INGEDRIVE

User’s Control Manual

User Manual
AR1701IKR07[EN] Rev.A
No part of this publication may be
reproduced by whatever means without
the prior written permission of Ingeteam
Power Technology.

One of the main aims of Ingeteam Power

Technology lies in the continuous
improvement of the company’s
equipment and, therefore, the information
contained in this catalogue may be
modified without prior notification.

For further information, consult the

corresponding manual or contact us
directly.
User control manual

Table of contents

7. User’s Control Manual .............................................................................................. 4

7.1 Basic concepts ................................................................................................................................................... 4

7.2 Local/Remote Logic .......................................................................................................................................... 5
7.3 Connection/Disconnection Logic .................................................................................................................. 6
7.3.1 MV equipment.................................................................................................................................................. 6
7.3.2 LV equipment................................................................................................................................................... 6
7.4 Start/Stop Logic and regulation mode .......................................................................................................... 7
7.5 Reaction in the event of trips and alarms..................................................................................................... 8
7.6 Encoder logic ...................................................................................................................................................... 9
7.6.1 Trip/alarm generation logic and encoder selection ................................................................................ 9
7.7 Cooling Logic.................................................................................................................................................... 10
7.7.1 ACU Logic ...................................................................................................................................................... 10
7.7.1.1 Operating modes ........................................................................................................................... 10
7.7.1.2 Fan selection................................................................................................................................... 10
7.7.1.3 Fan error management ................................................................................................................. 11
7.7.1.4 Resetting the operating timer ..................................................................................................... 11
7.7.1.5 MV100 ACU Logic.......................................................................................................................... 11
7.7.2 WCU Logic ..................................................................................................................................................... 13
7.7.2.1 Operating modes ........................................................................................................................... 13
7.7.2.2 Initial conditions............................................................................................................................. 14
7.7.2.3 Pump selection .............................................................................................................................. 14
7.8 Excitation logic ................................................................................................................................................. 16
7.8.1 Connection/ Disconnection logic.............................................................................................................. 16
7.8.2 Error management ....................................................................................................................................... 17
7.9 Índice de revisiones ...........................................................................................¡Error! Marcador no definido.

MV5000IKE07 Rev._
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7. User’s Control Manual

7.1 Basic concepts

Certain concepts used throughout this chapter are explained below:

• Air Cooling Unit (ACU): Equipment cooling system.

• Water Cooling Unit (WCU): Equipment cooling system.

• Main Circuit Breaker (MCB): Main equipment input switch.

• Internal Circuit Breaker (ICB): In addition to the MCB mentioned above, some equipment can
include a circuit breaker.

• Ready for Running (RFR): Indicator showing the user that the equipment is connected to the grid
and that there is no alarm preventing it from firing.

• Ready For Use (RFU): An indicator that informs the user that the equipment is ready to precharge
the system.

• Firing: Indicator showing the user that the equipment is firing, that is to say, imposing output
voltage.

• Alarm: An on-screen warning that does not prevent the equipment from operating.

• Trips: This refers to serious alarms that can be either Shutdown or Lockout.

• Warning: Warning, indicating a possible future alarm. This does not give rise to any converter
action.

• Slowdown: Warning, indicating a possible future alarm. This gives rise to a reduction of power at
the converter output.

• Shutdown: Alarm that implies the chopping of equipment output current. Gives rise to the
immediate stopping of firing thus losing control over the load.

• Lockout: Alarm, which as well as shutdown, involves chopping equipment power voltage. This
gives rise to the immediate cutting-off from the grid by means of opening the MCB/ICB and the
discharging of the DC BUS.

• Grid Side Converter (GSC): This refers to the rectifier.

• Motor Side Converter (MSC): This refers to the inverter.

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7.2 Local/Remote Logic

The equipment enables two operating modes:

• Local: Commands are generated from the equipment's integrated HMI. Only local signals are
taken into account with respect to system protection. This mode enables the user to reset
equipment warnings and alarms. Moreover, the following operations can be carried out from the
HMI LOCAL panel (See Chapter 9) enabled to this end:

o Generation of equipment connection/disconnection commands.

o Selection of the desired motor, whenever the equipment is fitted with two motors.

o Generation of equipment stop/start commands, as well as the imposition of the desired

speed setting.

o Whenever the equipment has a redundant encoder, the user can select the encoder he
wishes to use for adjustment purposes.

• Remote: The equipment receives the commands and restrictions from the automation in which it is
integrated, either by means of wired signals, or by means of field bus communications.

To ensure correct operation of the equipment, the following must be complied with when changing
from one mode to another:

From Remote to Local: The Local Mode must maintain the status and freeze the
Remote setpoints.

From Local to Remote: First, monitor the maximum difference of the speed setpoint
between Local and Remote to ensure that the change to Remote is effective.

The transitions between the two modes of operation can be made from the HMI Local panel (See
Chapter 9).

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7.3 Connection/Disconnection Logic

7.3.1 MV equipment

This logic refers to the equipment connection and disconnection at the grid that is carried out by
means of the MCB.

The equipment must be in RFU status when the connection command is given. This process
consists in closing the input breaker, pre-charging the BUS and closing the MCB. If the operation
is completed correctly, the equipment connected indicator is activated, which is one of the
conditions for RFR generation. If during the connection any error is detected, the equipment is
disconnected and the corresponding alarm is triggered.

The disconnection command, contrary to the connection one, is accepted regardless of the
equipment status, and is always carried out. The disconnection consists in opening the MCB and
discharging the BUS through the discharge resistor. Once the BUS is discharged to a safe value,
the input breaker can be opened.

In the event that MCB opening cannot be ensured without errors, the BUS will be discharged
without the discharge resistor, thus discharge time will be longer.

NOTE: The BUS is pre-charged until reaching a value that can be modified by the user
depending on the input voltage conditions.

7.3.2 LV equipment

The equipment must be in RFU status when the connection command is given. This process
consists in closing the MCB and the precharge contactor. After this, the exponential curve and
the final precharge voltage begins to be calculated to verify correct DC Bus charge. Once the
voltage obtained for the bus is higher than the pre-established minimum defined by the user, the
order to open the precharge contactor is given and the ICB contactor closes, if there is one. In
equipment with an AFE rectifier, if the filter connection is enabled, a command will be given to
close it and the precharge will be considered completed. If the operation is completed correctly,
the equipment connected indicator is activated, which is one of the conditions for RFR
generation. If during the connection any error is detected, the equipment is disconnected and the
corresponding alarm is triggered.

The disconnection command, contrary to the connection one, is accepted regardless of the
equipment status, and is always carried out. The discharge sequence will open the MCB and
ICB (if applicable) contactors to discharge the bus through the discharge resistor, after which the

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filter will open and then the precharge contactor will open. Finally, if the bus voltage is less than
or equal to the minimum established voltage, the discharge will be considered completed.

However, if the bus voltage is less than or equal to a threshold level, the RFU signal has not
been lost and there is a connection signal the precharge will be repeated.

7.4 Start/Stop Logic and regulation mode

This functionality refers to starting and stopping the drive.

In order to run the inverter, drive has to be in RFR status, which means that the bus has to be pre-charged
and the MCB closed. When a run command is accepted, the inverter magnetises the motor and turns it at
the indicated setpoint speed.

The action of the motor varies, depending on the conditions detailed below:

• If the inverter receives a stop command, the motor stops and is demagnetised.

• If a shutdown error is activated, the inverter stops, allowing the motor to spin freely.

• If a lockout error is activated, the inverter stops, allowing the motor to spin freely.

Selection of the desired regulation mode:

• Speed mode: the setpoint for this type of regulation will be the speed.

• Power mode: the speed setpoint is carried to the maximum to regulate constant power.

• Torque mode: the setpoint for this type of regulation will be the torque.

• AvTorque mode: the setpoint for this type of regulation will be the torque, but in contrast to the
Torque mode, regulation will be carried out in the closed loop, since torque measurement is
obtained by means of the torque meter.

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7.5 Reaction in the event of trips and alarms

Any event capable of damaging the equipment if it remains connected to the main power supply is
considered a Lockout trip. This type of alarm causes immediate ceasing of operation. Therefore,
the equipment must be isolated from any input voltage; that is, it will involve opening the MCB/ICB
and discharging the bus.

Any event capable of damaging the equipment if it remains connected to the main power supply is
considered a Shutdown trip. This type of alarm causes immediate stopping of equipment
operation. In contrast to the situation mentioned previously, it is not necessary to isolate the
equipment from all the input voltage. The inverters will stop firing and the motor will therefore
continue rotating without regulating the speed.

Slowdown gives rise to a reduction of power at the converter output.

The aim of the Common alarm is to indicate a possible future trip. This does not give rise to any
converter action.

RFU is a signal that informs the user that the equipment is ready to pre-charge the system. The
following conditions must be present, otherwise RFU condition will not be available:

Water Cooling Unit OK

Water Cooling Unit not in manual mode

Not opened doors alarm

No lockout

In drives with air cooling unit, other RFU conditions need to be accomplished:

Cooling fans in automatic mode

RFR is a signal that informs that system pre-charge has been performed correctly User can
therefore proceed to start up the equipment. The following conditions must be present, otherwise
RFR condition will not be available:

Setpoint at zero

Start interlock released

No Shutdown

Precharge done (It is necessary to have RFU = 1 to initiate the precharge)

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7.6 Encoder logic

The motor to be controlled may be fitted with 1 or 2 encoders, depending on the customer's needs.

If the motor has only one encoder and an error associated with it is detected, a Shutdown trip will be
provoked.

If it has a redundant encoder, the customer can select which to use as default from the HMI LOCAL panel
(See Chapter 9) by means of the following parameters: “EncUser1” (if working with encoder 1) or
“EncUser2” (if working with encoder 2). This selection will always become effective as long as the selected
encoder has no associated error, otherwise the corresponding encoder error alarm will be indicated and
the other encoder will be used, as long as this has not any referred error. If both encoders are in error, a
Shutdown trip will be provoked.

7.6.1 Trip/alarm generation logic and encoder selection

There are four types of possible errors:

• Power supply error: indicates an encoder power failure.

• Glitch: indicates that some discordance has come about in some of the signal pairs: A/!A, B/!B or
S/!S.

• Synchronism error: indicates that the synchronism pulse has not been received within the pulse
margin setting.

• Speed reading error: indicates that the speed derivative is exceeding the limit settings.

A distinction is made on the basis of the number of encoders there are in order to generate the
alarms and warnings.

If the motor has only one encoder, all the errors are viewed as shutdown and alarm.

Si If the motor has a double encoder the following cases may arise:

• None of the encoders is in error: If an error is generated in the encoder being used, it is viewed as
an alarm and the equipment switches over to working with the standby encoder.

• The standby encoder is in error: If an error is generated in the encoder being used, it is viewed as
an alarm and a shutdown in case an error happens in the one that was in standby.

NOTE: The resetting of encoder alarm is possible when the equipment is running.

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7.7 Cooling Logic

7.7.1 ACU Logic

7.7.1.1 Operating modes

The ACU enables two operating modes: manual and automatic.

Switchover to another operating mode is only possible when the equipment is disconnected.

The ACU must be in automatic mode in order to generate equipment RFU.

7.7.1.1.1 Manual Mode

This enables the starting and stopping of the ACU with the fan that has been selected by the
user. The HMI has a specific screen to carry out these operations.

7.7.1.1.2 Automatic Mode

This mode does not accept the commands used in manual mode and ACU operation is
managed internally, depending on the needs of the equipment.

As a general rule, the ACU is always active as long as the equipment power is on. Therefore, it
starts up when the equipment is connected and stops when it is turned off. The turning-off
process is carried out with a lag for better cooling after the converter is disconnected.

On the other hand, logical maintenance is carried out on the ACU in order to ensure that it is in
the requisite condition for proper equipment operation, when the latter is disconnected. This logic
monitors differential pressure, input and output temperature, starting and stopping the ACU with
the aim in mind of keeping them within the set values.

7.7.1.2 Fan selection

The ACU is fitted with a pair of extra fans which work in case of redundancy mode is activated, the
primary ones are not capable of cooling the converter or some of the primary fans are in error. The
ACU logic is capable to detect the fan errors and is indicated as alarms on the corresponding
screen and as an error on the ACU screen.

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7.7.1.3 Fan error management

Whenever an error is indicated on any of the fans, a warning is shown. If the failing fan was
active, it stops and the redundancy mode is activated. The error fan remains out of service and if
at this time, any error is detected in any of main fans, a trip is triggered resulting in lack of
cooling system.

7.7.1.4 Resetting the operating timer

A timer that measures the total operating time of each fan is activated in order to manage a
correct working condition for the fans.

If a fan is replaced, this timer must be reset by means of the reset button on the ACU panel for
this purpose.

7.7.1.5 MV100 ACU Logic

7.7.1.5.1 Operating modes

The ACU accepts two operating modes: manual and automatic.

Switchover to another operating mode is only possible when the equipment is disconnected.

The ACU must be in automatic mode in order to provide equipment RFU condition.

7.7.1.5.2 Manual mode

This enables the user to command the starting and stopping of the ACU. The user must assign a
speed setpoint (in percent) in order to run the cooling unit. The HMI has a specific screen to
carry out these operations.

7.7.1.5.3 Automatic mode

The cooling control is performed automatically, based on the needs of the equipment at all times.

As a general rule, the ACU is always active as long as the equipment power is on. Therefore, it
starts up when the equipment is connected and stops when it is turned off. The turning-off
process is carried out with a lag for better cooling after the converter is disconnected.

During a normal operation of the drive, the fan is running at a defined percent speed. In case of
detecting an alarm related to any of the monitored temperatures considered critical for the
converter (the actual value of the temperature measurement exceeds the high limit established),

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the speed will rise up to 100%. The fan maintains this speed until the drive detects a drop in the
temperature of 4-5 degrees. In that case, the fan recovers its regular speed value.

7.7.1.5.2 Fan error management

A fan failure is considered a lockout trip, so this event causes the immediate ceasing of the
drive’s operation.

7.7.1.6 LV400 ACU Logic

The air cooling unit consists of a dual fan system. By the action of only one connexion order,
both cooling units (main fans and redundant fans) are activated at the same time.

7.7.1.6.1 Operating modes

The ACU accepts two operating modes: manual and automatic.

Switchover to another operating mode is only possible when the equipment is disconnected.

The ACU must be in automatic mode in order to provide equipment RFU condition.

7.7.1.6.2 Manual mode

This enables the user to command the starting and stopping of the ACU. As stated above, just
one order is required to connect the cooling unit. The HMI has a specific screen to carry out
these operations.

7.7.1.6.3 Automatic mode

The cooling control is performed automatically, based on the needs of the equipment at all times.

As a general rule, the ACU is always active as long as the equipment power is on. Therefore, it
starts up when the equipment is connected and stops when it is turned off. The turning-off
process is carried out with a lag for better cooling after the converter is disconnected.

7.7.1.6.4 Fan error management

A fan failure (whether from the main cooling fan or the auxiliary system) is considered a lockout
trip, so this event causes the immediate ceasing of the drive’s operation.

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7.7.2 WCU Logic

The water cooling unit consists in:

• Water/ Air Heat-exchanger

• Temperature controlled motor driven three-way valve
• Redundant pump set
• Sensors for temperature and pressure

7.7.2.1 Operating modes

The WCU accepts two operating modes: manual and automatic.

Switchover to another operating mode is only possible when the equipment is disconnected.

The WCU must be in automatic mode in order to provide equipment RFU condition.

7.7.2.1.1 Manual mode

This enables the starting and stopping of the WCU with the pump that has been selected by the
user. It only makes sense to use manual mode to check that the pumps are working properly and
to supervise pressures and possible leaks. The HMI has a specific screen to carry out these
operations.

7.7.2.1.2 Automatic mode

This mode does not accept the commands used in manual mode; WCU operation is managed
internally, depending on the needs of the equipment.

As a general rule, the WCU is always active as long as the equipment power is on. Therefore, it
starts up when the equipment is connected and stops when it is turned off. The turning-off
process is carried out with a lag for better cooling after the converter is disconnected.

On the other hand, maintenance logic is carried out on the WCU in order to ensure that it is in
the required condition for proper equipment operation, when the latter is disconnected. This logic
monitors differential pressure, inlet and outlet temperature, conductivity (only when used),
starting and stopping the WCU with the aim in mind of keeping them within the set values.

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7.7.2.2 Initial conditions

Check whether the temperature and pressure settings of the secondary circuit are within their
limits before starting up the WCU. The initial conditions of the WCU will be the RFU conditions of
the equipment and can only be generated in automatic mode.

The following conditions must be present to start up the equipment; otherwise the RFU
conditions will not be available:

• The cold water temperature must be between the upper and lower limit established for the initial
conditions.

• The water pressure must be between the upper and lower limit established for the initial conditions.

• In addition, in equipment with MV IGCTs, the upper and lower conductivity limits will also be
checked.

7.7.2.3 Pump selection

The WCU is fitted with a redundant pump system that works in complementary fashion. The operating
philosophy of these pumps consists in defining a work cycle for each one, so that each pump works
continuously during the defined cycle.

After this cycle is completed, in the next WCU start-up a pump switchover will come about if both pumps
are free of errors.

7.7.2.3.1 Pumps error management

Whenever an error is indicated on any of the pumps, an alarm is shown. If the pump in question
was active, it stops and the other one starts. The pump with the error remains out of service and,
therefore, the redundancy disappears. If at that time an error is detected in the active pump, a
trip is given since there is no cooling system available.

To recover pump redundancy, the cause of the error in the pump must be solved and afterwards
the pump error reset button on the WCU screen must be pressed. This error cannot be reset
from the alarm or trip reset command; therefore, the pump in error will remain out of service until
the specific pump error reset button is activated.

7.7.2.3.2 Operating time counter

When either pump exceeds its pre-established operating hours an alarm message appears to indicate the
need to replace the pump by a new one.

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Once the pump is replaced, it must be reset with the reset button prepared for that purpose on the WCU
panel.

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7.8 Excitation logic

This functionality refers to the excitation module: connection/ disconnection logic, error
management…

The excitation cabinet is provided with two displays:

• Input excitation voltage, RMS.

• Output current generated by the excitation.

On the other hand, as it happens in any equipment, an interlock doors logic will be applied
whenever an input voltage is detected.

7.8.1 Connection/ Disconnection logic

Sending the connection command to the excitation module implies:

NOTE: In order to get RFU conditions it’s strictly necessary to have the doors closed.

• The connection of the excitation external breaker.

• The connection of excitation fans.

• The closure of the excitation internal switch.

• Starting with current regulation.

NOTE: It’s necessary to keep in mind that equipments provided with excitation, the
inverter is not going to be able to start until the excitation is regulating the current.

As regards disconnection, the sequence is carried out as connection but in reverse order and
with some differences:

• The current setpoint of the excitation will be internally imposed to 0. Once the current is
extinguished, the firing will be stopped.

• The bar switch will be opened and fans disconnection timer activated.

• The external breaker will remain connected. The equipment can receive an opening command to
open the breaker from the touch screen or control room.

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7.8.2 Error management

The excitation module generates its own errors, alarms and trips. If the excitation is not firing it is
not possible to remain the bar switch connected, therefore, a trip will involve the total
disconnection of the module. On the other hand:

• Any excitation trip, lockout or shutdown will suppose a MSC Shutdown, instead of affecting the
whole drive.

In this kind of applications a MSC/ Motor Shutdown does not imply the stop of the GSC, but in
contrast, a GSC Shutdown does involve the stop of the MSC. In addition, a Shutdown trip in the
MSC causes an immediate disconnection of the excitation.

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7.9 Static converter logic

In that case, the aim of the static converter is to provide constant values of voltage (400V) and
frequency (60Hz) in the converter output. Moreover, a load could be connected to this constant
net.

The drive is design to endure 200% overloads for a maximum period of 1 second. The time
between overloads is 300 seconds. In case of an overload does not reach the maximum
predefined time of one second, the next overload can occur before having past the 300 seconds.

7.9.1 Connection/ Disconnection logic

For the net generation, after having ensured that the AFE is firing, a connection order of the
static module is needed. This way, the required output voltage and frequency will be
accomplished. The loads could be directly attached at the connection point of the drive. This is
possible due to the fact that the output circuit breaker (OCB) of the equipment has been
connected when the precharge is considered completed.

The disconnection of the static converter is carried out by means of the corresponding order of
the module. This command does not imply to stop firing the AFE.

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7.10 Revision Index

REV DESCRIPTION DATE

._ AR1/01IKR07A_ Original Version 03/10/2013

.A AR1/01IKR07A – Static Converter Description 07/02/2014

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