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CW 2.5 MW Wind Turbine Generator Power Conversion System Installation, Operation & Maintenance Manual

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Final revision of Xantrex 1.3 MW Power Inverter Manual pior to aquisition by Shneider Electric

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Page 1: Xantrex 1.3 MW Power Inverter Manual

CW 2.5 MW Wind Turbine Generator Power Conversion System

Installation, Operation & Maintenance Manual

Page 2: Xantrex 1.3 MW Power Inverter Manual
Page 3: Xantrex 1.3 MW Power Inverter Manual

CW 2.5 MW Wind Turbine Generator Power Conversion System

Installation, Operation & Maintenance Manual

Page 4: Xantrex 1.3 MW Power Inverter Manual

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About XantrexXantrex Technology Inc. (www.xantrex.com), a subsidiary of Schneider Electric, is a world leader in the development, manufacturing and marketing of advanced power electronic products and systems for the renewable and mobile power markets. The company's products convert and control raw electrical power from any central, distributed, renewable, or backup power source into high-quality power required by electronic equipment and the electricity grid. Xantrex is headquartered in Vancouver, Canada, with facilities in the United States, Germany, Spain, and a joint venture in China.

About Schneider ElectricAs a global specialist in energy management with operations in more than 100 countries, Schneider Electric offers integrated solutions across multiple market segments, including leadership positions in energy and infrastructure, industrial processes, building automation, and data centres/networks, as well as a broad presence in residential applications. Focused on making energy safe, reliable, and efficient, the company's 120,000 employees achieved sales of more than 17.3 billion euros in 2007, through an active commitment to help individuals and organisations "Make the most of their energy™". www.schneider-electric.com

TrademarksXantrex and Smart choice for power are trademarks of Schneider Electric Services International sprl, registered in the U.S. and other countries. Other trademarks, registered trademarks, and product names are the property of their respective owners and are used herein for identification purposes only.

Notice of CopyrightCopyright © 2006, 2009 Xantrex Technology Inc. No part of this document may be reproduced in any form or disclosed to third parties without the express written consent of:Xantrex Technology Inc.161-G South Vasco Road Livermore, California USA 94551Xantrex Technology Inc. reserves the right to revise this document and to periodically make changes to the content hereof without obligation or organization of such revisions or changes unless required to do so by prior arrangement.

Exclusion for DocumentationUNLESS SPECIFICALLY AGREED TO IN WRITING, XANTREX® TECHNOLOGY INC. (“XANTREX”)(a) MAKES NO WARRANTY AS TO THE ACCURACY, SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION.(b) ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSSES, DAMAGES, COSTS OR EXPENSES, WHETHER SPECIAL, DIRECT, INDIRECT, CONSEQUENTIAL OR INCIDENTAL, WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION. THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER’S RISK; AND(c) REMINDS YOU THAT IF THIS MANUAL IS IN ANY LANGUAGE OTHER THAN ENGLISH, ALTHOUGH STEPS HAVE BEEN TAKEN TO MAINTAIN THE ACCURACY OF THE TRANSLATION, THE ACCURACY CANNOT BE GUARANTEED. APPROVED XANTREX CONTENT IS CONTAINED WITH THE ENGLISH LANGUAGE VERSION WHICH IS POSTED AT WWW.XANTREX.COM.Due to continuous quality improvement and product updates, the illustrations shown in this manual may not exactly match the unit purchased.

Date and RevisionFebruary 2009 Revision C

Document Part Number152874

Product Part Number1-152859-01Contact InformationTelephone: 1 800 670 0707 (toll free North America)

1 408 987 6030 (direct)Fax: 1 800 994 7828 (toll free North America)

1 360 925 5143 (direct)Email: [email protected]: www.xantrex.com

Page 5: Xantrex 1.3 MW Power Inverter Manual

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About This ManualPurpose

The Installation, Operation & Maintenance Manual provides comprehensive information and procedures for installing, operating, and maintaining theCW 2.5 MW Wind Turbine Generator Power Conversion System (CW 2.5 MW Inverters).

ScopeThe Manual provides safety guidelines, detailed installation and commissioning information, as well as information about operating, servicing and troubleshooting the CW 2.5 MW Wind Turbine Generator Power Conversion System. The Manual does not contain information about operating a wind turbine, the generators and other large components of a wind turbine.

AudienceThe Manual is intended for a multiple audience.The primary end users are the field service technicians who are qualified and trained to provide field support for the inverters. The secondary users are Clipper (OEM) engineers who need to know how to install, operate and maintain the CW 2.5 MW Inverters.Installers should be certified technicians or electricians.System providers should be knowledgeable about three-phase industrial inverters, wind turbines and balance of systems.

OrganizationThis Manual is organized into ten chapters and three appendixes.Chapter 1, Product Description, describes the features and functions of the CW 2.5 MW Wind Turbine Generator Power Conversion System (CW 2.5 MW Inverters) and how the inverters interface to the wind turbine generators.Chapter 2, Installation, provides information and procedures to unpack, move and install the CW 2.5 MW Inverters.Chapter 3, Commissioning, describes how to test the electrical integrity of the CW 2.5 MW Inverters. Successful completion of these tests ensures that the installation was properly performed and the CW 2.5 MW Inverters are ready for operation.Chapter 4, Operation, describes the theory of operation of the CW 2.5 MW Inverters and the various operating states of the inverter.

Page 6: Xantrex 1.3 MW Power Inverter Manual

About This Manual

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Chapter 5, GUI, provides information and procedures on using the GUI software application for the CW 2.5 MW Inverters.Chapter 6, Flow Charts, provides the flow charts which display the high level software logic information. Chapter 7, Fault Conditions, provides a list of fault conditions which may appear on the GUI.Chapter 8, Troubleshooting, is designed to help you determine where problems are occurring in the CW 2.5 MW Inverters and how to resolve them.Chapter 9, Maintenance, provides information and procedures for maintaining the optimal performance of the CW 2.5 MW Inverters.Chapter 10, Component Replacement, provides procedures for replacing specific components in the CW 2.5 MW Inverters.Appendix A, Specifications, provides the electrical and environmental specifications for the CW 2.5 MW Inverters.Appendix B, Drawings, provides detailed information on the system schematics of the CW 2.5 MW Inverters.Appendix C, Glossary, provides a list of acronyms used in this Manual.

Conventions UsedThe following conventions are used in this guide.

Related Information For related material on the CW 2.5 MW Inverters, see also:• Fan Assembly Installation Instructions: CW 2.5 MW Wind Turbine Generator

Power Conversion System (part number 1-152946-01)• CW 2.5 MW Wind Turbine Generator Power Conversion System Lifting

Instructions (part number 1-152947-01)You can find more information about Xantrex Technology Inc. as well as its products and services at www.xantrex.com

WARNINGWarnings identify conditions or practices that could result in personal injury or loss of life

CAUTIONCautions identify conditions or practices that could result in damage to the unit or other equipment.

Important: Important notes provide information that is important for you to know. They are not as critical as Warnings or Cautions.

Page 7: Xantrex 1.3 MW Power Inverter Manual

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Important Safety Instructions

READ AND SAVE THESE INSTRUCTIONS

The CW 2.5 MW Wind Turbine Generator Converter Installation, Operation & Maintenance Manual provides important safety instructions.Before you install and operate the CW 2.5 MW Wind Turbine Generator Power Conversion System, be sure to read, understand and save these safety instructions and those in the other product guides.Read all instructions and cautionary markings on the CW 2.5 MW Wind Turbine Generator Power Conversion System and all appropriate sections of this Manual.This safety section describes specific safety warnings associated with the CW 2.5 MW Wind Turbine Generator Power Conversion System. Failure to adhere to these warnings could result in shock or possible death. Exercise extreme caution at all times to prevent accidents. This section does not take the place of, nor supersede, any or all Clipper® Windpower Technology, Inc. safety procedures.

WARNING: High voltageDo not open the inverter enclosure doors without applying parking brake and rotor lock. Make certain the wind turbine rotor is locked and cannot turn.

WARNING: Lethal voltageThe CW 2.5 MW Wind Turbine Generator Power Conversion System contains exposed live surfaces operating at lethal voltages. The inverter enclosure doors should remain closed with latches tightened, except during maintenance or testing. Technicians working on this equipment must be familiar with and skilled with high voltage procedures. Only authorized personnel should be allowed to work on the equipment.

WARNING: Shock hazardIn order to remove all sources of voltage from the CW 2.5 MW Wind Turbine Generator Power Conversion System, the incoming power must be de-energized at the source. See “Removing All Power and High Voltage” on page 9–2. This may be done at the pad-mounted transformer. Review the system configuration to determine all of the possible sources of energy.

WARNING: Shock hazardWhen turning any circuit breaker On or Off, place one hand on the operating mechanism (for example, a handle or push button), turn your body and eyes away from the breaker, and then turn the breaker on.

WARNING: High voltageAllow 30 minutes for the DC bus capacitors, located on the matrixes, to discharge after removing all power.

Page 8: Xantrex 1.3 MW Power Inverter Manual

Safety

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Personal Safety

Standard Safety EquipmentAuthorized service personnel must be equipped with standard safety equipment which includes the following:• Safety Glasses• Ear Protection• Safety Boots• Safety Hard Hats• Site approved Personal Protective Equipment (PPE) • Padlock, Lock Out and Tag Out• Appropriate meter (600 Vac rated, minimum/1000 Vdc rated, minimum) to

verify that the circuits are de-energized.Instructions

Never work alone when servicing this equipment. A team of two is required until the CW 2.5 MW Wind Turbine Generator Power Conversion System is properly de-energized, locked out and tagged out, and verified to be de-energized with a meter.Thoroughly inspect the CW 2.5 MW Wind Turbine Generator Power Conversion System prior to energizing. Verify that no tools or equipment are inadvertently left behind.

WARNING: Shock hazardThe DC bus can reach a potential of 2000 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC bus directly. Use the Graphical User Interface (GUI) to determine the DC bus voltage. The DC bus can be verified to be discharged by a DVM once a 30-minute discharge period has expired, or the GUI shows the DC bus has discharged.

WARNING: Limitations on useThe CW 2.5 MW Wind Turbine Generator Power Conversion System is not intended for use in connection with life support systems or other medical equipment or devices.

Page 9: Xantrex 1.3 MW Power Inverter Manual

Safety

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Lock Out and Tag Out Prior to Servicing the CW 2.5 MW Inverters

Safety requirements mandate that CW 2.5 MW Wind Turbine Generator Power Conversion System must be de-energized prior to servicing. Power sources for the inverters must be locked out and tagged out prior to servicing. To lock out and tag out the CW 2.5 MW Inverters prior to servicing:1. Open, lock out, and tag out the incoming power at the pad-mounted

transformer.2. Each service technician should have a padlock, lock out and tag out installed

on each energy source prior to servicing.

Before Servicing the CW 2.5 MW Inverters

Before servicing the CW 2.5 MW Inverters:1. Transition the inverter to Idle Mode at the GUI, if connected. 2. Remove all power from the generators to the DC bus bars in the inverters.

Make certain that the generators are stopped.3. Open the 690 Vac three-phase power to the inverter. Lock out the circuit

breaker that supplies this power to the enclosure.4. Check for any other voltage sources to the enclosure.5. Wait 30 minutes to allow the bus capacitors to discharge.6. Turn SW1 to disable and verify the state changes from Ready to Idle.

WARNING: High voltageDo not open the inverter enclosure doors without applying the parking brake and rotor lock. Make certain the wind turbine rotor is locked and cannot turn.

WARNING: Shock hazardReview the system schematics for the installation to verify that all available energy sources are de-energized. See Appendix B, “Drawings” on page B–1. DC bus voltage may also be present. Be sure to wait the full 30 minutes to allow the DC bus voltage to discharge completely.

WARNING: High voltageBe sure to wait the full 30 minutes to allow the DC bus voltage to discharge completely.

Page 10: Xantrex 1.3 MW Power Inverter Manual

Safety

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Taking Measurements Safely

Use the following safety procedure to take measurements that require the CW 2.5 MW Inverters to be energized.To take measurements with the CW 2.5 MW Inverters energized:1. Lock out and tag out all incoming power sources. Follow the instructions for

“Lock Out and Tag Out Prior to Servicing the CW 2.5 MW Inverters” on page vii.

2. Connect the test equipment.3. Secure the doors and panels.4. Re-energize the inverter enclosures.5. Take the measurements without touching the circuits under test.6. De-energize the inverter enclosures.7. Lock out the power.8. Remove the test equipment.

CAUTIONWhen taking measurements, be sure to use the correct voltmeter. Use a DC voltmeter to measure DC values and an AC voltmeter to measure AC values.

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Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v

1 Product DescriptionIntroduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–3System Configuration- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–4Exterior Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–5

Power Electronics Matrixes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6

Interior Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7Upper Left Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8

Left Panel and Left Rear Current Transducers (CTs) Panels - - - - - - - - - - - - - - - - - - - - 1–8Left Internal Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10Left Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11

Upper Right Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12LVRT CCU2 Circuit Board Panel and Rear CT Panel - - - - - - - - - - - - - - - - - - - - - - - 1–12Right Internal Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–15Lower Left Magnetics Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–17Lower Right Magnetics Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–19

2 InstallationEquipment Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2Unpacking the Inverter Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2Moving Instructions—Forklift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–2Moving Instructions—Lifting Straps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3Mounting Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4

Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4Mounting the Inverter Enclosures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–4Mounting the Matrix Fan Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–6

Connecting the DC Generator Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–9Connecting the AC Power and Ground Cable- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11

Phasing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–11Installing the Safety Shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12Control Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14Turbine Control Unit (TCU) to Inverter Communication - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15

Contents

Page 12: Xantrex 1.3 MW Power Inverter Manual

Contents

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3 CommissioningGetting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–2Taking Measurements — Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–3Grounding- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4690 Volt Utility Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4Preparing to Energize the Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–4

Two Inverter Enclosures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5Power On Tests - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7Downloading Operational Software- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–7E-Stop Circuit Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8Matrix Test, Generators Idle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–8Matrix Test, Generators Operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–9Full Operation Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -3–10

4 OperationTheory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–2

Low-Voltage Ride-Through - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4System Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6

Inverter Operating States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6Initializing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6Idle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6Ready - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6Manual Command - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–6Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7Matrix Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

Converter Control Unit (CCU2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–7

5 GUIMain Window of the GUI - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2

File Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4Set Colors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4Message Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5Select Database - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5Exit (F12) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5

CommPort Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6Connect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6

Tools Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7

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Read/Write (F2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7Shutdown (F3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7Troubleshooting (F4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7Data Logging (F5) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7Downloader (F6) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8Fault Analysis/History (F7) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8General Procedures (F9) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8

Help Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8Technical Support - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8About - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8

Toolbar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9GUI Elements and Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10

Data Boxes and Parameter Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10Shutdown and Clear Fault Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10Status Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–10Read/Write by ID# Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11

Selecting a Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–11Identifying the Serial Number of the CCU2 Board - - - - - - - - - - - - - - - - - - - - - - - - - - 5–12

Data Logging Set Up Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–13GUI Data Logging Set Up Window- Fields Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–13

Selecting Parameters to Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–14Working with .Xmdb files - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–15

Graphs Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–16Downloader Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–19Troubleshooting Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–22

Working in On line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–23Clearing Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–23Working in Off Line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–23Listing Inverter Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–24

Fault Analysis and Fault History Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–25Fault History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–31

General Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–36Choose Parameter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–37

6 Flow ChartsFlow Chart 1 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–2Flow Chart 2 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3Flow Chart 3 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–4

7 Fault ConditionsCW 2.5 MW Inverters Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2

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8 TroubleshootingBefore You Start Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2Servicing Safety Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2

Lock Out and Tag Out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–2Fault Conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3

0000 - No Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–3F000 - Download Software - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30001 - State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30002 - Interrupt Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30010 - External Disable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–40015 - Inductor Compartment High Temp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–40029 - Serial Communication Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–50040 - In Programming Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–50042 - Bad Memory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–50043 - SEEPROM Write Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–60028 - SEEPROM Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–60080 Left Ripple Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–600DE Right Ripple Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–60120 - Line Frequency Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–60220 - Line Frequency High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–60130 - AC Line Voltage Too Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–70230 - Line Voltage Too High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–7

Left Matrix Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–80155 - Left Matrix State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–80156 - Left Matrix Control Failure to Turn Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–80256 - Left Matrix Control Failure to Turn On - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–80157 - Left Matrix DC Bus Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–80257 - Left Matrix DC Bus Voltage High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–90158 - Left Matrix Temperature Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–100258 - Left Matrix Over-Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–10XX66 - Left Matrix Gate Drive Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–10XX77 - Left Matrix Over Current Fault (H/S) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–110078 - Left Matrix DC Bus Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–12

Right Matrix Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1301AA - Right Matrix State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1301AB - Right Matrix Control Failure to Turn Off - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1302AB - Right Matrix Control Failure to Turn On - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1301AC - Right Matrix DC Bus Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1302AC - Right Matrix DC Bus Voltage High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1401AD - Right Matrix Temperature Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–1502AD - Right Matrix Over-temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–15XXBB - Right Matrix Gate Drive Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–15

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XXCC - Right Matrix Over Current Fault (H/S) - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–1700DD - Right Matrix DC Bus Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–17

230/120/22 Vac Control Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–18690 Vac Utility Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–18230 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19120 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–1924 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–19

CCU2 Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20CCU2 Circuit Board Power Supplies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–20Contactor Control Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–22Space Heaters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23Magnetics Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–23Current Transducers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–24Filter Capacitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–25Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26

IGBTs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–26Fiber Optics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27AC Phases - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–27

Matrix Test- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–28IGBT Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–30High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–31Matrix Damage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–33Fiber Optic Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–34Matrix Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–35Matrix Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–36

Checking the Line Matrix Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8–36

9 MaintenanceEquipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–2Removing All Power and High Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–2Upper Compartments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–2Lower Compartments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3Cable Glands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3Ground/Power Terminations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3Heatsinks and Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3Gate Drive Fiber Optic Cables- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9–3

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10 Component ReplacementEquipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–2Before You Start Replacing Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–3

Safety Requirements for Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–3Identifying Components for Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–3Replacing the CCU2 Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–4

Removing the CCU2 Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–4Installing the CCU2 Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–5

Replacing the Current Transducer (CT) Modules- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–6Removing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–6Installing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–6

Replacing the Line Contactors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–8Removing the Line Contactor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–8Installing the Line Contactor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–8

Replacing the Solid State Relays (SSR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–9Removing the Solid State Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–9Installing the Solid State Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–9

Replacing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–10Removing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–10Installing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–10

Replacing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–11Removing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–11Installing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–11

Replacing the Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–12Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–13Removing a Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–14Installing a Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–15

Replacing the Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–16Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–16Removing a Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–17Installing a Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–18

Replacing the Matrix Sub-Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–19Removing the High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–19Installing the High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–19

Replacing the Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–20Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–20Removing an Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–20Installing an Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–21

Replacing the Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–23Removing a Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–23Installing a Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -10–23

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Replacing the Internal Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–24Removing an Internal Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–24Installing an Internal Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–24

Replacing the Lower Magnetics Compartment Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–25Removing a Lower Compartment Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–25Installing a Lower Compartment Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–25

Replacing the Wiring Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–26Minor Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–26Removing the Wire Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–26Installing the Wire Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–26

A SpecificationsElectrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–2Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3Physical Specifications- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–3CW 2.5 MW Inverter Enclosure Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4

B DrawingsSchematic Diagram of Main Power Distribution- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2Schematic Diagram of Control Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–3Schematic Diagram of CCU2 Circuit Board- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4Left Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5Right Side Compartment Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6Component Replacement Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–7Component Replacement List for CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–8

C GlossaryAcronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C–2

Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX–1

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Table 1-1 Exterior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - 1–5Table 1-2 Interior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7Table 1-3 Voltages and Protective Fuses on Left Main Panel - - - - - - - - - - - - - - - - - - - - - - - - - 1–11Table 1-4 Components on Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–16Table 4-1 LVRT Line Voltage Limits and Time Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–4Table 5-1 Elements and Features of the GUI Main Window- - - - - - - - - - - - - - - - - - - - - - - - - - - 5–3Table 5-2 Toolbar Icons and Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9Table 7-1 List of Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7–2Table 8-1 Device Detecting the Right Matrix Gate Driver Fault - - - - - - - - - - - - - - - - - - - - - - - 8–15Table B-1 Assembly Description for Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - -B–8

Tables

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Figure 1-1 Outline of the CW 2.5 MW Inverters Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–2Figure 1-2 CW 2.5 MW Inverters Orientation in the Downtower - - - - - - - - - - - - - - - - - - - - - - - - 1–4Figure 1-3 Exterior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - 1–5Figure 1-4 Power Electronics Matrix–Left Side- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–6Figure 1-5 Interior View of the 2.5 MW Inverter Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–7Figure 1-6 Current Transducers (CT) Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–8Figure 1-7 Left Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–9Figure 1-8 Left Internal Fan Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–10Figure 1-9 Left Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–11Figure 1-10 CCU2 Circuit Board Panel and CT Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–12Figure 1-11 Right Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–13Figure 1-12 Right Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–14Figure 1-13 Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–16Figure 1-14 Left Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–17Figure 1-15 Left AC Connection Ground Bus- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–18Figure 1-16 Right Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–19Figure 1-17 Right AC Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1–20Figure 2-1 Inverter Enclosure Lifting Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–3Figure 2-2 Mounting Hole Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–5Figure 2-3 Mounting Right Matrix Fan Assembly to Cabinet- - - - - - - - - - - - - - - - - - - - - - - - - - - 2–7Figure 2-4 Matrix Fan Cable Fitting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–8Figure 2-5 Matrix Fan Power Cable Quick Disconnect Terminals - - - - - - - - - - - - - - - - - - - - - - - 2–8Figure 2-6 DC Cable Entry Covers on the Back of the Inverter Enclosure - - - - - - - - - - - - - - - - - - 2–9Figure 2-7 DC Cable Connections on Left and Right Side of CW 2.5 MW Inverters - - - - - - - - - - 2–10Figure 2-8 DC Cable Components (Ø.66 hole for 5/8 bolt size; quantity 4) - - - - - - - - - - - - - - - - 2–10Figure 2-9 Making Left AC Connections and Ground Bus Connection - - - - - - - - - - - - - - - - - - - 2–11Figure 2-10 Making Right AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–12Figure 2-11 Installing the Safety Shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–13Figure 2-12 External Fault and Stop Interlocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–14Figure 2-13 Connection between CCU2 Board and TCU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2–15Figure 3-1 Enable/Disable Selector SW1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–5Figure 3-2 External GUI Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3–6Figure 4-1 Communication To and From the Turbine Control Unit (TCU) - - - - - - - - - - - - - - - - - 4–2Figure 4-2 650 kW Converter Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4–3Figure 4-3 Transient Voltage and Frequency Ride-Through Characteristics - - - - - - - - - - - - - - - - - 4–5Figure 5-1 Main Window of the GUI- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–2

Figures

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Figures

xx 152874

Figure 5-2 File Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4Figure 5-3 Choose Color Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–4Figure 5-4 Message Rate Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–5Figure 5-5 CommPort Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6Figure 5-6 CommPort Properties window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–6Figure 5-7 Tools Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–7Figure 5-8 Help Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–8Figure 5-9 Toolbar Icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5–9Figure 5-10 Data Boxes and Parameter Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–10Figure 5-11 ShutDown and Clear Fault Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–10Figure 5-12 Status Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–10Figure 5-13 Read/Write by ID# Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–11Figure 5-14 Data Logging Set Up Window - Custom Fields- - - - - - - - - - - - - - - - - - - - - - - - - - - -5–13Figure 5-15 GUI Data Logging Set Up Window - Fixed Fields- - - - - - - - - - - - - - - - - - - - - - - - - -5–14Figure 5-16 Saving a Parameter Log File - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–15Figure 5-17 Graphs Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–16Figure 5-18 Graph View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–17Figure 5-19 Data View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–18Figure 5-20 Downloader Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–19Figure 5-21 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–20Figure 5-22 Downloader Window with Status Information - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–20Figure 5-23 Troubleshooter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–22Figure 5-24 Working in Off Line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–24Figure 5-25 Fault Analysis and Fault History Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–26Figure 5-26 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–27Figure 5-27 Retrieving Fault History Data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–28Figure 5-28 Graph View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–29Figure 5-29 Data Table View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–30Figure 5-30 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–31Figure 5-31 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–32Figure 5-32 Retrieving Fault History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–33Figure 5-33 Print Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–34Figure 5-34 Typical Fault History File - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–35Figure 5-35 General Procedures Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–36Figure 5-36 Choose Parameter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–37Figure 5-37 Choose Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–38Figure 5-38 Select Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -5–38Figure 6-39 Flow Chart 1 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–2Figure 6-40 Flow Chart 2 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–3Figure 6-41 Flow Chart 3 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6–4Figure 8-1 Power Electronic Converter Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -8–26

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Figures

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Figure 10-1 Installing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–6Figure 10-2 Power Electronics Matrix - Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–12Figure 10-3 Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–16Figure 10-4 Hardware Stack Up and Application of Anti-Corrosion Compound

at Aluminum Inductors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10–22Figure A-1 CW 2.5 MW Inverter Enclosure Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A–4Figure B-1 Schematic Diagram of Main Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - - -B–2Figure B-2 Schematic Diagram of Control Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - -B–3Figure B-3 Schematic Diagram of CCU2 Circuit Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–4Figure B-4 Left Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–5Figure B-5 Right Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B–6Figure B-6 Clipper 2.5 MW Inverter Component Replacement Model- - - - - - - - - - - - - - - - - - - - -B–7

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1 Product Description

Chapter 1, Product Description, describes the features and functions of the CW 2.5 MW Wind Turbine Generator Power Conversion System (CW 2.5 MW Inverters) and how the inverters interface to the wind turbine generators.

The topics in this chapter are organized as follows:• “Introduction” on page 1–2• “Safety Features” on page 1–3• “System Configuration” on page 1–4• “Exterior Components” on page 1–5• “Interior Components” on page 1–7

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Product Description

1–2 152874

IntroductionThe CW 2.5 MW Wind Turbine Generator Power Conversion System utilizes advanced high power electronics to allow the interface of wind turbine synchronous generators to the utility grid. Variable speed operation of the generators is made possible by the inverter’s control of generator current.The system is comprised of four identical sub-systems, each with a 650 kW inverter which is fed from an individual 650 kW generator. Two inverters are contained in one inverter enclosure. See Figure 1-1 for the physical outline of an inverter enclosure. The system utilizes two identical inverter enclosures. See Figure 1-2 on page 1–4.The generators are permanent magnet type with internal three-phase full wave rectifiers, the output of which is connected directly to the DC bus of its corresponding inverter. The three-phase AC output of each inverter is connected (by others) to the 690 Vac side of a utility matching power transformer. Individual current (torque) of each generator is controlled by the inverter’s internal hardware and software as commanded by the Turbine Control Unit (TCU) on each wind turbine. The TCU determines when the inverters are activated and it interfaces a number of protective functions and safety features between the inverters and the entire system.

Figure 1-1 Outline of the CW 2.5 MW Inverters Enclosure

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Safety Features

152874 1–3

Safety FeaturesThe steel inverter enclosures provide four types of protection:• Prevents contact with live electrical circuits.• Contains the electrical parts in the event that a component should fail and

explode.• Contains the flames of a fire should one occur.• Protects the internal components from contaminants such as dust or water.In order to prevent access by unauthorized personnel, a tool or key is required to open the doors and panels. It is important that the doors and panels remain in place, except when access by authorized service personnel is required.

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Product Description

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System ConfigurationTwo inverter enclosures are utilized in each CW 2.5 MW Wind Turbine Generator Power Conversion System. The inverter enclosures are located in the wind turbine generator tower facing each other.References to the left or right side of the enclosure assume you are standing at the door, facing toward the tower. Although the two enclosures are identical from a system viewpoint, the inverter enclosure on the right side contains Clipper Inverter #1 and Clipper Inverter #2. The inverter enclosure on the left side contains Clipper Inverter #3 and Clipper Inverter #4. See Figure 1-2.

Figure 1-2 CW 2.5 MW Inverters Orientation in the Downtower

Clipper Inverter# 4

Clipper Inverter# 3

Clipper Inverter# 1

Clipper Inverter# 2

Door

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Exterior Components

152874 1–5

Exterior ComponentsFigure 1-3 identifies the exterior components of an enclosure in the CW 2.5 MW Wind Turbine Generator Power Conversion System. Two separate inverters are in each enclosure. There are four major compartments in each inverter enclosure:

Upper Left Compartment Upper Right Compartment

Lower Left Compartment Lower Right Compartment

Figure 1-3 Exterior Components of the CW 2.5 MW Inverters

Table 1-1 Exterior Components of the CW 2.5 MW Inverters

Left Side Feature

Description Right Side Feature

Description

1 Left Heatsink Fan 2 Right Heatsink Fan

3 Left Fan Housing 4 Right Fan Housing

5 Left Power Electronics Matrix 6 Right Power Electronics Matrix

7 Door Latches (4 in total) 8 Door Latches (4 in total)

9 Upper Left Front Access Door 10 Upper Right Front Access Door

11 Lower Left Front Access Door 12 Lower Right Front Access Door

13 Mounting Holes (1 in front, 1 in rear) 14 Mounting Holes (1 in front, 1 in rear)

6

8

10

12

14

5

7

9

11

13

Upper Right CompartmentUpper Left Compartment

Lower Right CompartmentLower Left Compartment

21

43

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Product Description

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Power Electronics Matrixes

Components

Two power electronics matrixes are located at the top of the inverter enclosure (see Figure 1-3). Each power electronics matrix includes the following components (see Figure 1-4).• IGBTs• Isolated high voltage driver board• Large laminated power bus• DC filter capacitor bank.All of these components are attached to the top aluminum heatsink. A large cooling fan is mounted on the top of the heatsink assembly. See Figure 1-3.

Function

The power electronics matrix controls the transfer of power between the DC bus and the utility power grid. There are six IGBT transistors which operate in a pulse width modulated (PWM) bridge configuration to convert the 1350 volt DC bus voltage to match the 690 volt utility voltage. The switching frequency of the inverter is relatively high, 1.6 kHz. This high frequency, in combination with the output filter, results in an output waveform that has very low harmonic distortion.The isolated high voltage driver board receives logic and timing signals from the CCU2 circuit board and converts these signals to levels required for the IGBT transistors. Additionally, the isolated high voltage driver board monitors the condition of the IGBTs and reports any faults to the CCU2 board through a bi-directional fiber optic link. The fiber optic link is utilized in order to provide noise immunity.

Figure 1-4 Power Electronics Matrix–Left Side

Heatsink

Fan Motor

Fan Venturi

Fan Housing

Laminated Power Bus

IGBTs

DC Filter Capacitors

High Voltage Driver Board

Power ElectronicsMaxtrix

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Interior Components

152874 1–7

Interior ComponentsFigure 1-5 identifies the four interior compartments of the inverter enclosure.

Table 1-2 describes the components in the compartments.

Upper Left Compartment Upper Right Compartment

Lower Left Compartment Lower Right Compartment

Figure 1-5 Interior View of the 2.5 MW Inverter EnclosureTable 1-2 Interior Components of the CW 2.5 MW Inverters

Left Side Feature

Description Right Side Feature

Description

1 Left Internal Fan Panel 2 Right Internal Fan Panel

3 Left Rear Panel (DC Connection) 4 Right Rear Panel (DC Connection)

5 Left Current Transducer (CT) Panel 6 Converter Control Unit (CCU2) Board

7 Left Main Panel 8 Right Main Panel

9 Left Inductor 10 Right Inductor

11 Left AC Connection 12 Right AC Connection

13 Ground Bus 14 Power Factor Fuses

15 Power Factor Cap

Upper Left Compartment Upper Right Compartment

Lower Left Compartment Lower Right Compartment

1

5

7

9

11

13

2

4

68

10141215

3

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Product Description

1–8 152874

Upper Left Compartment

The upper left compartment houses the following components:• Control power circuits and fuses• Left inverter current transducers (CTs)• Left inverter AC contactor• Left side internal fan.

Left Panel and Left Rear Current Transducers (CTs) Panels

AC Current Transducers

The AC current transducers, CT22 and CT23, are located on the left side panel assembly. See Figure 1-6. CT22 and CT23 are connected in phases A and C of the 690 volt AC power cables. Their function is to sense the level of the three-phase current that the inverter outputs to the utility. The three-phase AC current output signals are displayed on the GUI.

Figure 1-6 Current Transducers (CT) Panel

CT22

CT23

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Interior Components

152874 1–9

DC Current Transducer

The DC current transducer, CT21, is located on the left rear panel assembly. See Figure 1-7. CT21 is used to sense the level of DC current from the generator to the left matrix. This transducer is directly connected to the positive (+) DC bus bar where the connections are made to the power cables from the generator. The DC current level is also displayed on the GUI.

Figure 1-7 Left Rear Panel

1

6

TB21

TB22

TB25

(+DC CABLE CONNECTION)

(–DC CABLE CONNECTION)

CT21

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Product Description

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Left Internal Fan Panel

The internal ventilation fan for the left side, B22, is located directly above the internal space heater strip, SH21. See Figure 1-8. The fan is operational any time 690 volts power is applied to the inverter. The fan circulates air throughout the compartment to cool the matrix capacitor assembly and the CCU2 circuit board assembly. If the temperature is 40 °F (4 °C) or lower, the fan circulates warm air to elevate the internal temperature of the enclosure. The backup power board, CW-BUP, is located below the space heater on the left internal fan panel. See Figure 1-8. This high density capacitor provides short term power to the CCU2 circuit board in the event of a momentary loss of grid power.

Figure 1-8 Left Internal Fan Panel

B22

SH21

CW-BUP(HOT!)

Controlled by thermostat

Page 35: Xantrex 1.3 MW Power Inverter Manual

Interior Components

152874 1–11

Left Main Panel Assembly

The control power transformer, T1, and the associated control voltage fuses: F54, 55, 56, 57, 59, and 60 are located on the left main panel. See Figure 1-9.The line contactor, K21, is also located on the left main panel assembly. This line contactor connects the left matrix to the 690 volt AC utility grid. K21 is controlled by the CCU2 circuit board which receives commands to open or close the contactor from the external Turbine Control Unit (TCU).

Table 1-3 lists the control voltage and circuit functions of these voltages and protective fuses.

Figure 1-9 Left Main Panel Assembly

K21

T1

RTB21R12 R13

DB1

T1-TB

DB3

F54,55,56,57,59,60

1

5L3

3L2

1L1

6T3

4T2

2T1

K21-AUX

K21-AUX

10

Table 1-3 Voltages and Protective Fuses on Left Main Panel

Reference Designation Control Voltage Circuit Function

F54, F55 24 Vac Voltage for the CCU2 circuit board and 24 Vdc internal power.

F56 115 Vac Voltage for internal fans and contactor coil power supply.

F57 230 Vac Voltage for internal space heaters.F59, F60 Voltage for matrix fan motors.

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Upper Right Compartment

The upper right compartment houses the panels for the following:• CCU2 circuit board assembly• Right inverter AC and DC current transducers • Inverter utility contactor• Right inverter internal fan.The upper right compartment also contains some of the AC control circuit components, including the Enable/Disable selector switch (SW 1) and the 690 volt AC fusing.

LVRT CCU2 Circuit Board Panel and Rear CT Panel

The LVRT (Low-Voltage Ride-Through) CCU2 circuit board is located on the left side of the upper right compartment. See Figure 1-10. The CCU2 circuit board assembly is a Digital Signal Processor (DSP) based control board that performs numerous control and diagnostic functions which are required to operate the inverters. It contains several internal power supplies necessary for operation as well as high and low level signal conditioning circuits. An important function of the CCU2 circuit board is communication with the system sensors to control electromechanical components within the inverters.

Important: The CCU2 circuit board controls both the left and right inverter power electronics matrixes.

Figure 1-10 CCU2 Circuit Board Panel and CT Panel

CCU2

CT12

Page 37: Xantrex 1.3 MW Power Inverter Manual

Interior Components

152874 1–13

AC Current Transducers

The AC current transducers, CT12 and CT13, are located behind the CCU2 circuit board assembly on the left side of the interior panel. See Figure 1-10 and Figure 1-11. CT12 and CT 13 are connected in phases A and C of the 690 volt AC power cables. Their function is to sense the level of the three-phase current that the inverter outputs to the utility. The three-phase AC output signals are displayed at the GUI.

DC Current Transducer

The DC current transducer, CT11, is located on the right panel assembly. CT11 is used to sense the level of DC current from the generator to the right matrix. This current transducer is connected directly to the positive (+) DC bus bar where connections are made to the power cables from the generator. The DC current level is also displayed at the GUI.

Figure 1-11 Right Rear Panel

CT13

C Ø

TB11

TB12

TB15

1

6

CT11

–DC CABLE CONNECTION

+DC CABLE CONNECTION

Page 38: Xantrex 1.3 MW Power Inverter Manual

Product Description

1–14 152874

Right Internal Fan Panel

The internal ventilation fan for the right side, B12, is located directly above the internal space heater strip, SH11. The fan is operational any time 690 volts power is applied to the inverter. The fan circulates air throughout the compartment to cool the matrix capacitor assembly and the CCU2 circuit board assembly. If the temperature is 41 °F (5 °C) or lower, the fan circulates warm air to elevate the internal temperature of the enclosure.

Figure 1-12 Right Fan Panel

B12

SH11

(HOT!)

Controlled by a thermostat

Page 39: Xantrex 1.3 MW Power Inverter Manual

Interior Components

152874 1–15

Right Main Panel Assembly

The 690 volt reference fuses, F51, 52 and 53, are located on the right front side of the main panel assembly along with the AC voltage divider, TB14. See Figure 1-13 on page 1–16 for the location of all components on the right main panel.The Enable/Disable selector switch, SW1, is also mounted near the front of the panel. TS11, the adjustable thermostat for the space heaters, is located adjacent to the switch. Solid state relays, SSR11, 12 and 21 are located near the center of the panel. SSR11 and 21 are used to interface the contactor coils to the CCU2 circuit board. SSR12 is used as an auxiliary control for the space heaters. Also located near the center of the panel are capacitor C2 and diode bridge DB2. These components make up the DC power supply for the contactor coils. The external control circuit terminal block, TB5, is located near the left edge of this panel.Fuses for the output filter capacitor, F11, 12 and 13, are mounted on the right side of the main panel assembly. See Figure 1-12 on page 1–14.

Page 40: Xantrex 1.3 MW Power Inverter Manual

Product Description

1–16 152874

Figure 1-13 Right Main Panel Assembly

Table 1-4 Components on Right Main Panel Assembly

Component Description

F51 690 volt reference fuseF52 690 volt reference fuseF53 690 volt reference fuseTB14 AC voltage dividerSW1 Enable/Disable selector switchTS11 Adjustable thermostat for the space heatersSSR11 Solid state relay used to interface the contactor coils to the CCU2

circuit boardSSR12 Solid state relay used as an auxiliary control for the space heatersSSR21 Solid state relay used to interface the contactor coils to the CCU2

circuit boardC2 CapacitorDB2 Diode bridgeTB5 External control circuit terminal blockK11 Line contactorRTB11 DC Power supply for the contactor coils

K11

TB5 C2

DB2

TB14

SW1 TS11

F51,52,53

RTB11

10

1

2T1

4T2

6T3

K11-AUX

5L3

3L2

1L1

K11-AUXAØ AØ

BØ BØ

CØ CØ

R14

Page 41: Xantrex 1.3 MW Power Inverter Manual

Interior Components

152874 1–17

Lower Left Magnetics Compartment

The lower left compartment contains the large three-phase PWM inductor for the left matrix, L21. It is used in conjunction with the output filter capacitor to filter and smooth the PWM output waveform of the inverter matrix so that it is suitable for connection to the utility grid. Cooling fans B23, 24 and 25 are mounted to the front cover of the magnetics compartment.

Three-phase AC power bus bars for the left side inverter, TB23-A, TB23-B and TB23-C, are located on the center panel of this section. External connections are made here to the 690 volt utility. See Figure 1-15.

Figure 1-14 Left Inductor

L21

C ØB ØA Ø

1 4 32 6 5

Page 42: Xantrex 1.3 MW Power Inverter Manual

Product Description

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Figure 1-15 Left AC Connection Ground Bus

CØBØAØTB23

TB10-GND

LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS

ALL GROUNDING CONNECTIONS

Page 43: Xantrex 1.3 MW Power Inverter Manual

Interior Components

152874 1–19

Lower Right Magnetics Compartment

The lower right compartment contains the large three-phase PWM inductor for the right matrix, L11. The inductor is used in conjunction with the output filter capacitor PFC11 to filter and smooth the PWM output waveform of the inverter matrix so that it is suitable for connection to the utility grid. PFC11 is mounted to the right side of the inductor in this compartment. See Figure 1-16. Cooling fans B13, 14 and 15 are mounted to the front cover of the magnetics compartment.

.

Three phase AC power bus bars for the right side inverter, TB13-A, TB13-B and TB13-C, are located on the center panel of this section. External connections are made here to the 690 volt utility. See Figure 1-17.

Figure 1-16 Right Inductor

L11

6 54 312

CØBØAØ

PFC11

Page 44: Xantrex 1.3 MW Power Inverter Manual

Product Description

1–20 152874

Figure 1-17 Right AC Connection

LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS

GROUND TO TB10-GND

CØBØ

TB13

Page 45: Xantrex 1.3 MW Power Inverter Manual

2 Installation

Chapter 2, Installation, provides information and procedures to unpack, move and install the CW 2.5 MW Inverters.

This topics in this chapter are organized as follows:• “Equipment Storage” on page 2–2• “Unpacking the Inverter Enclosure” on page 2–2• “Moving Instructions—Forklift” on page 2–2• “Moving Instructions—Lifting Straps” on page 2–3• “Mounting Instructions” on page 2–4• “Connecting the DC Generator Cables” on page 2–9• “Connecting the AC Power and Ground Cable” on page 2–11• “Phasing” on page 2–11• “Control Wiring” on page 2–14• “Turbine Control Unit (TCU) to Inverter Communication” on

page 2–15

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Installation

2–2 152874

Equipment StorageInverter enclosures Store the inverter enclosures in a clean, dry location until the enclosures are ready

for installation in the tower.Matrix fan assemblies

The matrix fan assemblies are shipped separately from the inverter enclosures. Each inverter enclosure requires a left side and a right side matrix fan assembly. The fan assemblies are marked left and right. Keep the fan assemblies on their shipping pallets in a clean, dry location until ready for installation on the inverter enclosures.

Unpacking the Inverter EnclosureDo not remove the plastic or cardboard wrapping material until the inverter enclosure is installed in the tower. Keep the plastic and cardboard wrapping material on the enclosures for protection during the installation process.

Moving Instructions—Forklift

To move the inverter enclosures with a forklift:1. Lift the inverter enclosures with a single forklift with sufficiently spaced fork

span.2. Lift from the bottom of the inverter enclosures only. See Figure 2-1, “Inverter

Enclosure Lifting Locations” on page 2–3 for forklift points.3. Keep the doors closed and latched when moving the inverter enclosures.

WARNINGThe approximate weight of each inverter enclosure is approximately 6500 lbs.

WARNING: Physical injuryAttempting to lift the inverter enclosure by other than the recommended lifting points may damage the equipment or present a safety hazard to personnel and void the warranty. Keep the doors closed and latched when moving the enclosure. Leaving the doors unlatched may result in a violation of the warranty.

CAUTION: Equipment damageBefore lifting the inverter enclosure, verify that all of the front access doors are securely attached with the appropriate hardware and all of the cabinet’s bolts and screws are securely in place.

CAUTION: Equipment damageDo not attempt to use the top heatsink matrix brackets to lift the inverter enclosure. Lift from the bottom of the inverter enclosures only.

Page 47: Xantrex 1.3 MW Power Inverter Manual

Moving Instructions—Lifting Straps

152874 2–3

Moving Instructions—Lifting Straps

To move the inverter enclosures using lifting straps:1. Use 2 lifting straps. 2. Place the lifting straps through the outer bottom mounting channels. See

Figure 2-1 for placement of the lifting straps.3. Keep the compartment doors closed and latched when moving the inverter

enclosures.

CAUTION: Equipment damageBefore lifting the inverter enclosure, verify that all of the front access doors are securely attached with the appropriate hardware and all of the cabinet’s bolts and screws are securely in place.

CAUTION: Equipment damageWhen using the lifting straps, the fan assemblies must not be installed.

Figure 2-1 Inverter Enclosure Lifting Locations

Forklift locations

Recommended locations for lifting straps

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Installation

2–4 152874

Mounting Instructions

Equipment Required

The following items are necessary to install each inverter enclosure:• Ratchet handle• Extension• Socket set• Wrench set• Torque wrench with 0 to 50 Ft-lbs minimum range• Small slotted screwdriver• Phillips screwdriver• Anchoring hardware (not provided with the inverter enclosures)

Mounting the Inverter Enclosures

To place the inverter enclosure on the mounting surface:1. The mounting location should be level and free of debris so that the

enclosures can be properly aligned.2. Move each enclosure into position. 3. Shim the enclosure if necessary to level and anchor the enclosure to the

mounting surface with the anchoring hardware.Four Ø.75 mounting holes are provided on the bottom channels: two at the front and two at the back of the enclosure. See Figure 2-2 on page 2–5 for mounting hole size and locations.

Important: Two inverter enclosures are utilized in each CW 2.5 MW Wind Turbine Generator Power Conversion System. The following procedure applies to each inverter enclosure.

Important: Anchoring hardware is not provided with the inverter enclosures.

Page 49: Xantrex 1.3 MW Power Inverter Manual

Mounting Instructions

152874 2–5

Back

4. Remove the plastic and cardboard wrapping material from the outside of the inverter enclosures when ready to proceed with the installation.

5. Open both doors for the upper left and right compartments. When the unit is shipped, the key for the door locks is attached to the fan guard on the front of the unit.

6. Remove the packing material that secures the high voltage driver boards for shipping. The driver boards are located in each of the matrix capacitor assemblies inside the compartments just behind the circuit boards.

Figure 2-2 Mounting Hole Locations

Front Side Back

2 × Ø.75 Mounting Holeson right side: 1 in front and1 in back

2 × Ø.75 Mounting Holeson left side: 1 in front and1 in back

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Installation

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Mounting the Matrix Fan Assemblies

Left and right matrix fan assemblies

The matrix fan assemblies are marked either L (left) or R (right). One of each fan assembly is required for each enclosure. See Figure 2-3 which shows the right matrix fan assembly being installed.

Outer matrix edge mounting bolts

The outer matrix edge mounting bolts are enclosed in a bag attached to the fan cord. The bag contains:• 12 (twelve) hex flange mounting bolts for the left and right fan assemblies• ¼-20 × .50 LThe recommended torque specifications are 96 in-lbs.To mount the left matrix fan assembly:1. Remove the outer edge mounting bolts from the bag attached to the fan cord

and install the bolts on the end of the heat sink. Do not tighten.2. Mount the left matrix fan assembly first.

The left side of the housing has slotted holes for ease of mounting.3. Slip the left edge into position at the mounting bolts and gently place it on top

of the heatsink.The housing has a connecting plate that bolts to the top of the left assembly housing.

4. Install the mounting bolts but do not tighten.To mount the right matrix fan assembly:1. Remove the outer edge mounting bolts from the bag attached to the fan cord

and install the bolts on the end of the heat sink. Do not tighten.2. Mount the right matrix fan assembly.

The right side of the housing has slotted holes for ease of mounting. 3. Slip the right edge into the position at the mounting bolts and gently place it

on top of the heatsink. The housing has a connecting plate that bolts to the top of the left assembly housing.

4. Install the mounting bolts but do not tighten.

WARNING: Risk of injuryThe matrix fan assembly weighs 125 pounds. The unit is too heavy for one person to lift and mount safely. Xantrex recommends that two people lift and mount the unit. Always use proper lifting techniques during installation to prevent personal injury.

CAUTION: Equipment damageBe careful not to drop the housing or damage the heatsink cooling fins.

Page 51: Xantrex 1.3 MW Power Inverter Manual

Mounting Instructions

152874 2–7

To complete the matrix fan assemblies:1. Square up both fan assemblies on the heatsinks and tighten the mounting

hardware to a recommended torque of 96 in-lbs.2. Unwrap each fan power cable from the motor brackets and route the cables

into the enclosure at the rear. The power cables are pre-cut to length. The cable should be dressed at the rear of the enclosure so there is only a small amount of slack to the entry hole. See Figure 2-4.

Figure 2-3 Mounting Right Matrix Fan Assembly to Cabinet

Slotted holes onhousing

Outer edge mountingbolts

Connecting plate withmounting bolts

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Installation

2–8 152874

3. Secure the cable compression fitting to the enclosure.

4. Inside the enclosure, connect the fan power wire with the quick disconnect terminals provided. Make sure the spade inside the male connection is centered.

This completes the installation of the left and right fan assemblies.

Figure 2-4 Matrix Fan Cable Fitting

Figure 2-5 Matrix Fan Power Cable Quick Disconnect Terminals

Page 53: Xantrex 1.3 MW Power Inverter Manual

Connecting the DC Generator Cables

152874 2–9

Connecting the DC Generator Cables

To connect the DC generator cables:1. Locate and remove the two DC cable entry covers from the back of the

inverter enclosure. See Figure 2-6. The top bus bar is the positive (+) DC connection and the bottom bus bar is the negative (–) DC connection.

2. Punch holes for the DC power cable gland fittings.

CAUTION: Reverse polarity damageBefore making the final DC connection or closing the DC breaker or disconnect, check cable polarity at the DC bus bars. Positive (+) must be connected to positive (+).Negative (–) must be connected to negative (–).

Important: Two inverter enclosures are utilized in each CW 2.5 MW Wind Turbine Generator Power Conversion System. The following procedure applies to each inverter enclosure.

Figure 2-6 DC Cable Entry Covers on the Back of the Inverter Enclosure

Positive (+) DC cable connection

Negative (–) DC cable connection

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Installation

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3. Reinstall the two DC cable entry covers with gland fittings and route the DC power cables from the generator through the fittings to the DC bus bars. See Figure 2-7.

4. Terminate the cables and attach to the bus bars carefully observing polarity. See Figure 2-7.

Figure 2-7 DC Cable Connections on Left and Right Side of CW 2.5 MW Inverters

Figure 2-8 DC Cable Components (Ø.66 hole for 5/8 bolt size; quantity 4)

Feature Description Feature Description

1 Positive (+) DC cable connection 2 Positive (+) DC cable connection

3 Negative (–) DC cable connection 4 Negative (–) DC cable connection

CAUTION: Reverse polarity damageBefore making the final DC connections or closing the DC breaker or disconnect, check cable polarity at the DC bus bars. Positive (+) must be connected to positive (+).Negative (–) must be connected to negative (–).

1

3

2

4

DC cable entry

Page 55: Xantrex 1.3 MW Power Inverter Manual

Connecting the AC Power and Ground Cable

152874 2–11

Connecting the AC Power and Ground CableTo access the AC power and ground bus bars, remove the front covers from the inverter enclosure. Take care to unplug the magnetics fan connections. The lower cover mounting holes are slotted so these bolts need only be loosened, not removed. Remove the two AC power cable entry covers from the bottom of the enclosure and punch holes for the three-phase power cable gland fittings. The right cover requires an entry hole for the ground cable also.

Phasing

1. Identify the three-phase bus bars on each side of the inverter enclosure. Carefully observe the phasing which is A – B – C, left to right. See Figure 2-9 for making the left AC connections and ground bus connections. See Figure 2-10 for the making right AC connections.

Figure 2-9 Making Left AC Connections and Ground Bus Connection

BA

C

GN

Ø.66 HOLE FOR 5/8 BOLT SIZE (QTY: 6)

3/8 THREADEDHOLE (QTY: 4)

AC & GROUNDCABLE ENTRY

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Installation

2–12 152874

2. Reinstall the covers with gland fittings and route the 690 volt AC power cables through the fittings to the bus bars.

3. Terminate the cables (2 each per phase) to the bottom of the bus bars. Make certain there is adequate clearance between bare portions of the cable lugs. See Figure 2-9.

4. Attach the ground cable to the copper bus bar at the bottom of the enclosure. 5. Following AC power cable and ground wiring, check for proper connections

then install the front covers.6. Connect the fan connectors.

Installing the Safety ShieldA safety shield will be installed in each unit, one per door. See Figure 2-11 on page 2–13.

1. Remove the safety shield from the inverter enclosure.2. Remove the protective layers from the safety shield.3. Unlock and open one of the upper compartment doors of the inverter

enclosure.

Figure 2-10 Making Right AC Connections

AB

C

Ø.66 HOLE FOR 5/8BOLT SIZE (QTY: 6)

AC CABLE ENTRY

Important: The safety shield should only be installed once the CW 2.5 MW Inverters have been unwrapped and installed.

Page 57: Xantrex 1.3 MW Power Inverter Manual

Installing the Safety Shield

152874 2–13

4. Angle the safety shield through the opening with the mounting holes facing upwards.

5. Locate the two mounting bolts inside the inverter enclosure above the upper door opening.

6. Slide the safety shield onto the mounting bolts. The safety shield will hang in place.

7. Discard the protective layers and close and lock the compartment door.

Figure 2-11 Installing the Safety Shield

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Installation

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Control WiringEach inverter enclosure has a fault interlock that should to be tied into the associated turbine shutdown circuit at the turbine control unit (TCU). This circuit is at terminal block TB5, terminals 1 and 2. See Figure 2-12. This fault circuit is common to both the left and right side inverters in each enclosure. The outputs at each enclosure can be connected in series, if desired, for a common fault shutdown circuit. The on-board components for this external interlock circuitry consist of opt-isolated solid state switches (FETs) rated at 2 amps, 60 volts maximum. It is suggested that a relay is utilized to interface with the TCU.

An external shutdown switch (such as an E-Stop push button) can be connected to TB5 terminals 4 and 5 to shut down the inverter immediately. See Figure 2-12. If this feature is not desired, the two terminals should be connected together.

CAUTION: Reverse polarity damagePositive (+) must be connected to positive (+).Negative (–) must be connected to negative (–).

CAUTIONDo not connect this circuit to 115 Vac.

Figure 2-12 External Fault and Stop Interlocks

Fault interlock

External shutdown switchJumper if not used

TB5

123456789

10

(+)

(+)

(–)

(–)

Page 59: Xantrex 1.3 MW Power Inverter Manual

Turbine Control Unit (TCU) to Inverter Communication

152874 2–15

Turbine Control Unit (TCU) to Inverter CommunicationCommunication between the Turbine Control Unit (TCU) and each inverter is via a fiber optic cable pair. Connection is made directly to the CCU2 circuit board. This connection controls both the left side and the right side inverter in each enclosure. A separate transmit/receive cable is required for each inverter enclosure. Figure 2-13 shows the basic connection.

Figure 2-13 Connection between CCU2 Board and TCU

U1002 Tx

U1001 RxCommunication signal to/from TCU via Opto-cable Tx/Rx

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Page 61: Xantrex 1.3 MW Power Inverter Manual

3 Commissioning

Chapter 3, Commissioning, describes how to test the electrical integrity of the CW 2.5 MW Inverters. Successful completion of these tests ensures that the installation was properly performed and the CW 2.5 MW Inverters are ready for operation.

This topics in this chapter are organized as follows:• “Getting Started” on page 3–2• “Equipment Required” on page 3–2• “Taking Measurements — Overview” on page 3–3• “Visual Inspection” on page 3–3• “Grounding” on page 3–4• “690 Volt Utility Connections” on page 3–4• “Preparing to Energize the Inverters” on page 3–4• “Power On Tests” on page 3–7• “Downloading Operational Software” on page 3–7• “E-Stop Circuit Check” on page 3–8• “Matrix Test, Generators Idle” on page 3–8• “Matrix Test, Generators Operating” on page 3–9• “Full Operation Test” on page 3–10

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Getting Started Before beginning these tests, the two inverter enclosures must be installed in the tower and have all electrical connections in place. Refer to Chapters 1 through 5 of this Manual to get an overview of how the inverter interacts with the wind turbine generators and to know what to expect during the startup procedure.

Equipment RequiredThe following equipment is required for the startup testing:• Computer with Xantrex Technology Inc. Graphical User Interface (GUI)

communication software• Communication Cable, fiber optic with RS-232 converter (or USB, depending

on computer interface)• RMS voltmeter • Clamp-on ammeter• Screwdrivers• Wrenches and socket setThe test equipment must be rated to at least 700 Vac and 1000 Vdc.

Important: Two inverter enclosures are utilized in each CW 2.5 MW Power Conversion System. This procedure applies to each one.

WARNING: Shock hazardPerform this procedure in dry conditions.

WARNING: Lethal voltagesThe CW 2.5 MW Wind Turbine Generator Power Conversion System contains exposed live surfaces operating at lethal voltages. The enclosure doors should remain closed at all times with latches tightened, except during maintenance or testing.

Technicians working on this equipment must be familiar with and skilled with high voltage procedures. Only authorized personnel should be allowed to work on the equipment.

Do not open the enclosure doors if extreme moisture is present such as rain or heavy dew.

CAUTION: Risk of equipment damage due to moistureIf power has been removed and the inverters exposed to cold temperatures, frost or moisture may be present inside the enclosure. Close and latch both doors. Apply 690 V power but do not turn on the inverters. Allow the internal heater to warm up the unit for a minimum of 4 hours or until the inside of the enclosure is dry before operating the inverter.

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Taking Measurements — Overview

152874 3–3

Taking Measurements — OverviewUse the following safety procedure to take measurements that require the enclosure to be energized.For measurements that are taken with the unit energized:1. Lock out and tag out ALL incoming power sources. See “Lock Out and Tag

Out Prior to Servicing the CW 2.5 MW Inverters” on page vii in the “Important Safety Instructions” for mandatory safety equipment related to this procedure.

2. Connect the test equipment.3. Secure the doors and panels.4. Re-energize the cabinet.5. Take the measurements without contacting the circuits under test.6. De-energize the inverter.7. Lock out the power.8. Remove the test equipment.

Visual InspectionVerify that all power is removed before beginning the visual inspection of the inverter. This includes the 690 volt power source as well as the wind turbine rotor. Make certain the wind turbine rotor is locked and cannot turn.To perform a visual inspection:1. Open the upper left and upper right compartment doors and make a general

inspection to see if any components have loosened during shipment.2. Inspect the power cables to the matrixes and contactors. Check to see that

connections are tight. Verify that torque marks are present.3. Verify terminations have proper clearance from other conductors and the

cabinet itself.4. Check for any rubber shavings which would indicate rubbing or chafing of

cables.5. Check the fiber optic connections between the CCU2 board and the Gate

Driver Boards to be certain connectors are properly seated.6. Make certain the IGBT device gate leads are properly plugged into their

respective connectors on the Gate Driver Board.7. Check the connectors on the CCU2 circuit board to be certain they are fully

seated.8. Make certain all fuseholders are in their fully closed positions.

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9. Remove the lower left and lower right magnetics compartment cover, taking care to unplug the fan connectors. Check the power cable connections to the inductors as described above.

GroundingVerify the ground connection has been made to the ground bus bar connection at the bottom of the enclosure.

690 Volt Utility ConnectionsTo verify the 690 volt utility connections:1. Verify that the 690 volt utility connection cables are tightly bolted to the bus

bars. 2. Visually check to see that phase connections are made A - B - C, left to right

when facing the bus bars. 3. Check for adequate clearance between power lead terminations.4. Attach the fan connectors.5. When the visual inspection is complete, reinstall the front covers at the

bottom magnetics compartments.

Preparing to Energize the Inverters

WARNING: High voltageDo not open the inverter enclosure doors without applying parking brake and rotor lock.

WARNING: Shock hazardIf DC voltage has been applied to the inverter matrix due to generator operation, allow 30 minutes for the DC bus capacitors, located on the matrixes, to discharge after removing all power.

WARNING: Lethal voltagesThe inverter enclosures contain high voltages: 115 Vac, 230 Vac, 690 Vac and 1400 Vdc.

WARNING: Shock hazardThe DC bus can reach a potential of 1400 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC bus directly. Use the Graphical User Interface (GUI) to determine the DC bus voltage. The DC bus can be verified to be discharged by a DVM once the 30 minute discharge period has expired, or the GUI shows it has discharged.

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Two Inverter Enclosures

• Be aware that when 690 volts power is applied, it is applied to both enclosures.

• Be aware that when the generators are operating, DC bus voltage is applied to both enclosures.

To energize the inverter enclosures:1. At the upper right compartment of both enclosures in the system, locate the

Enable/Disable selector, SW1, and switch to the Disable (CCW) position. See Figure 3-1.

2. Check the heater thermostat. It should be set to a low value, approximately 40 °F.

3. Close and latch both upper compartment doors.

Important: Two inverter enclosures are utilized in each CW 2.5 MW Power Conversion System. This procedure applies to each one.

Figure 3-1 Enable/Disable Selector SW1

K11

TB5 C2

DB2

TB14

SW1 TS11

F51,52,53

RTB11

10

1

2T1

4T2

6T3

K11-AUX

5L3

3L2

1L1

K11-AUXAØ AØ

BØ BØ

CØ CØ

R14

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4. Connect the external computer containing the GUI program to the GUI test port at the front of the enclosure. See Figure 3-2.

5. Open the GUI program on the computer. 6. Using the Tools menu, configure the screen to display:

• Line Voltage, Vab• Line Voltage, Vbc• Line Voltage, Vca• LM DC Bus • RM DC Bus

Figure 3-2 External GUI Connection

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Power On Tests

To perform a power on test:1. Apply 690 Vac three-phase power to the enclosure.

The internal enclosure fans should start.After a few seconds, communication should be established between the CCU2 circuit board and the computer.When communication is established, an 8 digit number will be displayed as the software (S/W) version in the upper left side of the main screen. If communication has not been established, refer to Chapter 5, “GUI” and Chapter 8, “Troubleshooting”.

2. Read the 690 volt line voltage on the GUI screen. Each phase should read 675 to 700 Vac.The GUI screen should indicate a Faulted condition.

Downloading Operational SoftwareTo download operational software for the CCU2 circuit board:1. Click on the Downloader Icon on the GUI screen toolbar.

A window will open to select the file to open.2. Click Open.

The file S/W Version will indicate the selected program. This is the version that will be downloaded to the CCU2 circuit board.

3. Click Start Download. The program will begin to download the new file. This will take several minutes. Progress of the download is indicated by the progress bar moving across the bottom of the screen.

4. When the download is complete, verify that the board S/W Version and FileS/W Version are the same.

5. Return to the initial GUI program.

CAUTION: Risk of equipment damage due to moistureIf power has been removed and the inverters exposed to cold temperatures, frost or moisture may be present inside the enclosure. Close and latch both doors. Apply 690 V power but do not turn on the inverters. Allow the internal heater to warm up the unit for a minimum of 4 hours or until the inside of the enclosure is dry before operating the inverter.

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E-Stop Circuit CheckTo check the E-Stop (Emergency Stop) circuit:1. Press the external E-Stop push button on the tower wall.

The GUI should indicate a Fault condition.2. Reset the E-Stop push button and clear the fault at the GUI by clicking on the

Clear Fault button. The GUI should indicate No Faults.

3. Check the GUI E-Stop function by clicking on the Shutdown button. The GUI should immediately indicate Fault.

4. Clear the fault by clicking on the Clear Fault button.The GUI should indicate No Faults.

Matrix Test, Generators IdleBefore beginning the matrix test for both inverters, the GUI should indicate that the inverters are in the Idle State. To perform the matrix test with the generators idle:1. Using the Tools menu on the GUI, load in the LM Matrix Test and RM Matrix

Test. See “GUI” on page 5–1 for more information regarding this procedure.2. Start the matrix test for both inverters.3. Open the upper compartment doors, one at a time, and check the IGBT high

voltage driver boards for yellow blinking LEDs. All six LEDs should be blinking. If they don't blink properly or not at all, refer to “Troubleshooting” on page 8–1.

4. Stop the blink test after confirming proper operation of the LEDs and close the upper compartment doors.

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Matrix Test, Generators Operating

To perform the matrix test with the generators operating:1. Monitor the LM DC Bus and RM DC Bus voltages on the GUI. 2. Allow the wind turbine to start to turn at a slow speed (approximately 20% of

full speed). The GUI should indicate that DC bus voltage is present from the generators, approximately 200 Volts DC.

3. Stop the wind turbine. The DC bus voltage will slowly bleed down (due to discharge resistors), but DC bus voltage will still be present.

4. Put both the left and right inverters into the Matrix Test modes. See “Matrix Test, Generators Idle”.This should immediately start to discharge the bus at a higher rate. A faint high pitched sound may be heard coming from the matrixes. This is normal. The sound will become more faint as the bus voltage decreases.

5. Stop the matrix test and then allow the wind turbine to operate to a higher speed (approximately 50% of full speed). The GUI should indicate that the DC bus voltage at each matrix is approximately 500 volts DC.

6. Stop the turbine and repeat the matrix test. 7. Confirm that the DC bus voltage at each matrix discharges to a low value (less

than 100 volts) after about 30 seconds. This completes initial Power On testing. The inverter is now ready for a full operational check.

Important: The matrix test is made with the generators operating. This test must be coordinated and performed with wind generator personnel.

WARNING: Shock hazardAny time the generators are operating, DC bus voltage is present.

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Full Operation Test

To perform a full operation test:1. Open the upper right compartment door and switch the Enable/Disable

selector, SW1, to the Enable (CW) position. 2. Close and latch the door.3. Make certain there are no objects on the enclosure or the matrix fans.4. Connect the external computer containing the GUI program to the fiber optic

port at the front of the enclosure. 5. Open the GUI program on the computer and, using the Tools menu, configure

the screen to show:• Line Voltage, Vab• Line Voltage, Vbc• Line Voltage, Vca• LM DC Bus• LM DC Current• RM DC Bus• RM DC Current

6. Apply 690 Vac three-phase power to the inverter enclosure. The internal fans in the inverter should start. After a few seconds, communication should be established between the CCU2 circuit board and the computer.

7. Click on the Clear Fault button. Both the left and right inverters should indicate that they are in Idle mode.

8. Read the 690 volt line voltage on the GUI screen. Each phase should read 675 to 700 Vac.

9. Release the turbine rotor's brakes to allow it to operate in the normal manner.

WARNING: Flying debrisWear safety glasses and protect your eyes. This is the first time the fans are operating. Any debris in the matrix may become dislodged. Do not look into the fins of the heatsink matrix when the fans start. Observe safety procedures described in “Personal Safety” on page vi.

Important: The following tests are made with the generators operating. These tests must be coordinated and performed with wind generator personnel.

Important: At any time during this startup procedure, if something unexpected happens, shutdown the wind turbine by clicking on the Shutdown button on the GUI screen.

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10. Observe the bus voltage of both inverters at the GUI.The bus voltage of each inverter should increase directly with generator speed. The bus voltage of both inverters should be approximately equal.

11. When the bus voltage reaches minimum cut-in level of 1,000 Vdc, the Turbine Control Unit (TCU) will call the inverters to come on line. Observe the following: • The GUI should show that the inverters have switched to the "Ready"

state.• The line contactors in both the left and right side inverters should

energize.• Both matrix fans on top of the inverter should start.• Both sets of magnetics fans on the front of the inverter should start.• The inverter matrixes will begin to switch and an audible noise will be

heard (approximately 1.6kHz).• The TCU will begin to command line current indicating the inverters are

operating in the normal manner.• Check the DC current of each generator on the GUI screen. The two

currents should read approximately the same.• Configure the GUI Screen to read each phase of the line current of both

inverters and check the currents. Each of the three-phases on each inverter should be balanced and read approximately the same as the other inverter.

12. If at any time during this startup procedure, an alarm occurs or the inverter fails to start as described, refer to Chapter 8, “Troubleshooting”.

Be aware that when the turbine speed falls below approximately 900 RPM (900 Vdc bus voltage), the inverters will shut down and revert to the Idle mode. When the inverters shut down, the matrixes cease operation, line contactors open and fans are stopped.

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4 Operation

Chapter 4, Operation, describes the theory of operation of the CW 2.5 MW Inverters and the various operating states of the inverter.

The topics in this chapter are organized as follows:• “Theory of Operation” on page 4–2• “System Operation” on page 4–6

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Theory of OperationThe CW 2.5 MW Wind Turbine Generator Power Conversion System consists of four identical sub-systems, each having a 650 kW inverter fed from a 650 kW generator. The inverters are contained in two identical enclosures, each with two inverters. The generators are permanent magnet type with internal 3-phase full wave rectifiers. The output of each generator is connected directly to the DC bus of its corresponding inverter. The 3-phase AC output of each inverter is connected (by others) to the 690 Vac side of a utility matching power transformer. Individual current (torque) of each generator is controlled by inverter internal hardware and software as commanded by the Turbine Control Unit (TCU) on the wind turbine. The TCU determines when the inverters are activated and it interfaces a number of protective functions and safety features between the inverter and the entire system. Figure 4-1 shows the overall configuration of the system.

Figure 4-1 Communication To and From the Turbine Control Unit (TCU)

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The generators are permanent magnet excited machines with a fixed voltage constant of 1.16 Volts/RPM (cold generator, AC line-line volts RMS). The generator has a slightly lower voltage constant when hot. Torque is controlled on the generator shaft by commanding DC current at the line interface inverter stage. The DC current is controlled by means of a closed loop DC current regulator within the inverter. Feedback for the current regulator is provided by a transducer in the DC power leads. A filter is utilized on the line side of the inverter to provide filtering such that the combined currents of the four inverters meets the IEEE 519 power quality requirements. Bandpass filters are incorporated within each inverter to actively dampen structural modes of the wind turbine system. This filter uses the DC bus voltage as the stimulus to detect and correct for main shaft oscillations at three different frequencies. The output of the filter is returned to the summing junction of the current input through adjustable gain factors. Figure 4-2 shows a block diagram of how this is implemented in the inverter.

Figure 4-2 650 kW Converter Section

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Low-Voltage Ride-Through

The inverter is Low-Voltage Ride-Through (LVRT) capable, offering over- and under-voltage and over- and under-frequency protection. The inverter is capable of meeting the run-time requirements outlined in Table 4-1.

The guidelines above enable the Liberty Wind Turbine to ride through transient voltage conditions that can be seen in Figure 4-3. All voltages and frequencies are referenced to the 690 Volt side of the pad mount transformer. The inverter shuts down immediately once it is outside the operating region (light blue shaded portions in Figure 4-3). The inverter has a user selectable setting (0 to 5 seconds) for the fault time of the over- or under-frequency fault. The power factor may deviate during a LVRT event.

Table 4-1 LVRT Line Voltage Limits and Time Delay

Line Voltage Limits(% of nominal) Time Delay Before Drop Out

100% thru110% Nominal Operation110% thru 120% 5 Seconds120% thru 130% 0.5 Seconds130% and Above Instantaneous100% thru 90% Nominal Operation90% thru 10% 5 Seconds10% and below 5 Seconds

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Figure 4-3 Transient Voltage and Frequency Ride-Through Characteristics

Clipper Windpower Liberty Wind Turbine Transient Frequncy Ride-Through Characteristics

Turbine remains online in this area

Clipper Windpower Liberty Wind Turbine Transient Voltage Ride-Through Characteristics

Turbine remains online in this area

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System OperationIn operation, torque is controlled on the generator shaft by commanding DC current at the line interface inverter. The DC current is controlled by means of a closed loop current regulator within the inverter. Feedback for this current loop is the actual DC current from the generator which is directly measured by a DC current sensor. The internal DC current feedback loop is extremely fast with a current rise time of 10 milliseconds from minimum to maximum (within DC bus voltage and current limits). The actual current rise time can be set from the Graphical User Interface (GUI) and is typically much slower in order to minimize mechanical forces on the equipment.

Inverter Operating States

The inverter has six different operating states.

Initializing

Initializing occurs at 690 Vac power up. The CCU2 unit goes through a self-test and initialization process. When this process is complete, the state changes to Idle.

Idle

Assuming there are no faults, the inverter automatically enters the Idle mode after initialization. When AC power is applied, control voltage for both inverters in the enclosure is also applied.

Ready

The DC bus is charged as the generators are brought up to speed. When the DC bus voltage reaches approximately 1000 volts, the inverter operating state changes to Ready. Assuming no other faults, the normal inverter operating range for the DC bus voltage is 900 to 1400 volts DC.

Manual Command

When the DC bus is in normal operating range and there are no faults, the Turbine Control Unit (TCU) determines that the turbine is ready to deliver power to the utility. The TCU sends a signal to the CCU2 unit to start the inverter. The CCU2 closes the 690 volt line contactor in each inverter. This places the inverter in the normal operating mode for the generators to supply power to the utility. At this time the cooling fans for the inverter heatsink matrix and magnetics compartments come on. Power to the utility is determined by controlling the DC current from each generator. The DC current level, up to rated maximum, is set with the current command from the TCU. The rate that the current ramps to the commanded level (di/dt) is settable. It can be varied from extremely fast to 25,000 Amps/Sec to very slow (25 Amps/Sec). Refer to Chapter 5, “GUI” of the Manual for a description

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for setting this ramp rate. The current command from the TCU is sent to all four inverters in the tower simultaneously. When the generator speed falls below minimum operating level, the TCU signals the inverters to shut down (revert to the Idle state). This stops matrix operation, opens the line contactors and stops the cooling fans. Assuming no faults, the inverters will remain in the Idle state until the generators bring the bus voltage back to the minimum start level.

Fault

If a fault occurs in one inverter, it will execute an orderly shutdown of both inverters in the enclosure. An interlock signal is wired to the TCU so it can shut down the other inverters in the system and stop the generators. If a fault occurs, the inverter will remain in the fault mode until it is cleared. The fault can be cleared through a command from the TCU or it can be manually cleared at the GUI by clicking on the Clear Fault button. A description of the fault and the fault code is retained in the fault history log along with waveforms. This information can be called up with the GUI as a troubleshooting aid. The GUI is described in detail in Chapter 5, “GUI”.

Matrix Test

The Matrix Test mode is used for checking operation of the IGBT matrix and for rapid discharge of the capacitor bank when troubleshooting. This is not a normal operating state. It is entered and exited via the external GUI. The inverter can be placed in Matrix Test mode if the generators are not supplying power to the utility and the Enable/Disable selector, SW1 in the upper right compartment, is open.

Converter Control Unit (CCU2)

The Converter Control Unit (CCU2) controls all functions of both inverters in each enclosure. This circuit board contains all the required power supplies for internal operation and for the two matrix high voltage driver boards. It controls the switching of the power transistors (IGBTs) in the two matrixes and it has several binary outputs to control operation of the line contactors of both inverters and an auxiliary output to control the internal space heater. Inputs to the circuit board include voltage and current sensors plus several fiber optic ports for external communication with the TCU and the GUI.

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5 GUI

Chapter 5, GUI, provides information and procedures on using the GUI software application for the CW 2.5 MW Inverters.

The topics in this chapter are organized as follows:• “Main Window of the GUI” on page 5–2• “GUI Elements and Features” on page 5–10• “GUI Data Logging Set Up Window- Fields Selection” on

page 5–13• “Graphs Screen” on page 5–16• “Downloader Window” on page 5–19• “Troubleshooting Window” on page 5–22• “Fault Analysis and Fault History Window” on page 5–25• “General Procedures” on page 5–36• “Choose Parameter Window” on page 5–37

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Main Window of the GUIThe GUI program is used to control the Xantrex inverters. The GUI starts up by displaying two windows side by side. Each window allows the control of two inverters. Each window can be seen as two identical programs running side-by- side with each window connected to a different serial port of the computer. The title bar at the top of the window identifies the inverters connected to it, for example, Clipper Inverter #1 and 2. See Figure 5-1.The information displayed on these windows is updated every 500 milliseconds (user adjustable setting). The additional windows of the GUI provide software downloading, troubleshooting and data logging capabilities. These windows are accessed from the main window. For simplicity, this section describes the main windows controlling Inverter number 1 and 2. The windows controlling Inverters number 3 and 4 are identical except for the window's title bar, which identify the inverters. See Figure 5-1.

Figure 5-1 Main Window of the GUI

1

35

7

911

13

15

17

19

2

6

8

1012

14

16

18

2021 22 2423

4

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Table 5-1 describes the elements and features of the GUI main window.

Table 5-1 Elements and Features of the GUI Main Window

Inverter #1 and 2 Features

Inverter #3 and 4 Features Description

1 2 Title Bar identifies the inverters as #1, 2, 3 or 4.

3 4 Menus provide access to different functions of the software program. There are four submenus: • File Menu (see page 5–4)• CommPort Menu (see page 5–6)• Tools Menu (see page 5–7)• Help Menu (see page 5–8)

5 6 Toolbar (see page 5–9)

7 8 Inverter Operating States (see page 4–6)

9 10 Fault Conditions (see page 8–3)

11 12 Software Version (see page 5–8)

13 14 Data Boxes and Parameter Labels, LM (Left Matrix) (see page 5–10)

15 16 Data Boxes and Parameter Labels, RM (Right Matrix) (see page 5–10)

17 18 Status Bar (see page 5–10)

19 20 Shutdown Button (page 5–10)

21 22 Clear Fault Button (see page 5–10)

23 24 Matrix Test Panel allows you to switch the left or the right matrix to On and Off. In order for the inverter to accept this command, the operational state of the inverter and the matrix must be Idle.

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File MenuThe File Menu provides four selections: Set Colors, Message Rate, Select Database and Exit (F12). See Figure 5-2.

Set Colors

To change the color under Set Colors:1. Use Set Colors to change the color of any of the main window elements.

When you select one of the options from the submenu, a Choose Color window is displayed. See Figure 5-3.

2. Select the color of your choice and click on the OK button. You can return to the factory default colors by selecting Default from the Set Colors submenu. See Figure 5-2.

Figure 5-2 File Menu

Figure 5-3 Choose Color Window

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Message Rate

Use Message Rate to change the frequency at which the GUI requests new data from the CCU2 (converter control unit) board. The frequency rate is entered from the input dialog window. The data is displayed on the main window. See Figure 5-4.

The default value for the polling rate is 500 milliseconds. This means that every 500 milliseconds the controller sends a message to the CCU2 board requesting new data to update the main window.To change the polling rate, enter the new value and click OK or press Enter.

Select Database

Use Select Database to choose the configuration file for the application. These files have the extension ".xan" and contain information about parameters, faults and troubleshooting notes from field experience.

Exit (F12)

Use Exit to close the program. To close individual windows, click the X button located in the upper-right corner of the window you wish to close. You can also close windows by pressing F12 on your keyboard.

Figure 5-4 Message Rate Window

Important: The polling rate reverts to the default rate of 500 milliseconds every time you start the GUI. Xantrex recommends keeping the default rate at 500 milliseconds

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CommPort Menu

The CommPort menu offers three functions: Connect, Disconnect and Properties.

Connect

Use Connect to establish communication with the CCU2 board. It uses the serial port and settings selected through the CommPort Properties Window. The default selection is: Port Com1, 57600 baud, 8 data bits, none parity, 1 stop bits. When the program is first opened, it automatically tries to establish communication with the CCU2 board using the default settings.The status of the connection is displayed in the Status Bar at the bottom of the main window.

Disconnect

Use Disconnect to interrupt communications with the CCU2 board.

Properties

Use Properties to go to the CommPort Properties Window.

Figure 5-5 CommPort Menu

Figure 5-6 CommPort Properties window

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This window allows you to change the communication settings of the GUI program. See Figure 5-6. The changes will remain in the GUI next time you restart it.

Tools Menu

The Tools Menu offers seven options.

Read/Write (F2)

Use Read/Write to open the Read Write by Id window. From this window you can read and modify the value of specific parameters in the CCU2 board. (See “Read/Write by ID# Window” on page 5–11.)

Shutdown (F3)

Use Shutdown to send a shutdown message to the CCU2 board. The inverter will stop and go into fault mode under an "External disable" fault code 0010.

Troubleshooting (F4)

Use Troubleshooting to open the TroubleShooter window. From this window you can find information about the current inverter's fault and clear faults.(See “Troubleshooting Window” on page 5–22.)

Data Logging (F5)

Use Data Logging Tool to open the GUI Data Logging Set Up window where you can manage a data logging session. (See “GUI Data Logging Set Up Window- Fields Selection” on page 5–13.)

Figure 5-7 Tools Menu

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Downloader (F6)

Use Downloader to open the Downloader window for downloading software into the CCU2 board. (See “Downloader Window” on page 5–19.)

Fault Analysis/History (F7)

Use Fault Analysis/History to retrieve data logged inside the CCU2 board before and after the last fault occurred. (See “Fault Analysis and Fault History Window” on page 5–25.)

General Procedures (F9)

Use General Procedures to open the General Procedures window. Through this window you can perform commissioning, maintenance and other procedures. (See “General Procedures” on page 5–36.)

Help Menu

The Help Menu provides three options: Contents, Technical Support, and About.

Contents

Use Contents to open the help for the Clipper User Interface program. You can also access this help by pressing F1 from any screen for context-sensitive help.

Technical Support

Use Technical Support to obtain information about contacting the Xantrex technical support department.

About

Use About to see the software version of your Clipper GUI program.

Figure 5-8 Help Menu

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ToolbarThe toolbar is located in the upper section of the main window and provides the following eight icons: CommPort Properties, Read/Write, Shutdown, Troubleshooting, Data Logging, Downloader, Fault Analysis/History, General Procedures. See Figure 5-9. Table 5-2 identifies the toolbar icons and describes the different features available by clicking on the toolbar icons.

Figure 5-9 Toolbar IconsTable 5-2 Toolbar Icons and Descriptions

Icon Icon Name Description For more information …

CommPort Properties Clicking CommPort Properties opens the CommPort Properties window. You can then change the communication settings for your program. The changes will remain in the GUI next time you restart it.

See “CommPort Properties window” on page 5–6.

Read/Write Clicking Read/Write opens the Read Write by ID# window. You can then read and modify the value of specific parameters in the CCU2 board.

See “Read/Write by ID# Window” on page 5–11.

Shutdown Clicking Shutdown sends a shutdown message to the CCU2 board. The inverter will then stop and go into fault mode under an External disable fault code 0010.

Troubleshooting Clicking Troubleshooting opens the TroubleShooter window. You can then view information about the inverter's current fault and clear faults.

See “Troubleshooting Window” on page 5–22.

Data Logging Clicking Data Logging opens the GUI Data Logging Set Up window. You can then manage a data logging session.

See “GUI Data Logging Set Up Window- Fields Selection” on page 5–13.

Downloader Clicking Downloader opens the Downloader window. You can then download software into the CCU2 board.

See “Downloader Window” on page 5–19.

Fault Analysis/History Clicking Fault Analysis/History opens the Fault Analysis/History window. You can then retrieve data logged inside the CCU2 board before and after the last fault occurred.

See “Fault Analysis and Fault History Window” on page 5–25.

General Procedures Clicking General Procedures opens the General Procedures window. You can then perform commissioning, maintenance, and other procedures.

See “General Procedures” on page 5–36.

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GUI Elements and Features

Data Boxes and Parameter Labels

Data boxes display actual data transmitted by the CCU2 board. Parameter Labels describe the meaning of the data being displayed by the data box located to the right of the label. You can change the parameter being displayed by double clicking on the data box or parameter label. This action opens the Choose Parameter window. See page 5–37.

Shutdown and Clear Fault Buttons

Clicking on the Shutdown button sends a shutdown message to the CCU2 board. The inverter will then stop and go into fault mode under an External disable fault code 0010.Clicking on the Clear Fault button sends a clear fault message to the CCU2 board.

Status Bar

The Status Bar shows information about the connection to the CCU2 board including CommPort settings, board response status, and connection duration.

Figure 5-10 Data Boxes and Parameter Labels

Figure 5-11 ShutDown and Clear Fault Buttons

Figure 5-12 Status Bar

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Read/Write by ID# Window

To open the Read/Write by ID# Window, use any of the following methods:

• Click the Read/Write button on the toolbar.• Select Tools/Read/Write on the main window Tools menu.• Press F2 on your keyboard.From the Read/Write by ID# Window, you can see the current value of any of the parameters of the CCU2 circuit board. You can change the value of any parameter that is not read only. Four parameters can be selected simultaneously. See Figure 5-13.

Selecting a Parameter

To select a parameter:1. Click on the down arrow of one of the combo boxes.

A list of parameters appears.2. Use the Page Up key, Page Down key and the arrow keys on your keyboard or

use the scroll bar to navigate through the list.3. Once you select a parameter, its current value is displayed to the right. 4. To see a description of the selected parameter, pause your mouse over the

figure displaying the current value of the desired parameter.5. To change the value of the selected parameter, enter the desired value for that

parameter and click on the Write To ID button. This action sends a message to the CCU2 board with the desired parameter ID# and value. The current values of the parameters shown on this window are continuously being updated.

Figure 5-13 Read/Write by ID# Window

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6. Watch the Status Bar located at the bottom of the main window for messages during this action. If you try to write to a read-only parameter a Command ignored message will be displayed briefly.

The next time you open the Read/Write by ID# window, it will display the parameters you selected the last time you used it.

Identifying the Serial Number of the CCU2 Board

The 10 digit serial number of the CCU2 board is also displayed on Read/Write by ID# window, for example: Board S/N: 0000000000. See Figure 5-13. The serial number is read directly from the CCU2 board.

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Data Logging Set Up Window

Logging data You can log the data being received from the CCU board from the Data Logging Set Up window in two different ways.

Default mode In the default mode, the parameters being logged are fixed in the CCU2 board software and the file produced is a comma delimited one.

Custom Fields mode

In the Custom Fields mode, you can select which parameters to log and the file produced is a MS Access compatible file. To change the mode, click Custom Fields (see Figure 5-14) or Fixed Fields (Figure 5-15).

GUI Data Logging Set Up Window- Fields SelectionTo access the GUI Data Logging Set Up window, use any of the following methods:

• Click the Data Logging button on the toolbar.• Select Data Logging Tool on the main window Tools menu.• Press F5 on your keyboard.

Figure 5-14 Data Logging Set Up Window - Custom Fields

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The Fields Selection frame shows the available fields to be logged. This list is exactly the same as the list of parameters displayed on the main window. If you want to log a parameter that is not present on the list, go to your main window and replace one of the parameters being displayed with the one you want to log. See “Choose Parameter Window” on page 5–37.

Selecting Parameters to Log

To select the parameters to log:1. Select the check boxes for the parameters you want to log and clear the check

boxes for the parameters you do not want to log.2. To change the rate at which the data is being logged, enter the logging rate in

the Logging Rate in msec. text box. The rate is expressed in milliseconds.

3. Click the Go button to start the logging process. Clicking the Pause

button or Stop button will interrupt or halt the logging process.A Save As window opens.

4. Select the name and location of the file that will contain the data retrieved from the CCU board. See Figure 5-16.The Save As window offers a default file name.

Figure 5-15 GUI Data Logging Set Up Window - Fixed Fields

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5. Either accept this name by clicking Save or type a new file name in the File name text box.Choosing the default file name is useful for future reference since it includes the date and time that the data was logged. For example, in Figure 5-16, the file name indicates that the file was logged from the CCU Board on10/05/2000 at 8:53:31.Once you click Save, the path and name of the file are displayed on your screen as well as the number of records and the recording time.

Working with .Xmdb files

The button gives you access to the Graphic screen (see “Graphs Screen” on page 5–16) where you can graph or view the data. Files with the extension ".Xmdb" are compatible with Microsoft® Access files which have a .mdb file extension. You can open and analyze these files by importing them into Microsoft Excel spread sheets. You can also create new directories. If you already have a Log file saved, you can perform any of the file functions normally performed from this window. For example you can delete the file, send it by e-mail, or rename it.

Figure 5-16 Saving a Parameter Log File

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Graphs ScreenThis screen allows you to display data which was previously logged using the Data Logging Set Up window.

When you click the button of the Data Logging Set Up window, the Select file to be displayed dialog box opens as shown in Figure 5-17. Select the desired file and click Open. If the button is not enabled, click Custom Fields in the Data Logging Set Up window, shown in Figure 5-14.

Figure 5-17 Graphs Screen

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Graphs Screen

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At the top of the screen in Figure 5-18, you can see the complete path name to your file: C:\\WINDOWS\Desktop\\VSS Clipper GUI 092904\\VSS Clipper GUI1\SineWaves250msXmdb.To display data:1. Select the parameters listed on the right side of the screen that you wish to see

on the graph and clear those you don’t want to see on the graph.The colors of the graph match the colors of the check box label of the parameter. In Figure 5-18, the first parameter, amplitud C, which is black, and the third parameter, amplitud A, which is orange, are selected.

2. To change the scale of the grid, use the scroll bars in the upper right corner.The horizontal scroll bar will change the milliseconds per division that represent each square of the grid. The vertical scroll bar will change the units represented by each division of the grid vertically.

Figure 5-18 Graph View

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3. Click and hold the right mouse button on the grid to see exactly what the value of the point be clicked is with respect to the origin of the axis.

4. To display data from another file, click Get Data to display the Select File dialog box.

5. If you wish to see the actual numeric values which have been plotted, click Data View. Each parameter is now represented by a column in the table (see Figure 5-19).

6. Use the scroll bar located on the right to see the data which does not fit on the screen.

7. You can return to the graph by clicking Graph View.Clicking Graph View or Data View allows you to switch views between the graph and the data table.

The Graphics Screen can be accessed only by clicking the button on the Data Logging Set Up window. If the button is not enabled, click Custom Fields.

Figure 5-19 Data View

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Downloader WindowThe Downloader Window enables you to download software to the CCU board.To access the Downloader window, use any of the following methods:

• Click the Downloader button on the toolbar.• Select the Downloader Tool on the main window Tools menu.• Press F6 on your keyboard.

To download software:1. Click Select File.

A window appears with a list of different software versions. See Figure 5-21.

Figure 5-20 Downloader Window

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2. Select the file you wish to download and click Open. The Downloader window appears with information on the status of the file to be downloaded and the file currently installed. See Figure 5-22.

Figure 5-21 Save As Window

Figure 5-22 Downloader Window with Status Information

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The TAG File: line displays the path and name of the file to be downloaded. The Board S/W Ver.: line displays the current software version installed in the CCU2 circuit board. The File S/W Ver.: line displays the version of the software that you are about to download to the board. The Status: line indicates that the CCU is entering Programming Mode.

3. Click Start Download to begin downloading the software. At this point the status of the download process is shown in addition to any errors detected.

3. You may cancel the download by clicking Cancel.If the process was completed uneventfully, the Status line will read: Program Downloaded Successfully.ORIf you lose communication with the CCU board during the download, the download is canceled.

Important: Software is downloaded at 38400 baud. If the download process is interrupted before it finishes successfully, you may have to manually reset the CCU board in order to take it out of download mode and back to 57600 baud.

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Troubleshooting WindowThe Troubleshooting window displays faults on the inverter as well as a means of keeping notes and clearing faults.To access the Troubleshooting window, use any of the following methods:

• Click the Troubleshooting button on the toolbar.• Select Tools/Troubleshooting on the main window Tools menu.• Press F4 on your keyboard.The Troubleshooting window has two modes: Work On Line and Work Off Line. By default, it opens in Work On Line mode, which means that it is displaying the inverter's current fault. You can work online to troubleshoot a fault and then clear it. When working offline, you can list all faults and add any personal notes and observations to any faults. See Figure 5-23.

Figure 5-23 Troubleshooter Window

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Working in On line Mode

Fault Description section

The first line of text in the Fault Description section of the window shows the fault code followed by its name. More information is provided about the fault along with tips to fix it. You can only see the current fault when you are working in the Work On Line mode.

Personal Field Notes section

The Personal Field Notes section of the Troubleshooter window may contain notes that an operator added while working on this fault at another time. You can only add notes to the Personal Field Notes section when you are in the Work Off Line mode.

Clearing Faults

To clear a fault:◆ Click Clear Fault.

You must be in the Work On Line mode. A Clear Fault message is sent to the CCU board. If the cause of the fault is no longer present in the inverter, the fault is cleared.

Working in Off Line Mode

You can work offline by clicking Work Off Line. You can then add comments and observations to any of the faults. You can only add notes to the Personal Field Notes section in the Work Off Line mode. Figure 5-24 shows the Troubleshooter Window in Work Off Line mode. A flashing warning reminds you that you are in the Off Line mode.

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Listing Inverter Faults

In the Work Off Line mode, the window does not necessarily display the current inverter's fault.To list all inverter faults:1. Click the Select Fault from List arrow.2. Select one fault at a time.

The fault description appears in the Fault Description field of the window. 3. Add any notes you consider to be useful, such as how you fixed a fault, in the

Personal Field Notes section. The notes are saved for future reference.

Figure 5-24 Working in Off Line Mode

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Fault Analysis and Fault History WindowThe CCU2 circuit board records 250 pieces of data before a fault occurs and 250 pieces of data after a fault occurs. All this data is recorded in non-volatile memory, so powering down the CW 2.5 MW Inverters will not delete the data. The Fault Analysis Screen allows you to retrieve and display this data. See Figure 5-25. When a fault occurs, the data logger automatically stops after recording 250 pieces of data.

Restarting the data logger

◆ To restart the data logger, on the Tools menu, click Start Data Log. The data logger is automatically started every time you clear the fault from the GUI.

Clearing fault analysis data

◆ To clear the fault analysis data from non-volatile memory, on the Tools menu Tools, select Delete Data Log.

Viewing status of the data log

◆ To view the status of the data log, on the Tools menu, click See Log Info. The information provided is:

• Data logger Status • ON = Data logger is running.• OFF = Data logger is not running.• DONE = Fault analysis data was captured. The data logger is not running.

• Data logger Rate is the rate at which the samples are taking.• Event Position is the position of the circular buffer when the fault occurred.• Does All Data Belong to this Event?

• TRUE = all the data recorded belongs to the fault been analyzed.• FALSE = the fault occurred before a complete circle was completed by

the circular buffer. Some of the data belongs to a different event.

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Figure 5-25 shows what the Fault Analysis Screen looks like when you first open it. To start retrieving data, you can do one of the following:• Click the green Retrieve Fault Analysis Data button.

• Click the Retrieve button in the toolbar.• On the Tools menu, click Retrieve Fault Analysis Data.

A Save As window appears. See Figure 5-26.

Figure 5-25 Fault Analysis and Fault History Screen

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This window allows you to select the name and location of the file that will contain the data retrieved from the CCU2 circuit board. This window also lets you create new directories. If you already have a Fault Analysis file (*.xlog) in your computer, by right clicking on it, you will be able to perform any of the functions your computer normally allows you to do from this kind of window. For example, you can delete the file, send it by e-mail, and rename it.The Save As window offers a default file name. You can accept this name by clicking on the Save button or you can type a new file name.The default name has the advantage of identifying your file for future reference based on the fault, date and time. For example, in Figure 5-26, the file name of the second file listed (the file name box is blank) indicates that the code of the fault being analyzed in the file is "3F50", the date the data was retrieved from the CCU2 circuit board was 10/05/02 and the time of retrieving was 20:13:42.Files with extension .xlog are compatible with Microsoft Access files .mdb. You can open and analyze these files by importing them into Microsoft Excel spread sheets.Once you click Save, the data retrieving process starts. Information about the progression of this task will be displayed on the screen. You can stop retrieving at any time by clicking Stop. The path and name of the file into which the data is been recorded is shown on the screen.

Figure 5-26 Save As Window

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Figure 5-27 shows the screen in the process of retrieving data.

After the retrieving process is complete, the Open File button replaces the STOP button. To open the file containing the data, click Open File. The data will be displayed in the form of graphs, as shown in Figure 5-28. There are 10 fixed parameters represented by graphs.You will notice that more buttons are now available on the toolbar, as well as options in the Tool menu.

Figure 5-27 Retrieving Fault History Data

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The first line of the screen shows the code and description of the fault being analyzed and the time scale of the graphs. The dotted line shows the point where the fault occurred. To the left of this line, you can see the data before the fault and to the right of the line, the data after the fault happened. You can move this dotted line if you need to have a different reference. To move the line, drag it using the mouse.Use the scroll bar to see the graphs of the parameters that did not fit on the screen. You can also minimize the graph by clicking the button on the toolbar or by selecting Zoom Out from the Tools menu. Keep clicking till you can see all the parameters on one screen. You can reverse this by clicking the button or by selecting Zoom In from the Tools menu.

Figure 5-28 Graph View

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If you wish to display the data in numeric form instead of graphic form, click the button on the Toolbar or select Show Data Table from the Tools menu. Figure

5-29 shows data displayed in numeric form.

You can display the data in graph form again by clicking the button or by selecting Show Graphs from the Tools menu.There are times when you would like to open a file from your archive. To do so, click the button or select Open File from the File menu. Figure 5-30 appears. Select the file you want to display and click Open.This window also allows you to open Fault History files. On the Files of Type: box select the *.hlog filter to see the Fault History files that you have in your computer.By right clicking on any of the file names shown on this window, you will be able to perform any of the functions your computer normally allows you to do from this kind of window. For example you can delete the file, send it by e-mail, or rename it.

Figure 5-29 Data Table View

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Fault History

Every time a fault occurs, the CCU2 circuit board records the event and puts a time stamp on it. This data is saved into non-volatile memory. The maximum number of faults recorded is 200. Once this limit is reached, the fault history will be overwritten starting from the oldest fault recorded.The fault history can be cleared from non-volatile memory by selecting Delete Fault History from the Tools menu.The fault history log can be retrieved from the CCU2 circuit board from the Fault Analysis screen. To do so, do one of the following:• Click the Retrieve Fault History button.

• Click the button located on the toolbar.• Select Retrieve Fault History from the Tools menu.A Save As window appears.

Figure 5-30 Save As Window

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This window allows you to select the name and location of the file that will contain the data retrieved from the CCU2 circuit board. This window also lets you create new directories. If you already have a Fault History file (*.hlog) in your computer, by right clicking on it you will be able to perform any of the functions your computer normally allows you to do from this kind of window. For example, you can delete the file, send it by e-mail, or rename it.The Save As window offers a default file name. You can accept this name by clicking on the Save button or you can type a new file name.The default name has the advantage of identifying your file for future reference base on the date and time of retrieval. For example, in the figure above, the file name indicates that the file was retrieved from the CCU2 circuit board on 10/08/02 and the time of retrieval was 15:41:44.Files with the extension *.hlog are text files that can be viewed with any word processing software.Once you click Save, the data retrieving process starts. Information about the progression of this task will be displayed on the screen. You can stop retrieving at any time by clicking STOP. Figure 5-32 on page 5–33 shows the screen in the process of retrieving the fault history data.

Figure 5-31 Save As Window

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Once the data has been retrieved, the fault history will be displayed on your screen and the STOP button changes into a printer icon. To print the fault history, click the printer icon. See Figure 5-33.

Figure 5-32 Retrieving Fault History

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Figure 5-34 shows a typical fault history file. On it you will find information about the date and time of downloading of the file, information about the last fault recorded by the CCU2 circuit board (non-volatile memory), the number of faults recorded in the file and each of the faults recorded with their date, time, code and description. The first number of each line is only a line identification number.

Figure 5-33 Print Window

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The second line in the file makes reference to a CCU (CCU2 circuit board) number. This number identifies the CCU2 circuit board from which the data has been downloaded. The number is introduced on the CCU during commissioning at parameter ID# 65. It will probably match the number of the tower in which the CCU is installed.The name and path of the file been displayed is shown above the text box displaying the content of the file.The Fault Analysis Screen can be accessed through any of the following methods:1. Click the button on the toolbar.2. Select Fault Analysis/History from on the Tools menu.3. Press F7 on your keyboard.

Figure 5-34 Typical Fault History File

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General ProceduresThe General Procedures window provides a step-by-step procedure to perform on the inverter. See Figure 5-35.To access the General Procedures tool window, use any of the following methods:

• Click the button on the toolbar.• Select General Procedures from the Tools menu.• Press F5 on your keyboard.

The procedure steps are displayed one at a time. The orange panel provides instructions on the task to be executed during the step displayed. The picture to the right of the orange panel is a visual reference to the location of the components involved in the step shown. At any time during the procedure, you can click Make Notes, located below the picture, to type any comments about findings or observations. After entering comments, the picture can be displayed again by clicking on the same button. Notice that the caption of the button changed to Show Picture. Once the task described on the orange panel has been performed, click the check box, located below the Make Notes button, to acknowledge that the task was completed. This will be used during the final report.To go to the next step, click Next located in the lower right corner of the window.

Important: The Read/Write by Id# window is not available when the General Procedure Tool Window is open and vice versa.

Figure 5-35 General Procedures Window

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During the procedure, different controls in the window will become available as they are needed. At any time you can save the report for the procedure by clicking Save Report. Once the report is saved, it can be loaded at a later time to continue to work on it. To do so, select Load Report from the Tools menu. When you try to save a report, a dialog window offers a default name for the report file. This default name contains the converter number and the date. For example, Report_C44_022603.rep indicates that the report is for the procedure performed on converter 44 and that it was saved on February 26, 2003. You can change the name, but it must keep the extension rep.The General Procedures Tool window also allows you to load a different procedure. To do so, click Select Procedure from the Tools menu. You can then select the file containing the procedure you wish to perform. The name of the procedure being performed is part of the title of the General Procedures Tool window. Procedures files have the file extension .rex.

Choose Parameter WindowThe Choose Parameter window allows you to change one of the parameters being displayed on the main Window or to load a main window configuration (see Figure 5-1). The main window configurations hold colors and parameters to be displayed on the main window.

Only Inverter State, Fault Code and S/W Version located in the upper section of the main window, as well as Oper.State (LM) and Oper.State(RM), cannot be changed. To change any of the others on the main window, double click on the parameter to be changed. Figure 5-36 appears.To select a new parameter to be displayed on the position where you double clicked, simply select the new parameter from the Select Parameter list.

Figure 5-36 Choose Parameter Window

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Once you have the desired parameter selected from the list, click OK. At this point you will be back to the main window and the parameter selected will appear on it.To load a pre-saved screen configuration, select the desired configuration from the Select Configuration list.

Once you have the desired configuration selected from the list, click OK. At this point, you will be back to the main window and the configuration selected will be displayed.To add a new configuration, first select the parameters you want to be displayed when using this configuration. Do so by selecting the parameters one by one on the main window as described in “Choose Parameter Window” on page 5–37. You can also select different colors for the main screen elements to be saved with this configuration (see “File Menu” on page 5–4 for choosing colors).

Figure 5-37 Choose Parameter

Figure 5-38 Select Configuration

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Once the main screen configuration is set, open the Choose Parameter Window and click Save Current Configuration. Type the desired name for the current configuration and click OK. Your new configuration is added to the Select Configuration list.To delete a configuration, select the configuration to be deleted from the Select Configuration box and click Delete Configuration. A message asking you to confirm the deletion will appear. Click Yes to delete the configuration from the list.The Choose Parameter Window can only be accessed by double clicking the parameter, displayed on the main screen, that is going to be changed.

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6 Flow Charts

Chapter 6, Flow Charts, provides the flow charts which display the high level software logic information.

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Flow Chart 1 of 3

Figure 6-39 Flow Chart 1 of 3

Lmatrix_idle( )0

Systemfaulted?

NO

YES Lmatrix_faulted( )3

Lmatrix_matrix_test( )4

L Matrix Testcanceled by

GUI?

NO

YES

System IDLE ANDL Matrix Test

requested by GUI?

YES

NO

System READYAND

L Matrix DC BUS >VDC_PRE_LOW

ANDL Matrix Current Commandrequested by GUI Or TCU

0x01?

NO YES

Lmatrix_manual_Icmd( )2

Perform currentcontrol on left sidematrix according to

input from GUI.

NOTE: Right matrix flow chart is identicalto left matrix flow chart located in thispage.

K11 is used instead of K21.

NO YESSystemfaulted?

switch matrix OFFOpen K21.

Red LED ON.Green LED OFF.

YES NOSystemfaulted?

NO

YES

Systemfaulted?

Mask DC bus undervoltage fault.Open K21.

LM State = Matrix Test.Switch matrix ON.

Current Cmd = 35.Close K21.

Set settling timer.Lmatrix_ready( )

1

Check for DC bus Low.

YES

NO

L Matrix set toIDLE by GUI

ORE-Stop open?

L Matrix DC BUS>=

DCBUS_REF

YES

NO

L Matrix set toIDLE by GUI

ORE-Stop open?

NO

YES

LM state = faulted.LM goal state =Idle.switch matrix OFF.

LM state = IdleLM goal state =Idle.

Red LED OFF.Green LED ON.

LM state = IdleLM goal state =Idle.switch matrix OFF.

Systemfaulted?

NO

YES

LM state = faulted.LM goal state =Idle.

Current Cmd = 0.Switch Matrix OFF.

Open K21.

Current Cmd = 0.Switch Matrix OFF.

Open K21.

Switch matrixON.

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Flow Chart 2 of 3

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Flow Chart 2 of 3

Figure 6-40 Flow Chart 2 of 3

Enable/disableswitch closed?

J2_pin1to2

NO

YES sys_ready( )2

GUI request Lor and R matrix

test?

YES

NO

NO

YES

Systemfaulted?

YES

NO

Systemfaulted?

Boot up

sys_initializing( )0

sys_idle( )1

sys_faulted( )3

NO YESSystemfaulted?

Lmatrix_idle( ) Rmatrix_idle( )

Initialize all states andgoal states to Idle.

System goal state = Idle.

LM goal state = Matrix TestAND/OR

RM goal state = Matrix Test

E-Stop isclosed?

NO

YES

LM goal state = Idle.RM goal state = Idle.

LM goal state = Idle.RM goal state = Idle.

Set all states and goalstates to Idle.

NOTES:

J1 PIN1-2 will be open if the system is faulted.J1 PIN3-4 will be open if the system is faulted (temporary additionbecause J1 1-2 hardware damaged on board)

J1 PIN11-12 will be open if the system is faulted on a fault otherthan TWIN_INVERTER_FAULT.

Before opening K21, the L matrix current command is set to zeroand the L matrix is switched OFF.

Before opening K11, the R matrix current command is set to zeroand the R matrix is switched OFF.

K21 and K11 will open if any fault occurs.

The matrix current command is set to zero automatically whenexiting current command mode.

K21 will open if L matrix enters Matrix Test mode.

K11 will open if R matrix enters Matrix Test mode.

GREEN LED OFF REDLED ON

Close J1 pin1-2

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Flow Chart 3 of 3

Figure 6-41 Flow Chart 3 of 3

Main( )

bootSystem( )

Verify boot source.Initialize all variables.

Test memory, copy flash to RAMand execute from RAM.

Clear faults.Initialize hardware.

while(TRUE)

Do serial communication.Alternate serial port #1 and #2.

Check connector J2 inputs.

E-Stop isclosed?

NO

YESSet system goal state = Ready.

Set system goal state = Idle. L matrix state=

Matrix Test?

NO

YES

Set L Matrix goal state = Idle.

NO

YESSystemfaulted?

Do state machinesanity check.

Open J1 pin1-2.

Mask DC bus undervoltage fault.Set system state = Faulted.Set system goal state = Idle.

R matrix state=

Matrix Test?

NO

YES

Set R Matrix goal state = Idle.

c_int02( )Interrupt @

5700 Hz

Reset interrupt 2 watchdog timer.Keep Two AC cycle counter.Keep frequency test counter.

Check limits, trigger softwarefaults. Add fault to fault history log.

checkForFaults( )

Check FPGA fault register.

Check limits, triggersoftware faults.

checkForFaults( )

read_CCU_inputs_a2d( )

Read all A2D converters inputs.

line_volt_freq_calc( )

Do Line signal transformation,filtering and calculations.

matrixes_power_calc( )

Do Left matrix side powercalculation.

Do Right matrix side powercalculation.

L matrix state=

Matrix Test? NO

YES

L matrix state=

Manual I Cmd? NO

YES

L_matrix_test( )

Do_Rmatrix_DC_Icmd( )

R matrix state=

Matrix Test? NO

YES

R matrix state=

Manual I Cmd?NO

YES

R_matrix_test( )

Do_Rmatrix_DC_Icmd( )WriteD2A( )Set D2A outputs.

Do_data_logging( )

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7 Fault Conditions

Chapter 7, Fault Conditions, provides a list of fault conditions which may appear on the GUI.

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CW 2.5 MW Inverters Fault ConditionsFault condition codes which are displayed on the GUI are listed in Table 7-1.Fault code descriptions may be accompanied by an (H) or (S) to indicate what has triggered the fault: hardware, software or both.• (H) Fault – Triggered by Hardware• (S) Fault – Triggered by Software• (Checked) Where the software checks for this fault.• (Condition before checking) Conditions that need to be met before the software checks for this fault• (Triggered by) What causes the fault to be present.

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

0000 No Faults No fault conditions are detected.

F000 Download Software

This fault is displayed on the GUI by the shipping version of the CCU software. The purpose of this fault is to warn the user that the software installed on the CCU is NOT flying software and that he or she needs to download the appropriate software for the site where the inverter has been installed.

0001 State Machine Failure

(S) None The current system state is not a legal state.

0002 Interrupt Timeout

(S) None Interrupt c_int02 (5700 Hz) did NOT occur before checkForFaults ( ) function was called 1000 times.

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0010 External Disable

(S) This fault is set by the user by shutting down the inverter from the GUI

0015 Inductors Compartment High Temperature

(S) At least one of the matrixes is in Ready or Manual Current Command state.

CCU connector J2 pin 7-8 is not getting 15 Vdc. The Temperature switch is open.

0029 Serial Communication Timeout

(S) None No message has been received from TCU (through a serial port U1001 & U1002) for more than 150 milliseconds.

0040 In Programming Mode

(S) None The user requested the CCU to enter in download mode. The request was done through the serial port.Note: This fault does NOT indicate a malfunction of the CCU board. It is used to be able to download software into the board.

0042 Bad Memory (S) During boot_sys ( ) function called only once during system power up.

None The software wrote and read from static memory and the result of the reading did NOT agree with the data written to it.

0043 SEEPROM Write Error

(S) None The software performs a read from SEEPROM after it has written into it. The result of the reading did NOT agree with the data written to it.

0028 SEEPROM Timeout

300 milliseconds have passed and there is no response from SEEPROM.

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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0080 Left Ripple Current

(S) User settable, default 300A. Troubleshooting inspect the rectifier circuit.

0120 Line Frequency Low

(S) Line voltage greater than (AC_LINE_RMS * SQRT2 * 0.5)

Line frequency has been less than 57 Hz for one second.

0220 Line Frequency High

(S) None Line frequency has been greater than 63 Hz for one second.

0130 Line AC Voltage Too Low

(S) System passed the Initialize state

The line voltage is less than 10% of Nominal AC for 5 sec.ORThe line voltage is less than 90% of Nominal AC for 5 sec.

0230 Line AC Voltage Too High

(S) System passed the Initialize state.

The line voltage is between +10% and +20% of Nominal AC for 5 seconds.ORThe line voltage is between +20% and +30% of Nominal AC for 500 milliseconds.ORThe line voltage is greater than +30% of Nominal AC volts instantaneous.

0155 Left Matrix State Machine Failure

(S) None The current left matrix state is not a legal state.

0156 Left Matrix Control Failure to Turn Off

(S) None After disabling the left matrix, the software reads from the matrix controller that the matrix is NOT off.

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

gprice
Text Box
It is an AC voltage on the DC voltage from the rectifiers. It points to a problem in the rectifier/Gen circuit generally. The set default is 300 amps of ripple. Ripple Currents also shows up sometimes when the DC bus gets shorted. When the DC bus gets shorted, voltage dips down, current goes up and it essentially looks like a big ripple is about to happen.
gprice
Line
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0256 Left Matrix Control Failure to Turn On

(S) None After enabling the left matrix, the software reads from the matrix controller that the matrix is NOT on.

0157 Left Matrix DC Bus Voltage Low

(H/S) Matrix is ON (for hardware check)ANDMatrix state is NOT Matrix Test.ORMatrix state is NOT Idle.

Hardware (CCU) detects that the DC bus voltage is less than 848 volts DC.ORSoftware detects that the left matrix DC bus is less than Vdc_PRE_LOW (900) volts DC.

0257 Left Matrix DC Bus Voltage High

(H/S) None Hardware (CCU) detects that the left matrix DC bus voltage is more than 2014 volts DC.ORSoftware detects that the left matrix DC bus voltage is more than DCBUS_MAX_VOLT (1950) volts DC.

0158 Left Matrix Temperature Sensor Error

(S) None The temperature read from the left matrix at CCU-J7 pins 4-5 is less than –49 °F (–45 °C).

0258 Left Matrix Over- Temperature

(H/S) None The temperature read from the left matrix at CCU-J7 pins 4-5 is greater than 176 °F (80 °C).

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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XX66 Left Matrix Gate Drive Fault

(S) None Hardware (CCU) detects that one or more IGBTs from the left matrix have set a fault.Note: The first two digits of the fault code indicate the particular device that detected the fault, as follows:0166 Phase A+0266 Phase A–0466 Phase B+0866 Phase B–1066 Phase C+2066 Phase C–The two first digits of these numbers are added in hexadecimal for a multiple gate fault.

XX77 Left Matrix Overcurrent Fault

(H/S) None Hardware (CCU) detects that the left matrix current phase A is greater than 1142 amps peak. (0877)AND, ORHardware (CCU) detects that the left matrix current phase B is greater than 1142 amps peak. (1077)AND, ORHardware (CCU) detects that the left matrix current phase C is greater than 1142 amps peak. (2077).

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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XX77 Left Matrix Overcurrent Fault

(H/S) None Software (CCU) detects that left matrix current phase A is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (0177)

AND, ORSoftware (CCU) detects that left matrix current phase B is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (0277)

AND, ORSoftware (CCU) detects that left matrix current phase C is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (0477)

Note: The two first digits of these numbers are added in hexadecimal for a multiple overcurrent fault. For example, 0377 would indicate overcurrent fault on Phase A and B (01h+02h=03h).

0078 Left Matrix DC Bus Overcurrent

(S) None Software detects that the left matrix DC bus current is more than DCBUS_MAX_CURRENT (1000) amps DC.

01AA Right Matrix State Machine Failure

(S) None The current right matrix state is not a legal state.

01AB Right Matrix Control Failure to Turn Off

(S) None After disabling the right matrix, the software reads from the matrix controller that the matrix is NOT off.

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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02AB Right Matrix Control Failure to Turn On

(S) None After enabling the right matrix, the software reads from the matrix controller that the matrix is NOT on.

01AC Right Matrix DC Bus Voltage Low

(S) Matrix is NOT in Idle or Matrix Test Mode.

Software detects that the right matrix DC bus is less than Vdc_PRE_LOW (900) volts DC.

02AC Right Matrix DC Bus Voltage Low

(S) None Software detects that the right matrix DC bus voltage is more than DCBUS_MAX_VOLT (1950) volts DC.

01AD Right Matrix Temperature Sensor Error

(S) None The temperature read from the right matrix at CCU-J7 pins 6-7 is less than –49 °F (–45 °C).

02AD Right Matrix Over Temperature

(S) None The temperature read from the right matrix at CCU-J7 pins 6-7 is greater than 176 °F (80 °C).

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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XXBB Right Matrix Gate Drive Fault

(H) None Hardware (CCU) detects that one or more IGBTs from the right matrix have set a fault.Note: The first two digits of the fault code indicates the particular device that detected the fault, as follows:01BB Phase A+02BB Phase A–04BB Phase B+08BB Phase B–10BB Phase C+20BB Phase C–The two first digits of these numbers are added in hexadecimal for a multiple gate fault.

XXCC Right Matrix Overcurrent Fault

(H/S) None Hardware (CCU) detects that right matrix current phase A is greater than 1142 amps peak. (08CC)

AND, ORHardware (CCU) detects that right matrix current phase B is greater than 1142 amps peak. (10CC)

AND, ORHardware (CCU) detects that right matrix current phase C is greater than 1142 amps peak. (20CC).

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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XXCC Right Matrix Overcurrent Fault

(H/S) None Software (CCU) detects that the right matrix current phase A is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (01CC)

AND, ORSoftware (CCU) detects that the right matrix current phase B is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (02CC)

AND, ORSoftware (CCU) detects that the right matrix current phase C is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (04CC)Note: The two first digits of these numbers are added in hexadecimal for a multiple over-current fault. For example, 0377 would indicate over-current fault on Phase A and B (01h+02h=03h).

00DD Right Matrix DC Bus Over Current

(S) None Software detects that the right matrix DC bus current is more than DCBUS_MAX_CURRENT (1000) amps DC.

00DE Right Ripple Current

(S) User settable, default 300A. Troubleshooting inspect the rectifier circuit.

Table 7-1 List of Fault Conditions

Fault Number

Fault Title(H) or (S) or Both Fault Description

Condition Before Checking Triggered

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8 Troubleshooting

Chapter 8, Troubleshooting, is designed to help you determine where problems are occurring in the CW 2.5 MW Inverters and how to resolve them.

If the troubleshooting procedures provided in this chapter do not solve the problem, please contact the Xantrex Customer Service Department. See “Contact Information” on page ii.

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Before You Start Troubleshooting

Servicing Safety Requirements

Lock Out and Tag Out

Safety requirements mandate that this equipment not be serviced while energized. Power sources for the CW 2.5 MW Inverters must be locked out and tagged out prior to servicing. Each service technician should have a padlock and tag installed on each energy source prior to servicing.

Visual InspectionBefore any detailed troubleshooting of the CW 2.5 MW Inverters, verify that all power is removed before beginning the visual inspection of the inverter. This includes the 690 volt power source as well as the wind turbine rotor. Make certain the wind turbine rotor is locked and cannot turn.

WARNING: Lethal voltageIn order to complete these procedures, you will need to work in areas with lethal voltage. Before starting any troubleshooting procedures, review all the safety instructions provided in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematic to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the CW 2.5 MW Inverters operating.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

WARNING: Shock hazardThe matrix high voltage driver board is connected to the DC bus voltage (1400 Vdc). Do not touch the high voltage driver boards when the DC bus is charged.

CAUTION: Risk of equipment damage due to moistureIf power has been removed and the inverters exposed to cold temperatures, frost or moisture may be present inside the enclosure. Close and latch both doors. Apply 690 V power but do not turn on the inverters. Allow the internal heater to warm up the unit for a minimum of 4 hours or until the inside of the enclosure is dry before operating the inverter.

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Open both the upper right and upper left compartment doors and make a thorough inspection of the internal components and wiring. Look for any components that are dislocated or discolored. Look for any foreign debris that may have gotten into the enclosure.

Fault ConditionsFault condition codes are displayed at the GUI. The following information describes the fault codes and the procedures for troubleshooting the indicated fault conditions.The description of a fault code may be accompanied by a letter to indicate whether or not the fault is triggered by hardware or software or both:• (H) means the fault was triggered by hardware.• (S) means the fault was triggered by software.

0000 - No Faults

No fault conditions are detected.

F000 - Download Software

This fault is displayed at the GUI by the shipping version of the CCU2 software. This fault condition warns the user that the software installed in the CCU2 is only providing communication functions and not controlling the machine. To troubleshoot fault code F000:The appropriate software of the site where the inverter is installed needs to be downloaded. See Chapter 3, “Commissioning”, “Downloading Operational Software” on page 3–7.

0001 - State Machine Failure

This fault condition indicates the inverter is not in a legal state.To troubleshoot fault code 0001:1. Turn off the 690 volt power to the inverter. Wait 3 minutes until the backup

power board discharges the power to the CCU2 circuit board.2. Reapply 690 volt power.3. Clear the fault at the GUI.4. If the GUI still displays Fault 0001, replace the CCU2 circuit board.

0002 - Interrupt Timeout

This fault condition indicates a malfunction of the processor in the CCU2 circuit board.

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To troubleshoot fault code 0002:1. Turn off the 690 volt power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI. 5. If the GUI still displays Fault 0002, replace the CCU2 circuit board.

0010 - External Disable

This fault condition is set by a Shutdown (or F3) signal from the GUI.To troubleshoot fault code 0010:◆ Clear the fault at the GUI.

0015 - Inductor Compartment High Temp

This fault condition is triggered if one of the temperature sensors on the three-phase inductors in the lower magnetics compartment is open. This fault condition is triggered only if one of the inverters in the enclosure is in the Ready mode or in the Manual Current Command mode.To troubleshoot fault code 0015:1. Stop the generators and shut down the inverter.2. Wait 30 minutes for the inductors to cool. 3. Restart the system and check the operation of all three cooling fans in the

lower magnetics compartment. If the fans seem to operate properly, continue to the next step.

4. Remove all power and wait 30 minutes for the DC bus voltage to discharge.5. Remove the front covers of the lower left and lower right magnetics

compartments and check for an overheated inductor.6. Verify it is a real temperature alarm and not an electrical problem If so inspect

the 24V circuit including SW17. Using an ohmmeter, check the temperature sensor circuit for an open lead.

Refer to the schematic diagram (see Figure B-2 on page B–3). Check the connections at the inductors in the magnetics compartments. Check the connection up to the CCU2 circuit board connector.

8. If a temperature switch is open and it seems its associated inductor is not overheated, replace the temperature sensor.

9. If the temperature sensing circuit is intact, replace the magnetic compartment covers, taking care to connect the cooling fans.

10. Apply 690 Vac power to energize the control power circuit.

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11. Check for 20 volts DC minimum, at CCU2-P2-8 with respect to 24 V Rtn. If the voltage is not there, check the control voltage circuits as described later in this chapter.

12. Verify that the backup power board is operational. Measure at the backup board TB1-1 (+) positive to ground. Look for 24 Vdc. The LEDs on the board should be illuminated. If not, verify the 22 Vac at TB2 A to neutral. If the input voltage is good and there is no output voltage, replace the backup power board.

0029 - Serial Communication Timeout

This fault condition is triggered if no message has been received from the TCU at the serial port at U1001 and U1002 for more than 150 milliseconds.To troubleshoot fault code 0029:1. Remove all power and wait 30 minutes for the DC bus voltage to discharge.2. Check for a broken fiber optic connection from the TCU to the inverter.3. Check the fiber optic connections at the CCU2 circuit board, U1001 and

U1002.4. Remove the connectors and make certain connections are clean and that the

cable is properly seated in the connector.5. If the GUI still displays the fault, replace the CCU2 circuit board.

0040 - In Programming Mode

This fault condition indicates that the CCU2 is placed in programming mode from the GUI. This fault condition does NOT indicate a malfunction of the CCU2 board. It is used to download a software program into the board.

0042 - Bad Memory

This fault condition indicates a malfunction of the CCU2 board SCRAM or the program.To troubleshoot fault code 0042:1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI. 5. If the GUI still displays the fault, replace the CCU2 circuit board.

CAUTIONWhen removing and installing fiber optic connectors, pull off and push on with the connector only. Do not pull on the fiber cable.

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0043 - SEEPROM Write Error

This fault condition indicates that the software did not properly read the SEEPROM data on the CCU2 circuit board. To troubleshoot fault code 0043.1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI.5. If the GUI still displays the fault, replace the CCU2 circuit board

0028 - SEEPROM Timeout

This fault condition indicates that the CCU2 SEEPROM did not respond within 300 milliseconds after a write command was sent to the serial port.To troubleshoot fault code 0028:1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI. 5. If the GUI still displays the fault, replace the CCU2 circuit board.

0080 Left Ripple Current

Default is 300 amps. Troubleshooting inspect the rectifier circuit.

00DE Right Ripple Current

Default is 300 amps. Troubleshooting inspect the rectifier circuit.

0120 - Line Frequency Low

This fault condition is triggered if the software detects that the line frequency has been less than 57 Hz for one second.

0220 - Line Frequency High

This fault condition is triggered if the software detects that the line frequency has been greater than 63 Hz for one second.To troubleshoot fault code 0120 or 0220:◆ If the line frequency is known to be 60 Hz, and the fault does not clear,

replace the CCU2 circuit board.

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0130 - AC Line Voltage Too Low

This fault condition is triggered if the line voltage is:Less than 10% of Nominal AC for 5 sec.ORLess than 90% of Nominal AC for 5 sec.To troubleshoot fault code 0130:The inverter cannot deliver power from the generators to the utility if the line voltage is excessively low. To see if the inverter detected a low line voltage condition, look at the Fault History Data at the GUI. (See Chapter 5, “GUI”, “Fault History” on page 5–31.)If the line voltage is OK:1. Remove all power and wait 30 minutes for the bus voltage to discharge.2. At the upper right compartment of the inverter, check fuses F51, 52 and 53

with an ohmmeter. Make certain the fuseholder is fully closed.3. Using an ohmmeter, check the wiring to the line voltage sense circuit from

fuses F51, 52 and 53 to terminal strip TB12. 4. Check wiring from TB12 to the CCU2 circuit board at J1001.5. If the line voltage sense circuit is OK, replace the CCU2 circuit board.

0230 - Line Voltage Too High

This fault condition is triggered if the line voltage is:Between +10% and +20% of nominal for 5 secondsOrBetween +20% and +30% of nominal for 500 millisecondsOrGreater than +30% of nominal (instantaneous)The inverter cannot deliver power from the generators to the utility if the line voltage is excessively high. To see if the inverter detected a high line voltage condition, look at the Fault History Data at the GUI. (See Chapter 5, “GUI” “Fault History” on page 5–31.)If the line voltage is OK:1. Remove all power and wait 30 minutes for the DC bus voltage to discharge.2. At the upper right compartment of the inverter, check fuses F51, 52 and 53

with an ohmmeter. Make certain the fuseholder is fully closed.3. Using an ohmmeter, check the wiring to the line voltage sense circuit from

fuses F51, 52 and 53 to terminal strip TB12. 4. Check the wiring from TB12 to the CCU2 circuit board at J1001.

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Left Matrix Fault Conditions

0155 - Left Matrix State Machine Failure

This fault condition is triggered if the left inverter matrix is not in a legal state.To troubleshoot fault code 0155:1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI.5. If the GUI still displays the fault, replace the CCU2 circuit board.

0156 - Left Matrix Control Failure to Turn Off

This fault condition is triggered if the software reads that the matrix is NOT Off after being disabled.

0256 - Left Matrix Control Failure to Turn On

This fault condition is triggered if the software reads that the matrix is not NOT ON after being enabled.To troubleshoot fault code 0156 or 0256:1. Reset the CCU2 board by removing 690 Vac power to the inverter. Wait 3

minutes until the backup power board discharges the power to the CCU2 circuit board.

2. Reapply 690 volt power. Clear the fault at the GUI.3. If the GUI still displays the fault, replace the CCU2 circuit board.

0157 - Left Matrix DC Bus Voltage Low

This fault condition is triggered if CCU2 hardware detects that the DC bus voltage is less than 848 Volts DC.OrCCU2 software detects that the DC bus voltage is less than 900 Volts DC.To troubleshoot fault code 0157:1. Using the GUI, look at the Fault History Data for the DC bus (See Chapter 5,

“GUI”“Fault History” on page 5–31). Check both the numerical data and the oscillography. Check for a clean DC voltage signal from the generator bridge rectifiers.

2. Confirm that the generators are operating at rated speed.

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3. Remove all power and wait 30 minutes for the DC bus voltage to discharge. At the upper left compartment of the inverter, check power wiring from the generators to the DC bus terminals, TB21 and TB22. Using an ohmmeter, check the wiring to the DC bus sense circuit at TB25 and from TB25 to CCU2-J6.

4. If a high voltage DC voltmeter is available (1500 Vdc minimum), connect it to read the DC bus voltage and close up the inverter.

5. Restart the generators and measure the DC bus voltage with the external voltmeter to determine if the actual voltage is low.

0257 - Left Matrix DC Bus Voltage High

This fault condition is triggered if CCU2 hardware detects that the DC bus voltage is more than 2014 volts DC.OrCCU2 software detects that the DC bus voltage is more than 1950 volts DC.To troubleshoot fault code 0257:1. Using the GUI, look at the Fault History Data for the DC bus (see “Fault

History” on page 5–31). Check both the numerical data and the oscillography. Check for a clean DC voltage signal from the generator bridge rectifiers.

2. Confirm that the generators are operating at rated speed.3. Remove all power and wait 30 minutes for the DC bus voltage to discharge. At

the upper left compartment of the inverter, check power wiring from the generators to the DC bus terminals, TB21 and TB22. Using an ohmmeter, check the wiring to the DC bus sense circuit at TB21 and from TB21 to CCU2-J6.

4. If a high voltage DC voltmeter is available (2500 Vdc minimum), connect it to read the DC bus voltage and close up the inverter.

5. Restart the generators and measure the DC bus voltage with the external voltmeter to determine if the actual voltage is high.

WARNING: Shock hazardThe DC Bus can reach a potential of 1400 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC Bus directly. Use the Graphical User Interface (GUI) to determine the DC Bus voltage. The DC Bus can be verified to be discharged by a DVM once the 30 minute discharge period has expired, or the GUI shows it has discharged.

WARNING: Shock hazardThe DC Bus can reach a potential of 1400 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC Bus directly. Use the Graphical User Interface (GUI) to determine the DC Bus voltage. The DC Bus can be verified to be discharged by a DVM once the 30 minute discharge period has expired, or the GUI shows it has discharged.

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0158 - Left Matrix Temperature Sensor Error

This fault condition is triggered if the left matrix temperature sensor is shorted.To troubleshoot the fault code 0158:◆ Check the temperature sensor per the procedure described in “Matrix

Temperature Sensors” on page 8–36.

0258 - Left Matrix Over-Temperature

This fault condition is triggered if the temperature read at the left matrix heatsink is greater than 176 °F (80 °C).To troubleshoot the fault code 0258:1. Verify that the external matrix heatsink fan is operating properly. 2. If the fan is not operating, remove all power and check fuses in the control

circuit. See “Matrix Fans” on page 8–35.3. If the fan seems to be operating normally, check the temperature sensor per

the procedure “Matrix Temperature Sensors” on page 8–36.

XX66 - Left Matrix Gate Drive Fault

The two first digits of these numbers are added in hexadecimal for a multiple gate fault. For example, 0350 would indicate gate fault on Phase A+ and Phase A–. To troubleshoot fault code XX66:1. Remove all power and wait 30 minutes for the bus voltage to discharge. Open

the upper compartment enclosure (s) and conduct a thorough inspection, looking for any part damage or loose wiring.

2. Attempt to clear the fault condition from the GUI. a) If the fault condition clears, go to Step 6.b) If the fault condition does not clear, continue with Step 2.

3. Verify that all 6 green LEDs on the high voltage driver board are illuminated.a) If all 6 green LEDs are illuminated, continue with Step 3.b) If some of the green LEDs are illuminated and some are off, OR all of the

green LEDs are off, refer to “High Voltage Driver Board” on page 8–31.4. Verify that all 6 yellow LEDs are off.

If any of the yellow LEDs are illuminated, refer to “High Voltage Driver Board” on page 8–31. If no problems are found, replace the driver board and recheck.

5. Disconnect the fiber optic cable from the transmitter (gray connector) on the high voltage driver board that corresponds to the phase that the fault indicates. The phase order of the connectors on the driver board is A–, A+, B–, B+, C–, C+ starting with the closest to you. Verify that there is a solid red light coming out of the transmitter.a) If NO solid red light is present at the driver board transmitter, refer to

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“High Voltage Driver Board” on page 8–31.b) Otherwise, reconnect the fiber optic cable.

6. Disconnect the opposite end of the same fiber optic cable from the CCU2 circuit board. Verify that the light that you saw coming out of the driver board transmitter is visible at the end of the fiber optic cable.a) If the light is NOT present, replace the fiber optic cable.b) If the light is present, reconnect the cable into the CCU2 and attempt to

clear the fault.c) If the fault does not clear, replace the CCU2 board.

7. At this point, it means that the fault only occurs when the inverter starts, but not when the inverter is idle. Perform a matrix test. See “Matrix Test, Generators Idle” on page 3–8.a) If the matrix test was successful with an ohmmeter, verify that there are

no shorts between phases or phase to ground on the power cables that connect the matrix to the line contactor (K11, K21).

XX77 - Left Matrix Over Current Fault (H/S)

This fault condition is triggered if the CCU2 hardware detects that the current in one or more of the line phases is greater than 1142 amps.The first two digits of the fault code indicates the particular phase that detected the fault, as follows:

The two first digits of these numbers are added in hexadecimal for a multiple over-current fault. For example, 0377 would indicate over-current fault on Phase A and B (0lh+02h03h).To troubleshoot fault code XX77 (H/S):1. Remove all power. Using an ohmmeter, check for shorts from phase to phase

and from phase to ground at both sides of contactor K21.2. Check the matrix IGBTs using the ohmmeter procedure described “IGBT

Checks” on page 8–30.3. Verify proper operation of the current transformers CT22 and CT23. Refer to

the procedure “Current Transducers” on page 8–24.4. Verify proper operation of the high voltage driver board as described “High

Voltage Driver Board” on page 8–31.5. Replace the CCU2 circuit board.

Fault Code Phase

0877 Phase A

1077 Phase B

2077 Phase C

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0078 - Left Matrix DC Bus Over Current

This fault condition is triggered if the CCU2 software detects that the Left Matrix DC bus current exceeds 1000 amps.To troubleshoot fault code 0078:1. Remove all power. Using an ohmmeter, check for shorts from phase to phase

and from phase to ground at both sides of contactor K21.2. Check the matrix IGBTs using the ohmmeter procedure described in “IGBT

Checks” on page 8–30.3. Verify proper operation of the current transformer CT21. Refer to the

procedure described in “Current Transducers” on page 8–24.4. Verify proper operation of the high voltage driver board as described in “High

Voltage Driver Board” on page 8–31.5. Replace the CCU2 circuit board.

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Fault Conditions

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Right Matrix Fault Conditions

01AA - Right Matrix State Machine Failure

This fault condition is triggered if the right inverter matrix is not in a legal state.To troubleshoot fault code 01AA:1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power.4. Clear the fault at the GUI.5. If the GUI still displays the fault, replace the CCU2 circuit board.

01AB - Right Matrix Control Failure to Turn Off

This fault condition is triggered if the software reads that the right matrix is NOT Off after being disabled.

02AB - Right Matrix Control Failure to Turn On

This fault condition is triggered if the software reads that the right matrix is not NOT ON after being enabled.To troubleshoot fault code 01AB or 02AB:1. Reset the CCU2 board by removing 690 Vac power to the inverter. 2. Wait 3 minutes until the backup power board discharges the power to the

CCU2 circuit board.3. Reapply 690 volt power. 4. Clear the fault at the GUI.5. If the GUI still displays the fault, replace the CCU2 circuit board.

01AC - Right Matrix DC Bus Voltage Low

The CCU2 software detects that the DC bus voltage is less than 900 Volts DC. There is no hardware DC Bus Voltage Low fault on the right matrix.To troubleshoot fault code 01AC:1. Using the GUI, look at the Fault History Data for the DC bus (see “Fault

History” on page 5–31). Check both the numerical data and the oscillography. Check for a clean DC voltage signal from the generator bridge rectifiers.

2. Confirm that the generators are operating at rated speed.

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3. Remove all power and wait 30 minutes for the bus voltage to discharge. At the upper right compartment of the inverter, check power wiring from the generators to the DC bus terminals, TB11 and TB12. Using an ohmmeter, check the wiring to the DC bus sense circuit at TB15 and from TB15 to CCU2-J1000.

4. If a high voltage DC voltmeter is available (1500 Vdc minimum), connect it to read the DC bus voltage and close up the inverter.

5. Restart the generators and measure the DC bus voltage with the external voltmeter to determine if the actual voltage is low.

02AC - Right Matrix DC Bus Voltage High

The CCU2 software detects that the DC bus voltage is more than 1950 volts DC. There is no hardware DC Bus Voltage High fault on the right matrix.To troubleshoot fault code 02AC:1. Using the GUI, look at the Fault History Data for the DC bus (see “Fault

History” on page 5–31.) Check both the numerical data and the oscillography. Check for a clean DC voltage signal from the generator bridge rectifiers.

2. Confirm that the generators are operating at rated speed.3. Remove all power and wait 30 minutes for the bus voltage to discharge. At the

upper right compartment of the inverter, check power wiring from the generators to the DC bus terminals, TB11 and TB12. Using an ohmmeter, check the wiring to the DC bus sense circuit at TB15 and from TB15 to CCU2-J1000.

4. If a high voltage DC voltmeter is available (2500 Vdc minimum), connect it to read the DC bus voltage and close up the inverter.

5. Restart the generators and measure the DC bus voltage with the external voltmeter to determine if the actual voltage is high.

WARNING: Shock hazardThe DC Bus can reach a potential of 1400 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC Bus directly. Use the Graphical User Interface (GUI) to determine the DC Bus voltage. The DC Bus can be verified to be discharged by a DVM once the 30 minute discharge period has expired, or the GUI shows it has discharged.

WARNING: Shock hazardThe DC Bus can reach a potential of 1400 Vdc. This is beyond the range of a typical Digital Volt Meter (DVM). Do not measure the DC Bus directly. Use the Graphical User Interface (GUI) to determine the DC Bus voltage. The DC Bus can be verified to be discharged by a DVM once the 30 minute discharge period has expired, or the GUI shows it has discharged.

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01AD - Right Matrix Temperature Sensor Error

This fault condition is triggered if the right matrix temperature sensor is shorted.To troubleshoot the fault code 01AD:◆ Check the temperature sensor per the procedure described in “Matrix

Temperature Sensors” on page 8–36.

02AD - Right Matrix Over-temperature

This fault condition is triggered if the temperature read at the right matrix heatsink is greater than 176 °F (80 °C).To troubleshoot the fault code 02AD:1. Verify that the external matrix heatsink fan is operating properly. 2. If the fan is not operating, remove all power and check fuses in the control

circuit. See “Matrix Fans” on page 8–35.3. If the fan seems to be operating normally, check the temperature sensor per

the procedure described in “Matrix Temperature Sensors” on page 8–36.

XXBB - Right Matrix Gate Drive Fault

This fault condition is triggered if the CCU2 hardware detects that one or more IGBTs in the right matrix have set a fault. The IGBTs set the fault by switching off the corresponding transmitter (gray fiber optic connector) on the high voltage driver board.The first two digits of the fault code indicates the particular device that detected the fault. See Table 8-1.

The two first digits of these numbers are added in hexadecimal for a multiple gate fault. For example, 0350 would indicate gate fault on Phase A+ and Phase A–.

Table 8-1 Device Detecting the Right Matrix Gate Driver Fault

Fault Code Device Detecting the Fault

01BB Phase A+02BB Phase A–04BB Phase B+08BB Phase B–10BB Phase C+20BB Phase C–

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To troubleshoot fault code XXBB:1. Remove all power and wait 30 minutes for the bus voltage to discharge. Open

the upper compartment enclosure (s) and conduct a thorough inspection, looking for any part damage or loose wiring.

2. Attempt to clear the fault condition from the GUI. a) If the fault condition clears, go to Step 6.b) If the fault condition does not clear, continue with Step 2.

3. Verify that all 6 green LEDs on the high voltage driver board are illuminated.a) If all 6 green LEDs are illuminated, continue with Step 3.b) If some of the green LEDs are illuminated and some are off, OR all of the

green LEDs are off, refer to “High Voltage Driver Board” on page 8–31.4. Verify that all 6 yellow LEDs are off.

If any of the yellow LEDs are illuminated, refer to “High Voltage Driver Board” on page 8–31. If no problems are found, replace the driver board and recheck.

5. Disconnect the fiber optic cable from the transmitter (gray connector) on the high voltage driver board that corresponds to the phase that the fault indicates. The phase order of the connectors on the driver board is A–, A+, B–, B+, C–, C+ starting with the closest to you. Verify that there is a solid red light coming out of the transmitter.a) If NO solid red light is present at the driver board transmitter, refer to

“High Voltage Driver Board” on page 8–31.b) Otherwise, reconnect the fiber optic cable.

6. Disconnect the opposite end of the same fiber optic cable from the CCU2 circuit board. Verify that the light that you saw coming out of the driver board transmitter is visible at the end of the fiber optic cable.a) If the light is NOT present, replace the fiber optic cable.b) If the light is present, reconnect the cable into the CCU2 and attempt to

clear the fault.c) If the fault does not clear, replace the CCU2 board.

7. At this point, it means that the fault only occurs when the inverter starts, but not when the inverter is idle. Perform a matrix test. See “Matrix Test, Generators Idle” on page 3–8.a) If the matrix test was successful with an ohmmeter, verify that there are

no shorts between phases or phase to ground on the power cables that connect the matrix to the line contactor (K11, K21).

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XXCC - Right Matrix Over Current Fault (H/S)

This fault condition is triggered if the CCU2 hardware detects that the current in one or more of the line phases is greater than 1142 amps.The first two digits of the fault code indicates the particular phase that detected the fault, as follows:

The two first digits of these numbers are added in hexadecimal for a multiple over-current fault. For example 0377, would indicate over-current fault on Phase A and B (0lh+02h03h).To troubleshoot fault code XXCC (H/S):1. Remove all power. Using an ohmmeter, check for shorts from phase to phase

and from phase to ground at both sides of contactor K11.2. Check the matrix IGBTs using the ohmmeter procedure described in “IGBT

Checks” on page 8–30.3. Verify proper operation of the current transformers CT12 and CT13. Refer to

the procedure described in “Current Transducers” on page 8–24.4. Verify proper operation of the high voltage driver board as described in “High

Voltage Driver Board” on page 8–31.5. Replace the CCU2 circuit board.

00DD - Right Matrix DC Bus Over Current

This fault condition is triggered if the CCU2 software detects that the Right Matrix DC bus current exceeds 1000 amps.To troubleshoot fault code 00DD:1. Remove all power. Using an ohmmeter, check for shorts from phase to phase

and from phase to ground at both sides of contactor K11.2. Check the matrix IGBTs using the ohmmeter procedure described in “IGBT

Checks” on page 8–30.3. Verify proper operation of the current transformer CT11. Refer to the

procedure described in “Current Transducers” on page 8–24.4. Verify proper operation of the high voltage driver board as described in “High

Voltage Driver Board” on page 8–31.5. Replace the CCU2 circuit board.

Fault Code Phase

08CC Phase A

10CC Phase B

20CC Phase C

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230/120/22 Vac Control Power

The following sections describe how to check the various control voltages within the inverter enclosure.

690 Vac Utility Voltage

To check the 690 Vac utility voltage:1. Measure the voltage at the top of fuse holders F51, F52 and F53 at the upper

right compartment. (See Figure 1-13, “Right Main Panel Assembly” on page 1–16.)

2. Check the voltage between each fuse holder, all three-phases. The voltage should measure 690 Vac ± 10%.

3. Check the voltage at the bottom of fuse holders F51, F52 and F53 to be certain the fuses are not blown.

4. Check the voltage between each fuse holder, all three phases. If there is any question regarding the fuses, remove all power and check each fuse individually (out of the fuse holder) with an ohmmeter.

WARNING: Lethal voltageIn order to complete these procedures, you will need to work in areas with lethal voltage. Before starting any troubleshooting procedures, review all the safety instructions described in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematic to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the inverter running. Make certain the generators are locked and cannot turn.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

WARNING: Shock hazardThe matrix driver board is connected to the DC bus voltage which can be as high as 1050 Vdc. Do not touch the driver boards when the DC bus is charged.

CAUTIONUse a voltmeter with an AC volts rating of at least 1000 Vac.

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230/120/22 Vac Control Power

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230 Vac Secondary Voltage

The 230 Vac secondary voltage powers the matrix fans and the internal space heaters.To check the 230 Vac secondary voltage:1. Measure the voltage at the fuses in the upper left compartment. See Figure 1-

9, “Left Main Panel Assembly” on page 1–11.2. Measure with respect to chassis ground.

(The return winding, X0, is connected to chassis ground.) 3. For the matrix fans, measure at the top of fuses F59 and F60. 4. For the internal space heaters, measure at the top of fuse F57.

The voltage should measure 230 Vac ±10%.5. Check the voltage at the bottom of the fuse holders also to be certain the fuses

are OK.6. If there is any question regarding the fuses, remove all power and check each

fuse individually (out of the fuse holder) with an ohmmeter.

120 Vac Secondary Voltage

The 120 Vac secondary voltage is used for the contactor power supply and the magnetics compartment fans. To check the 120 Vac secondary voltage:1. Measure at the top of fuses F56 with respect to chassis ground.

The voltage should measure 120 Vac ± 10%. 2. Check the voltage at the bottom of the fuse holders also to be certain the fuses

are OK.3. If there is any question regarding the fuses, remove all power and check each

fuse individually (out of the fuse holder) with an ohmmeter.

24 Vac Secondary Voltage

The 24 Vac secondary voltage is used to supply power to the CCU2 circuit board and for the inboard 24 Vdc power supply for the auxiliary inputs to the board. To check the 24 Vac secondary voltage:1. Measure at the top of fuse holders F54 to F55. 2. Check the voltage at the bottom of the fuse holders also to be certain the fuses

are OK.3. If there is any question regarding the fuses, remove all power and check each

fuse individually (out of the fuse holder) with an ohmmeter.

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CCU2 Power The 24 volts AC voltage from transformer T1 is rectified with diode bridge DB1 and connected to the CCU2 circuit board at connector P5. The connection is made at terminal strip RTB21, located in the upper left compartment. If a problem is suspected with the incoming power to the board, measure this voltage at RTB21 terminal 5 to terminal 7. The voltage should be between 18 and 24 volts DC. The backup power board, CW-BUP, is also connected to this circuit through diode bridge DB3. The backup power board is essentially a very large capacitor which stores voltage for the CCU2 circuit board in case of a momentary power outage. The voltage here will be lower than normal when 690 volt power is applied to the inverter. This is normal and it can take several minutes for voltage to build up due to the large capacitance. The CCU2 circuit board will function normally even though the voltage is low. If there is no DC voltage at RTB21-5 to -7:1. Measure the voltage at fuses F54 to F55.2. If there is no AC voltage, remove all power and check fuses F54 and F55 with

an ohmmeter. If the fuses are OK, check 690 fuses F51 and F52.If the voltage at RTB21-5 to -7 is OK:1. Check the fuse on the CCU2 circuit board, F1.2. If the fuse is OK, check the CCU2 circuit board power supplies.

CCU2 Circuit Board Power SuppliesThere are four main power supplies on the CCU2 circuit board located in the lower section of the board. There are four large capacitors oriented in a horizontal row just above the heatsink. Test points for each supply are located to the left of each of these capacitors. From left to right, the power supply voltages are:• (–)15 Vdc for the analog circuitry• (+)15 Vdc for the analog circuitry• (+)5 Vdc for the digital circuitry• (+)15 Vdc for the high voltage driver boards.To check the CCU2 circuit board power supplies:1. Locate the two test points above connector J5 on the lower left side of the

board (Vac IN).2. With a Digital Volt Meter (DVM) set for DC Volts, connect the negative lead to

the right hand test point and the positive lead to the left hand test point. The voltage should read 22 to 30 Vdc.

3. If the voltage is not present, check fuses and AC power per the previous paragraphs. If the voltage is present, proceed to the next step.

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CCU2 Circuit Board Power Supplies

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4. Connect the negative lead of the DVM to an AGND terminal (Analog Ground) on the CCU2 board.

5. Check the voltages.

a) If this voltage is low, unplug connector P7 from the board and recheck the voltage.

b) If the voltage is OK, there is a problem with one of the high voltage driver boards. Refer to the “High Voltage Driver Board” on page 8–31 for trou-bleshooting information.

6. If the voltage is OK, proceed with checking the other onboard power supplies.

If any of the regulated power supply voltages are not within the specified limits but the +22 Vdc supply checks OK, replace the CCU2 circuit board.

CAUTIONTake care to not short any components on the CCU2 circuit board with the test leads.

Test Point Reading

+15 V DRV +14.5 to 15.5 Vdc

Test Point Reading

(+)5 Vdc +4.5 to 5.5 Vdc

(+)15 Vdc +14.5 to 15.5 Vdc

(-)15 Vdc –14.5 to 15.5 Vdc

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Contactor Control CircuitThere are two contactors in the inverter enclosure:• K21 for the left side inverter• K11 for the right side inverterThe function of these contactors is to connect the inverter to the utility line power when the inverter is in a mode that can deliver power from the generators to the utility. Coil power for the contactors is derived from the 115 Vac secondary winding on control transformer T1. This voltage is rectified by diode bridge DB2 and filtered with capacitor C2 which creates a DC power supply of approximately 160 Vdc to match the coil rating of the contactors. The contactor coils are controlled by the CCU2 circuit board in response from a signal from the TCU module. Each contactor coil is energized through a solid state relay (SSR) by means of a 15 volt DC control signal from the CCU2. SSR21 directly controls contactor K21 and SSR11 controls contactor K11. If a problem is suspected in either contactor control circuit:1. Make certain the DC bus voltage from the generators is of sufficient

magnitude for proper inverter operation. Check this at the GUI. The minimum operational bus voltage is 900 Vdc. In order to initially energize the contactor and start the inverter (that is, go from an Idle to a Ready state), the bus voltage must be 1000 Vdc.

2. Make certain the software installed in the CCU2 circuit board is up to date and appropriate for the site.

3. If a hardware problem is suspected with the contactor control circuit: a) Make certain the generators are stopped and cannot rotate.b) Allow 30 minutes for the bus voltage to discharge.

4. Check the contactor coil DC power supply voltage at RBT11 which is located in the upper right compartment of the inverter.

5. Measure the voltage at terminal 1 to 4. The voltage should be 140 to 180 Vdc.

6. Turn off all power and check wiring between the SSR and the contactor coil circuit. Check wiring from the CCU2 circuit board connector, P1, to the SSR.

7. If the wiring checks OK, replace the SSR.8. If replacement of the SSR does not correct the problem, replace the CCU2

circuit board. See “Replacing the CCU2 Board” on page 10–4.

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Space Heaters

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Space HeatersThe space heaters are controlled by thermostat TS11, located on the main panel in the upper right compartment. The thermostat is adjustable. The normal setting is 40 °F. Heater power is 230 Vac from control transformer T1 through fuse F57. The space heater operation is interlocked with the line contactors K11 and K21. When the contactors are energized, the heaters switch off.If a problem is suspected with a space heater:1. Check for 230 Vac at the top of fuse holder F57. If voltage is not present,

check for primary voltage on transformer T1.2. If voltage is OK at top of fuse holder F57, check voltage at the bottom.

Remove all power and check the fuse with an ohmmeter. 3. If the fuse is OK, look for a problem with the thermostat, TS11. The

thermostat can be temporarily turned up to a higher setting to bring on the heater. (Remember to turn it back down following the test.)

4. If the thermostat checks OK, look for a problem with the contactor auxiliary contact. They are removable and easily changeable.

Magnetics FansThe fans at the front of each magnetics compartment are powered from the 120 Vac secondary winding on control transformer T1. The fans are energized only when the inverter is operational and the line contactor is closed.If a fan(s) is not working:1. Check for 120 Vac at the top of fuse holder F56.2. Remove all power and open the front cover of the magnetics compartment.

Rest the cover on the lower bolts. 3. Check the fan power cable connector. 4. Check the wiring at the fan power terminal strip.5. If everything seems OK, look for a problem with the contactor auxiliary

contact.

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Current TransducersThere are three current transducers used in each inverter. On the left side inverter, CT21 is used to sense DC current from the generator. CT22 and CT23 are used to sense the AC current to the utility. On the right side inverter, CT11 is used to sense DC current from the generator. CT12 and CT13 are used to sense the AC current to the utility.All three current transducers in each inverter are of the same type. Each current transducer receives ±15 Vdc excitation from the CCU2 circuit board, and the output of each transducer is connected to a current sensing resistor on the circuit board. Preliminary checks of the current transducers can be made with 690 Vac control power. If a problem is suspected with a current transducer:1. Make certain the generators are stopped and cannot rotate. 2. Allow 30 minutes for the bus voltage to discharge.3. Refer to “Schematic Diagram of CCU2 Circuit Board” on page B–4 which

shows the transducer connections to the CCU2 circuit board.4. Check for +15 V and –15 V excitation for each transducer at the CCU2 circuit

board connector, P3. Make this measurement with respect to a (AGND) terminal on the CCU2 circuit board.

5. Check the output of each transducer at the CCU2 circuit board connector, P3. The output of the transducer is shown on the drawing as "M". The output signal (no current) should be less than 30 mVdc.

6. If the ±15 volt excitation is not present, the problem is probably with the CCU2 circuit board and it should be replaced. If the transducer output is above 30 mfg. (no current) the transducer should be replaced.

7. The burden resistors on each transducer can be checked with all power off.8. Check the burden resistor with an ohmmeter. Refer to Sheet 3 of the

schematic diagram. The burden resistors are shown on the schematic at connector P3. Transducers CT12, 13, 22 and 23 each have a 4.53 Ω burden resistor. Transducers CT11 and 21 have a 30.1 Ω burden resistor. These resistors can be measured in circuit (without disconnecting any wires).

9. Measure with respect to CCU2 (AGND) terminal.

CAUTION: Equipment damageBe careful not to short any components on the CCU2 circuit board with the test leads.

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Filter Capacitor

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Filter CapacitorIf the line filter capacitor, PFC11, is not functioning properly, the output waveform of the inverter may be distorted. Also, there may be an unusual audible noise coming from the line inductor. If a problem with the line filter capacitor is suspected:1. With 690 Vac line power applied but with the generators stopped, the current

in the capacitor can be checked with a clamp-on ammeter. 2. The current can be measured at fuses F11, 12 and 13 which are located in the

upper right compartment of the inverter. The current in each of the three phases should be equal and approximately 50 amps AC.

3. If currents are not measured or not equal, remove all power and wait 30 minutes for the bus voltage to discharge.

4. Check fuses F11, 12 and 13 with an ohmmeter.

5. If a blown fuse is found, check for a shorted capacitor. With an ohmmeter, check from terminal to terminal on the capacitor and from each terminal to case.

CAUTION: Wire damageWhen measuring the current in the filter capacitor, take care not to put excessive strain on any wiring which could possibly disconnect it from its termination.

CAUTION: Before opening the fuse holder, check for voltage on the filter capacitor by measuring terminal to terminal with a Digital Volt Meter (DVM). First set the DVM to measure for AC volts. Then set the DVM to measure for DC volts.

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Matrix

Figure 8-1 shows a laminated bus where the matrix is built. The laminated bus electrically and mechanically connects the IGBTs and the DC filter capacitor bank. The IGBTs are mounted to aluminum heatsink which, when mounted on the enclosure, have large external cooling. This laminated bus which is stuffed with all the necessary components is mounted on an aluminum heatsink.

IGBTs

One side of the matrix is connected to a three-phase AC system and the other is the DC bus. Each matrix has six Isolated Gate Bipolar Transistors (IGBTs). The IGBTs are controlled via a high voltage driver board. A capacitor bank with bleeding resistors is connected to the DC bus in the matrix.Each IGBT is controlled by one isolated section of the driver board. Each isolated section of the driver board is connected to only one IGBT via three wire harnesses. The wire connected to the emitter of the IGBT and the one connected to the gate of the IGBT form a twisted pair. This twisted pair is connected to connector Px02 on the assigned section of the driver board. The third wire is connected to the collector of the IGBT and to connector Px0l of the assigned section of the driver board.

LEDs

Each section of the driver board, except the center section, has a green LED and a yellow LED. • The green LED indicates whether this section is receiving its isolated ±15

Vdc power voltage. LED ON means voltage is present. • The yellow LED indicates whether the IGBT connected to this section is

being fired or not; LED ON means IGBT fired.

Figure 8-1 Power Electronic Converter Matrix

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Matrix

152874 8–27

Fiber Optics

In addition, each section of the driver board (except the center one) has two fiber optic connectors:Gray fiber optic connector The gray fiber optic connector is a transmitter and communicates to the CCU2 board whether the IGBT connected to this section is working properly or not. The connector is connected to the CCU board by a fiber optic cable.The status of the red light indicates the status of the IGBT:• A solid red light emitted from the connector means that the IGBT is working

correctly. • A red light is not present when the driver board detects that the IGBT is

having problems. In the event that the CCU is missing one of these red lights coming from the driver board, a Gate Drive fault is triggered.

Blue fiber optic connector The blue fiber optic connector is a receiver. The CCU sends a signal through this cable each time it wants the correspondent IGBT to be fired.The connector is connected to the CCU2 board by a fiber optic cable.

AC Phases

Each two sections of the driver board correspond to one AC phase. When the matrix is installed in the inverter, the section on your left is connected to A–, the next is A+, then B–, B+, C– and C+.The center section of the driver board provides a DC to DC power supply, with one input and 6 isolated outputs. The power for this board comes from the CCU board’s J7 connector through the DB9 female connector. The DB9 female connector also brings back to the CCU the reading from the temperature sensor connected to the white connector (P2) locate to the left of the DB9 connector. This temperature sensor is screwed into the matrix’s heat sink.

Short Circuit

The driver board adds IGBT short circuit protection. When a short circuit protection occurs, a high current will flow in the IGBT causing its collector to emit voltage to increase to a level much higher than normal. The driver board detects this condition, and quickly turns the IGBT off, at the same time it switches the opto-transmitter off, making the CCU to trigger a IGBT Gate fault.

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Matrix Test

To verify that the matrixes are working correctly:1. Verify that the green LED is On in each section of the driver board.

a) If none of the green LEDs are On, troubleshoot the +15 Vdc coming from the CCU2 board J7 through the driver board’s P1 connector.

b) If some of the green LEDs are on and some are Off, replace the high volt-age driver board.

2. Verify that the yellow LED is Off in each section of the driver board.a) If any of the yellow LEDs are On, replace the driver board.

3. Connect the computer to the CCU2 board. Run the GUI program and establish communication with the inverter. Clear any faults at the GUI.

4. Turn the Enable/disable select switch SW1 to the Off position.5. At the GUI, go to the Matrix test.6. If an IGBT Gate Drive fault is triggered, perform the following sub-steps.

Otherwise go to Step 8.a) Disconnect the fiber optic cable from the gray connector on the driver

board corresponding to the phase indicated in the fault.b) Verify that there is a solid red light coming from the gray connector on the

driver board.c) If there is no light, refer to Matrix Damage on page xx and IGBT Check

on page... If no problem is found, replace the driver board and retest.d) If there is light, continue with the next step.

WARNING: Lethal voltageIn order to complete these procedures, you will need to work in areas with lethal voltage. Before starting any troubleshooting procedures, review all the safety instructions described in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematic to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the inverter running. Make certain the generators are locked and cannot turn.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

WARNING: Shock hazardThe matrix driver board is connected to the DC bus voltage which can be as high as 1400 Vdc. Do not touch the driver boards when the DC bus is charged.

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Matrix Test

152874 8–29

7. Reconnect the fiber optic cable and disconnect is at its other end from the CCU board. This will be a blue connector on the CCU board.a) If you cannot see light at the end of the cable, replace the cable.b) If there is light and the CCU continues to report an IGBT Gate Drive fault

for this connector, replace the CCU board.8. With the inverter in Matrix Test mode, the yellow LEDs in all sections of the

driver board should be blinking.a) If any of the yellow LEDs are not blinking, disconnect the fiber optic

cable from the blue connector in that section and verify that a blinking red light is coming through the cable.

b) If the light is present, replace the driver board. Otherwise, check the fiber optic cable and, if the cable is good, replace the CCU board.

c) If all the yellow LEDs are blinking, go to the next step.9. If two yellow LEDs from the sections connected to the same phase (for

example, A– and A+) are On at the same time, replace the CCU board. Otherwise, the matrixes have passed the matrix test.

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IGBT ChecksBasic resistance and diode checks describe some checks that can be performed on the IGBTs to determine if there are any obvious shorts between collector and emitter terminals. These checks can be performed on a matrix that is installed and connected in the enclosure.

The IBGT can be checked for a shorted condition using an ohmmeter.To conduct resistance checks using an ohmmeter:1. Connect the positive lead of the ohmmeter to the (+) bus terminal. Connect

the negative lead of the ohmmeter to a phase terminal (A), (B) or (C). The reading should be 1 MΩ or higher.

2. Connect the negative lead of the ohmmeter to the (–) negative bus terminal. connect the positive lead of the voltmeter to a phase terminal (A), (B) or (C). The reading should be 1 MΩ or higher.

3. A reading of less than 1 MΩ could indicate a defective IGBT. Remove the power cables to the matrix and repeat the resistance check to verify.

There is a flyback diode inside each IGBT module that can be checked with a Digital Volt Meter (DVM) on diode scale.To conduct diode check using a DVM on diode scale:1. Connect the negative lead of the DVM to the (+) bus terminal. 2. Connect the positive lead of the DVM to a phase terminal (A), (B) or (C). The

reading should be 0.30 to 0.35 V.3. Connect the positive lead of the DVM to the (–) negative bus terminal. 4. Connect the negative lead of the DVM to a phase terminal (A), (B) or (C).

The reading should be 0.30 to 0.35 V.5. A reading of 0.00 V or a reading higher than 0.35 V indicates a defective

IGBT. 6. Remove the power cables to the matrix and repeat the test to verify.

WARNING: Shock hazardRemove all power. Make certain the generators are stopped and cannot rotate. Wait 30 minutes for the bus voltage to discharge.

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High Voltage Driver Board

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High Voltage Driver Board

These checks look at the matrix high voltage driver board to determine if it is functioning properly. Board failures are usually caused by a defective IGBT. If the board is found to be defective, check the IGBT per “IGBT Checks” on page 8–30.

1. Make a visual inspection of the circuit board. Look for any broken or burned components. If any are found, replace the circuit board.

2. In the upper right compartment, switch the Enable/Disable selector to Disable (Off).

3. Apply 690 Vac power and check the status of the LEDs on the high voltage driver board.a) If all 6 green LEDs are On, proceed with the “Matrix Test” on page 8–28.b) If all 6 green LEDs are not On or if any of the yellow LEDs are On, con-

tinue with Step 5.4. Using a voltmeter, check for (+)15 Vdc to the high voltage driver board at

TB1 to TB2 at the center of the board. The voltage should be +14.5 to +15.5 Vdc. If the voltage is not present:a) Check the power cable from the CCU2 circuit board to the P1.b) Check the “CCU2 Circuit Board Power Supplies” on page 8–20.

WARNING: Lethal voltageIn order to complete these procedures, you will need to work in areas with lethal voltage. Before starting any troubleshooting procedures, review all the safety instructions described in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematic to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the inverter running. Make certain the generators are locked and cannot turn.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

WARNING: Shock hazardThe matrix driver board is connected to the DC bus voltage which can be as high as 1400 Vdc. Do not touch the driver boards when the DC bus is charged.

WARNING: High voltageThe checks of the high voltage driver board will be made with 690 Vac power applied. Make certain the generators are stopped and cannot rotate. Wait 30 minutes for the bus voltage to discharge. Do not attempt to make any voltage measurements on this circuit board with bus voltage present.

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Troubleshooting

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5. If (+)15 Vdc is present at the TB1 to TB2 in the center of the board, the power supplies on the six individual driver sections of the board can be checked as follows:a) The six sections of the drive board from left to right are: A–, A+, B–, B+,

C– and C+. Start at the left with A–, check the voltage at TP101 (Gate) to TP102 (Emt). The voltage should be approximately fl9 Vdc.

b) Check the voltage from TP103 (+16) to TP105 (–10). The voltage should be approximately +26 Vdc.

c) Repeat these checks for all six sections of the board. If any of the power supply voltages measures incorrectly, replace the high voltage driver board.

6. If the power supplies are OK, check the fiber optic cables from the CCU2 circuit board to the high voltage driver board. See “Fiber Optic Cables” on page 8–34.

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Matrix Damage

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Matrix Damage

1. Open the enclosure doors and look for any debris on the main panels.2. Visually inspect the left and right matrixes for damage or fault components.3. If any components are damage, follow the instructions for replacing the

damaged components on “Replacing the Matrix Assembly” on page 10–12.4. Visually inspect the cable assemblies between the IGBTs and the high voltage

driver board.5. Repair or replace as required.6. If all matrixes pass a visual inspection, continue with the next step.7. Run a matrix test as described in “Matrix Test” on page 8–28.

WARNING: Lethal voltageIn order to complete these procedures, you will need to work in areas with lethal voltage. Before starting any troubleshooting procedures, review all the safety instructions described in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematic to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the inverter running. Make certain the generators are locked and cannot turn.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

WARNING: Shock hazardThe matrix driver board is connected to the DC bus voltage which can be as high as 1400 Vdc. Do not touch the driver boards when the DC bus is charged.

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Troubleshooting

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Fiber Optic Cables

1. Disconnect the high voltage driver board fiber optic connectors from the CCU2 board and the driver boards by depressing the locking tab and pulling on the connector, one at a time.

2. Inspect the cable ends for dirt and debris. Use a soft cloth to wipe away any dirt and debris that could diminish the intensity of the light signal being transmitted.

3. Verify the optical fibers at the connector tips are not recessed or protruding.4. Verify the fiber optic cables have a minimum of 2 inch radius bends along

their routing.5. Verify light transmission through the cables using a flashlight.6. Replace any fiber optic cables that do not pass inspection.7. Reconnect fiber optic cables to the CCU2 board and the driver boards.

WARNING: Shock hazardRemove all power. Make certain the generators are stopped and cannot rotate. Wait 30 minutes for the bus voltage to discharge.

CAUTION: Wire damageDo not pull on the fiber optic cable.

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Matrix Fans

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Matrix FansThis procedure verifies that the external matrix heatsink fans are working correctly.During normal operation the K11 or K21 external heatsink fans should be operating any time the line contactors K11 or K21 are closed. The heatsink fans also should blow air downwards onto the matrix heatsinks. If either one of the fans blow upwards, remove the cover from the electrical connection of the fan motor and refer to the wiring diagram on the back side of the cover for proper wiring to determine motor rotation direction.The following procedure assumes that one or both of the fans do NOT work when the contactors K11 or K21 closes.If the external matrix fan does not operate:1. Check fuse F60 for left matrix fan and F59 for right matrix fan.

a) If the fuses are good, continue with Step 2.b) If the fuses are not good, check that there are NO shorts in F59 or F60 cir-

cuits and replace the fuse.2. Check fan power connections inside the enclosure at the rear cable entry.3. Check fan connections in the motor conduit box at the top of the fan housing.4. Check wiring through the contactor auxiliary contact block that is associated

with the fan. If a problem is suspected with the contact block, replace it.

5. With 690 Vac power applied to the inverter enclosure, verify that there is 230 Vac between either end of F59 and F60 referenced to ground.

WARNING: Personal injury—rotating fan bladeDo not attempt to check fan voltage at the motor with the fan operating.

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Troubleshooting

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Matrix Temperature Sensors

Checking the Line Matrix Temperature Sensor

This procedure verifies that the heatsink matrix temperature sensor circuit is working correctly.The temperature of the heatsink matrix is read using a RTD (Resistance Temperature Detector). This resistor is screwed into the heatsink of the matrix and the RTD is connected to the matrix driver board at connector P2. The connector is also connected to pin 3 and pin 8 at connector P1 on each high voltage driver board. The CCU2 board connector J7 is connected to the high voltage driver board P1 connector. The CCU2 board received the reading of the temperature on the line matrix through this connection.To check the line matrix temperature sensor:1. Disconnect connector P7 from the CCU2 board and measure resistance

between pin 5 and pin 6 for the left side matrix.2. Measure resistance between pin 6 and pin 7 for the right side matrix.

At an ambient temperature of 68 °F (20 °C), the resistance between these two points should be around 2 kΩ.a) If the measurement shows a resistance less than 2.5 kΩ and the CCU2

still triggers a Line Matrix Over-Temperature faults, replace the CCU2 board.

b) If the measurement shows a resistance greater than 2.5 kΩ, go to Step 4.3. Replace connector P7 following the test.4. Disconnect the temperature sensor from the high voltage drive board

connector P2.5. Measure the resistance of the sensor at the sensor’s connector: P2, Pins 2 to 4.

At an ambient temperature of 68 °F (20 °C), the resistance should be around 2 kΩ. The resistance of the sensor increases with the temperature.

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9 Maintenance

Chapter 9, Maintenance, provides information and procedures for maintaining the optimal performance of the CW 2.5 MW Inverters.

The topics in this chapter are organized as follows:• “Equipment Required” on page 9–2• “Removing All Power and High Voltage” on page 9–2• “Upper Compartments” on page 9–2• “Lower Compartments” on page 9–3• “Cable Glands” on page 9–3• “Ground/Power Terminations” on page 9–3• “Electrical Connections” on page 9–3• “Heatsinks and Fans” on page 9–3• “Gate Drive Fiber Optic Cables” on page 9–3

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Maintenance

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Equipment RequiredThe following equipment is required to perform maintenance:• Small slotted screwdriver• Ratchet handle• Socket set• Wrench set• Hex wrench set• Ohmmeter

Removing All Power and High VoltageTo remove all power and high voltage from the enclosure:1. Open the padmount transformer disconnect feeding the enclosure. 2. Make certain the turbine rotor is stopped and locked. 3. In addition, allow 30 minutes for the DC bus capacitors, located on the

matrixes, to discharge after removing all power.

Upper CompartmentsVisually inspect the upper compartments of the inverter enclosures for any damages or leaks.Inspect the doors to verify that they close correctly and there are no leaks.

WARNING: Shock hazardRemove all power before performing any work in the CW 2.5 MW Inverters. To remove all high voltage from the enclosure, open the padmount transformer disconnect feeding the enclosure. Make certain the turbine rotor is stopped and locked. Allow 30 minutes for the DC bus capacitors, located on the matrixes, to discharge after removing all power.

CAUTION: Risk of equipment damage due to moistureIf power has been removed and the inverters exposed to cold temperatures, frost or moisture may be present inside the enclosure. Close and latch both doors. Apply 690 V power but do not turn on the inverters. Allow the internal heater to warm up the unit for a minimum of 4 hours or until the inside of the enclosure is dry before operating the inverter.

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Lower Compartments

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Lower CompartmentsRemove the lower compartment covers and visually inspect for any damage, debris, or loose connections.Look closely to the ground and power connections for signs of heat.Reconnect the fans and then replace the covers.

Cable GlandsVisually inspect the cable glands on the AC and DC power cables to verify that they are seated correctly against the enclosure and there are no leaks.

Ground/Power TerminationsVerify that there are no loose power and ground terminations in the main enclosure. Visually inspect all of the power cables for abrasions or cracks or discoloration. If cables are found damaged, repair or replace the cable.

Electrical ConnectionsVisually inspect all of the connectors to verify that they are seated properly on the CCU2 circuit control board and there are no loose connections.Visually inspect all of the electrical wiring for abrasions or cracks. If the wires are damaged, repair or replace them.

Heatsinks and FansVisually inspect the heatsinks to verify that they are seated correctly against the inverter enclosure and there are no leaks. Clean any collected debris off the fins and verify the fans turn freely and quietly without excessive vibration. Verify the electrical and mechanical connections are secure.If this is a LIPS system, inspect LIPS Retofit for proper sealing.

Gate Drive Fiber Optic CablesVerify the fiber optic cables from the CCU2 circuit board to the high voltage driver boards are fully seated to their connector.Verify the fiber optic cables have a minimum of 2-inch radius bends along their routing.

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9–4

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10Component Replacement

Chapter 10, Component Replacement, provides procedures for replacing specific components in the CW 2.5 MW Inverters.

The topics in this chapter are organized as follows:• “Equipment Required” on page 10–2• “Before You Start Replacing Components” on page 10–3• “Replacing the CCU2 Board” on page 10–4• “Replacing the Current Transducer (CT) Modules” on page 10–6• “Replacing the Line Contactors” on page 10–8• “Replacing the Solid State Relays (SSR)” on page 10–9• “Replacing the Control Transformer” on page 10–10• “Replacing the Matrix Fan Assembly” on page 10–11• “Replacing the Matrix Assembly” on page 10–12• “Replacing the Matrix Sub-Assemblies” on page 10–19• “Replacing the Inductor” on page 10–20• “Replacing the Fuses” on page 10–23• “Replacing the Internal Fans” on page 10–24• “Replacing the Lower Magnetics Compartment Fans” on

page 10–25• “Replacing the Wiring Harness” on page 10–26

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Component Replacement

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Equipment RequiredThe following equipment may be required to complete the procedures described in this chapter.• Ratchet handle• Extension• Socket set• Wrench set• Hex wrench set• 3/16" Allen head socket• Torque wrench with 0 to 50 Ft-lb. minimum range• Anti-oxidant agent for inductor electrical connections• Small slotted screwdriver• Phillips screwdriver• Slip joint pliers• Multimeter (DVM)• Ohmmeter

WARNING: Shock hazardBefore beginning any component replacement procedures, turn off power. See “Removing All Power and High Voltage” on page 9–2. See “Lock Out and Tag Out Prior to Servicing the CW 2.5 MW Inverters” on page vii in the “Important Safety Instructions” for mandatory Lockout and Tag procedures. Verify that 690 Vac is not present at the AC bus. Verify that the turbine is stopped and locked. Verify that the DC bus is discharged.

WARNING: Shock hazardAllow 30 minutes for the DC bus capacitors, located on the ceiling of the matrixes, to discharge after removing all power.

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Before You Start Replacing Components

152874 10–3

Before You Start Replacing Components

Safety Requirements for Service

Safety requirements mandate that this equipment NOT be serviced while energized. Power sources for the inverter must be locked-out and tagged prior to servicing. Each service technician should have a padlock and tag installed on each energy source prior to servicing. See “Lock Out and Tag Out Prior to Servicing the CW 2.5 MW Inverters” on page vii for more information.

Identifying Components for ReplacementAll of the replaceable components in the CW 2.5 MW Inverters are identified in the “Clipper 2.5 MW Inverter Component Replacement Model”. See Figure B-6 on page B–7. Refer to “Assembly Description for Component Replacement” for a complete list of reference designators with a part number and description.See Table B-1 on page B–8.

WARNING: Lethal voltagesIn order to complete these procedures, you will need to work in areas with lethal voltages. Before starting any troubleshooting procedures, review all the safety instructions provided in “Important Safety Instructions” on page v. Regardless of what the procedure says, always verify that it is safe to proceed. Always refer to the system schematics available in Appendix B, “Drawings” to understand what the procedure is asking you to do.

WARNING: Shock hazardNever attempt to perform these procedures with the inverter running.

WARNING: High voltageDo not use a voltmeter with a voltage rating below 1500 volts when working on the DC bus related circuits.

WARNING: Shock hazardReview the system schematic for the installation to verify that all available energy sources are de-energized. See Appendix B, “Drawings” on page B–1.

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Component Replacement

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Replacing the CCU2 BoardIf communication is still possible with the CCU2 board, record the software version before removing the CCU2 board. This information can be obtained with the GUI. See Figure B-6 on page B–7 to locate the CCU2 board (Item # 1). Then refer to Table B-1 on page B–8 to for detailed information on the component.

Removing the CCU2 Unit

To remove the CCU2 unit:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii in the “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Disconnect all the electrical connectors from the CCU2 board. 4. Disconnect the driver board fiber optic connectors from the board by pressing

the locking tap and pulling on the connector. DO NOT pull on the fiber cable to disconnect.

5. Remove the D-sub harness assembly at J1004 to J8 by loosening the screws on each end of the connector.

6. Pull the connector from the board.7. Loosen the four hex head nuts.8. Remove the four hex head screws securing the CCU2 mounting plate to the

side panel and remove the CCU2 from the enclosure.

CAUTION: CCU2 Compatability CheckThere are two versions of the CCU and they are not compatible. There is the older style CCU and the LVRT CCU. They have different part #s and LVRT CCU has a white 'LVRT' label located on the black heat sink of the CCU. Make sure to install the same version CCU that is being removed. Additionally the two versions of the CCU also use different operational software. Before downloading operational software, it should be confirmed that the correct software is being loaded. LVRT CCUs use software versions <3034> and higher.

CAUTION: Wire damageGrasp the connector by the edges and pull. Do not pull on the wires. Some of the connectors have locking taps. Press the latch before pulling on the connector.

Important: Make note of the rotor versus line side connections. The line-side fiber optic connections on the CCU = the left side matrix. Rotor-side fiber optic connections on the CCU = the right side matrix.

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Replacing the CCU2 Board

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Installing the CCU2 Unit

To install the CCU2 Unit:1. Verify that the same version of the CCU is being installed that was removed.

There are two versions of the CCU!2. Slip the CCU unit over the hex head nuts making sure that no wires are

pinching behind or under the CCU back plate. Tighten the mounting hex head nuts.

3. Reinstall all the electrical connectors in the CCU2 module.

4. Reconnect the driver board fiber optic connectors to the board. Verify the labels on the connectors match the markings on the module.

5. Reinstall the fiber cable (marked with a small A label on one side) by putting it on the SCADA RECV connector (U1012).

6. Reinstall the D-sub connectors and tighten the screws.7. Apply 690 Vac power. Verify the power supplies of the CCU2 are correct.8. Connect the laptop computer to the external fiber optic port and establish

communications with the new unit.9. Download the software version intended for this site. LVRT CCUs must use

software versions <3034> or higher. 10. Fill out the proper paperwork, recording the old and new serial numbers.

CAUTION: Equipment damageGrasp the connector by the edges and pull. Do not pull on the wires.

Important: Make note of the rotor versus line side connections. The line-side fiber optic connections on the CCU = the left side matrix. Rotor-side fiber optic connections on the CCU = the right side matrix.

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Component Replacement

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Replacing the Current Transducer (CT) ModulesTo replace the current transducer modules, see Figure B-6 on page B–7 to locate the current transducer CT module (Item 2). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 to for detailed information on the component.

Removing the Current Transducer Module

To remove the current transducer module:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off all power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Remove the single connector.4. Remove and label the power cables from the current transducer bus bar.

Remove the bus bar from the current transducer.5. Remove the four mounting screws holding the current tranducer to the panel.

Installing the Current Transducer Module

To replace the current transducer module:1. Mount the current transducer to the panel using the four mounting screws.2. Reconnect the connector to the current transducer.3. Install the tapered end of the bus bars through the current transducer in the

same direction as the arrow.

Figure 10-1 Installing the Current Transducer Module

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Replacing the Current Transducer (CT) Modules

152874 10–7

4. Connect the power cables to the ends of the bus bar. Tighten and torque the connections.

5. Apply 690 Vac power.6. Set a DVM for DC volts and connect the negative probe to the common bus.7. Verify that there is +14.5 to +15.5 Vdc on pin 3 of the current transducer.8. Move the probe to pin 1 and verify that there is –14.5 to –15.5 Vdc.9. Move the probe to pin 2 and verify the output offset is less than 30 mV.

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Component Replacement

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Replacing the Line ContactorsTo replace the line contactor, see Figure B-6 on page B–7 to locate the two line contactors, K11 and K21 (Item # 3). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 to for detailed information on the component.

Removing the Line Contactor

To remove the line contactor:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off the all the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Loosen and remove the hardware connecting cables. If required, mark the cables for re-assembly.

4. Remove and label the control wires to A1 and A2. 5. Remove the front and rear auxiliary contacts.6. Press the small white tab on the end of the contact block to release the latch.7. Remove the four mounting bolts holding the contactor to the panel.

Installing the Line Contactor

To install the line contactor:1. Mount the contactor to the power panel using the four mounting bolts.2. Remount the auxiliary contacts by snapping them into place.3. Connect the control wires to A2 and A1. 4. Reinstall the cables. Leave the hardware loose until it is all installed.5. Torque all the power connections to 240 in-lb.

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Replacing the Solid State Relays (SSR)

152874 10–9

Replacing the Solid State Relays (SSR)To replace the solid state relay components, see Figure B-6 on page B–7 to locate the solid state relays (Items # 4 and #5). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing the Solid State Relays

To remove the solid state relays:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Disconnect and label if necessary the control wires to terminal 1 though 4 on the SSR

4. Remove the capacitor from terminal 3 and 4.5. Remove the two mounting screws holding the SSR to the panel.

Installing the Solid State Relays

To install the solid state relays:1. Mount the SSR to the panel using the two mounting screws.2. Connect the control wires to terminal 1 though 4 on the SSR.3. Install the capacitor from terminal 3 and 4.

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Replacing the Control TransformerTo replace the control transformer, see Figure B-6 on page B–7 to locate the transformer (Item # 6). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing the Control Transformer

To remove the transformer:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Disconnect the secondary leads at T1-TB. 4. Disconnect the two primary leads at fuseholder F51 and F52 on the right main

panel.5. Remove the four mounting screws holding the transformer to the power panel.

Installing the Control Transformer

To install the transformer:1. Mount the transformer to the power panel using the four mounting screws.2. Connect primary leads to fuseholder F51 and F52 at the right main panel.3. Connect the secondary leads to T1-TB.4. Apply 690 Vac power.5. Verify that the secondary voltage is correct.

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Replacing the Matrix Fan Assembly

152874 10–11

Replacing the Matrix Fan AssemblyTo replace a matrix fan assembly, see Figure B-6 on page B–7 to locate the left and/or right matrix fan assembly (Items #7 and #8 respectively). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing the Matrix Fan Assembly

To remove the matrix fan assembly:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Inside the upper compartment, disconnect the two power wires and the ground wire for the fan.

4. Remove the compression fitting for the fan cable at the rear of the enclosure and remove the cable from the enclosure.

5. Up at the fan assembly, remove the bolts that mount the fan assembly to the fan housing the remove the fan.

Installing the Matrix Fan Assembly

To install the matrix fan assembly:1. Mount the new fan assembly on the fan housing.2. Do not tighten until all the hardware is installed and the fan assembly is

squared up on the housing.3. Make sure that the rotor of the fan is centered in the venturi and the motor is

free to turn.4. Dress the fan cable through the rear enclosure wall and secure the

compression fitting.5. Inside the upper compartment, connect the two power wires and the ground

wire.6. Apply power and check fan operation.

WARNING: Shock hazardVerify that the 690 Vac power is off and that the DC bus voltage is fully discharged. Make sure that the turbine generators cannot rotate.

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Replacing the Matrix AssemblyThere are two matrix assemblies mounted on top of the enclosure: the left hand matrix and the right hand matrix. Each matrix contains three heatsink assemblies, the Insulated Gate Bi-polar Transistors (IBGTs), the laminated bus with DC filter capacitors attached, the high voltage driver board, the matrix cover and associated mounting hardware.Refer to Figure 10-2 to locate the matrix assembly.

Figure 10-2 Power Electronics Matrix - Left Side

WARNING: Shock hazardVerify that 690 Vac is not present at the AC bus. Verify that the DC bus voltage is fully discharged. Allow 30 minutes for the DC bus capacitors, located on the inverter matrixes, to discharge after removing all power. Make certain that the turbine generators cannot rotate and are locked.

WARNING: Physical injuryThe matrix assembly weighs approximately 125 lbs. The recommended lifting procedure is to use slings or cables attached at each of the lifting eyes provided. Incorrect lifting could cause personal injury.

Important: If the IGBTs or capacitor assembly is physically damaged, it is recommended to replace the matrix assembly as a whole. This allows the turbine to be back in service in the least amount of downtime. It will also allow the repair of the matrix at an authorized service center.

Heatsink

MaxtrixCover

Fan Motor

Fan Venturi

High VoltageDriver Board

Laminated PowerBus

Insulated GateBi-Polar Transistors(IGBTs)

DC Filter Capacitors

Fan Housing

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Replacing the Matrix Assembly

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To replace a matrix assembly, see Figure B-6 on page B–7 to locate the left and/or right matrix assembly (Items #9 and #10 respectively). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Additional Equipment Required

In addition to the “Equipment Required” on page 10–2, the following additional equipment is required to replace the matrix assembly.• Needle nose pliers• Portable chain hoist or equivalent• Heatsink lifting eye angle brackets, 4 each• Lifting chain, with hooks for attaching to lifting brackets• RTV (if using a LIPS style replacement)

Note: There are two styles of matrices, LIPS and the new gasket system. You can use either a Gasket style matrix or a LIPS style matrix when replacing the part.

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Removing a Matrix Assembly

To remove a matrix assembly:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Inside the enclosure, loosen the screws and disconnect the D-sub connector from the high voltage driver board. Pull on the connector, not the cable.

4. Disconnect the fiber optic cables from the high voltage driver board. Depress the locking tab and pull on the connector, not the cable. Needle nose pliers can be used to grasp the locking tab.

5. Remove the six large cables from the A, B and C lugs of the laminated bus.6. Remove the two large cables at the (+) DC lugs and the (–) DC lugs at the

right side of the laminated bus.7. Remove the (+) and (–) DC sense leads from the left side of the laminated bus.8. Disconnect the fan power cable leads and remove the compression fitting at

the rear of the enclosure. Push the fan cable through the enclosure so it won't get caught when the fan assembly is removed.

9. At the top of the enclosure, remove the matrix fan assembly, complete with fan housing. (See “Replacing the Matrix Fan Assembly” on page 10–11.)

10. Remove the retainer bracket from the center of the two matrix covers.11. Remove the four bolts that retain the matrix cover to the enclosure.

The matrix assembly should now be resting on the enclosure without any attachment to the enclosure.

12. Mount the four lifting eye brackets to the heatsink mounting bolts at the points shown in the figure.

13. Place the two heatsink fin protective brackets on the heatsinks and attach the lifting cable to the brackets.

14. Gently lift the matrix assembly up and off the enclosure taking care not to damage any heatsink fins.

Page 189: Xantrex 1.3 MW Power Inverter Manual

Replacing the Matrix Assembly

152874 10–15

Installing a Matrix Assembly

To install a matrix assembly:1. Transfer the four lifting eye brackets to the replacement heatsink.2. Lift the replacement matrix into position and gently lower it to the top of the

enclosure. Remove the lifting cable and brackets.3. Install the four bolts that retain the matrix cover to the enclosure.4. Install the bracket at the center of the enclosure that retains the two matrix

covers to the enclosure.5. Install the matrix fan assembly with housing. See “Replacing the Matrix Fan

Assembly” on page 10–11.If using a LIPS style matrix, verify there are no gaps showing under the heatsink and matrix housing and also the corners of the matrix housing. If any gaps are present, apply some RTV silicone to completely seal the unit.

6. Dress the fan power cable to the entry hole in the rear of the enclosure and secure the compression fitting.

7. Inside the enclosure, connect the fan power lead connectors.8. Install the (+) and (–) DC sense leads to the left side of the laminated bus.9. Install the two large cables at the (+) DC lugs and the –) DC lugs at the right

side of the laminated bus. Press the lugs on the cables firmly against the mounting surface while tightening to assure a solid connection.

10. Install the six large cables to the A, B and C lugs on the laminated bus. Press the lugs on the cables firmly against the mounting surface while tightening to assure a solid connection.

11. Install the fiber optic cables to high voltage driver board. Use the connector, not the cable to do this. The connector should snap into place.

12. Install the D-sub connector in the high voltage driver board and secure its retaining screws.

13. This should complete the installation. Inspect all connections. Make certain there is sufficient clearance from the bare portion of the power terminals to ground.

14. Apply 690 Vac power and run a matrix test: a) First with generators idle, as described in “Matrix Test, Generators Idle”

on page 3–8. b) Then with generators operating. See “Matrix Test, Generators Operating”

on page 3–9.15. Operate the inverter under TCU control and check for proper inverter

operation. Check operation of the matrix fan. 16. Fill out the proper paperwork, recording the old and new serial numbers.

Page 190: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–16 152874

Replacing the Heatsink AssemblyThere are three heatsink assemblies located on the matrix assembly. Each heatsink assembly consists of the finned heatsink and two large IGBT transistors. The middle heatsink assembly also has the temperature sensor. See Figure 10-3. An individual heatsink assembly can be replaced with the matrix assembly in place on the enclosure. See also “Replacing the Matrix Assembly” on page 10–12.

Additional Equipment Required

In addition to the “Equipment Required” on page 10–2, the following equipment is required to complete this procedure:• 3/16 inch Allen wrench suitable for use with socket set

Figure 10-3 Heatsink Assembly

FAN MOTOR

FAN VENTURI

FAN HOUSING

HEATSINK

MATRIX COVER LAMINATEDPOWER BUS

INSULATED GATEBI-POLAR TRANSISTORS (IGBT)

DC FILTER CAPACITORS

HIGH VOLTAGE DRIVER BOARD

WARNING: Personal injuryRemoval and replacement of a heatsink assembly requires two persons—one working at the front and one working at the rear of the inverter enclosure.

WARNING: Shock hazardVerify that 690 Vac is not present at the AC bus. Verify that the DC bus voltage is fully discharged. Allow 30 minutes for the DC bus capacitors, located on the inverter matrixes, to discharge after removing all power. Make certain that the turbine generators cannot rotate and are locked.

Page 191: Xantrex 1.3 MW Power Inverter Manual

Replacing the Heatsink Assembly

152874 10–17

Removing a Heatsink Assembly

To remove any of the three heatsink assemblies:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. At the top of the enclosure, remove the matrix fan assembly, with housing. (See “Replacing the Matrix Fan Assembly” on page 10–11.)

4. Inside the enclosure, remove the front and back clear plastic capacitor retainers from the bottom of the capacitors associated with the heatsink to be replaced. To do this, remove the bolts that hold the retainers from the hex spacers and gently pull off the retainers. (They are held to the capacitors with a spot of silicon glue.)

5. Remove the six hex spacers that hold the capacitor retainers.6. Remove the High Voltage Driver circuit board. See “Removing the High

Voltage Driver Board” on page 10–19.7. Push the gate wire bundle for the two IGBTs up through the laminated bus so

that the wires won't get caught when the heatsink is lifted. (The wires are attached to the IGBT.)

8. If the heatsink assembly to be replaced is the middle one, push the temperature sensor wire bundle up through the laminated bus so that it won't get caught when the heatsink is lifted.

9. Remove the six Allen screws that attach each IGBT transistor to the laminated bus.

10. Remove the four bolts that attach the heatsink to the matrix cover.11. On the outside of the enclosure, lift the heatsink assembly straight up and out

of the matrix assembly. (This requires two persons to lift.) Make certain the gate lead wire bundle for each IGBT is free. Take care not to damage the heatsink fins.

12. Make a note of the location of the laminated bus hex spacers on the heatsink. The replacement heatsink must be installed in the same orientation.

Page 192: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–18 152874

Installing a Heatsink Assembly

To install a heatsink assembly:1. Transfer the laminated bus hex spacers from the old heatsink to the new

heatsink assembly.2. If the heatsink to be replaced is the middle one, transfer the temperature

sensor from the old heatsink to the new heatsink assembly.3. On the outside of the enclosure, lift the new heatsink assembly into position

making certain the hex spacer orientation is the same as the one that was removed. (This requires two persons.) Place each IGBT gate lead bundle through the nearest pass through hole in the laminated bus. (One gate lead bundle per hole.) Dress the gate lead bundle to the side of the IGBT so as not to get it caught between an IGBT power terminal and the laminated bus.

4. If the heatsink assembly to be replaced is the middle one, place the temperature sensor cable through its pass through hole in the laminated bus. Dress this wire bundle to the side of the IGBT transistors so as not to get it caught between an IGBT power terminal and the laminated bus.

5. Carefully lower the heatsink assembly into position, taking care not to damage the heatsink fins. Install the six Allen screws in each IGBT power terminal. Install all screws before tightening. Torque to 90 in-lbs.

6. Install the four bolts (3/8-16) that secure the heatsink to the matrix cover. Torque to 35 ft-lbs.

7. At the inside of the enclosure, install the high voltage driver board. (See “Installing the High Voltage Driver Board” on page 10–19.)

8. Install the six hex spacers that hold the capacitor retainers.9. Install the clear plastic capacitor retainers.10. On the outside of the enclosure, install the matrix fan assembly with housing.

Refer to the procedure elsewhere in this section.11. Apply 690 Vac power and run a matrix test as described in “Matrix Test,

Generators Idle” on page 3–8, first with generators idle, then with generators operating. See “Matrix Test, Generators Operating” on page 3–9.

12. Operate the inverter under TCU control and check for proper inverter operation. Check operation of the matrix fan.

Page 193: Xantrex 1.3 MW Power Inverter Manual

Replacing the Matrix Sub-Assemblies

152874 10–19

Replacing the Matrix Sub-Assemblies

Removing the High Voltage Driver Board

To remove the high voltage driver board:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Disconnect the D-sub connector from the high voltage driver board.4. Pull on the connector, do not pull on the cable.5. Disconnect the fiber optic cables from the driver board. 6. Press the locking tab and pull on the connector. Do not pull on the cable.7. Disconnect the temperature sense cable from the driver board.8. Press the locking tab and pull on the connector. Do not pull on the cable.9. Remove the three hex standoffs and gently lower the driver board away from

the matrix.10. While holding the board, gently remove the IGBT cables from the driver

board.

Installing the High Voltage Driver Board

To install the high voltage driver board:1. While holding the board, connect the IGBT cables to the driver board at the

appropriate connectors.2. Slowly raise the driver board onto the lower standoffs while making sure the

IGBT cables don’t become disconnected or pinched. 3. Install and tighten upper standoffs to hold the driver board in place.4. Connect the temperature sense cable to the driver board.5. Connect the fiber optic cables to the driver board according to the labels on

the cables. Be careful to align the connector with the socket.6. Connect the D-sub connector to the driver board.7. To test the assembly, follow the instructions in “Matrix Test, Generators Idle”

on page 3–8.

CAUTION: Wire damageGrasp the connector by the edges and pull. Do not pull on the cable. Some of the connectors have locking taps. Press the locking tab before pulling on the connector.

Page 194: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–20 152874

Replacing the InductorTo replace an inductor, see Figure B-6 on page B–7 to locate the left and/or right inductor (Item #13). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Additional Equipment Required

In addition to “Equipment Required” on page 10–2, additional equipment may be required to complete this replacement procedure:• Portable chain hoist or equivalent• Chain

Removing an Inductor

To remove an inductor:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii of the “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Remove the mounting bolts from the top and sides holding the cover plates to the enclosure. Loosen the bottom mounting bolts and remove the cover plate, taking care to disconnect the fan connector.

WARNING: Shock hazardVerify that the 690 Vac power is off and that the DC bus voltage is fully discharged. Allow 30 minutes for the DC bus capacitors, located on the inverter matrixes, to discharge after removing all power. Make certain that the turbine generators cannot rotate and are locked.

WARNING: Personal injuryThe inductors weigh more than 1300 lbs. Exercise caution during this procedure to avoid personal injury.

Important: There are two types of inductors. Check the serial number of the unit on the name plate to verify the type of inductor that is installed.• Units with serial numbers ranging from #0001–0144 have inductors with copper

windings installed. • Units with serial numbers ranging from #0145–onward have inductors with aluminum

winding installed. The aluminum inductor is much smaller than the copper inductor. All replacements will be the aluminum inductor type.

Page 195: Xantrex 1.3 MW Power Inverter Manual

Replacing the Inductor

152874 10–21

4. Remove and label the power cables from the inductor. Remove the four mounting bolts holding the inductor to the bottom of the cabinet.

5. Remove the thermal switches from the protective tubes inside the core of the inductor.

6. Attach a chain or sling on the inductor.7. Pull out the inductor with some equipment or manual labor.

Installing an Inductor

Units with serial numbers ranging from #0001–0144 have inductors with copper windings installed. These units require that you modify the fan shroud.A fan shroud extension piece will be included with the replacement inductor. This fan shroud is universal for both the left and the right side of the unit.To install the fan shroud extension:1. Put the short side of the shroud extension towards the fuses. 2. Line up the extension piece to the existing shroud’s bottom edge.

The two shrouds will have one common hole in the middle that match up.3. Use the 6 × self tapping screws to secure the extension piece.To install an inductor:1. Move the inductor to the front of the enclosure. 2. Lift the inductor up into the enclosure and slide into place.3. Align the inductor mounting holes with the holes on the bottom of the

inductor enclosure.4. Mount the new inductor to the bottom of the cabinet using the four mounting

bolts.

5. Apply the anti-corrosion compound to the inductor mounting tabs. See Figure 10-4 and follow the three steps described.

WARNING: Personal injuryThe inductors weigh more than 1300 lbs. Exercise caution during this procedure to avoid personal injury.

CAUTION: Equipment damageWhen installing the cables onto the inductor, be careful not to bend or deform the inductor terminals.

Page 196: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–22 152874

6. Connect the power cables to the inductor. Make sure the hardware is stacked up as shown in Figure 10-4. Torque the hardware to 41 ft-lb.

7. Refer to the system schematics in the Appendix B, “Drawings” on page B–1.

8. Install the thermal switches in the protective tubes in the inductor core. 9. If installing a replacement inductor in units #0001–0144, secure a tie wrap

5 ½ inches above the sensors to prevent the sensor from sliding down the protective tube beyond its designed location.

10. Replace the enclosure cover plate.

Figure 10-4 Hardware Stack Up and Application of Anti-Corrosion Compound at Aluminum Inductors

Inductor Mounting Tab

Cable Cut-away

Cable Cut-awayStep 2: Apply a thin layer ofanti-corrosion compoundto the bottom surface of theinductor mounting tab.

Inductor Cut-away

Step 3: Clean out excess anti-corrosioncompound from the mounting holeto prevent the compound from transferringto threads of the bolt.

Step 1: Apply a thin layer of anti-corrosion compoundto the top surface ofthe inductor mounting tab.

Important: The replacement inductor should have the protective tubes already installed. If not, contact Xantrex for further instructions. See “Contact Information” on page ii.

Page 197: Xantrex 1.3 MW Power Inverter Manual

Replacing the Fuses

152874 10–23

Replacing the FusesTo remove and replace the fuses, see Figure B-6 on page B–7 to locate the correct fuse (Items #12, 15 or 17). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing a Fuse

To remove a fuse:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Pull the fuse holder to open and remove the fuse from its holder.

Installing a Fuse

To install a fuse:1. Verify that the new fuse is good by measuring the resistance through the fuse

with an ohmmeter. The resistance should be less than 2 Ω.

2. Install the new fuse in the holder, with the point facing down. 3. Fully close the fuse holder.4. Turn on power. Verify proper operation.

Page 198: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–24 152874

Replacing the Internal FansTo replace an internal fan, see Figure B-6 on page B–7 to locate the left and/or right internal fan (Item #19). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing an Internal Fan

To remove an internal fan:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii and “Important Safety Instructions”.

2. Turn off the power by following the instructions for “Removing All Power and High Voltage” on page 9–2.

3. Disconnect the power wires from the fan. Mark them if necessary.4. Remove the hardware holding the fan in place.5. Remove the finger guard.

Installing an Internal Fan

To install an internal fan:1. Install finger guard.2. Mount the fan. Ensure the fan is oriented to blow air onto the capacitor

matrix.3. Reconnect the power wires.4. Turn on power.5. Verify the fan blows air onto the capacitor matrix.

Page 199: Xantrex 1.3 MW Power Inverter Manual

Replacing the Lower Magnetics Compartment Fans

152874 10–25

Replacing the Lower Magnetics Compartment FansTo replace a lower magnetics compartment fan, see Figure B-6 on page B–7 to locate the left and/or right fan (Item #19). Then refer to Table B-1, “Assembly Description for Component Replacement” on page B–8 for detailed information on the component.

Removing a Lower Compartment Fan

To remove an lower compartment fan:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to Servicing

the CW 2.5 MW Inverters” on page vii and “Important Safety Instructions”.2. Turn off the power by following the instructions for “Removing All Power and High

Voltage” on page 9–2.3. Remove top and side cover bolts.4. Loosen the bottom bolts and remove the cover, taking care to disconnect fan power

connector.5. Remove power wires from the fan. Mark them if necessary.6. Remove the hardware holding the fan in place.7. Remove finger guard.

Installing a Lower Compartment Fan

To install a lower compartment fan:1. Install finger guard.2. Mount the fan on cover. Ensure the fan is oriented to blow air in the proper direction.3. Reconnect the power wires.4. Connect fan connector and mount cover on the inverter enclosure.5. Turn on power.6. Verify all the fans are operating.

Page 200: Xantrex 1.3 MW Power Inverter Manual

Component Replacement

10–26 152874

Replacing the Wiring HarnessBefore replacing the wiring harness, determine if a minor repair can be made to the harness.

Minor Repairs

Minor repairs include:• Cutting off and stripping or lugging individual terminations (if enough slack

is available).• Replacing the individual wires.

Removing the Wire Harness

To remove the wiring harness:1. Follow the Lockout and Tag Procedure on “Lock Out and Tag Out Prior to

Servicing the CW 2.5 MW Inverters” on page vii.2. Turn off the power by following the instructions for “Removing All Power

and High Voltage” on page 9–2.3. Disconnect the terminations and remove the wiring harness.

Installing the Wire Harness

To install the wiring harnesses:◆ Place the wiring harness in position and reconnect the terminations as

indicated by the destination labels on the wires.

Page 201: Xantrex 1.3 MW Power Inverter Manual

A Specifications

Appendix A, Specifications, provides the electrical and environmental specifications for the CW 2.5 MW Inverters.

Page 202: Xantrex 1.3 MW Power Inverter Manual

Specifications

A–2 152874

Electrical Specifications

Rated Power, Continuous at 50 °C Ambient 4 × 650 kW Inverter

Inverter DC input Voltage 900 to 1400 Vdc

Maximum Transient DC Voltage 2014 Vdc

Inverter Pre-Charge Method Inverter Pre-Charge via Generator Operation

Nominal AC Voltage and Frequency 690 Vac, 60 Hz

Operational AC Voltage Tolerance 690 ± 10% Continuous

Operational AC Frequency Tolerance 60 Hz ± 3 Hz

Efficiency, DC Input to AC Output 97%, Minimum at Rated Power

Power Quality IEEE 519, PCC is 2.5 MW 690 V Transformer Connection

Inverter Switching Frequency 1.6 kHz

Inverter AC Current Rating (Each Inverter) 650 kW

Individual Inverter Power Factor 0.95 Lead or Lag

Individual Inverter Protective Functions Power Transistor De-Sat DetectionAdjustable Current Limit (Software)Utility Fuse ProtectionOver-Current ProtectionOver-Voltage ProtectionMatrix Over-temperature Protection

Power Transistor Gate Drive Interface Fiber-optic Link, Bi-Directional

Finish White Polyester Urethane Powder Coat

Cooling Fan Cooled - Main Inverter heatsink to dissipate heat outside enclosure.

Design Life 30 years

Audible Noise 98 dB Max., ISO 9614 A-Weighted Scale90 dB Max., Single Pronounced Tone

Page 203: Xantrex 1.3 MW Power Inverter Manual

Environmental Specifications

152874 A–3

Environmental Specifications

Physical Specifications

Operating Temperature Range –40 °C to 50 °C

Non-Operating Temperature Range –40 °C to 50 °C

Altitude 0 to 2000 meters above sea level

Relative Humidity 0 to 100% condensing

Inverter Enclosure

Width 80 inches

Height 113 inches

Depth (front to back) 30 inches

Weight 6500 lb

Page 204: Xantrex 1.3 MW Power Inverter Manual

Specifications

A–4 152874

CW 2.5 MW Inverter Enclosure Dimensions

Figure A-1 CW 2.5 MW Inverter Enclosure Dimensions

A A

80"

113"

30"

26"

Ø0.75 Clearance HoleQuantity 4

VIEW A-A

76"

Note: All dimensions are in inches.

Page 205: Xantrex 1.3 MW Power Inverter Manual

B Drawings

Appendix B, Drawings, provides detailed information on the system schematics of the CW 2.5 MW Inverters.

Page 206: Xantrex 1.3 MW Power Inverter Manual

Drawings

B–2 152874

Schematic Diagram of Main Power Distribution

Figure B-1 Schematic Diagram of Main Power Distribution

Page 207: Xantrex 1.3 MW Power Inverter Manual

Schematic Diagram of Control Power Distribution

152874 B–3

Schematic Diagram of Control Power Distribution

Figure B-2 Schematic Diagram of Control Power Distribution

Page 208: Xantrex 1.3 MW Power Inverter Manual

Drawings

B–4 152874

Schematic Diagram of CCU2 Circuit Board

Figure B-3 Schematic Diagram of CCU2 Circuit Board

Page 209: Xantrex 1.3 MW Power Inverter Manual

Left Side Component Designators

152874 B–5

Left Side Component Designators

Figure B-4 Left Side Component Designators

6

TB21

TB22

TB251

(+DC CABLE CONNECTION)

(-DC CABLE CONNECTION)

CT21

15A, 600V

10A, 500V

LEFT SIDE

10A, 500VF5715A, 600V

VALUE

BRAD SMITH

50 FT LBS

FUSE CHARTDESIGNATOR

50 FT LBS

DOUG

DESIGNATORTORQUE CHART

F59

TB21

10A, 500V

VALUE

SARGENTMICHAEL

F55F56

F60

BILL FOSTER02-28-06 BLODGETT

TB22

15A, 600VF54

REVISIONSCC REV DESCRIPTION AUT DATE CHK'D ENG MFG QA

A ECO 5197 GB

TORQUE CHARTDESIGNATOR VALUE

TB23 50 FT LBSTB10 50 FT LBS

3 64

L21

A B

2 1

C

5

SH21

B22

(HOT!) CW-BUP

CONTROLLED BY THERMOSTAT

1.0

CONFIDENTIAL INFORMATION OF XANTREX TECHNOLOGY INC.

COMPONENT DESIGNATORS, LEFT, CW2.5 MW

152891 AREV.DWG No.

DSIZE

TITLE:

02-28-06G. BELTRANDES

AUT

PROJECTION

2 13456

4 12

SCALE:

3

B

5

C

D

B

C

D

6

INCHES UNLESS

A A

NTS

.010 .02X.XX ANGLESX.XXX

DIMENSIONS ARE IN

BASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT, WITHOUT THE EXPRESS WRITTEN

(UNLESS OTHERWISE SHOWN)

3RD ANGLE

OTHERWISE SHOWN

PERMISSION OF: XANTREX TECHNOLOGY INC.

OF1 1SHT

COPYRIGHT 2004 XANTREX TECHNOLOGY INC.. THIS DOCUMENT IS THE PROPERTY OF XANTREX TECHNOLOGY INC., AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE

TOLERANCES:TM

DB1

T1-TB

DB3

F54,55,56,57,59,60

C

B B

R13

A

K21-AUX

K21-AUX

1

1

5L3

3L2

1L1

6T3

4T2

2T1

C

10

K21

T1

RTB21R12

A

8

A

CT22

C

CT23

TB10-GND

POWER)

& BACK OF BUS BARS)

CBTB23

A

(CONNECT 3

(LUGS CAN BE BOLTED TO FRONT

(ALL GROUNDING CONNECTIONS)

Page 210: Xantrex 1.3 MW Power Inverter Manual

Drawings

B–6 152874

Right Side Compartment Designators

Figure B-5 Right Side Component Designators

B12

SH11

(HOT!)

CONTROLLED BY THERMOSTAT

K11

TB5 C2

DB2

SSR11 SSR12 SSR21

C11 C12 C21

TB14

SW1 TS11

F51,52,53

RTB116

10

1

2T1

4T2

6T3

K11-AUX

5L3

3L2

1L1

K11-AUXA A

B B

C C

1

R14

1 6

CCU2

CT12

A

LVRT

CT13

C

(+DC CABLE CONNECTION)

(-DC CABLE CONNECTION)

TB11

TB12

TB151

6

CT11

L11

6 54 312

CBA(CONNECT 3 POWER)

(LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS)

(GROUND TO TB10-GND)

CBTB13

A

PFC11

F11,12,13

RIGHT SIDE TORQUE CHARTDESIGNATOR VALUE

TB11 50 FT LBSTB12 50 FT LBS

FUSE CHARTDESIGNATOR VALUE

F11 63A, 690VF12 63A, 690VF13 63A, 690VF51 10A, 690VF52 10A, 690VF53 10A, 690V

REVISIONSCC REV DESCRIPTION AUT DATE REG ENG MFG MFG

A ECO 5197 GB 02-28-06 BILL FOSTER DOUG BLODGETT BRAD SMITH MICHAEL

SARGENT

B ECO 6260 GB 09-07-07 BILL FOSTER ANTONIO MANTILLA VAL ARTMAN N/A

C ECO 6991 G. BELTRAN 01-30-09 N/A CHARLES STAUFFER VAL ARTMAN EMMANUEL

BOSOMPRA

DESIGNATOR VALUETB13 50 FT LBS

3RD ANGLEPROJECTION

2 13456

4 12356

A

B

C

D

B

C

D

A

CONFIDENTIAL INFORMATION OF XANTREX TECHNOLOGY INC.

1.0 .010 .02X.XX ANGLESX.XXX

DIMENSIONS ARE ININCHES UNLESS

OTHERWISE SHOWN

COPYRIGHT 2004 XANTREX TECHNOLOGY INC.. THIS DOCUMENT IS THE PROPERTY OF XANTREX TECHNOLOGY INC., AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THEBASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT, WITHOUT THE EXPRESS WRITTENPERMISSION OF: XANTREX TECHNOLOGY INC.

OF1 1SHTNTS

SCALE:

COMPONENT DESIGNATORS, RIGHT, CW2.5 MW

152892 CREV.DWG No.

DSIZE

TITLE:

02-28-06G. BELTRANDES

AUT

TOLERANCES:(UNLESS OTHERWISE SHOWN) TM

Page 211: Xantrex 1.3 MW Power Inverter Manual

Component Replacement Model

152874 B–7

Component Replacement Model

Figure B-6 Clipper 2.5 MW Inverter Component Replacement Model

CT21

CCU2

CT12

CT11

CT13

CT23

CT22

K21

T1

B22

CW-BUP

SSR11,12,21

F51-53

L11L21

1

2

3

5

12

11

10

7

6

14

15

18

20

19

19

2

2

2

2

2

3

4

8

9

1313

3X

3X

16

17

19

19 3X

B12

F11-13

6X

3X

3X

21

22

2X

B23-25 B13-15

PFC11

3X

Page 212: Xantrex 1.3 MW Power Inverter Manual

Component Replacement List for CW 2.5 MW Inverters

152874 B–8

Component Replacement List for CW 2.5 MW InvertersTable B-1 provides a detailed list of the components which are identified in Figure B-6 on page B–7.

Item Quantity Reference Designator Xantrex Part No. Description

1 1 CCU2 110-0821-01-02 PCB Assembly, LVRT CCU2 board, tested2 6 CT11, 12, 13, 21, 22,

231-151988-02 Current transducer, 1000 A Hall Effect, 100 A/µs DC to 150 kHz

bandwidth, 3 kVac PCB mount; Operating temperature range: –10 to +85 °C

3 2 K11, 21 1-151786-01 Contactor, 3 Pole, 750 A, 120 Vac4 2 SSR 11, 21 1-151495-01 Solid state relay, 12 A, 200 Vdc, UL Rated5 1 SSR 12 1-112129-01 Solid state relay, 10 A, 240 Vac, Crydom D24106 1 T1 1-152861-01 Transformer, 4.5 kVA,1 Pole, 690 V/115–230 V, 22 V, 50/60 Hz7 1 N/A 1-152916-01 Left matrix fan assembly8 1 N/A 1-152915-01 Right matrix fan assembly9 1 N/A 1-152767-01 Left matrix assembly, 1200 A, 2500 V10 1 N/A 1-152767-02 Right matrix assembly, 1200 A, 2500 V11 1 F11, 12, 13 054-2005-02 Modular fuseholder, 600 Vac, 100 A, 22 mm (D) × 58 mm Fuse DIN rail

mount, UL/CSA/IEC12 3 F11, 12,13 054-0030-02 Fuse, 63A, 690 Vac 22D x 58mm, 2s@500A 0.2s@800A 4.7W-LOSS 13 2 L11, 21 1-152769-01 Inductor, Copper windings, PWM, 3 Phase, 0.8 mH, 580 A

019-0008-01 Inductor, Aluminum windings, PWM, 3 Phase, 0.8 mH, 580 A14 1 F51, 52, 53 054-2005-01 Modular fuseholder, 40 A, 600 Vac, 14 mm (D) × 51mm Fuse DIN rail

mount, UL/CSA/IEC15 3 F51, 52, 53 054-0028-01 Fuse, 10 A, 690 Vac, 14 mm (D) × 51mm, 2s@40 A 0.1s@80 A,

1.5W-Loss16 6 F54, 55, 56, 57, 59,

601-151523-01 Fuseholder, 1 Pole, TCHSAF, Class CC

Table B-1 Assembly Description for Component Replacement

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Component Replacement List for CW 2.5 MW Inverters

152874 B–9

17 3 F54, 55, 56 1-150772-09 Fuse, 15 A, 600 Vac, FNQ-R-1518 3 F57, 59, 60 1-150772-08 Control fuse, 10 A, 500 Vac19 8 B12, 13, 14, 15, 22,

23, 24, 251-151024-01 Fan, 225SQX80,115 V

20 1 C2 1-112340-01 Cap, Elect, 3300 µF, 450 Vdc21 1 PFC11 015-0050-04 Cap FLM, 3 × 24.9 µF, 800 Vac, 10.8 A, 5% 15 kVAR@50 Hz, PP

PNL-MT, 116 mm (D) ×164 mm (H); Operating temperature range: –40 to +55 °C

22 1 C2W-BUP 1-152863-01 CW, Backup power board, 24 V, output

Item Quantity Reference Designator Xantrex Part No. Description

Table B-1 Assembly Description for Component Replacement

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B–10

Page 215: Xantrex 1.3 MW Power Inverter Manual

C Glossary

Appendix C, Glossary, provides a list of acronyms used in this Manual.

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Glossary

C–2 152874

Acronyms

Acronym Definition

CB Circuit Breaker

CCU Converter Control Unit

CT Current Transformer

DSP Digital Signal Processing

DVM Digital Volt Meter

EMI Electro-Magnetic Interference

EEPROM Erasable Programmable Read-Only Memory

GUI Graphical User Interface

IGBT Insulated Gate Bipolar Transistors

LVRT Low-voltage Ride-through

MW Mega watt

PC Personal Computer

PF Power Factor

PLC Programmable Logic Controller

PWM Pulse Width Modulated

RFI Radio Frequency Interference

RTD Resistance Temperature Detector

SEEPROM Serial EPROM

SSR Solid State Relay

TCU Turbine Control Unit

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152874 IX-1

AAC and ground cable entry, illustrated 2–11AC connections

left 2–11right 2–11

AC phases, troubleshooting 8–27

CCCU2 circuit board

connecting to TCU 2–15downloading software 3–7resetting out of download mode 5–21

circuit breakerlocking out viisafety warning v

clear fault button, illustrated 5–10commissioning

defined 3–1General Procedures window 5–9

CommPort Menufunctions 5–6illustrated 5–6

CW 2.5 MW Invertersorientation of 1–4

DDC cable components, hole diameter and quantity 2–10DC cable connections, illustrated 2–10DC cable entry covers 2–9DC connection, negative

illustrated 2–9DC connection, positive

illustrated 2–9DC generator cables, connecting 2–9

EE-Stop push button 2–14

Ffan shroud extension, to install 10–21fan shroud, when to modify 10–21faults, explanations 8–3fiber optic connector, blue

receiver 8–27fiber optic connector, gray

transmitter 8–27fuses, replacing 10–23

Gground bus connections

hole diameter and quantity 2–11illustrated 2–11

grounding 3–4

Iinductor, replacing 10–20inverter enclosure

mounting holes 2–5storage of 2–2

inverter switching frequency 1–6

Kkey location 2–5

Lleft AC connection, hole diameter 2–11line contactor, replacing 10–8line-side fiber optic connections 10–4lockout and tag vii, 8–2

Mmatrix assembly, replacing 10–19matrix fan assembly

storage of 2–2weight of 2–6

Oouter matrix edge mounting bolts 2–6

Ppersonal safety vi

Qquick disconnect terminals, illustrated 2–8

Index

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Index

152874 IX–2

Ssafety

features 1–3personal vi

serial number location 10–20short circuit, troubleshooting 8–27shutdown button, illustrated 5–10software, downloading rate 5–21solid state relays, replacing 10–9

TTCU, described 2–15transformer, replacing 10–10turbine control unit

function of 1–2

Wwiring harness, replacing 10–26

XXantrex

web site iv

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Xantrex Technology Inc.

1 800 670 0707 Tel toll free North America1 360 925 5097 Tel direct1 360 925 5143 Fax [email protected]

152874 Printed in USA