1
1.2
1.3
1.4
1.5
Safety Instruction for Troubleshooting

Safety Instruction for Functional Checks
Safety Instruction for Converter Inspection
Safety instruction for Inspection, Maintenance and Repair
Safety Instruction for Replacement of items
Alarms and Trips Handling
5
6
7
7
9
10
Page
No. of
pages
60
Safety Instructions
Safety Instructions for Part 4 ( Maintenance & Troubleshooting)
1. To avoid risk of electrical shock or fire, the safety instructions

and guidelines in this manual must be followed.
Caution
2. When working on the equipment make sure there are always

at least 2 people present. Never work alone!
3. Make sure that you wear insulated gloves while performing
any work on the rectifier.
1. The Enclosure door must remain closed at all times during
operation to ensure safety of personnel. Only authorized
personnel should be allowed to open & service the unit.
Notice
2. Use of the equipment in a manner not specified by the
manufacturer could impair the protection provided within.
High temperature!
Danger of burning!
Caution
Danger!
High Voltage!
Always consider high temperature at bus bars.
Before you start with any rectifier maintenance task, the following
are the minimum safety measures should be applied (verify with
the responsible person for operation the complete set of
measures to be taken before starting to work):
1. Open the AC circuit breaker feeding the Rectifier Group and
the DC isolators of the DC bus bars. Lock there switches.
2. Check that there is no voltage at in- coming and out-going DC
bus bars.
3. Close the grounding switch of the feeder connected to the
rectifier transformer or ground the transformer primary side
with a portable grounding set.
4. Connect the in- coming and out-going DC bus bars to ground
with a grounding set according the grounding instructions.
5. Never remove safety signs.
6 Coordinate the work with the responsible person for operation
for final work permit and safety measures.
1.1
Safety Instructions for Trouble Shooting
Never operate the Rectifier Equipment with the rectifier enclosure

doors open.
Danger!
Danger!
After a trip of one unit, the remaining units could possibly remain
energized. This means that the load side of the DC Isolators could
also be energized. Before doing any maintenance on the DC
Isolators, ensure that the other units have been switched off! Check
if there is no voltage on any of the DC busbars concerned.
High Voltage!
There may be an external auxiliary voltage present even if you

disconnect the system from the main power supply. Check this!
Danger!
Auxiliary
Voltage!
Static discharge can damage electronic parts
Caution
Always wear the anti-static protection strap before you handle

any PCB's. The anti-static protection strap is part of the delivery
and can be found at the PCB rack door.
Do not enter while energised.
Caution
Electric
Shocks
Refer to users manual & Circuit diagrams before starting

with the service.
Part of this equipment may be energised or controlled
from multiple sources.
Burning
Hazard
Notice
1.2
Always check the description of the Alarms and Trips in the

Users Manual Part 4 Maintenance and Trouble Shooting.
Safety Instructions for Functional checks
Notice
Every printed circuit board (PCB) has a fault dedection and

indication system (red LED on: fault / green LED on: working
properly (optional). set to REMOTE control.
High Voltage! Danger!

Stop!
!
Follow all safety instructions before you start any functional

check.
Notice
For remote control, the Mode Control switch on the local control
panel must be set to REMOTE (control).
Notice
Do the inspection work that is mentioned in Part 4, Maintenance

and Trouble Shooting, monthly, if possible.
1.3
Remark for Converter Inspection
Notice
1.4
Greasy dust, metallic particles and humidity/moisture could

damage the converter! Protect the equipment from adverse
environmental conditions.
Safety Instructions for Inspection, Maintenance and Repair

Before starting commissioning and maintenance work, the unit has
to be grounded according to the following description:
Danger!
High
Voltage!
1.
2.
3.
4.
5.
6.
Open main circuit breaker

Open DC Isolators
Lock the circuit breaker
Close grounding switch
Measure AC and DC Voltage at the Rectifier (must be zero)
Connect the grounding equipment to the transformer
secondary bushings
All national, local and proprietary safety instructions have to

be followed!
Temperature!
Danger of burning!
Caution
Consider high temperature at bus bars, reactors and heaters.
High!
Static discharge can damage electronic parts

Caution
Always wear the anti-static protection strap before you touch any
PCB's. The anti-static protection strap is part of the delivery and
can be found at the PCB rack door.
Caution
Danger!
You could be injured if you try to perform trouble shooting work

on the Rectifier Equipment without sufficient knowledge. Be sure
you have the knowledge, experience, and the proper
replacement parts and tools before you attempt any trouble
shooting
After a trip of one unit, the remaining units could possibly remain
energized. This means that the load side of the DC Isolators
could also be energized. Check if there is no voltage on any of
the DC busbars concerned!
High Voltage!
Notice
If you try to perform trouble shooting work on the Rectifier

Equipment without sufficient knowledge, the converter unit could
be damaged. Be sure you have sufficient knowledge, experience,
and the proper replacement parts and tools before you attempt
any trouble shooting
Notice
Do not install any replacement part in the Rectifier Equipment

unless you first check with the recommended spare parts list (see
Part 4, Maintenance and Trouble Shooting) or with ABB for
correctness. Some can damage the converter. Your warranty
would not cover that. Some may disturbe proper operation.
1.5 Safety Instructions for Replacement of Items
Danger!
There may be auxiliary voltage present even if you disconnect

the system from the main power supply.
Auxiliary
Voltage!
High temperature!
Danger of burning!
Caution
Always consider high temperature at bus bars, reactors and

heaters.
Use centering pin ONLY for centering of fuse and spring!
Caution
If you use centering pin for the semiconductor you could cause
severe damage to the semiconductor.
Caution
You could be injured if you try to perform trouble shooting work

on the Rectifier Equipment without sufficient knowledge. Be sure
you have the knowledge, experience, proper replacement parts
and tools before you attempt any trouble shooting.
Check for correct polarity when mounting a new semiconductor.
Notice
Notice
Caution
Do not add any replacement part to the Rectifier Equipment

unless you check with the recommended spare parts list (see
Part 4, Maintenance and Trouble Shooting) or with ABB
Switzerland Ltd. Some can damage the converter. Your warranty
would not cover that. Some may disturbs proper operation.
When a thyristor has to be replaced, make sure that the new one
is of the same type or a proofed replacement type. Thus it is
mandatory that orders for spare thyristors are sent to ABB
Switzerland Ltd.
Alarms and Trips Handling
A_Diw Conductivity_High
Message:
Fault:
The conductivity of the de-ionized cooling water, measured with

the conductivity meter in the cooling unit has risen above the
limit of 5 S/cm.
The measuring instrument is defective
The conductivity sensor is faulty
Possible Cause:
Recently filled distilled water has not been circulating through

the de-ionizer long enough
Too little flow through de-ionizer
The resin of the de-ionizer is exhausted
Action:
Increase flow through de-ionizer and observe the conductivity

for a few hours
If the conductivity remains high, replace the resin
The cartridge has to be replaced
Effect:
High conductivity of cooling water can cause leakage currents in

the rectifier and destroy the equipment
Remarks:
Use only resin recommended by ABB or approved equal.

Refer to manual of cooling unit and cooling flow diagram.
Refer to DWG 3AYN128156-CAC

SEN005109 Rev 2
A_Rect_DIW_Level_Low
Message:
Fault:
De-ionized water level in the expansion vessel dropped below

the 1st indicated low limit
Possible Cause:
Evaporation due to high temperature

Leakage in the DIW cooling circuit
Action:
Check cooling circuit

Refill with deionized water (possible during operation)
Effect:
Overheating of rectifier and pump dry running
Remarks:
Due to evaporation, the DIW cooling circuit has to be refilled

approximately every six to twelve months. We recommend keeping
some pure water nearby.
Refer to maintenance manual
Filling with water has to be done slowly enough in order to maintain

conductivity low.
A_Rect_DIW_Cooling_Pump_ Flow_Failure
Message:
Fault:
The flow of the deionized water in the closed loop rectifier

cooling circuit has dropped below the allowed limit of 422.4
l/min..
Possible Cause:
Action:
Check if cooling circuit is in operation

Check if valves are open
Check motor starters for DIW pumps in cooling control panel.
Effect:
Overheating of thyristors
Damage of pump when running dry
Remarks:
One of the two pumps is in standby. If the running pump fails, the
system will automatically changeover to the pump in standby, if the
cooling is Remote controlled.
Air in the cooling circuit

Heavy leak in the cooling circuit
Valves closed
Failure in a water pump, changeover to standby pump
Motor starter for pump has tripped

SEN005109 Rev 2
Message:
A_Rect_DIW_Inlet_Temperature_High/
A_Rect_Diw_Output_Temperature_ High
Fault:
The cooling water temperature in the outlet pipe increased

above 40 C / inlet teperature increased above 45 C
Possible Cause:
Re-cooling not in operation

Valves closed
Dirty heat exchanger
Failure in cooling control circuit
Low DIW flow
Malfunction of thermostat
Action:
Check if re-cooling circuit is in operation

Check if DIW fan motors safety switch and MCB is closed
Check thermostat and setting
Check PT100 in the DIW circuit. Check its wiring and calibration
Effect:
Overheating of semi conductors
Remarks:

SEN005109 Rev 2
Message:
A_Raw_Water_Inlet_ Temperature_High_Stage1/
A_Raw_Water_Outlet_ Temperature_High_Stage1
Fault:
The cooling Raw water temperature in the Inlet pipe increased

above 35 C / Outlet temperature increased above 40 C
Possible Cause:
Raw water-cooling not in operation

Valves closed
Low Raw water low
Action:
Check if raw water-cooling circuit is in operation

Check PT100 in the Raw water cooling circuit. Check its wiring
and calibration
Effect:
Increase in Raw water temprature ,henceforth increase in DIW

temprature
Remarks:

SEN005109 Rev 2
Message:
A_Raw_Water_Inlet_ Temperature_High_Stage2/
A_Raw_Water_Outlet_ Temperature_High_Stage2
Fault:
The cooling Raw water temperature in the Inlet pipe increased

above 40 C / Outlet teperature increased above 45 C
Possible Cause:
Raw water-cooling not in operation

Valves closed
Low Raw water low
Action:
Check if raw water-cooling circuit is in operation

Check PT100 in the Raw water cooling circuit. Check its wiring
and calibration
Effect:
Increase in Raw water temprature ,henceforth Overheating of

semi conductors
Remarks:

SEN005109 Rev 2
A_Rect_Raw_Water_Flow_Fail
Message:
Fault:
The flow of the Raw water in the closed loop rectifier cooling
circuit has dropped below the allowed limit of 422.4 l/min..
Possible Cause:
Action:
Check if raw water cooling circuit is in operation

Increse flow in raw water cooling circuit
Effect:
Overheating of rectifier cooling circuit,henceforth overheating of

thyristors
Remarks:

SEN005109 Rev 2
Air in the Raw water cooling circuit

Heavy leak in the Raw water cooling circuit
Very low flow from Raw water cooling circuit
Valves closed
Failure in a raw water pump
Message:
A_Rect_Diw_ Cooling_Pump1_ Trip/

A_Rect_Diw_ Cooling_Pump2_ Trip
Fault:
DIW pump1/pump2 starter has tripped
Possible Cause:
Overload at the DIW Pump

Damage in the motor (bearing, winding)
Short-circuit at the cable between the motor starter and the
motor.
Action:
Check motor starter (K1,K2) in Cooling System panel

Check DIW Pump and Power supply voltage
Check the motor and cables.
Effect:
Remarks:

SEN005109 Rev 1
A_Rect_Cooling_System_Control_Supply_Fail
Message:
Fault:
Cooling system Panel 110VDC MCB has tripped
Possible Cause:
Overload at the DIW Pump

MCB switched off manually
Failure of the monitoring relay
Short-circuit at the cable between the motor starter and the
motor.
Shortcircuit in the control circuit
Action:
Check all MCBs , Motors and FANs
Effect:
Other alarms may appear
Remarks:
If an MCB is switched off for safety reasons (maintenance) it has to

be marked for explanation with tape, to prevent somebody else
switching it on.

SEN005109 Rev 2
A_ Rectifier_Cooling_Fan_Fail
Message:
Fault:
DIW FAN Status Relay(C3) not oprated.
Possible Cause:
Fan On command not given from remote or local control.

Damage in the FAN (bearing, winding)
Short-circuit at the cable between the motor starter and the FAN
Action:
Check Fan on command from pec.

motor starter in Cooling System panel fail.
Check the Fans and cables.
Effect:
DIW FAN ready staus is not OK.Diw Fan On command can not
be given.
Remarks:
Overload at the FAN

Damage in the FAN (bearing, winding)
Short-circuit at the cable between the motor starter and the FAN

SEN005109 Rev 2
A_RectTx_Bucholz
Message:
Fault:
Gas concentration in the Buchholz relay located on the top of

the transformer
Possible Cause:
Short circuit between windings due to weak insulation,

overvoltage, and external short circuit.
Bad connection inside the transformer, hot spot, mechanical
failure, short circuit in the transformer core
Action:
Release the gas from the relay, observe and record gas
development during the following days and weeks.
Oil and gas analysis can give useful hints about nature and
location of failure
Oil sampling and testing must be carried out by transformer
specialists who can also give advice about further steps to be
taken
Eventually cross check with the gas concentration value given
by the online system
Effect:
Destruction of transformer and environment
Remarks:
This alarm might appear after months or years of operation. As

long as it is not appearing periodically within weeks (after releasing
the gas) the behavior is normal. Otherwise consult transformer
specialist and do oil and gas analysis.
Refer to Transformer Manual
620013/24/05
A_RectTx_Oil_Temperature_High
Message:
Fault:
Increase of oil temperature above 90C
Possible Cause:
Loss of transformer cooling

Transformer radiators / heat exchanger dirty, because of sludge
and sediments present in the cooling water
Loss of flow in cooling circuits due to closed valves
Abnormally high ambient temperature coupled with high load on
the rectifier unit
Oil pump not in operation
Failure in PT100, transducer or wiring
Failure of the temperature supervision thermostat
Action:

Clean, check radiators / heat exchanger
Reduce load on rectifier (if possible) to maintain constant
temperature and to avoid a trip of the system
Check PT100 located in the transformer-cooling compartment.
Check wiring and transducer
Check motor starter and control circuit
Effect:
Trip of the system after raising the temperature to trip level.

Damage of insulating material on the windings
Remarks:
Refer to Transformer Manual for additional hints

620013/24/05
Message:
A_RectTx_Sys1_Winding_Temperature_High/
A_RectTx_Sys2_Winding_Temperature_High
Fault:
Increase of star or delta bridge winding temperature above the

limit of 90 deg C
Possible Cause:

Transformer radiators / heat exchanger dirty
the rectifier unit
Failure in the temperature control
Action:
Compare oil and winding temperature for future investigations

Clean, check radiators / heat exchanger
Reduce load on rectifier (if possible) to maintain constant
temperature and to avoid a trip of the system
Check motor starter and cooling control circuit
Effect:
Trip of the system after raise of the temperature to trip level

Remarks:

620013/24/05
A_RectTx_Oil_Level_Low
Message:
Fault:
Oil level in the transformer main tank expansion tank dropped

below the minimum level
Possible Cause:
Low oil temperature due to light or no load condition and low

ambient temperature
Oil leak in transformer main tank
Malfunction of the indicator
Loose wiring or terminals
Action:
Check oil temperature and level

Check for any oil leak at the rectifier transformer main tank
Check indicator, wiring and terminals
Effect:
If oil level drops further the transformer could be destroyed

because of a weak insulation of the windings and insufficient
cooling.
Remarks:
When filling or draining oil, the level should correspond to the oil
temperature. Higher level for high temperature and lower level for
low temperature

620013/24/05
Message:
A_ RectTx_Oil_ Pump1_Flow_Failure /
A_RectTx_Oil_Pump2_Flow_ Failure
Fault:
The oil flow in the closed loop transformer cooling circuit has
dropped below 700lpm on one of the heat exchanger bank.
Possible Cause:

Valves closed
Failure of one or two oil pump,
MCB for pump has tripped
Main incomer in has tripped
Action:
Check cooling circuit for oil

Check valve positions
Check MCBs in the transformer auxiliary panel.
Check pump; Exchange faulty pump or repair it (winding,
bearing)
Effect:
Overheating of transformer
Remarks:

620013/24/05
Message:
A_RectTX_Cooler1_Leakage/
A_RectTX_Cooler2_Leakage
Fault:
Transformer differential pressure acted
Possible Cause:
Raw water input pressure into heat exchanger greater

than oil pressure
Closed valve copper tubing between DPS measuring

instrument and the point tapped
Oil pump switched off condition
Control wiring faulty (Interconnection RCP &

Transformer marshalling box)
Ensure raw water pressure lesser than oil pressure
Check associated valve positions, copper tube

connections
Check appropriate pump for the heat exchanger and

raw water inlet connected
Action:
Check control wiring, and terminal block tightness

Effect:
Remarks:
Message:
Fault:
Possible Cause:
Action:
Effect:
Refer DWG:
3AYN122174-CAC
620013/24/05
A_RectTx_Cooler1_Plant_Water_Flow/
A_RectTx_Cooler2_Plant_Water_Flow
Failure of raw water flow from pump 1 & pump2 to cool the DM water
in the cooling circuit
Valves in the raw water supply is closed
Failure of raw water supply
Check whether the valves in raw water line are properly open
Recover the raw water supply
1. Raw water failure in the cooling system will result in temperature

rise of DM water. If the fault is not cleared, DM water temp rises above
trip level resulting in the trip of the system
Remarks:
Refer DWG: 3AYN122174-CAC

620013/24/05
A_Earthfault_In_Celline
Message:
Fault:
The earth fault monitoring cubicle has a ground fault higher

than 2.5A.
Possible Cause:
Action:
Check short circuit possibility

Check wiring and load and switch it once again .
Inspect visually the Rectifier cubicle in order to find a
insulation fault
Short circuit of the cable leading to the rectifier

Short circuit of the power supply of the relay
The ground fault relay is out of order
The Rectfier cubicle has a leakage to ground
Shorcircuit in the Earthfault Monitoring Unit
No critical effect is to be awaited. Nevertheless the

maintenance has to fix the fault because a major insulation
fault could occur without detection
Effect:
Remarks:

3AYN122174-CAG
A_Rect_ Temperature_High
Message:
Fault:
The temperature in the rectifier cubicle is high
Possible Cause:
Re-cooling fans are not in operation

Failure in cubicle cooling control circuit
Fans motors safety switch off
Action:
Effect:
Overheating of semi conductors
Remarks:

3AYN122174-CAB

Check if fan motors safety switch and MCB is closed
Check thermostats and setting
Message:
A_Rect_ Sys1_Fuse Monitoring Card_Failure/

A_Rect_ Sys2_Fuse Monitoring Card_Failure
Fault:
Failure of Thyristor fuse monitoring Unit
Possible Cause:
Internal failure of fuse monitoring board D141 /-D142 (+A120)
Action:
Check the fuse monitoring boards.

Check the control cable.
Effect:
Remarks:
All spares in the stock are modified and t ested. However, a visual
check for proper settings has to be done.
As long as this alarm is present, no Thyristor fuse failure could

be detected. Running the unit in these conditions is particularly
risky for the semi-conductors.

3AYN122174-CAB
Message:
A_ Rect_Sys1_Heatsink Temperature High /

A_ Rect_Sys2_Heatsink Temperature High
Fault:
Temperature of one or several Heat-sink Thermostats has

increased above 70C
Possible Cause:
Loss of cooling due to closed valves

Re-cooling circuit is not in operation
Failure of thermostats or loose connections (open loop)
Action:
Check cooling unit and rectifier heat exchanger for dirt and open
valves
Check wiring for open loops. Wiring loops have to be closed.
Effect:
Over-temperature could destroy semiconductor
Remarks:
For wiring and location of thermostats

Refer to DWG
Message:
Fault:
3AYN122174-CAC
3AYN122174-CAB
A_ Rect_Sys1_First Fuse_Failure/
A_ Rect_Sys2_First Fuse_Failure
In one or several legs of the rectifier one Thyristor fuse has
blown
A multiple Thyristor fuse failure can happen for various reasons.
In most cases other signals will appear and are to be taken into
consideration to locate the source of the fault.
Possible Cause:
Loss of cooling and the temperature supervision has failed air in the cooling system, rupture of a water connection, loss of
re-cooling circuit, valve in the cooling circuit closed
Loss of over-voltage protection. (The over-voltage protection is
designed to protect the rectifier against transient over-voltages
and surges)
DC overload caused by malfunction of regulation and protection.
In this case it is likely that the fuses have interrupted the current
and the Thyristors are still good.
Action:
Locate the blown fuse by means of the fuse indicator micro

switches (red flag will be out) and the indications of the leg given
by the board D141/142
Check cooling
Check over-voltage protection (connections, fuses, Thyristors,
capacitors, resistors)
Check regulation and over-current protection system in particular
reference and actual current value
Check the Thyristor
Check wiring and fuse supervision card.
Effect:
Remarks:
The system is designed for n-1 Thyristors in operation. If more than

one Thyristor is out of service, the remaining Thyristors have to
carry the current. They will be overloaded leading to a shorter life of
the device.
Always replace Thyristor and fuse as a set .
Use special tool kit which is available on site to replace the
Thyristor and the fuse.
Record location and component number of the failed Thyristor and
fuse for further inquiries
Refer to DWG
3AYN122174-CAC
3AYN122174-CAB
Message:
A_Sys1_AC DC_Fuse_Fail_Sync_Supply
Fault:
One of the AC over voltage protection fuse has blown

One of the Hole storage fuses on rectifier +G10/+G20 has blown
One of the fuses in the DC circuit of the over-voltage protection

has blown
Possible Cause:
Short circuit in the capacitor of the OVP circuit

Short circuit in the hole storage protection circuit
Action:
Refer to the fuse monitoring board in order to know which

rectifier G10/G20 is affected.
Check fuse indicators at the rectifier
Check over-voltage protection devices for faulty components
Replace fuse and faulty components
Effect:
Some of the semi conductors could not be protected against

transient over voltage peaks.
The Breaker cannot be closed since AC Over Voltage Protection
are not healthy
The OVP switched off by fuses will no longer protect the
Thyristor against over-voltages and surges
Destruction of Thyristor
Remarks:
The over-voltage protection devices are located on top of the

rectifiers. There is one over-voltage protection device for each
rectifier system.
Refer DWG:
Message:
Fault:
3AYN122174-CAC
3AYN122174-CAB
A_Rect_Sys1_Switch On Protection_Fail_to_Close/
A_ Rect_Sys2_Switch On Protection_Fail_to_Close
Switch on protection Failed.
Possible Cause:
K1,K2 contactor failed

Auxiliary contact block of K1, K2 not operating.
Interrogation supply failed
Action:
Check contactor K1,K2.

Check Auxiliary contact block of K1, K2.
Check interrogation supply
Effect:
Rectifier System trip after 6 second time delay.
Remarks:
Refer DWG: 3AYN122174-CAC
A_Rect_Door_Open
Message:
Fault:
Rectifier cubicle door is open
Possible Cause:
Action:
Effect:
Danger to personal
Remarks:
Entry to the rectifier compartment for maintenance works was

attempted while unit was switched on.
Close rectifier compartment doors

Close the DC isolators
Check that cubicle fans are running again
Instruct personnel on proper operation of equipment.
Do not enter to rectifier compartment while the unit is in

operation!
Ensure that the rectifier compartment is empty before re-energizing
the transformer.
Refer to DWG
3AYN122174-CAC
3AYN122174-CAB
A_FOCS_General_Alarm
Message:
Fiber optic current sensor unit alarm.
PT100 temperature LOW or HIGH alarm.

PT100 measurement failure
IFSM temperature LOW or HIGH alarm
IFSM error
Fault:
Possible Cause:
Action:
Check sensor electronics PPD 115 controller for following:

One red LED to indicate device errors.
Three green LEDs to indicate normal operation conditions.
Two yellow LEDs for temperature and IFSM monitoring.
Effect:
Relay 3 in PPD 115 is Denergized , indicating fault.
Remarks:
FOCS controller PPD 115 needs to be reset.

Check for any temperature related problems.
For additional information refer:3BHS207392 ZAB E01

Refer DWG 3AYN122174-CAC
3AYN122174-CAF
A_RCP_DC_Control_Voltage_MCB_Failure
Message:
Fault:
MCB(Q600) providing the 110V DC control voltage has

tripped.
Possible Cause:
Overload of this MCB

MCB switched off manually
Failure of the monitoring relay
Action:
Check which MCB is switched off

Check its wiring and load
Switch it on again if it is not switched off for safety
reasons
Verify the 110V DC, 1ph, is present from the ACDCDB
Effect:
Other alarms may appear
If an MCB is switched off for safety reasons (maintenance,..)

it has to be marked for explanation with tape, to prevent
somebody else switching it on.
Refer Scheme 3AYN122174-CAC
A_RCP_1-Phase_Light_Voltage_MCB_Failure
Message:
Fault:
The any one of the MCB Q500,Q501,Q503 have tripped.
Possible Cause:
Overload of the MCB

MCB switched off manually (for maintenance or
troubleshooting reason)
Short circuit in the lighting / socket
Action:
Check which MCB has tripped

Check MCB wiring and load and switch it once again if it
is not switched off for safety reasons.
Effect:
No critical effect is to be awaited. Nevertheless the

maintenance has to fix the fault
If a MCB is switched off for safety reasons (i.e. maintenance)

it has to be marked for explanation with tape, to prevent
somebody else switching it on.
Message:
A_Rect_TX_Star_Protection_Fail/
A_Rect_TX_Delta_Protection_Fail
Fault:
Trip due to Rectifier Transformer over-current star / delta

system. The over-current relay F301,=F302 SPAJ 140C of star /
delta system has tripped.
Possible Cause:
Transformer in rush current

Transformer internal faults: winding fault
Rectifier short circuit: insulation breakdown due to high
temperature, moisture and chemicals, carbonization and surface
tracking
Bus-bar overload, malfunction of current regulation.
Loss of supply voltage
Action:
Before resetting the protection relay SPAJ 140C refer to its

manual (in Part 3 of the User's Manual). Take readings of fault
indication (MODE) and fault level (VALUE) for further inquires.
Check protection relay settings
Check transformer ratio, measurement of exciting current,
resistance and mutual inductance between windings.
Check rectifier and regulation circuits
Effect:
Remarks:
Overload and destruction of transformer and rectifier

620013/24/05
A_Breaker_Trip_Circuit_Supervision
Message:
Fault:
Possible Cause:
Action:
Effect:
Remarks:
Supervision relay F601 in RCP operated
Power supply for the breaker coil failed
Check the breaker panel circuits
The breaker coil will not operate
Refer to breaker drawings for addition hints.

Refer DWG. 3AYN122174-CAC
Message:
T_Rect_Diw_Output_Temp_ High/
T_Rect_DIW_Inlet_ Temperature_High
Fault:
The cooling water temperature in the outlet pipe (from rectifier to

cooling unit) increased above 50 C / inlet pipe to rectifier
increased above 45 C
Possible Cause:

Valves closed
Heat exchanger fan switched off
Action:

Check if DIW pump MCB are closed
Check if cubicle fan motor MCB is closed
Effect:
Overheating of semi-conductors
Remarks:
Do not re-energize the unit before the temperature drops

below critical level.
The primary breaker will be blocked in the off position as long as
the trip is present.
Refer to DWG
3AYN122174-CAC
3AYN122174-CAB
T_ Rect _DIW_Tank_Level_Low
Message:
Fault:
Deionized water level in the expansion vessel dropped below

the indicated low trip limit
Possible Cause:
Evaporation due to high temperature

Leakage in the DIW cooling circuit
If A-DIW level low indication is not present, the level switch has
a malfunction
Action:
Check that 1st stage alarm has also occurred firstly

Check cooling circuit and dont let the pumps run dry
Refill with deionized water
Effect:
Overheating of rectifier and pump dry running
Remarks:
Due to evaporation, the DIW cooling circuit has to be refilled

approximately every six to twelve months. We recommend keeping
some pure water nearby.
Before switching on the rectifiers after filling the cooling circuit with
fresh water, start the pumps and let them run for some time to mix
the water and maintain conductivity low.
Refer to DWG
3AYN122174-CAC
3AYN122174-CAB
T_Rect_DIW_Cooling_Flow_Low
Message:
Fault:
Possible Cause:
Action:
Effect:
Remarks:
The flow of the de-ionized water in the closed loop rectifier

cooling circuit has dropped below 369.6 l/min. for longer than 4
seconds. The standby pump has not started or has also failed.
Air in the cooling circuit

Valves closed
Failure in a water pump, changeover to the standby pump did
not take place
MCB for pump has tripped
Check cooling circuit for air

Check valves positions
Check MCBs in the rectifier local control panel
Check both pumps; Exchange faulty pump or repair it (winding,
bearing)
Switch on cooling circuit; check the automatically changeover
without trip. (by closing a valve in the cooling circuit)
Overheating of Thyristors
One of the two pumps is in standby. If the running pump fails, the
system wills automatically changeover to the pump in standby.
In case of low flow at the rectifiers, the pumps will automatically be

stopped after a few seconds to prevent running dry, if they are
Remote controlled.
To restart the pumps:
Press alarm reset button or
Stop and start auxiliaries or
Select the other pump as the active
T_Rect _Diw_Conductivity_High
Message:
Fault:
The conductivity of the de-ionized cooling water, measured with

the conductivity meter in the cooling unit has risen above the
limit of 10 S/cm.
The measuring instrument is defective
The conductivity sensor is faulty
Possible Cause:
Recently filled distilled water has not been circulating through

the de-ionizer long enough
Too little flow through de-ionizer
The resin of the de-ionizer is exhausted
Action:
Increase flow through de-ionizer and observe the conductivity

for a few hours
If the conductivity remains high, replace the resin
The cartridge has to be replaced
Effect:
High conductivity of cooling water can cause leakage currents in

the rectifier and destroy the equipment
Remarks:
Use only resin recommended by ABB or approved equal.
Refer to manual of cooling unit and cooling flow diagram.

SEN005109 Rev 2
T_RectTx_Bucholtz
Message:
Fault:
The Buchholz relay of rectifier transformer has tripped due to

strong oil flow in the transformer tank
Possible Cause:
Short circuit between windings due to weak insulation,

over voltage, external short circuit.
Bad connection inside the transformer, hot spot, mechanical
failure, short circuit in the transformer core.
Action:
location of failure
Oil sampling and testing must be carried out by transformer
specialists who can also give advice about further steps to be
taken
Transformer should not be taken back to operation before
transformer has been inspected carefully
Eventually cross check with the gas concentration value given
by the online system
Effect:
Remarks:
Destruction of transformer and environment
Do not re-energize the transformer before cause of tripping is

known, rectified and a safe operation is reestablished.

620013/24/05
T_RectTx_Oil_Level_Low
Message:
Fault:
Drop of the oil level in the transformer expansion tank on the top
of the transformer below indicated minimum level
Possible Cause:
Low oil temperature

Oil leakage
Low oil level
Action:
Check oil temperature and level

Check for oil leakage
Refill transformer oil
Effect:
Remarks:
When filling or draining oil, the level should correspond to the oil
temperature. Higher level for high temperature and lower level for
low temperature
Destruction of the transformer

620013/24/05
T_RectTx_Oil_Temperature_High
Message:
Fault:
Transformer oil temperature has increased above 105 deg C
Possible Cause:

Transformer heat exchanger dirty or not running properly
the rectifier unit
Action:
Check the analog oil temperature measurement equipment

Check wiring of the thermostat as well as its proper functioning
Check heat exchangers for dirt
Check if valves are open and fans, pumps correctly running
Clean heat exchangers
Effect:

Primary breaker is blocked in the off position as long as the trip
is present.
Remarks:
Do not re-energize the transformer

Before the temperature drops below a critical level.

620013/24/05
T_RectTx_Pressure_ReliefValve_Operated
Message:
Fault:
Rectifier Transformer oil pressure relief
Possible Cause:
Short circuit between windings due to weak insulation

Over voltage
External short circuit
Bad connection or mechanical failure in the transformer
Action:
location of failure.
Oil sampling and testing has to be carried out by transformer
specialist who can also give advice about further steps to be
taken.
Effect:

is present.
Remarks:
Do not re-energize the transformer before cause of

tripping is known, rectified and a safe operation is
Reestablished.

620013/24/05
Message:
Fault:
T_RectTx_Sys2_Winding_Temperature_ High
Transformer Delta winding over temperature.

Increase of winding temperature above 135 deg C
Possible Cause:
Action:
Check winding temperature device for proper operation

Compare oil and winding temperature for further investigations
Clean heat exchanger

Transformer heat exchanger dirty
Loss of flow in cooling circuits
the rectifier unit

3620013/24/10 Rev_01
Effect:
Remarks:

is present.

Before the temperature drops below critical level
Message:
Fault:
T_RectTx_Sys1_Winding_Temperature_ High
Transformer Star winding over temperature.
Increase of winding temperature above 135 deg C
Possible Cause:
Action:
Check winding temperature device for proper operation

Compare oil and winding temperature for further investigations
Clean heat exchanger

Transformer heat exchanger dirty
Loss of flow in cooling circuits
the rectifier unit

3620013/24/10 Rev_01
is present.
Effect:
Remarks:

Before the temperature drops below critical level
T_RectTx_ Primary_Star_Over_Current
Message:
Fault:
Trip due to Rectifier Transformer over-current star system. The

over-current relay F301 SPAJ 140C of star system has tripped.

tracking
Possible Cause:
Before resetting the protection relay SPAJ 140C refer to its manual (in
Part 3 of the User's Manual). Take readings of fault indication (MODE)
and fault level (VALUE) for further inquires.
Check transformer ratio, measurement of exciting current, resistance
and mutual inductance between windings.
Action:
Refer to Rectifier Control Circuit Diagram 3AYN128156-CAC
Effect:
Remarks:
Do not proceed with operation without consulting transformer

respectively rectifier expert if there are any indications, which
cannot be verified!
Before withdrawing the SPAJ 140C from its casing switch off the
auxiliary supply.
When replacing the relay with a spare, modify its settings according
to the setting table.
In most cases other transformer/rectifier related signals would also
be activated, which will be helpful for inquiries.
Message:
T_RectTx_ Primary_Delta_Over_Current

Fault:
Trip due to Rectifier Transformer over-current - delta system. The

over-current relay F302 SPAJ 140C of DELTA system has
tripped.
tracking
Possible Cause:
Before resetting the protection relay SPAJ 140C refer to its manual (in
Part 3 of the User's Manual). Take readings of fault indication (MODE)
and fault level (VALUE) for further inquires.
Check transformer ratio, measurement of exciting current, resistance
and mutual inductance between windings.
Action:
Refer to Rectifier Control Circuit Diagram 3AYN128156-CAC
Effect:
Remarks:
Do not proceed with operation without consulting transformer

respectively rectifier expert if there are any indications, which
cannot be verified!
Before withdrawing the SPAJ 140C from its casing switch off the
auxiliary supply.
When replacing the relay with a spare, modify its settings according
to the setting table.
In most cases other transformer/rectifier related signals would also
be activated, which will be helpful for inquiries.
Message:
T_Rect_Sys1_Second_ Fuse_ Failure/

T_Rect_Sys2_Second_ Fuse_ Failure
Fault:
In one or several legs of the rectifier more than one Thyristor

fuse has blown
A multiple Thyristor fuse failure can happen for various reasons.
In most cases other signals will appear and are to be taken into
consideration to locate the source of the fault.
Possible Cause:
Loss of cooling and the temperature supervision has failed air in the cooling system, rupture of a water connection, loss of
re-cooling circuit, valve in the cooling circuit closed.
Loss of over-voltage protection. (The over-voltage protection is
designed to protect the rectifier against transient over-voltages
and surges).
DC overload caused by malfunction of regulation and protection.
In this case it is likely that the fuses have interrupted the current
and the Thyristors are still good.
Action:
Locate the blown fuse by means of the fuse indicator micro

switches (red flag will be out)
Check cooling
Check over-voltage protection (connections, fuses, Thyristors,
capacitors, resistors)
Check regulation and over-current protection system in particular
reference and actual current value
Check wiring and fuse supervision card.
Effect:
The system is designed for n-1 Thyristors in operation. If more

than one Thyristor is out of service, the remaining Thyristors
have to carry the current. They will be overloaded leading to a
shorter life of the device.
Remarks:
Always replace Thyristor and fuse as a set.

Use special tool kit which is available on site to replace the
Thyristor and the fuse
Record location and component number of the failed Thyristor and

fuse for further inquiries
3AYN122174-CAB
T_Rect_Sys1_Heatsink Temperature High/

Message:
T_ Rect_Sys2_HeatSink Temperature High

Fault:
Temperature of one or several Heat-sink Thermostats has

increased above 75C
Possible Cause:
Loss of cooling due to closed valves

Re-cooling circuit is not in operation
Failure of thermostats or open loop
Action:
Check cooling unit and rectifier heat exchanger for dirt and open
valves
Check wiring for open loops. Wiring loops have to be closed.
Effect:
Over-temperature could destroy semiconductor
Remarks:
Do not re-energize the unit before the temperature has

dropped below critical level
The primary breaker will be blocked in the off position as long as
the trip is present
For wiring of thermostats refer to:

DWG 3AYN122174-CAC
3AYN122174-CAB
Message:
Fault:
T_Rect_Sys1_Over Voltage_ Prot_ Fuse_ Failure /

T_Rect_Sys2_Over Voltage_ Prot_ Fuse_ Failure
One of the AC over voltage protection fuse has blown

One of the Hole storage fuses on rectifier +G10/+G20 has blown
Possible Cause:
Short circuit in the capacitor of the OVP circuit

Short circuit in the hole storage protection circuit
Action:
Refer to the fuse monitoring board in order to know which

rectifier G10/G20 is affected.
Check fuse indicators at the rectifier
Effect:
Remarks:
Some of the semi conductors could not be protected against

transient over voltage peaks.
The Breaker cannot be closed since AC Over Voltage Protection
are not healthy
Message:
Fault:
Possible Cause:
T_MB_Electrical_Fault
The system tripped on fault from the Transformer HT breaker end.

Master trip relay at the breaker panel activated
Actual fault occurred at the HT breaker panel
Control circuit wiring fault
Action:
Check for actual fault at the breaker end

Reset the master trip relay at the HT breaker panel
Check the control wiring between breaker panel & rectifier
control panel and internal wiring of RCP
Effect:
Trip the system and the breaker locked in off position
Remarks:
Do not Energize the Transformer until fault is cleared.
T_RCP_EMERG_STOP
Message:
Fault:
The unit was switched off by pressing on the EMERGENCY OFF

push button located on the RCP.
Possible Cause:
Observation of high danger for persons or equipment or both

and activation of emergency off
Action:
Check the reason for pushing the emergency off

Check for personnel safety
Instruct personnel on proper operation of equipment
Reset the emergency off push button
Effect:
Remarks:
Danger to personnel or equipment
Do not re-energize the transformer into operation before

checking reason for the Emergency Off.
The rectifier units can not be switched on again as long as the
emergency off button is not released

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Users Manual

Maintenance and Troubleshooting

ABB INDIA Ltd

NUBERG_FLUODER, South America

ABB INDIA Ltd

Safety Instruction for Troubleshooting

Alarms and Trips Handling

Safety Instructions for Part 4 ( Maintenance & Troubleshooting)

1. To avoid risk of electrical shock or fire, the safety instructions

2. When working on the equipment make sure there are always

Always consider high temperature at bus bars.

Safety Instructions for Trouble Shooting

Never operate the Rectifier Equipment with the rectifier enclosure

There may be an external auxiliary voltage present even if you

Static discharge can damage electronic parts

Always wear the anti-static protection strap before you handle

Do not enter while energised.

Refer to users manual & Circuit diagrams before starting

Always check the description of the Alarms and Trips in the

Safety Instructions for Functional checks

Every printed circuit board (PCB) has a fault dedection and

High Voltage! Danger!

Follow all safety instructions before you start any functional

Do the inspection work that is mentioned in Part 4, Maintenance

Remark for Converter Inspection

Greasy dust, metallic particles and humidity/moisture could

Safety Instructions for Inspection, Maintenance and Repair

Open main circuit breaker

All national, local and proprietary safety instructions have to

Consider high temperature at bus bars, reactors and heaters.

Static discharge can damage electronic parts

You could be injured if you try to perform trouble shooting work

If you try to perform trouble shooting work on the Rectifier

Do not install any replacement part in the Rectifier Equipment

1.5 Safety Instructions for Replacement of Items

There may be auxiliary voltage present even if you disconnect

Always consider high temperature at bus bars, reactors and

You could be injured if you try to perform trouble shooting work

Check for correct polarity when mounting a new semiconductor.

Do not add any replacement part to the Rectifier Equipment

Alarms and Trips Handling

The conductivity of the de-ionized cooling water, measured with

Recently filled distilled water has not been circulating through

Increase flow through de-ionizer and observe the conductivity

High conductivity of cooling water can cause leakage currents in

Use only resin recommended by ABB or approved equal.

Refer to DWG 3AYN128156-CAC

De-ionized water level in the expansion vessel dropped below

Evaporation due to high temperature

Check cooling circuit

Overheating of rectifier and pump dry running

Due to evaporation, the DIW cooling circuit has to be refilled

Filling with water has to be done slowly enough in order to maintain

The flow of the deionized water in the closed loop rectifier

Check if cooling circuit is in operation

Air in the cooling circuit

Refer to DWG 3AYN122174-CAC

The cooling water temperature in the outlet pipe increased