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FCX Solid State Frequency Converter Troubleshooting Guide
Estimated completion time: 45 minutes
Please ensure you have enough time to complete the training in one session.
Overview & Purpose
This document serves as a high-level troubleshooting guide based on interactions with the FCX Tech Rep. These steps were used to troubleshoot the SSFC (Solid State Frequency Converter) after replacing a damaged circuit board and a blown 700V 40A in-line fuse.
This interactive training will guide you through:
- Essential safety procedures for working with high voltage equipment
- Tools required for troubleshooting
- Step-by-step troubleshooting procedures
- Verification process
Upon completion, you will be able to:
- Safely troubleshoot the FCX Solid State Frequency Converter
- Identify and replace damaged components
- Verify proper system operation
- Follow all safety protocols during maintenance
Safety Guidelines
HIGH VOLTAGE WARNING
The FCX SSFC is a HIGH VOLTAGE system. Exercise extreme caution while troubleshooting when the system is energized.
Critical Safety Procedures
Ensure that ALL applicable safety procedures are followed while performing troubleshooting on the FCX SSFC, including Lock-out/Tag-out procedures.
Personal Protective Equipment
Always wear the following PPE when working on the FCX SSFC:
- Insulated gloves rated for appropriate voltage
- Safety glasses
- Non-conductive footwear
- Arc flash protection when required
Lock-out/Tag-out Procedures
Before beginning work:
- Identify all energy sources
- Notify affected personnel
- Shut down equipment
- Isolate energy sources
- Apply lockout/tagout devices
- Verify zero energy state
Important Note
If the SSFC was previously energized, allow 15-20 minutes for the system voltage to dissipate before beginning work.
Safety Check
Please answer the following question before proceeding:
How long should you wait after power-down before working on a previously energized SSFC?
Correct! Always allow 15-20 minutes for system voltage to dissipate.
Incorrect. The correct answer is 15-20 minutes. This waiting period is crucial for safety.
Tools Required
The following tools are needed to properly troubleshoot the FCX Solid State Frequency Converter:
Voltmeter
For measuring voltage and checking continuity
Jeweler's Flat Tip Screwdriver
For adjusting the manual voltage tuner
Lock-out/Tag-out Kit
For safely de-energizing equipment before maintenance
Tool Specifications
- Voltmeter: Must be rated for at least 700V AC/DC
- Jeweler's Screwdriver: Small flat tip for precision adjustments
- Lock-out/Tag-out Kit: Must include appropriate locks and tags for electrical equipment
Step-by-Step Troubleshooting Procedure
SAFETY REMINDER
Ensure that ALL applicable safety procedures are followed while performing troubleshooting on the FCX SSFC, including Lock-out/Tag-out procedures.
De-energize and Lockout System
De-energize and lockout CB1, CB2 (located on the FCX SSFC) and switch the Tether Converter Circuit Breaker to the OPEN (Off) position.
Note: If the SSFC was previously energized, allow 15-20 minutes for the system voltage to dissipate.
Check Fuse Continuity
Ensure that the 700V 40A Fuse passes for continuity by using a voltmeter.
Open Cabinet and Disengage Safety
Open the Frequency Converter cabinet and disengage the safety switch.
Set Auto/Manual Switch
Locate the AMA335B circuit board and toggle the Auto/Manual Switch to Manual.
Bypass Safety Switch
Locate the Cabinet Safety Switch and gently pull the plunger towards you. This engages the Safety Switch Bypass, allowing for the cabinet to be energized while open.
Apply Power
Apply power up to CB1, then engage CB1 to the ON position.
Initiate Startup
Once energized, on the cabinet display panel, press the START button (Power On and Converter On should be lit green, voltage should be ~0).
Adjust Voltage
Using a flat tip jewelers screwdriver, slowly rotate the manual voltage tuner clockwise to raise the voltage.
Voltage Adjustment Steps:
Verify Voltage
Verify voltage is similar to the display during each stop by testing each phase at CB2 (Black lead to neutral, Red lead to 1st, 2nd, then 3rd phase wire).
Decrease Voltage
Slowly turn the manual voltage tuner counter-clockwise to ~0.
Power Down
Press the STOP button on the cabinet display keypad.
De-energize System
De-energize CB1.
Return to Auto Mode
Set the Auto/Manual Switch located on the AMA335B circuit board to AUTO.
Verification
Once you're satisfied with the results of the manual testing, energize the system in Auto mode by performing RIOS (Reset Input Output Start).
Verification Steps
- Carefully observe the voltage and amps readings on the Input and Output voltage pages during system operation.
- Listen for any weird noises or sounds of arcing while energized.
- Power cycle the system a few times to ensure that the system starts up consistently with no issues.
Acceptable Parameters
The system should maintain consistent voltage readings within ±5% of the expected values.
Warning Signs
- Fluctuating voltage readings
- Unusual sounds during operation
- Inconsistent startup behavior
- Error codes on display panel
Verification Check
Please answer the following question:
What does RIOS stand for?
Correct! RIOS stands for Reset Input Output Start.
Incorrect. RIOS stands for Reset Input Output Start.
Final Assessment
Complete this assessment to test your understanding of the FCX Solid State Frequency Converter troubleshooting procedures.
1. How long should you wait after power-down before working on a previously energized SSFC?
2. What switch must be toggled on the AMA335B circuit board before manual testing?
3. What is the correct sequence for testing voltage at CB2?
4. What component allows the cabinet to be energized while open?
5. What voltage levels should be tested during manual voltage adjustment?
Review the questions you missed:
Completion Certificate
Congratulations on completing the FCX Solid State Frequency Converter Troubleshooting Training! Please enter your name to generate your certificate.
Certificate of Completion
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FCX Solid State Frequency Converter
Troubleshooting Training
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Date
Certificate ID: FCX-SSFC-00000