080-MV7000 User Manual Section6 - Maintenance - 4MKG0016 - Rev C PDF

MV7000 MEDIUM VOLTAGE DRIVE RANGE
USER MANUAL
SECTION 6: MAINTENANCE AND SAFETY
AUTHORISED FOR ISSUE BY: Samir Soua
C 01/09/07 L.Brohl/E.A.Thufail Updated

B 07 Dec 06 M POSTIC Revised based on users feedback
A 18/01/2006 C COUSSEAU Initial Issue
Version Date Author Reason for new issue (see last pages for modification record)
Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Project : USER MANUAL Version Ind-Work : C
Document : SECTION 6: MAINTENANCE AND SAFETY Date : 01.09.2007
File : MV7000 User Manual Section 6_Maintenance_4MKG0016_rev C Page : 6-1 / 38
©2007 CONVERTEAM For support and comments contact MV7000usermanual@converteam.com
This document is the exclusive property of CONVERTEAM and cannot be reproduced, transmitted or disclosed without prior authorisation.
CONTENTS
FOREWORD ............................................................................................................................... 6-4
SECURITY WARNING ................................................................................................................ 6-4
6. MAINTENANCE AND SAFETY............................................................................................ 6-4

6.1 INTRODUCTION........................................................................................................... 6-5
6.2 DRIVE GROUNDING PROCEDURE............................................................................. 6-5
6.2.1 General ................................................................................................................... 6-5
6.2.2 Measurement, Grounding and Personal Safety Equipment ..................................... 6-6
6.2.3 Kirk key interlock system......................................................................................... 6-7
6.2.4 Drive Shutdown and Grounding Steps .................................................................... 6-8
6.3 PREVENTIVE MAINTENANCE................................................................................... 6-18
6.4 POWER PARTS REPLACEMENT .............................................................................. 6-19
6.4.1 Preliminary Checks ............................................................................................... 6-19
6.4.2 Torque table.......................................................................................................... 6-19
6.4.3 IGBT Module Replacement ................................................................................... 6-20
6.4.4 0V Diode replacement........................................................................................... 6-22
6.4.5 Freewheeling diode stack replacement ................................................................. 6-22
6.4.6 IGBT Power stack replacement............................................................................. 6-24
6.4.7 Rectifier diode stack replacement ......................................................................... 6-26
6.5 COOLING UNIT INSTRUCTIONS ............................................................................... 6-28
6.5.1 Cooling unit main data .......................................................................................... 6-30
6.5.2 List of settings ....................................................................................................... 6-31
6.5.3 Commissioning ..................................................................................................... 6-32
6.5.4 Maintenance ......................................................................................................... 6-33
6.5.5 Cleaning instructions............................................................................................. 6-35
6.6 ELECTRONIC CONTROL BOARDS ........................................................................... 6-36
6.6.1 Preliminary steps .................................................................................................. 6-36
6.6.2 Control Boards Replacement ................................................................................ 6-36
6.6.3 Restart after servicing control boards.................................................................... 6-37
LIMITATION OF LIABILITY ...................................................................................................... 6-37
MODIFICATION RECORD ........................................................................................................ 6-38

TABLE OF ILLUSTRATIONS
Figure 6-1 Kirk Key Interlock System Principle .............................................................................................. 6-7

Figure 6-2 Drive Shutdown and Grounding Flow Chart (main steps only)..................................................... 6-9
Figure 6-3 IGBT Inverter Stack with Gate Driver Indicators ......................................................................... 6-12
Figure 6-4 Measuring points in DC link cubicle ............................................................................................ 6-13
Figure 6-5 Measuring points at MV73xx IGBT inverter stack....................................................................... 6-15
Figure 6-6 Measuring points at MV76xx IGBT inverter stacks ..................................................................... 6-16
Figure 6-7 Drive grounding completed ......................................................................................................... 6-17
Figure 6-8 IGBT replacement - 1/4............................................................................................................... 6-20
Figure 6-9 IGBT replacement - 2/4............................................................................................................... 6-20
Figure 6-10 IGBT replacement - 3/4............................................................................................................. 6-20
Figure 6-11 IGBT replacement - 4/4............................................................................................................. 6-20
Figure 6-12 Plastic tool to remove IGBT ...................................................................................................... 6-21
Figure 6-13 Freewheeling diode stack replacement - 1/4 ............................................................................ 6-22
Figure 6-17 IGBT stack replacement - 1/5 ................................................................................................... 6-24
Figure 6-22 Rectifier diode stack replacement - 1/2..................................................................................... 6-26
Figure 6-23 Rectifier diode stack replacement - 2/2..................................................................................... 6-26
Figure 6-24 Typical flow diagram of the cooling unit .................................................................................... 6-29

FOREWORD
The following signs will require reader attention in this manual.
Note:
Notes separate important information from the text and give

additional information.
Important!
Important means that the relevant instruction must be followed

exactly to avoid loss of data or damage.
Warning!
Warning means that the operator may be injured if the

instructions are not followed.
SECURITY WARNING
Users shall read safety instructions available in Section 1 of User manual.
6. MAINTENANCE AND SAFETY

This document is the Section 6 of MV7000 User manual:
SECTION 1:
Introduction
SECTION 2:
Technical Data
SECTION 3:
Installation
SECTION 4:
Operating Instructions
SECTION 5:
Protection & Diagnostic
SECTION 6:
Maintenance & Safety

WARNING
• Hazardous Voltages are present in this equipment. These voltages may exist even after
isolation of the main and auxiliary supply sources.
• Wait at least 10 minutes after isolation and lockout of all external supply sources
before closing grounding switch and opening doors of Medium Voltage compartments.
• CONFIRM that the DC link stored energy is DISCHARGED and the drive system is
GROUNDED before working on the equipment.
6.1 INTRODUCTION
This section describes:
• Maintenance of the MV7000 power stacks, fans and control boards.
• Safety procedures to be carried out prior to servicing MV7000.
No component level maintenance is described. If either power stacks or control boards require
component level maintenance, a request for assistance should be made to CONVERTEAM.
Note: This document provides help for maintenance operation, but does not provide practical
training for the described operations. In addition, maintenance staff shall attend a
dedicated CONVERTEAM training session.
6.2 DRIVE GROUNDING PROCEDURE
6.2.1 General
Medium voltage capacitors are used in MV7000
• to provide the two voltage levels of the DC link.
• as an integral part of the optional filter circuits (output dv/dt, sinus, …).
• as snubber capacitors in the rectifier.
These capacitors are provided with passive discharge resistors, which allow the stored energy in
each capacitor to be discharged. The discharge circuit is designed to discharge the stored energy
to less than 50V, within 10 minutes after the main AC supply and the auxiliary supply are
disconnected.
WARNING
• To ensure that the equipment is safe to work on, it is mandatory that all external supply
sources be disconnected and locked out, the stored energy in the capacitors
discharged, the absence of voltage verified, and the equipment grounded. Failure to do
so may result in personal injury and/or death.
The minimum required equipment and the procedure to make the drive safe to work on are
described further in this document.
Note: A warning label on the grounding switch cabinet door summarizes the various
requirements for a safe access to the equipment.

6.2.2 Measurement, Grounding and Personal Safety Equipment
6.2.2.1 Measurement and Grounding Tools

The following tools are required for working on the equipment:
• Medium voltage voltmeter – for measurement of

AC and DC voltages,
up to 4kV AC and 6.5kV DC for MV73xx,
up to 8kV AC and 13kV DC for MV76xx.
Check for proper function before use.
• 3 sets of 3-pole grounding and short-circuiting leads

(called “grounding leads” below).
2 sets are needed for a 6-pulse AFE drive;
5 sets are needed for a 24-pulse DFE drive.
• Isolating handle to connect/disconnect grounding leads.
The above tools and accessories can be supplied

by CONVERTEAM on request.
On the drive side, fixed ballpoints of 18 mm Ø are provided as

measuring and grounding points, to be contacted with these tools.
(Sample photos by courtesy of

www.tietzsch.de and
www.dehn.de .)
6.2.2.2 Personal Safety Equipment

For arc protection it is required that personnel working on the MV7000 wear the following safety
equipment during the grounding procedure:
• Fire retardant/arc resistant coveralls.
• Medium voltage safety gloves, certified for working on medium voltage equipment
up to 4kV AC and 6.5kV DC for MV73xx
up to 8kV AC and 13kV DC for MV76xx.
• Safety hard hat with full face shield.
• Earmuffs for ear protection.
• Safety shoes.

6.2.3 Kirk key interlock system
6.2.3.1 Stand-alone single drive

After the motor has been stopped, the Kirk key interlock system will synchronize the operations as
following:
• Open MV incoming breaker, close grounding switch of supply => get Key X from Box 1.
• Open precharge supply 400V breaker => get Key A.
• Put Keys X and A into Box 2.
• Wait 10 min to allow capacitors discharge.
• Get Key B from Box 2 to close MV7000 grounding switch.
• Get Key C from grounding switch closed to release Keys D from Box 3 to open each
MV7000 medium voltage cubicle.
Nb of locks = N
ORDER OF THE
OPERATIONS
SYMBOLS
Nb of locks = N
Figure 6-1 Kirk Key Interlock System Principle
WARNING
For safety reasons, it is prohibited to reproduce duplicate interlock keys.

6.2.3.2 Parallel drives and DC bus systems
For MV7000 parallel drives (MV7312 / MV7316 / MV7624 / M7632) or DC bus system
configurations, a grounding switch is fitted on each of the parallel units. A Kirk key interlock system
similar to Figure 6-1 will ensure that all grounding switches are closed before releasing access to
any MV7000 medium voltage cubicle.
6.2.4 Drive Shutdown and Grounding Steps

An overview of the drive shutdown and grounding procedure is shown in Figure 6-2. It is detailed
on the following pages.
Note: This procedure applies to MV7000 standard drives only, which are fitted with
• a Kirk key interlock system according to Section 6.2.3,
• an MV supply circuit breaker and a corresponding grounding switch on the main
transformer primary side, (all out of MV7000 scope of supply)
both switchgear included in the key interlock system,
• an MV7000 grounding switch,
• no DC link voltmeter,
• neither fuses nor switchgear in the DC link connection inside the drive system.
For other MV7000 project specific drive systems, refer to the project documentation.

Start grounding
STOP the motor
Wait until standstill
Open and lock out MV supply cicuit breaker

Shut down and precharge breaker
procedure (and excitation supply circuit breaker,
if synchronous motor)
Close grounding switch of supply
Wait 10 minutes
Close MV7000 grounding switch
Drive cubicle doors can be opened
Check gate driver fault indicators
Open and lock out auxiliary supplies
Measure DC link voltage
Voltage yes
> 50 V DC?
no
Measure voltage at input terminals
Grounding Voltage yes

> 50 V
procedure AC or DC?
no
Ground input terminals
Measure voltage at output terminals
Voltage yes
> 50 V
AC or DC?
no
Ground output terminals
Measure voltage at the inverter stacks
Abnormal condition
yes during grounding procedure.
Voltage
> 50 V DC? Damage probably!
Call CONVERTEAM
no
Grounding finished
Figure 6-2 Drive Shutdown and Grounding Flow Chart (main steps only)

6.2.4.1 Shutdown Procedure
Before grounding medium voltage sections, the MV7000 drive should be shut down in an orderly
manner. Please follow the stepwise shutdown procedure below.
Step 1: Stop the motor

• by pressing the “STOP” key on the MV7000 keypad in Local Mode or
• on remote request in Normal Operating Mode.
(Refer to User manual Section 4 for operating mode description, and refer to project
specific documentation for remote operation.)
Step 2: Wait until the motor has come to a standstill.
Step 3: Open the MV supply circuit breaker

• in Local Mode: by pressing the “STOP” key on the MV7000 keypad once
again. Depending on software version, the MV supply
circuit breaker may already have opened automatically.
• in Normal Operating Mode: Refer to project specific documentation for the MV supply
circuit breaker opening procedure. (It may be necessary
to open the circuit breaker by means of its local
command.)
Step 4: Open the precharge circuit breaker.

For synchronous motor drives, open the excitation supply circuit breaker, too.
Verify the absence of voltage at the low-voltage side of the precharge circuit and at the
excitation supply circuit.
Leave the other auxiliary supplies (cooling, fans, controller, etc.) energized until Step 14.
Step 5: Isolate the MV supply circuit breaker by racking it out. Lock out in accordance with local
codes and with installation specific lockout procedures.
Lock out the precharge circuit breaker.
Lock out the excitation supply circuit breaker, if applicable.
Step 6: Close and lock the grounding switch corresponding to the MV supply circuit breaker.
Step 7: Visually inspect

• that the contacts of the supply grounding switch are closed,
• the PE connection of the grounding switch.
Step 8: Wait 10 minutes to allow for capacitor discharge. You may use the keypad display to
watch the DC link voltage decreasing. However, from a safety viewpoint, this is not a safe
voltage indicator.
After 10 minutes, proceed to the grounding procedure.

6.2.4.2 Grounding Procedure
Prior to carrying out the grounding procedure,
• confirm that the motor has come to standstill,
• confirm that the MV supply circuit breaker and the precharge circuit breaker have been
isolated and locked out,
• confirm that the contacts of the supply grounding switch are closed and that this switch is
locked out,
• confirm that the requisite 10 minutes have elapsed after opening the two breakers
mentioned above,
• ensure that the required tools as per Section 6.2.2.1 are available and verified for proper
function,
• ensure that the required personal safety equipment as per Section 6.2.2.2 is being worn.
For grounding the drive, please follow the stepwise procedure below.
Step 9: Get the key(s) to operate the grounding switch(es) from the Kirk key interlocking system.
(Refer to Section 6.2.3.)
Step 10: Close the MV7000 grounding switch(es).
Step 11: Get the keys to open the doors of the drive cubicles from the Kirk key interlocking system.
(Refer to Section 6.2.3.)
Open the door of the cubicle with the grounding switch at first.
WARNING
• Be aware of possibly live parts in your proximity.
Step 12: Visually inspect

• the MV7000 grounding switch,
• its contact areas
• that the contacts are closed,
• the PE connection of the grounding switch.

Step 13: Open the doors of the inverter cubicles.
If the drive has tripped on some IGBT fault before, the gate driver fault indicators
(red LEDs) provide additional information for later fault finding. (The green and yellow
LEDs on the gate driver boards can be ignored here.)
If any of these red LEDs in Figure 6-3 is lit, please note the type of fault indicated
according to section 5 and the position at which IGBT it occurred.
Gate driver indicators
Figure 6-3 IGBT Inverter Stack with Gate Driver Indicators
Step 14: Open and lock out all remaining auxiliary supplies:
• 3AC 400V for cooling pumps,
• 1AC 230V for cubicle fans,
• 1AC 230V UPS-buffered supply for the controller,
• 1AC 230V for receptacles (socket outlets),
• and others (project specific).
Verify the absence of voltage in all these low-voltage circuits.
Step 15: Verify proper function of the medium voltage voltmeter.
Step 16: Open the doors of the MV7000 DC capacitors cubicle(s).

Step 17: Measure the DC link voltages at the marked locations in each DC capacitors cubicle.
For each line of (up to) 3 capacitors, measure the “pole-to-pole-voltage” and the voltage
“from one pole to ground”.
Since the Grounding Switch is closed, the voltages should all be 0 V.
If any of the voltages is > 50 V DC, stop the grounding procedure and proceed to
Section 6.2.4.3.
measure at the
copper plates
Figure 6-4 Measuring points in DC link cubicle

Step 18: Open the doors to get access to the MV7000 input terminals:
With DFE drives, the input terminals are located in the Diode Front End cubicle(s).
There are 6 terminals U1, V1, W1, U2, V2, W2 for a 12-pulse configuration and
12 terminals for a 24-pulse configuration.
With AFE drives, the 3 input terminals of a 6-pulse configuration are located in the
Input cubicle.
Measure the voltage at the input terminals of MV7000. Proceed as follows for each 3-phase system
of the input voltage, starting with the rearmost system.
Step 19: Measure the phase-to-phase voltages and the phase-to-ground voltages.
If any of the voltages is > 50 V DC or AC, stop the grounding procedure and proceed to
Section 6.2.4.3.
Step 20: If all voltages of this 3-phase system are < 50 V DC or AC, connect the ground clamp of
the grounding lead for the input terminals to the copper ground bar.
WARNING
• For handling the ball head caps, always use the isolating handle.
Step 21: Connect the grounding lead to the 3 fixed ball points of the input terminals for this
3-phase system.
Step 22: Repeat Step 19 to Step 21 for the other 3-phase systems of the input voltage. (2 systems
for 12-pulse, 4 systems for 24-pulse configuration.)
Step 23: Open the doors to get access to the MV7000 output terminals:
If the drive is equipped with a filter, the output terminals U, V, W are located in the filter
cubicle; otherwise they are located in the inverter cubicle (AC output section).
For parallel drives, there may be two filter cubicles with 3 output terminals each; start with
one filter cubicle then.
Step 24: Measure the voltage at the output terminals of MV7000: Measure the phase-to-phase
voltages and the phase-to-ground voltages.
If any of the voltages is > 50 V DC or AC, stop the grounding procedure and proceed to
Section 6.2.4.3.
Step 25: If all voltages are < 50 V DC or AC, connect the ground clamp of the grounding lead for
the output terminals to the copper ground bar.
Step 26: Connect the grounding lead to the 3 fixed ball points of the output terminals U, V, W.
Step 27: For parallel drives with two filter cubicles (3 output terminals each), repeat Step 24 to
Step 26 for the other set of output terminals.

Step 28: Measure the clamp capacitors’ voltage in each inverter cubicle:
Measure the “pole-to-pole-voltage” and the voltage “from one pole to ground” once per
megamodule, at the middle IGBT stack. Because the clamp capacitors are located
behind the IGBT stack, suitable measuring points are marked in Figure 6-5 and
Figure 6-6.
Since the Grounding Switch is closed, the voltages should all be 0 V.
If any of the voltages is > 50 V DC, stop the grounding procedure and proceed to
Section 6.2.4.3.
+ 0 –
clamp capacitors
(behind inverter stack)
inverter stack
+ 0 –
(at center heatsink)
Figure 6-5 Measuring points at MV73xx IGBT inverter stack

+ 0 –
clamp capacitors
(behind inverter stacks)
inverter stacks
+ 0 0 –
(at heatsink between (at heatsink between
diode and isolation) diode and isolation)
Figure 6-6 Measuring points at MV76xx IGBT inverter stacks

The drive with all grounding leads should now look like Figure 6-7.
U1,V1,W1
U,V,W
M
U2,V2,W2
Input terminals Grounding switch Output terminals

grounded closed grounded
Figure 6-7 Drive grounding completed
The equipment is now safe to access.

Depending on the location of maintenance work to be performed subsequently:
• If you’re working in a DC capacitors cubicle, verify for each individual capacitor that it is
discharged.
• If you’re working in an inverter cubicle and you are planning to access the clamp capacitors
behind the megamodule, verify that each clamp capacitor is discharged.
Measure the “pole-to-pole-voltage” and the voltage “from one pole to ground” directly at the
capacitors terminal bolts. If any of the voltages is > 50 V DC, stop the grounding procedure and
proceed to Section 6.2.4.3.
If you’re working at one of the capacitors of the dv/dt-filter, sinus filter, rectifier snubbers,
IGBT snubbers (MV76xx) or 0V-diode snubbers (MV76xx), verify directly at its terminals that it is
discharged. If any of the voltages is > 50 V DC, stop the grounding procedure and proceed to
Section 6.2.4.3.
6.2.4.3 Abnormal conditions during Grounding Procedure

If, during the course of the normal Grounding Procedure, you are advised to proceed to this
section, then a voltage > 50 V has been measured at a point where it should be approx. 0 V.
This indicates that some component (internal discharge circuit / ground switch /
key interlocking system) has failed, or that the motor has not come to a standstill. In all these
cases, consequential damage (of capacitors / rectifier / IGBTs / etc.) probably has occurred.
If you have been advised to proceed to this section, close and lock all doors and contact
Converteam for further fault finding assistance and repair.

6.3 PREVENTIVE MAINTENANCE
Preventive maintenance schedule for MV7000 drive is given in following chart.
Prior to working on MV7000, ensure that the drive has been safely grounded in accordance with
the Drive Grounding Procedure. Refer to Section 6.2 of this manual.
Once in a Once in a Once in

Operation
month year 5 years
Refer to dedicated Section 6.5.4, and to

Cooling Unit
cooling unit supplier documentation
Visual inspection of the following items:
Frame painting (corrosion) X
Bus bars (overheating) X
Wiring (corrosion or overheating) X
Water leakage X
Component deterioration X
Air filters (clean if necessary) X
Clean inside the cabinets X
Clean controller rack air filters X
Check electrical connections are tightened X
Check water connections are tightened X
Check the fans (converter and controller) X
Capacitors measurement (disconnected) X

6.4 POWER PARTS REPLACEMENT
6.4.1 Preliminary Checks
Prior to working on MV7000, ensure that the drive has been safely grounded in accordance with
the Drive Grounding Procedure. Refer to Section 6.2 of this manual.
Only staff trained by CONVERTEAM must carry out maintenance operation described in this
section.
6.4.2 Torque table

Note the following Torque table, which is to be followed for tightening of the various nuts and bolts
in the MV7000 drive unit.
Hydraulic connections on IGBT stack - 30Nm.
Capacitors - 25 Nm on DC bus capacitors, 13 Nm on clamp capacitors. For filter capacitors, refer to
indication on capacitor, the recommended torque is usually specified.
METAL BOLTS ELECTRICAL CONNECTIONS
size M4 M5 M6 M8 M10 M12 M14

with flat washers 1.5 3 6 12 24 45 65
with contact type washer 2 4 6.5 16 31 54 85
Add torque with Philidas self +0.5 +1 +1.4 +3.5 +7 +10 +17
locking nuts
PLASTIC BOLTS (polyamide)
size M4 M5 M6 M8 M10 M12

torque 0.5 1 1.5 3 8 15
Metal bolts and screws must never be replaced by an isolating type and vice versa.

6.4.3 IGBT Module Replacement
This module comprises
- IGBT semiconductor
- Gate driver
- DC/DC converter for 17V DC supply
These components are integrated into an extractor to ease mechanical handling. Due to the
sensitivity of the IGBT semiconductor to incorrect mounting or mechanical impact, it is not allowed
to dismantle the IGBT out of the extractor and replace it separately.
4a
2
1 3
0
6
4b
Figure 6-8 IGBT replacement - 1/4 Figure 6-9 IGBT replacement - 2/4
9
5
10
pin (black)
Do not adjust this central nut
Figure 6-10 IGBT replacement - 3/4 Figure 6-11 IGBT replacement - 4/4

Procedure to remove the module
0 – Disconnect the optical fibers, as a first step to avoid any further damage. (See Figure 6-8).
1 – (Depending on IGBT position) Disconnect the gray power cables to ease your access (See
Figure 6-8).
2 – Disconnect the cable between the module and the heat sink (See Figure 6-8).
3 – Disconnect the 24V wires (See Figure 6-8).
4a – Remove the isolated bus bars in the path, if required (See Figure 6-9).
5 – Remove the pin, lift the spacer (washer under the central nut) and keep it in this position.
Unscrew (5 mm) the 2 external nuts of the clamping system (See Figure 6-10).
Do not adjust the central nut of the inverter stack. If accidentally it got disturbed, then
this stack should not be installed in MV7000. Contact CONVERTEAM.
6 – Take off the module (See Figure 6-9). The module

can stick between the heat sink (water boxes) due
to grease on contact surfaces. To release it,
carefully insert a suitable plastic tool (see
Figure 6-12) between module and heat sink.
Figure 6-12 Plastic tool to remove IGBT

7 – Remove the IGBT module
Preparation before new module insertion

8 – Clean the area of the heat sinks in contact with the IGBT using a soft rag and alcohol (like
“Beltane” for example).
9 – Revive the IGBT faces using a scotch brite (See Figure 6-11).
3
10 – Apply grease NIKKEI S200 (1/4 of cm ) on both faces of IGBT (See Figure 6-11).
Procedure to insert the new module

11 – Push the IGBT module between the heat sinks.
12 – Screw the 2 external nuts of the clamping system (half turn per half turn). When the spacer
becomes loose again, stop screw. Insert the pin again (See Figure 6-10).
13 – Reconnect the isolated bus bars, if previously disconnected (See Figure 6-9).
14 – Reconnect the 24V wires, and the cable between the module and the heat sink.
(See Figure 6-8).
15 –Reconnect the gray cables, if previously disconnected.
16 –Reconnect the optical fibers.

6.4.4 0V Diode replacement
The 2 diodes are located in the central part of the stack. The replacement procedure is the same
as for IGBT, but operations linked to the cabling (i.e., steps 0-2-3 and 14-16) are not applicable.
Step 4a is to be replaced by 4b, which means removing the flexible bus bars on top and bottom
parts of the stack.
6.4.5 Freewheeling diode stack replacement

This procedure is applicable only to MV7308, MV7316, MV7616, and MV7632.
The freewheeling diode must be removed as a complete stack. A forklift is required, as this weighs
about 20kg.
Before changing a stack, stop the cooling unit and decrease the hydraulic pressure.
(Refer to Section 6.5)
Figure 6-13 Freewheeling diode stack Figure 6-14 Freewheeling diode stack
replacement - 1/4 replacement - 2/4
3
6
Forklift supporting
Figure 6-15 Freewheeling diode stack Figure 6-16 Freewheeling diode stack

Procedure to extract the freewheeling diode stack
1 – Unscrew the external hydraulic connections (front nut only). (See Figure 6-13).
2 – Unscrew the mechanical and electrical connections with the IGBT stack. (See Figure 6-14).
3 – Unscrew the connection between the stack and the busbar. (See Figure 6-15).
4 – Remove the stack using a forklift. (See Figure 6-15).
Procedure before insertion of the new freewheeling diode stack

5 – Clean all water leakages resulting from above operations.
6 – Clean the contact area of the busbar. (See Figure 6-16).
Procedure to insert the freewheeling diode stack

7 – Using the forklift, advance the stack to the correct place. When stack is in place, screw the
connection between the stack and the busbar. (See Figure 6-15).
8 – Screw the mechanical and electrical connections with the IGBT stack. (See Figure 6-15).
9 – Screw the external hydraulic connections (see Figure 6-13), at torque specified in section 6.4.2.
After the replacement, add de-ionized water to the cooling unit. (Refer to Section 6.5.)
Check that there is no leakage in the inverter cubicle before starting MV7000.

6.4.6 IGBT Power stack replacement
To replace the IGBT stack, a forklift is required. (Weight is about 90 kg)
(Refer to Section 6.5)
3
1
Figure 6-17 IGBT stack replacement - 1/5 Figure 6-18 IGBT stack replacement - 2/5
5
8
4
Forklift supporting
Figure 6-19 IGBT stack replacement - 3/5 Figure 6-20 IGBT stack replacement - 4/5
Figure 6-21 IGBT stack replacement - 5/5

Procedure to extract the IGBT stack
0 – Disconnect the optical fibers, as a first step to avoid any further damage (See Figure 6-17).
1 – Disconnect the gray power cables in front of the stack to be changed (See Figure 6-17).
2 – Unscrew the external hydraulic connections (front nut) (See Figure 6-17).
3 – Disconnect 24V wires. (See Figure 6-18)
4 – Unscrew the mechanical and electrical connections with the freewheeling diode stack (if used)
(See Figure 6-19)
5 – Unscrew the connection between the stack and the busbar (See Figure 6-19)
6 – Remove the stack using a forklift.
Procedure before insertion of the new IGBT stack

7 – Clean all water leakages resulting from above operations.
8 – Clean the contact area of the busbar. (See Figure 6-20).
Procedure to insert the new IGBT stack

9 – Using the forklift, advance the stack to the correct position. When it is in place, push the stack
to plug the contact located behind the stack (See Figure 6-21).
10 – Screw the connection between the stack and the busbar (See Figure 6-19).
11 – Screw the mechanical and electrical connections with the freewheeling diode stack (if used)
(See Figure 6-18).
12 – Reconnect 24V wires. (See Figure 6-18).
13 – Screw the external hydraulic connections (See Figure 6-17), at torque specified in
Section 6.4.2.
14 – Reconnect the gray power cables (See Figure 6-17).
15 – Reconnect optic fibers. (See Figure 6-17)
Check that there is no leakage in the inverter cubicle before starting MV7000.

6.4.7 Rectifier diode stack replacement
To replace rectifier diode stack, a forklift is required (Weight is about 30 kg).
(Refer to Section 6.5.)
1
3 4
2
5 8
Forklift supporting
Figure 6-22 Rectifier diode stack Figure 6-23 Rectifier diode stack
Procedure to remove a rectifier diode stack

1 – Unscrew the external hydraulic connections (front nut)(See Figure 6-22).
2 – Disconnect all DC power bars on the connection plate located on the front of the stack.
(See Figure 6-23).
3 – Disconnect all cables of the link between the stack and the RC system. (See Figure 6-23).
4 – Disconnect all power bars on the connection plate located on the back of the stack.
(See Figure 6-23).
5 – Unscrew the connection between the stack and the busbar (See Figure 6-22).
6 – Remove the stack using a forklift.
Procedure before insertion of the new rectifier diode stack

7 – Stop all leakages.
8 – Clean the contact area of the busbar (See Figure 6-22).

Procedure to insert the new rectifier diode stack
9 – Using the forklift, advance the stack to the correct position. When it’s in place, screw the
external connection between the stack and the busbar (See Figure 6-23).
10 – Reconnect all power bars on the plate located on the back of the stack (See Figure 6-23).
11 – Reconnect all power cables of the link between the stack and the RC system.
(See Figure 6-23).
12 – Reconnect all DC power bars on the plate located on the front of the stack (See Figure 6-22).
13 – Screw the external hydraulic connections (See Figure 6-22).
Check that there is no leakage in the diode front-end cubicle before starting MV7000.

6.5 COOLING UNIT INSTRUCTIONS
The detailed description regarding the cooling unit is described in the documentation from cooling
unit supplier, which is delivered along with MV7000 documentation.
MV7000 user manual gives a general-purpose introduction to cooling unit, and guidelines for
maintenance and commissioning of the same. It is important to refer detailed data and
documentation of cooling unit supplier (provided by CONVERTEAM) in conjunction with
user manual before doing procedures for the cooling units.
The cooling unit is housed in a cabinet mounted inside the converter. Water circuits are distributed
in the converter power cabinets. Figure 6-24 shows a typical flow diagram.
Deionized water main circuit is composed of:
• the heat exchanger (deionized water circuit to raw water circuit).
• a screen filter.
• the pumping circuit.
The water circulation can be made using a single pump (standard) or two pumps in redundancy
(option).
Precharge and purification circuit:

• It is connected in parallel to the main circuit between inlet and outlet.
• Precharge circuit is fitted with a membrane expansion tank providing a reserve of pressurized
water in the circuit (to compensate eventual loss of volume of pure water). It also includes a
pressure measurement device.
• Purification circuit ensures water deionization. It includes a filter, a deionization cartridge for
water purification and a valve controlled by a conductivity meter.
Filling circuit:
• Filling circuit enables to fill the water circuit with pure water and to add some water after
draining or after a leakage. It is fixed with a screwed type connection of size 3/8’’ and a valve.

RAW
WATER
VG031
Figure 6-24 Typical flow diagram of the cooling unit

6.5.1 Cooling unit main data
DEIONIZED WATER
MAIN CHARACTERISTICS RAW WATER CIRCUIT
CIRCUIT
Static operating pressure 1.5 bar
Maximum operating pressure (Ps) 6 bar 6 bar
Test pressure 10 bar 10 bar
Pressure drop ≤ 1 bar
Filling circuit pressure 1.5 bar (-0 to +0.5)
Minimal Flow Refer to specific project documents
Initial pressure at empty tank 0.4 bar
Nominal water conductivity 0.5 µS/cm (2 MΩ · cm)

Raw water characteristics
15°C to 38°C (>38°C or
Temperature
<0°C with de-rating
(1)
Hardness 25°F
3
Chloride level 50 mg/dm
Ammonium level 0
pH value 6.5 to 8
Maximum 0.5 mm,
Solid particles size
use an appropriate filter
Pump supply voltage Refer to specific project schematics
Supply voltage of auxiliary devices Refer to specific project schematics
Note (1): To convert following calcium hardness units to French degree (°F), use the following
multiplication factors.
mmol/l of alkaline ion 10

mEq/l of alkaline ion 5
ppm of CaCO3 0.1
German degree (°D) 1.78
English degree (°A) 1.43

6.5.2 List of settings
The proper operation of cooling unit is subject to adequate settings.
Parameter Device Alarm Fault

Conductivity DP030 1.5µS/cm 1.9µS/cm
Switch VS030 open >0.6µS/cm
Switch VS030 closed <0.4µS/cm
Deionized water temperature TP080 43°C 45°C
Deionized water pressure PG040 0.9bar 0.5bar
Deionized water flow FM100 X X
X: Deionized water flow alarm and fault settings are defined in project documents, as they depend
on project configuration (MV7000 rating and optional items).
Please refer to cooling unit supplier document for settings and adjustments procedure.

6.5.3 Commissioning
Commissioning recommendations are included in this maintenance manual as they are useful for
several maintenance operations.
6.5.3.1 Checks Prior To Commissioning
Before starting work on MV7000, ensure that the drive has been safely grounded in accordance
with the Drive Grounding Procedure. Refer to Section 6.2 of this manual.
6.5.3.2 Visual checks

Make sure that the items have not been damaged during transportation, handling or after the
cooling unit has been mounted back into the cabinet if latter was removed for maintenance
operations.
6.5.3.3 Hydraulic checks before filling

Check that all flanges and connections are tight.
Check that all connected circuits are connected properly.
Check that filters FI030 and FI020 (cartridge) are in position and locked properly.
Caution: the valves on main pipes must be fully open!
6.5.3.4 Electrical checks

Check that all probes have been connected to their sensors, and have been properly mounted into
the corresponding casing socket.
Make sure that all fault-indicating contacts are connected to terminal blocks in the electrical panel
and check that terminal block connecting screws are tight.
These checks are mandatory for the following situations.
• After unit transportation
• After unit dismantling during maintenance
• During periodical preventive maintenance
6.5.3.5 Water Filling

Refer to the cooling unit supplier document.
6.5.3.6 Starting the pump

Refer to the cooling unit supplier document.

6.5.4 Maintenance
6.5.4.1 Prepare circuit for maintenance
The deionized water flow circuit can be divided into two sections, which will be prepared
independently:
• Main flow circuit: pump(s), exchanger, rectifier and inverter heat sinks,
• Deionization flow circuit (interfaces at points P0, P1 and P6 in hydraulic diagram): deionization
cartridge, expansion tank and filling circuit.
VD090
Main circuit
VG140, rectifier and

VD140 inverter
exchanger
heatsinks
Deionization circuit
VD031
VG040
pumps
To prepare the cooling unit for the maintenance procedures as per Section 6.5.4.2, the following
steps must be performed:
Preparation step Main circuit Deionization circuit
Operation number 6,7,9 Operation number 4,5,8,9
Stop the water circulation Stop pump PE060 (or PE061)
Isolate main circuit from Close valves VG031 and VG040

deionization circuit
Decrease pressure to zero Open tap VD090 Open valve VG140

(wait a few seconds after and tap VD140
tap/valve opening)
Close circuit Close tap VD090 Close tap VD140

6.5.4.2 Preventive maintenance schedule
After
Every Every Every Every Every main part
Operation Conditions
month year 2 years 5 years 10 years replacement
(1)
1 Water pressure check During operation X X
Blow air from water

2 During operation X X
circuit through VD090
Measurement of motor
3 During operation X
pump current
During operation,
Deionization cartridge
4 no pressure in X
replacement
During operation,
5 Cleaning of filter FI030 no pressure in X X
6 Cleaning of filter FI020 Stopped X X
Cleaning of raw water

7 circuit of internal heat Stopped X
exchanger
Pressure check in
8 expansion tank and Stopped X
inflate if needed
9 Replacement of hoses Stopped X
Note (1): main part replacement means: pump, exchanger, power stack, etc.
To carry out the mentioned operations, please refer to detailed instructions in the cooling
unit supplier documentation.
For replacement of hoses, contact CONVERTEAM. Only qualified personnel must supervise this
operation.
The preventive maintenance schedule shown below is based on raw water quality as per
CONVERTEAM specification (refer to section 6.5.1). Non-compliant water quality may result
in more frequent needs for maintenance operation and possible damage to the cooling unit.

6.5.5 Cleaning instructions
6.5.5.1 Cooling Unit Cleaning

Do not store anything in the cooling unit cabinet.
Always perform careful inspection and cleaning after any intervention.
6.5.5.2 Water to Water Heat Exchanger Cleaning

It is recommended to avoid dismantling or inspection operations on the heat exchanger.
Carry out simple operations by flushing the circuit (raw water side especially).

6.6 ELECTRONIC CONTROL BOARDS
6.6.1 Preliminary steps

The servicing operation will be decided based on alarm/fault messages displayed on MV7000
keypad (refer to User Manual section 5).
If the controller rack should be monitored for diagnosis, it is acceptable to operate MV7000 with
low voltage compartment door open.
Before servicing the controller (including program loading):
• Carry out the Shutdown Procedure according to Section 6.2.4.1.
• It is strictly recommended to close the grounding switch even though there is no need to
open medium voltage compartments during work on the controller. This will avoid any
hazardous behavior during controller switch off or program loading.
Therefore:
Carry out the beginning of the Grounding Procedure up to and including Step 10 (closing the
Grounding Switch). Refer to Section 6.2.4.2.
• Switch off the controller rack.
• Carry out Step 14 of the Grounding Procedure (isolating the auxiliary supplies). Refer to
Section 6.2.4.2.
• Depending on site installation, if some of the digital I/O’s are supplied by an external source,
lock out this source(s) also.
6.6.2 Control Boards Replacement

If a control board is to be replaced, disconnect all cables from the board, unscrew the fasteners
and then remove the board from the rack.
Notes:
• Wear a grounded wrist strap to protect electronic boards sensitive to electrostatic discharge.
• Handle fiber optic cables with care. Do not bend or crimp and don’t use cable ties!
Prior to inserting the replacement board:

• make sure all jumpers are set as on the original board (refer to the specific project
documentation).
• make sure firmware versions are identical by comparing the relevant labels on the replacement
board.
• record board serial numbers (original one and replacement one).

6.6.3 Restart after servicing control boards
Depending on the type of board replacement performed, the following may be a guideline when
restarting the drive.
6.6.3.1 Preliminary check

Conditions:
• MV7000 grounding switch closed.
• Main supply and pre-charge supply isolated and locked.
Check sequence:
• Switch on the controller rack supply only.
• Monitor the LED indicators on modules front plate, check against normal status (refer to
User Manual section 5).
• If fiber optic cables have been disconnected during maintenance operations, the pulse test
mode must be activated by specially trained personnel afterwards. By using pulse test
mode, the following will be checked:
o Pulses send to the respective IGBT,
o Gate driver feedback.
6.6.3.2 Restart
Preparation:
• Close MV7000 cubicle doors.
• Open grounding switch.
• Unlock and switch on main supply and pre-charge supply.
• Select MV7000 normal control mode.
Starting:
• Start auxiliaries, check for no fault and no alarm (1).
• Start drive, check for no fault and no alarm (1).
• Increase the set point slowly to the required operational value, check for no fault and no
alarm.
Note: (1) According to project conditions, these steps are in sequence or both together.
LIMITATION OF LIABILITY
Before following the instructions of this user manual and operating the MV7000 drive, users are
advised to refer to Section 1 of user manual – “limitation of liability”.

MODIFICATION RECORD
Issue Date Author Details

A 18/01/2006 C COUSSEAU Initial Issue
Aa 23/03/2006 C COUSSEAU Update
Ab 09/06/2006 AL GAJENDRAN Name changed to CONVERTEAM
B 07 Dec 06 M POSTIC Revised based on users feedback
C 01/09/07 L.Brohl/E.A.Thufail Updated
C 10.05.2007 L. Brohl Section 6.2 rewritten, others updated
Our products are continuously improved. As a result, specifications are subject to

change at any time without notice, and should not be considered as contractual.


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MV7000 MEDIUM VOLTAGE DRIVE RANGE

SECTION 6: MAINTENANCE AND SAFETY

AUTHORISED FOR ISSUE BY: Samir Soua

C 01/09/07 L.Brohl/E.A.Thufail Updated

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

FOREWORD ............................................................................................................................... 6-4

SECURITY WARNING ................................................................................................................ 6-4

6. MAINTENANCE AND SAFETY............................................................................................ 6-4

MODIFICATION RECORD ........................................................................................................ 6-38

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Figure 6-1 Kirk Key Interlock System Principle .............................................................................................. 6-7

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Notes separate important information from the text and give

Important means that the relevant instruction must be followed

Warning means that the operator may be injured if the

6. MAINTENANCE AND SAFETY

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

6.2 DRIVE GROUNDING PROCEDURE

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

6.2.2.1 Measurement and Grounding Tools

• Medium voltage voltmeter – for measurement of

• 3 sets of 3-pole grounding and short-circuiting leads

• Isolating handle to connect/disconnect grounding leads.

The above tools and accessories can be supplied

On the drive side, fixed ballpoints of 18 mm Ø are provided as

(Sample photos by courtesy of

6.2.2.2 Personal Safety Equipment

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

6.2.3.1 Stand-alone single drive

Figure 6-1 Kirk Key Interlock System Principle

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

6.2.4 Drive Shutdown and Grounding Steps

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

STOP the motor

Wait until standstill

Open and lock out MV supply cicuit breaker

Close grounding switch of supply

Close MV7000 grounding switch

Drive cubicle doors can be opened

Check gate driver fault indicators

Open and lock out auxiliary supplies

Measure DC link voltage

Measure voltage at input terminals

Grounding Voltage yes

Ground input terminals

Measure voltage at output terminals

Ground output terminals

Measure voltage at the inverter stacks

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Step 1: Stop the motor

Step 2: Wait until the motor has come to a standstill.

Step 3: Open the MV supply circuit breaker

Step 4: Open the precharge circuit breaker.

Step 7: Visually inspect

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Step 10: Close the MV7000 grounding switch(es).

Step 12: Visually inspect

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016

Gate driver indicators

Figure 6-3 IGBT Inverter Stack with Gate Driver Indicators

Step 15: Verify proper function of the medium voltage voltmeter.

Step 16: Open the doors of the MV7000 DC capacitors cubicle(s).

Customer : MV7000 MEDIUM VOLTAGE DRIVE RANGE Ref : 4MKG0016