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Table of Contents

Content Page
Alarm and Fault Management .................................................................................................... 3
Assignment of Properties............................................................................................................ 4
Definition of Monitoring Levels.................................................................................................... 5
Current and Voltage Measurement on the “System I/O-Board“................................................... 6
Alarm / Faults Group “Line Input”................................................................................................ 7
Alarm / Faults Group “Output and Motor” ................................................................................... 10
Alarm / Faults Group “Transformer”............................................................................................ 14
Alarm / Faults Group “Cells”........................................................................................................ 15
Alarm / Faults Group “Cell Bypass”............................................................................................. 16
Alarm / Faults Group “Controls”.................................................................................................. 18
Alarm / Faults Group “Human- and Field-Interface”.................................................................... 20
Alarm / Faults Group “General”................................................................................................... 21
Alarm / Faults Group “Sync Transfer”......................................................................................... 22
Alarm / Faults Group “Reactor”................................................................................................... 23

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Alarm and Fault Management

A large number of operating conditions is monitored and checked against permissive state or compared to defined limit
values. Any “deviation from normal” thus identified will issue either an Alarm Message (Warning) or a Fault Message.

Messages regarding vital conditions are fixed by software (eagle code); some of these can be
deactivated via SOP:
Alarm via Software Fault via Software

Messages of secondary impact can be programmed in the System Operational Program (SOP):
Alarm via SOP Fault via SOP

For a number of messages the monitoring levels are adjustable via parameters.

Depending on the physical location within the drive system where the malfunction occurs, derived messages are
received from functional groups of the VFD itself or of the drive in general (a listing of messages starts on page 7).

line
input transformer output and motor

human/field options /
interface controls general

cell
cells
bypass

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Assignment of Properties

Individually
Individually differing
differing properties
properties are
are assigned
assigned to
to alarms
alarms (”Type”
(”Type” == A)
A) as
as well
well as
as to
to faults
faults (”Type”
(”Type” == F):
F):



alarms
alarms or
or faults
faults with
with fixed
fixed definition
definition via
via Eagle
Eagle Code
Code and
and invariable
invariable assignment
assignment of of aa reaction
reaction (column
(column ”Enable”
”Enable” == Fixed)
Fixed)



alarms
alarms or
or faults
faults which
which have
have to
to be
be enabled
enabled via
via SOP
SOP and
and whose
whose reaction
reaction is
is programmable
programmable (column
(column ”Enable”
”Enable” == SOP)
SOP)

Medium
Medium voltage
voltage low
low fault
fault
uline < 55% Fault via SW

Medium
Medium voltage
voltage low
low 11
uline < 90% Alarm via SOP

1) identification of the alarm-, fault condition:

MediumVoltageLowAlarm1En_O = TRUE

2) signal for further evaluation of the condition:

MediumVoltageLowAlarm1_I

3) assignment of a response via SOP:

ExternalDigitalOutput02a_O =
MediumVoltageLowAlarm1_I

13_Next Gen Faults page 4 © Siemens Industry 2013 - subject to modification

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Definition of Monitoring Levels

Input
Input One
One Cycle
Cycle
ireactive too large Fault via SW

Unless the medium voltage is just being switched on the line-side reactive
current may only read the value of the magnetizing current of the transformer.
The reactive current on the primary side of the transformer is monitored.
If the sensitivity is too high (sporadic trips), ID7080 should be reduced and
ID7081 should be increased.

Motor
Motor Thermal
Thermal Overload
Overload Fault
Fault
motor current > ID1140 Fault via SW
AND time > ID1150

IOC
IOC (Instantaneous
(Instantaneous Over
Over Current)
Current)

motor current > ID7110 Fault via SW

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Current and Voltage Measurement on the “System I/O-Board“

Voltages and currents at the converter input and at the inverter output are scaled as follows:
voltages NXG IB, II 1.91 Vrms [5.40 Vpp] if the actual input (output) voltage corresponds to the input (output)
NXG IA 3.82 Vrms [10.8 Vpp] voltage which is specified on the nameplate of the particular drive:
vrated,HW,in = 6600V vline,act = 6600V value = 1.91V
vrated,HW,out = 6000V vout,act = 5000V value = 1.60V

currents NXG IB, II 1.77 Vrms [5.00 Vpp] if the actual input (output) current corresponds to the input (output)
NXG IA 3.54 Vrms [10.0 Vpp] current which is specified on the nameplate of the particular drive:
irated,HW,in = 195A iline,act = 195A value = 1.77V
irated,HW,out = 172A iout,act = 85A value = 0.87V

measuring
measuring points
points input
input voltages
voltages output
output voltages
voltages input
input currents
currents output
output currents
currents
physical quantity Vin,L1 Vin,L2 Vin,L3 Vout,T1 Vout,T2 Vout,T3 Iin,L2 Iin,L3 Iout,T1 Iout,T2 Iout,T3
name of test-point V1A V1B V1C VMA VMB VMC IIB IIC IMA IMB IMC
no. of test-point TP1 TP2 TP3 TP5 TP6 TP7 TP12 TP13 TP21 TP22 TP23

TP 4, 9, 11, 14, 18, 20 ground connections TP 47, 48 analog output (1, 2) TP 52 analog input break-out board
TP 15, 16, 17 output filter currents TP 49, 50, 51 analog inputs (no. 3, 2, 1) TP 19 IOC feedback
TP 24 - 26, 28, 29, 31 programmable (  table 4-81) TP 35, 36, 37 motor voltage TP 10 AI/O (non-isolated input SCB)
TP 44, 45 encoder feedback (track A, B) TP 31, 32 analog output ( – , +) TP 8 not used

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Alarm / Faults Group “Line Input” 1(3)

Medium voltage faults

All detected off the input line voltage
Through attenuation feedback
3.82 (1.91) Vrms. on V1A, VIB, VIC @ rated voltage
Not running trips on fault < 55%
When running if line is lost then the drive will run based upon the load

Medium voltage low 1 < 90% Alarm in SOP

MediumVoltageLowAlarm1En_O = TRUE; not a fatal fault

Medium voltage low 2 < 70% Alarm in software

Medium voltage low flt < 55% Fault in software

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Alarm / Faults Group “Line Input” 2(3)

Line overvoltage faults

All detected off the input line voltage
Through attenuation feedback
3.82 (1.91) Vrms. on V1A, VIB, VIC @ rated voltage

Line Overvoltage 1 >110% Alarm in SOP

LineOverVoltage1En_O = TRUE;
LineOverVoltage1_I used to pick up other variables

Line Overvoltage 2 >115% Alarm in SOP

LineOverVoltage2En_O = TRUE;
LineOverVoltage2_I used to pick up other variables

Line Overvoltage fault flt >120% Fault in software

LineOverVoltageFault_I used to pick up other variables

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Alarm / Faults Group “Line Input” 3(3)

Input phase imbalance fault Fault in software

detected off the input current feedbacks
compared to the setting of parameter ID1244 phase imbalance limit.
Default is 40% and adjustable

Input ground Alarm in software

detected off the input voltage feedbacks
verify symmetry on V1A, V1B, V1C on system interface board

Input One Cycle Fault in software

detected off the input CT’s
detects excessive reactive current in the transformer
• Reduce the 1 Cyc protect integ gain (7080) and 1 Cyc protect limit
(7081) to avoid nuisance trips
• Should always tie this back to shut off the mains.

Input phase loss Alarm in software

detected off the input voltage feedback
any input drops below 50% of rated voltage
verify voltage feedback on V1A, V1B, V1C on system interface board

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Alarm / Faults Group “Output and Motor” 1(4)

Overspeed
detected off the speed feedback

Overspeed Alarm in SOP

motor speed is greater than 95% of the overspeed parameter (ID1170)

Overspeed Fault in software

motor speed exceeds the overspeed parameter (ID1170) at 100%

Output Ground fault Alarm in software

detected off the motor voltage feedback
Ground Fault Limit ID1245; default value 5%
Ground Fault Time Constant ID1246; default value 0.017
through attenuation feedback
verify symmetry on VMA, VMB, VMC on system interface board
check the motor connections. Megger the motor after disconnecting leads from the VFD.
UserFault4_O = OutputGroundFault_I;
UserText4 = “Motor Ground Fault”
UserFault4_I can be used in the SOP
UserFault4Wn_O = True; Alarm again

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Alarm / Faults Group “Output and Motor” 2(4)

Encoder loss for CLVC Fault in software

detected off the encoder feedback
run the drive in open loop vector control (ID2050)
with oscilloscope look at the encoder feedback to verify a 90 degree phase shift
and a good pulse
program a meter display (ID8001 - ID8004) for ERPM and motor speed.
Verify that they track each other

Motor Thermal Overload 1 Alarm in SOP

MotorThermalOverload1En_O = TRUE;
I overload pending setting ID1139

Motor Thermal Overload 2 Alarm in SOP

MotorThermalOverload2En_O = TRUE;
I overload setting ID1140

Motor Thermal Overload Fault Fault in software

Overload setting and Overload timeout
ID1140 and ID1150
Resets on an algorithm.

IOC Fault in software

Instantaneous Over Current. Motor current exceeded a preset threshold
adjustable via the IOC trip point in the drive protection menu.
150% is the typical setpoint. Menu 7110

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Alarm / Faults Group “Output and Motor” 3(4)

Motor Over voltage Alarm Alarm in SOP

MotorOverVoltageAlarmEn_O = TRUE;
Exceeds 90% of motor overvoltage limit in menu

Motor Over voltage Fault Fault in software

Exceeds motor overvoltage limit in menu ID1160;
motor trip volts. That should be setup
at 4800 volts on a 4160 volt application.

Under Load Alarm Alarm in SOP

UnderLoadAlarm_O = True
Active when menu limit is reached

Under Load Fault Fault in software

that can be shut off through menu 1180
Active when menu limit is reached with time limit
(ID1182 is the underload level and ID1186 is the time)

Output Phase Imbalance Alarm in software

Motor current or voltage imbalance > Phase Imbalance Limit in the
Motor Menu Limits. Default is 40%; Menu 1244

Output Phase Open Alarm in SOP

OutputPhaseOpenEn_O = TRUE;
Detects a single phase condition in the drive motor output.
Looks at the current feedback

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Alarm / Faults Group “Output and Motor” 4(4)

In Torque Limit Alarm in SOP

In torque limit for more than 1 minute
InTorqueLimitEn_O = True;

In Torque Limit Rollback Alarm/Fault in SOP

In torque limit for more than 20 minutes
InTorqueLimitRollback_O = True;
InTorqueLimitRollbackEn_O = True;
InTorqueLimitRollbackWn_O = True; makes it an alarm
DigitalOutput1_e = InTorqueLimit_I ;

Low Motor Speed Fault in software

Motor Speed is below Zero Speed (ID2200) parameter.
This condition exist in the stalled condition, based on 15 sec

Loss of Field (sync motor only) Fault in software

Field power supply not working properly.
Check Field Supply and Wago output for Field Current command.
Active with Synchronous motor mode only

Fail to magnetize Fault in software

Drive unable to build motor flux. Check if stator resistance is correct
and if spinning load is correctly set up (ID2430)

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Alarm / Faults Group “Transformer”

Xformer Temperature 1 Alarm in SOP

XformerOverTempAlarm1En_O = TRUE;
XformerOverTempAlarm1_O = /ExternalDigitalInput01f_I ;
Transformer temperature above 150F (may vary per design)

Xformer Temperature 2 Alarm in SOP

XformerOverTempAlarm2En_O = TRUE;
XformerOverTempAlarm2_O = /ExternalDigitalInput01g_I ;
Transformer temperature above 180F (may vary per design)

Xformer Temperature Fault Fault in SOP

Transformer water temperature above 140F & 180F for 30 minutes.
Timer00(1.000000) = /TempFlag01_O;
TempFlag01_O = Timer00;
Counter04(1800) = XformerOverTempAlarm1_I * XformerOverTempAlarm2_I * Timer00;
CounterReset04 = ExternalDigitalInput01f_I;
XformerOverTempFaultEn_O = TRUE;
XformerOverTempFault_O = Counter04;

Xformer Water Temp High Alarm/Fault in SOP

Transformer manifold water temperature above 140F.
XformerWaterTempHighEn_O = True;
XformerWaterTempHigh_O = Comparator5_I;
Then setup an output via the overtemp
ExternalDigitalOutput01a_O = XformerWaterTempHigh_I;

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Alarm / Faults Group “Cells”

The
The “Cell
“Cell Control
Control Board“
Board“ monitors
monitors the
the function
function of
of the
the power
power cell
cell and
and identifies
identifies following
following warnings
warnings (A)
(A) and
and faults
faults (F):
(F):

Power Fuse Blown Failure of fuse between converter and inverter of the power cell (Gen I, II / WC I, II) F
Voltage Available Supply voltage of the power cell is less than the monitoring limit F
Control Power Control voltage of the ”Cell Control Board” is missing or outside tolerance F
Over Temp Warning Feedback bit Q5 triggers the alarm limit value (defined in eagle code) A

Over Temperature Feedback bit Q5 triggers the fault limit value (defined in eagle code) F

DC Bus Over Voltage DC-link voltage exceeds the fixed limit (>800/1200 VDC for 460/630,690 VAC) F
DC Bus Low Warning DC-link voltage is < 65 % rated A
DC Bus Under Voltage DC-link voltage is < 55 % rated F
IGBT OOS 1, 2, 3, 4 Device failed to turn on while in “operation” F
(UCE > 50V in case of an IGBT being triggered; has to be = 0V)
Blocking Q1, 2, 3, 4 Device failed to assume blocking state when requested in “cell diagnostics” F
(UCE = 0 in case of an IGBT not being triggered; has to be >> 0V)
Switching Q1, 2, 3, 4 Device failed to turn on when requested in “cell diagnostics” (refer to “IGBT OOS”) F
Cap Share * Voltage on one of the DC-link caps in series is larger than 425 VDC F

Communication Transmission of telegrams is faulty F

Link Transmission of telegrams is missing all together F
* only for cells with more than one capacitor in series all of the above warnings and faults are set by software (eagle code)

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Alarm / Faults Group “Cell Bypass” 1(2)

Cell Bypass Com Alarm Alarm in software

Any Medium Voltage Board Communication failure.
Only if bypass is not being utilized while drive is running

Cell Bypass COM Fail Fault in software

Cell Bypass Communication failure, Bits are missing
When cell bypass is required the fault will be initiated

Cell Bypass Acknowledge Fault in software

Cell Bypass Contactor Acknowledge alarm. Only when bypass is not in use.

Cell Bypass Link Fault in software

Cell Bypass communication failure, no communication
Link is disconnected

Cell Bypass Link Alarm Alarm in software

Medium Voltage Bypass board communication  Modulator link failed.
Only if bypass is not used.

Cell Bypass Fault Fault in software

Any Cell bypass Fault

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Alarm / Faults Group “Cell Bypass” 2(2)

Bypass Verify Failed Fault in software

Bypass Verify Failed

Bypass Ack Failed Fault in software

Bypass Contactor closure acknowledge failed

Bypass Avail Warning Alarm in software

Cell level Bypass Available alarm. Only if bypass is used.

Cell Bypass Link Fault in software

Medium Voltage Board  Modulator board Link failure

Cell count Mismatch Fault in software

Mismatch of cells with what controls is set for

Back EMF Timeout Fault in software

Back EMF to high to complete cell bypass operation
Limit set by ID2580 timeout.

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Alarm / Faults Group “Controls” 1(2)

Modulator Configuration Fault in software

Modulator cannot determine cell configuration
Bad modulator board, Replace

Modulator Board Fault Fault in software

Defect determined on modulator board
Replace modulator board

Carrier Frequency Set too low Alarm in software

Carrier frequency selection below system configuration capability.
Control will select closest achievable value
You only have to acknowledge the alarm.

Cell Fault/Modulator Fault in software

An undefined fault from a cell.

Bad Cell Data Fault in software

Cell data packet mode bits incorrect

Cell Config Fault Fault in software

Modulator Cell configuration does not agree with Menu setting of Installed cells.

Modulator Watchdog Fault Fault in software

Modulator detected that the CPU stop communicating with it.

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Alarm / Faults Group “Controls” 2(2)

Loss of Drive Enable Fault in SOP

Modulator detected loss of Drive Enable
LossOfDriveEnable_I

Menu Initialization Fault in software

Unable to correctly initialize menu system with the text or configuration file.

Weak Battery Fault in software

Non-Volatile RAM battery on Modulator board weak

Loss of Signal (1-24) Alarm in SOP

Analog input below to Menu setting of loss of signal point (Menu)
LossOfSignal1_O = True
Setup Loss of signal input in Menu

User Defined Faults (up to 64) Alarm/Fault in SOP

This is a system program fault or alarm flag that is user programmable; e.g.
UserFault45_O = ExternalDigitalInput01a_I; Fatal Fault
UserText45 = ‘Blower failure’
UserFault45Wn_O = True; makes it a warning
This has to be set before userfault45_O

For more examples of frequently used “User Defined Faults” refer to section “PH Main Software, page 13”.

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Alarm / Faults Group “Human- and Field-Interface”

Wago Communication Fault Fault in software

Control can't communicate with Wago, exceeds timeout.

Wago configuration Fault in software

Wago configuration is different from the Menu settings for external I/O
(I/O type or count)

Tool Communication Alarm/Fault in SOP

ToolCommunicationEn_O = True; Fatal fault
ToolCommunicationWn_O = True; makes it an alarm

Keypad Communication Alarm/Fault in SOP

KeypadCommunicationEn_O = True; Fatal
KeypadCommunicationWn_O = True; makes it an alarm
Keypad failed to communicate with CPU.
This is a system program fault or alarm flag that is user programmable.

Network 1 Communication Alarm/Fault in SOP

Network 1 communication failed.
This is a system program fault or alarm flag that is user programmable.
Network1Communication_O = True;
Network1CommunicationWn_O = True; Fault unless this line is in. Then alarm
ExternalDigitalOutput01a_O = Network1CommOk_I

Network 2 Communication Alarm/Fault in SOP

Same setup as Network 1

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Alarm / Faults Group “General”

System Program Fault in software

System Program corrupt or not on FLASH disk
After formatting a new disk this will occur if the SOP is not installed

Hall Effect Power Supply Fault in software

Hall effect sensor power supply fail (one or both)

Power Supply Fault in software

Control power supply failed

Excessive Drive Losses Fault in software

Can be made a warning in the SOP
Drive Losses are too high. Check if input and output voltage and current
scalars are correctly adjusted to display true Volts, and Amps.
If nothing in the SOP file then a fatal fault
Should be tied into the customers MV shutoff
ExcessiveDriveLossesWn_O = True; sets it to a warning
(5% when drive runs, else 31%).

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Alarm / Faults Group “Sync Transfer”

Up Transfer Fault in SOP

UpTransferFaultEn_O = True;

Down Transfer Fault in SOP

DownTransferFaultEn_O = True;
(Future)

Phase Sequence Alarm/Fault in SOP

Phase sequence of the drive input power and output power wiring is different.
PhaseSequenceEn_O = True;
ExternalDigitalOutput02a_O = PhaseSequence_I;
(Future)

Excessive Phase Error Alarm/Fault in SOP

Phase error between the input and output signals is above the
phase error limit for performing a synch transfer.
ExcessivePhaseErrorEn_O = True;
ExternalDigitalOutput02b_O = ExcessivePhaseError_I;
(Future)

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Alarm / Faults Group “Reactor”

Output Reactor for filtering; pick-up via temperature switches

Reactor Temperature 1 Alarm in SOP
ReactorTemperature1En_O = ExternalDigitalInput01f_I;
Setup by comparator

Reactor Temperature 2 Alarm in SOP

ReactorTemperature2En_O = ExternalDigitalInput01f_I;

Reactor Temperature Fault Fault in SOP

ReactorTemperatureFaultEn_O = Comparator3_I;

For examples of applications with Reactors on Perfect Harmony Drives

please refer to Section “Electronic Power Devices, page 10”.

13_Next Gen Faults page 23 © Siemens Industry 2013 - subject to modification