This document provides troubleshooting information for common Variable Speed Drive (VSD) problems including:
- GX errors related to hardware issues, overcurrent, overheating, and more.
- VSD errors related to synchronization between the VSD and UniConn control system, overcurrent, communication errors, and more.
- Non-error problems like the VSD accelerating but not reaching target speed or 240V control voltage fuses blowing constantly.
It identifies likely causes and recommends solutions such as checking for proper setup, voltages, wiring, components, and communicating with application engineers. The goal is to quickly and safely diagnose and resolve issues.
This document provides troubleshooting information for common Variable Speed Drive (VSD) problems including:
- GX errors related to hardware issues, overcurrent, overheating, and more.
- VSD errors related to synchronization between the VSD and UniConn control system, overcurrent, communication errors, and more.
- Non-error problems like the VSD accelerating but not reaching target speed or 240V control voltage fuses blowing constantly.
It identifies likely causes and recommends solutions such as checking for proper setup, voltages, wiring, components, and communicating with application engineers. The goal is to quickly and safely diagnose and resolve issues.
This document provides troubleshooting information for common Variable Speed Drive (VSD) problems including:
- GX errors related to hardware issues, overcurrent, overheating, and more.
- VSD errors related to synchronization between the VSD and UniConn control system, overcurrent, communication errors, and more.
- Non-error problems like the VSD accelerating but not reaching target speed or 240V control voltage fuses blowing constantly.
It identifies likely causes and recommends solutions such as checking for proper setup, voltages, wiring, components, and communicating with application engineers. The goal is to quickly and safely diagnose and resolve issues.
This document provides troubleshooting information for common Variable Speed Drive (VSD) problems including:
- GX errors related to hardware issues, overcurrent, overheating, and more.
- VSD errors related to synchronization between the VSD and UniConn control system, overcurrent, communication errors, and more.
- Non-error problems like the VSD accelerating but not reaching target speed or 240V control voltage fuses blowing constantly.
It identifies likely causes and recommends solutions such as checking for proper setup, voltages, wiring, components, and communicating with application engineers. The goal is to quickly and safely diagnose and resolve issues.
VSD School Objectives At the end of this presentation you should: ▪ Identify Common reasons for VSD Shutdowns/trips due to downhole Problems ▪ Identify Common reasons for VSD Shutdowns/trips due to surface Problems ▪ Be able to quickly and safely find the problem ▪ Be able to quickly and safely solve the problem Most Common Problems
▪ GX Errors
▪ VSD Errors
▪ NON-ERROR GENERATING PROBLEMS.
GX Errors ̶ Any alarm that starts with a GX represents a trip code from the VSD hardware; this is not a UniConn generated alarm. ̶ The “G” refers to the first letter of the drive “Series”, and the “X” refers to the “Type” of the VSD for example: G3, G7 GX Errors ̶ GX CPU ERR: CPU ERROR ̶ GX OPT ERR: OPTION ROM ERROR ̶ GX ROM ERR:
Reason Solution ROM (chip) not secure in place Check and secure the ROM in place Ground connected to CC on terminal board Remove ground An external source connected to PP on terminal board? Remove external source Change out control board and option ROM. GX Errors ̶ GX DC OC R: DC OVERCURRENT (RUN) ̶ GX DC OC A: DC OVERCURRENT (ACCELERATION)
Reason Solution Wrong CPTs tape Tape CPTs for the correct incoming voltage (output of CPTs should be ~240V.) No or wrong control voltages present on the terminal board Test terminal board as outlined in SWD manual section 11.4.1.5 Control Power Supply Checks. Fans drawing undue amount of power from wear or bad bearings. Check all fans functioning properly
Incorrect wire routing in the VSD for MS2 Refer to InTouch 4288313.
Incoming power have loading problems upon startup Check incoming power system, perform power analysis if needed. GX Errors ̶ GX E HARD: EARTH FAULT (HARD)
Reason Solution Current unbalance on the three phases that enter the Make all attempts to balance the three phases. VSD Disable the ZCTs, use with care GX Errors ̶ GX INV OL: INVERTER OVERLOAD
Reason Solution Input voltage not in the nominal range (380V or 460V +/- 10 %.) Check input voltage, perform power analyses if needed.
Poor configuration Make sure the size of the VSD ample for the project Make sure the surface voltage is correct for downhole equipment and voltage loss GX Errors ̶ GX OH ERR OR GX OC (ACC): OVERHEAT TRIP • THE VSD HAS EXCEEDED 83C (181F)
Reason Solution Fans are not operational Check if 240VAC control voltage functional? Check CPT1.
Heat sink blocked or not functional Check nothing is blocking the heat sink and there is 240V power to it Capacitor mal-functioning Replace Capacitor “Check this by disconnecting the two wires leading to the capacitor on the terminal block and replacing them with a jumper” GX Errors ̶ GX TF ERR: INVERTER TYPEFORM ERROR
Reason Solution The control board is not configured to the drive’s rating In the VSD section, go to the advanced area. Then set VSD Reset to Initialize Type Form and Accept. UniConn software and Firmware is not up to date Upgrade UniConn Firmware GX Errors ̶ GX PH U SHT: U-PHASE SHORT CIRCUIT ̶ GX PH V SHT: V-PHASE SHORT CIRCUIT ̶ GX PH W SHT: W-PHASE SHORT CIRCUIT
Reason Solution Short-circuit in IGBT, bad IGBT Change out all IGBTs in the phase plus snubber boards
checked by using the process outlined in the SWD Manual section 11.4.1.3 Checking Single-Transistor IGBTs. VSD Errors ̶ VSD SYNC: UNICONN AND VSD RUN STATUS ARE NOT “SYNCHRONIZED”
Reason Solution CPTs not tapped correctly to reflect the incoming power Make sure CPTs have an output of 240V and 120V respectively. Incoming power sag significantly during start up Check incoming power, perform power analysis if needed. Communication cable between VSD and UniConn get interference from Replace cable or the change the cable route any other source in the VSD Change out Gate Driver and Inverter boards if all above doesn’t work. VSD Errors ̶ U_BAT: INTERNAL BATTERY NEEDS TO BE REPLACED IN UNICONN.
Reason Solution UniConn internal battery dead. UniConn should be replaced and returned to the factory. Do not attempt to replace battery in field. VSD Errors ̶ VSD_COMM: COMMUNICATION ERROR VSD AND UNICONN ARE NOT COMMUNICATING
Reason Solution Main circuit breaker not closed properly Open and close MCCB again, alarm should go away within a minute.
Wrong communication cable connected between UniConn control card and Make sure to use a cable as per UniConn Manual section Controller board 7.2.4.3 UniConn Parameter Configuration
Wrong set up for Port with the VSD control card Make sure all the setting as per UniConn Manual section 6.1.9 Expansion Cards Communication cable tie wrapped to other cables or near other boards, causing Check wiring and remove other cables connected noise to the communication cable. Replace inverter board, if all above doesn’t work. VSD Errors ̶ VSD_OLOAD: OVERCURRENT Reason Solution Downhole condition “increased WC, solid production, …) Work with AE to see if motor can be saturated to decrease run amperage Incorrect overload settings (value and trip time) Check setting and re-do calculation. Downhole equipment electrically failed Test Downhole continuity and insulation. Transformer failure Perform no-load test without the VSD connected to the transformer
Wrong transformer ratio set up Check setting to reflect the correct ones Sags in the incoming power Check incoming power, perform power analysis if needed
Pump stuck downhole With AE consent… try rocking starts.
If this error occur on start up, changing the acceleration time might solve it. VSD Errors ̶ VSD_ULOAD: LOW CURRENT TRIP MOTOR AMPERAGE IS BELOW SET POINT.
Reason Solution Mechanical problem downhole (i.e. broken shaft, plugged intake) May try to inject fluid in the well to release the plugged intake.
Reservoir changing condition (decrease in WC, lighter fluid, pump gas Discuss with AE the possibility of lowering underload locking, …) The well pumping off Set the well to work in intermittent mode NON-ERROR GENERATING PROBLEMS. ̶ VSD accelerates to minimum frequency but does not increase to target speed.
Reason Solution Extended Ramp Setup in the VSD section Correct the setting to ON selected to OFF VSD reaching Thermal Stall Correct the setting NON-ERROR GENERATING PROBLEMS. ̶ Control voltage (240V) fuse blows constantly
Reason Solution UniConn rated less than 240V Connect UniConn to 120V to eliminate it as a cause of the problem One of the fans, heat sink or heat exchanger is shorted out. Check for grounding and or problems with the one if these devices To detect the above problem, disconnect fans, heat sink and heat exchanger. Reconnect one at a time until fuse blows again. Replace component. NON-ERROR GENERATING PROBLEMS.
■ VSD is running at normal speed and amperage but fluid is not being produced at surface. ̶ Most likely there is a hole in the tubing. Questions?
