Xantrex 1.3 MW Power Inverter Manual

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

Installation, Operation & Maintenance Manual
About Xantrex
Xantrex 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 Electric

As 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
Trademarks
Xantrex 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 Copyright
Copyright 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 94551 Xantrex 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 Documentation

UNLESS 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 USERS 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 Revision

February 2009 Revision C
Document Part Number

152874
Product Part Number 1-152859-01 Contact Information

Telephone: Fax: Email: Web: 1 800 670 0707 (toll free North America) 1 408 987 6030 (direct) 1 800 994 7828 (toll free North America) 1 360 925 5143 (direct) customerservice@xantrex.com www.xantrex.com
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About This Manual

Purpose
The Installation, Operation & Maintenance Manual provides comprehensive information and procedures for installing, operating, and maintaining the CW 2.5 MW Wind Turbine Generator Power Conversion System (CW 2.5 MW Inverters).
Scope
The 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.
Audience
The 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.
Organization
This 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.
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About This Manual
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 Used
The following conventions are used in this guide.
WARNING
Warnings identify conditions or practices that could result in personal injury or loss of life
CAUTION
Cautions 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.
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
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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 voltage

Do 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 voltage

The 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 hazard

In 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 92. This may be done at the padmounted transformer. Review the system configuration to determine all of the possible sources of energy.

When 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.

Allow 30 minutes for the DC bus capacitors, located on the matrixes, to discharge after removing all power.
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Safety

The 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 use

The 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.
Personal Safety
Standard Safety Equipment Authorized service personnel must be equipped with standard safety equipment which includes the following: 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. 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.
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Safety
Lock Out and Tag Out Prior to Servicing the CW 2.5 MW Inverters
Do 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.

Review the system schematics for the installation to verify that all available energy sources are de-energized. See Appendix B, Drawings on page B1. DC bus voltage may also be present. Be sure to wait the full 30 minutes to allow the DC bus voltage to discharge completely.
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

Be sure to wait the full 30 minutes to allow the DC bus voltage to discharge completely.
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.
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Safety
Taking Measurements Safely

CAUTION
When 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.
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.
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Important Safety Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -v 1 Product Description
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12 Safety Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13 System Configuration- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14 Exterior Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15 Power Electronics Matrixes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 Interior Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Upper Left Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Left Panel and Left Rear Current Transducers (CTs) Panels - - - - - - - - - - - - - - - - - - - - 18 Left Internal Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110 Left Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 Upper Right Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 LVRT CCU2 Circuit Board Panel and Rear CT Panel - - - - - - - - - - - - - - - - - - - - - - - 112 Right Internal Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 115 Lower Left Magnetics Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 Lower Right Magnetics Compartment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119
2 Installation
Equipment Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Unpacking the Inverter Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Moving InstructionsForklift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 22 Moving InstructionsLifting Straps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23 Mounting Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Mounting the Inverter Enclosures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Mounting the Matrix Fan Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 26 Connecting the DC Generator Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 29 Connecting the AC Power and Ground Cable- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 211 Phasing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 211 Installing the Safety Shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 212 Control Wiring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214 Turbine Control Unit (TCU) to Inverter Communication - - - - - - - - - - - - - - - - - - - - - - - - - - - 215
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Contents
3 Commissioning
Getting Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32 Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 32 Taking Measurements Overview- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 33 Grounding - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 690 Volt Utility Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Preparing to Energize the Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 34 Two Inverter Enclosures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35 Power On Tests - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37 Downloading Operational Software- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 37 E-Stop Circuit Check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 Matrix Test, Generators Idle- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 Matrix Test, Generators Operating - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 39 Full Operation Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -310
4 Operation
Theory of Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Low-Voltage Ride-Through - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - System Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Inverter Operating States - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Initializing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Idle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ready - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Manual Command - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix Test - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Converter Control Unit (CCU2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 42 44 46 46 46 46 46 46 47 47 47
5 GUI
Main Window of the GUI - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - File Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Set Colors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Message Rate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Select Database - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Exit (F12) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CommPort Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Connect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Disconnect - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Properties - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Tools Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52 54 54 55 55 55 56 56 56 56 57
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Read/Write (F2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Shutdown (F3) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Troubleshooting (F4) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Data Logging (F5) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Downloader (F6) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Fault Analysis/History (F7) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 General Procedures (F9) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Help Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Technical Support - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 About - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Toolbar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 GUI Elements and Features- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 510 Data Boxes and Parameter Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 510 Shutdown and Clear Fault Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 510 Status Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 510 Read/Write by ID# Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 511 Selecting a Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 511 Identifying the Serial Number of the CCU2 Board - - - - - - - - - - - - - - - - - - - - - - - - - - 512 Data Logging Set Up Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 513 GUI Data Logging Set Up Window- Fields Selection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 513 Selecting Parameters to Log - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 514 Working with .Xmdb files - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 515 Graphs Screen- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 516 Downloader Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 519 Troubleshooting Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 522 Working in On line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 523 Clearing Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 523 Working in Off Line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 523 Listing Inverter Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 524 Fault Analysis and Fault History Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 525 Fault History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 531 General Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 536 Choose Parameter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 537
6 Flow Charts
Flow Chart 1 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62 Flow Chart 2 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63 Flow Chart 3 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64
7 Fault Conditions
CW 2.5 MW Inverters Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72
152874
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Contents
8 Troubleshooting
Before You Start Troubleshooting- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82 Servicing Safety Requirements - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82 Lock Out and Tag Out - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82 Visual Inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 82 Fault Conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 0000 - No Faults - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 F000 - Download Software - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 0001 - State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 0002 - Interrupt Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 83 0010 - External Disable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84 0015 - Inductor Compartment High Temp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 84 0029 - Serial Communication Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85 0040 - In Programming Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85 0042 - Bad Memory - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 85 0043 - SEEPROM Write Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 0028 - SEEPROM Timeout - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 0080 Left Ripple Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 00DE Right Ripple Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 0120 - Line Frequency Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 0220 - Line Frequency High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 86 0130 - AC Line Voltage Too Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 0230 - Line Voltage Too High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 87 Left Matrix Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 0155 - Left Matrix State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 0156 - Left Matrix Control Failure to Turn Off - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 0256 - Left Matrix Control Failure to Turn On - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 0157 - Left Matrix DC Bus Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 88 0257 - Left Matrix DC Bus Voltage High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 89 0158 - Left Matrix Temperature Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - - -810 0258 - Left Matrix Over-Temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -810 XX66 - Left Matrix Gate Drive Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -810 XX77 - Left Matrix Over Current Fault (H/S) - - - - - - - - - - - - - - - - - - - - - - - - - - - - -811 0078 - Left Matrix DC Bus Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -812 Right Matrix Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -813 01AA - Right Matrix State Machine Failure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -813 01AB - Right Matrix Control Failure to Turn Off - - - - - - - - - - - - - - - - - - - - - - - - - - -813 02AB - Right Matrix Control Failure to Turn On - - - - - - - - - - - - - - - - - - - - - - - - - - -813 01AC - Right Matrix DC Bus Voltage Low - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -813 02AC - Right Matrix DC Bus Voltage High - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -814 01AD - Right Matrix Temperature Sensor Error - - - - - - - - - - - - - - - - - - - - - - - - - - - -815 02AD - Right Matrix Over-temperature - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -815 XXBB - Right Matrix Gate Drive Fault - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -815
xii 152874
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XXCC - Right Matrix Over Current Fault (H/S) - - - - - - - - - - - - - - - - - - - - - - - - - - 00DD - Right Matrix DC Bus Over Current - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230/120/22 Vac Control Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 690 Vac Utility Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 230 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 24 Vac Secondary Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CCU2 Power - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - CCU2 Circuit Board Power Supplies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Contactor Control Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Space Heaters - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Magnetics Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Current Transducers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Filter Capacitor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IGBTs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LEDs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fiber Optics - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - AC Phases - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Short Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix Test- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IGBT Checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix Damage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Fiber Optic Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Matrix Temperature Sensors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Checking the Line Matrix Temperature Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
817 817 818 818 819 819 819 820 820 822 823 823 824 825 826 826 826 827 827 827 828 830 831 833 834 835 836 836
9 Maintenance
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92 Removing All Power and High Voltage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92 Upper Compartments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92 Lower Compartments- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Cable Glands - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Ground/Power Terminations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Electrical Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Heatsinks and Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93 Gate Drive Fiber Optic Cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 93
152874
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10
Component Replacement
Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -102 Before You Start Replacing Components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -103 Safety Requirements for Service - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -103 Identifying Components for Replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -103 Replacing the CCU2 Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 Removing the CCU2 Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -104 Installing the CCU2 Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -105 Replacing the Current Transducer (CT) Modules- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -106 Removing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -106 Installing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -106 Replacing the Line Contactors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -108 Removing the Line Contactor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -108 Installing the Line Contactor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -108 Replacing the Solid State Relays (SSR) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -109 Removing the Solid State Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -109 Installing the Solid State Relays - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -109 Replacing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1010 Removing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1010 Installing the Control Transformer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1010 Replacing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1011 Removing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1011 Installing the Matrix Fan Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1011 Replacing the Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1012 Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1013 Removing a Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1014 Installing a Matrix Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1015 Replacing the Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1016 Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1016 Removing a Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1017 Installing a Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1018 Replacing the Matrix Sub-Assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1019 Removing the High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1019 Installing the High Voltage Driver Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1019 Replacing the Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1020 Additional Equipment Required - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1020 Removing an Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1020 Installing an Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1021 Replacing the Fuses - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1023 Removing a Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1023 Installing a Fuse - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1023
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Replacing the Internal Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Removing an Internal Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing an Internal Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Replacing the Lower Magnetics Compartment Fans - - - - - - - - - - - - - - - - - - - - - - - - - - - - Removing a Lower Compartment Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing a Lower Compartment Fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Replacing the Wiring Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Minor Repairs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Removing the Wire Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Installing the Wire Harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
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Specifications
Electrical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A2 Environmental Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A3 Physical Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A3 CW 2.5 MW Inverter Enclosure Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A4
Drawings
Schematic Diagram of Main Power Distribution- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B2 Schematic Diagram of Control Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B3 Schematic Diagram of CCU2 Circuit Board- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B4 Left Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B5 Right Side Compartment Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B6 Component Replacement Model - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B7 Component Replacement List for CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - - -B8
Glossary
Acronyms - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -C2
Index - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - IX1
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Tables
Table 1-1 Table 1-2 Table 1-3 Table 1-4 Table 4-1 Table 5-1 Table 5-2 Table 7-1 Table 8-1 Table B-1 Exterior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - 15 Interior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Voltages and Protective Fuses on Left Main Panel - - - - - - - - - - - - - - - - - - - - - - - - - 111 Components on Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 LVRT Line Voltage Limits and Time Delay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 44 Elements and Features of the GUI Main Window - - - - - - - - - - - - - - - - - - - - - - - - - - - 53 Toolbar Icons and Descriptions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 List of Fault Conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 72 Device Detecting the Right Matrix Gate Driver Fault - - - - - - - - - - - - - - - - - - - - - - - 815 Assembly Description for Component Replacement - - - - - - - - - - - - - - - - - - - - - - - - -B8
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Figures
Figure 1-1 Figure 1-2 Figure 1-3 Figure 1-4 Figure 1-5 Figure 1-6 Figure 1-7 Figure 1-8 Figure 1-9 Figure 1-10 Figure 1-11 Figure 1-12 Figure 1-13 Figure 1-14 Figure 1-15 Figure 1-16 Figure 1-17 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 3-1 Figure 3-2 Figure 4-1 Figure 4-2 Figure 4-3 Figure 5-1 Outline of the CW 2.5 MW Inverters Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - - 12 CW 2.5 MW Inverters Orientation in the Downtower - - - - - - - - - - - - - - - - - - - - - - - - 14 Exterior Components of the CW 2.5 MW Inverters - - - - - - - - - - - - - - - - - - - - - - - - - 15 Power Electronics MatrixLeft Side- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 16 Interior View of the 2.5 MW Inverter Enclosure - - - - - - - - - - - - - - - - - - - - - - - - - - - 17 Current Transducers (CT) Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18 Left Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19 Left Internal Fan Panel- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 110 Left Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 111 CCU2 Circuit Board Panel and CT Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 112 Right Rear Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 113 Right Fan Panel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 114 Right Main Panel Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 116 Left Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 117 Left AC Connection Ground Bus - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 118 Right Inductor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 119 Right AC Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 120 Inverter Enclosure Lifting Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 23 Mounting Hole Locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Mounting Right Matrix Fan Assembly to Cabinet- - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Matrix Fan Cable Fitting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 28 Matrix Fan Power Cable Quick Disconnect Terminals - - - - - - - - - - - - - - - - - - - - - - - 28 DC Cable Entry Covers on the Back of the Inverter Enclosure - - - - - - - - - - - - - - - - - - 29 DC Cable Connections on Left and Right Side of CW 2.5 MW Inverters - - - - - - - - - - 210 DC Cable Components (.66 hole for 5/8 bolt size; quantity 4) - - - - - - - - - - - - - - - - 210 Making Left AC Connections and Ground Bus Connection - - - - - - - - - - - - - - - - - - - 211 Making Right AC Connections - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 212 Installing the Safety Shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 213 External Fault and Stop Interlocks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 214 Connection between CCU2 Board and TCU - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 215 Enable/Disable Selector SW1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 35 External GUI Connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 36 Communication To and From the Turbine Control Unit (TCU) - - - - - - - - - - - - - - - - - 42 650 kW Converter Section - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 43 Transient Voltage and Frequency Ride-Through Characteristics - - - - - - - - - - - - - - - - - 45 Main Window of the GUI- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52
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Figures
Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 5-7 Figure 5-8 Figure 5-9 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 Figure 5-15 Figure 5-16 Figure 5-17 Figure 5-18 Figure 5-19 Figure 5-20 Figure 5-21 Figure 5-22 Figure 5-23 Figure 5-24 Figure 5-25 Figure 5-26 Figure 5-27 Figure 5-28 Figure 5-29 Figure 5-30 Figure 5-31 Figure 5-32 Figure 5-33 Figure 5-34 Figure 5-35 Figure 5-36 Figure 5-37 Figure 5-38 Figure 6-39 Figure 6-40 Figure 6-41 Figure 8-1
File Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 Choose Color Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 54 Message Rate Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55 CommPort Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56 CommPort Properties window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 56 Tools Menu- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Help Menu - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 58 Toolbar Icons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 Data Boxes and Parameter Labels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -510 ShutDown and Clear Fault Buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -510 Status Bar - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -510 Read/Write by ID# Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -511 Data Logging Set Up Window - Custom Fields- - - - - - - - - - - - - - - - - - - - - - - - - - - -513 GUI Data Logging Set Up Window - Fixed Fields- - - - - - - - - - - - - - - - - - - - - - - - - -514 Saving a Parameter Log File - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -515 Graphs Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -516 Graph View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -517 Data View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -518 Downloader Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -519 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -520 Downloader Window with Status Information - - - - - - - - - - - - - - - - - - - - - - - - - - - -520 Troubleshooter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -522 Working in Off Line Mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -524 Fault Analysis and Fault History Screen - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -526 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -527 Retrieving Fault History Data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -528 Graph View- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -529 Data Table View - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -530 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -531 Save As Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -532 Retrieving Fault History - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -533 Print Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -534 Typical Fault History File - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -535 General Procedures Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -536 Choose Parameter Window - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -537 Choose Parameter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -538 Select Configuration - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -538 Flow Chart 1 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62 Flow Chart 2 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63 Flow Chart 3 of 3 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 64 Power Electronic Converter Matrix - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -826
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Figures
Figure 10-1 Figure 10-2 Figure 10-3 Figure 10-4 Figure A-1 Figure B-1 Figure B-2 Figure B-3 Figure B-4 Figure B-5 Figure B-6
Installing the Current Transducer Module - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 106 Power Electronics Matrix - Left Side - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1012 Heatsink Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1016 Hardware Stack Up and Application of Anti-Corrosion Compound at Aluminum Inductors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1022 CW 2.5 MW Inverter Enclosure Dimensions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -A4 Schematic Diagram of Main Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - - -B2 Schematic Diagram of Control Power Distribution - - - - - - - - - - - - - - - - - - - - - - - - - -B3 Schematic Diagram of CCU2 Circuit Board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B4 Left Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B5 Right Side Component Designators - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -B6 Clipper 2.5 MW Inverter Component Replacement Model- - - - - - - - - - - - - - - - - - - - -B7
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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 12 Safety Features on page 13 System Configuration on page 14 Exterior Components on page 15 Interior Components on page 17
Product Description
Introduction
The 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 inverters 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 14. 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 inverters 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
Safety Features
The 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
System Configuration
Two 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.
Clipper Inverter #4
Clipper Inverter #1
Clipper Inverter #3
Clipper Inverter #2
Door
Figure 1-2 CW 2.5 MW Inverters Orientation in the Downtower
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Exterior Components
Exterior Components
Figure 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 Lower Left Compartment Upper Right Compartment Lower Right Compartment
1 3 5 Upper Left Compartment 7 9
2 4 6 Upper Right Compartment 8
10
Lower Left Compartment
Lower Right Compartment
11
12
13
14
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 1 3 5 7 9 11 13 Description Left Heatsink Fan Left Fan Housing Left Power Electronics Matrix Door Latches (4 in total) Upper Left Front Access Door Lower Left Front Access Door Mounting Holes (1 in front, 1 in rear) Right Side Feature 2 4 6 8 10 12 14 Description Right Heatsink Fan Right Fan Housing Right Power Electronics Matrix Door Latches (4 in total) Upper Right Front Access Door Lower Right Front Access Door Mounting Holes (1 in front, 1 in rear)
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Product Description
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.
Fan Motor Fan Venturi Fan Housing Heatsink Power Electronics Maxtrix Laminated Power Bus DC Filter Capacitors High Voltage Driver Board IGBTs
Figure 1-4 Power Electronics MatrixLeft Side
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Interior Components
Interior Components
Figure 1-5 identifies the four interior compartments of the inverter enclosure.
Upper Left Compartment Lower Left Compartment Upper Right Compartment Lower Right Compartment
Table 1-2 describes the components in the compartments.
Upper Left Compartment 1 3 5 7 Lower Left Compartment 9 11
Upper Right Compartment 2 4 6 8 Lower Right Compartment 10 14 12 15
13
Figure 1-5 Interior View of the 2.5 MW Inverter Enclosure Table 1-2 Interior Components of the CW 2.5 MW Inverters
Left Side Feature 1 3 5 7 9 11 13 Description Left Internal Fan Panel Left Rear Panel (DC Connection) Left Current Transducer (CT) Panel Left Main Panel Left Inductor Left AC Connection Ground Bus Right Side Feature 2 4 6 8 10 12 14 15 152874 Description Right Internal Fan Panel Right Rear Panel (DC Connection) Converter Control Unit (CCU2) Board Right Main Panel Right Inductor Right AC Connection Power Factor Fuses Power Factor Cap 17
Product Description
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.
CT23
CT22
Figure 1-6 Current Transducers (CT) Panel
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Interior Components
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.
CT21 (+DC CABLE CONNECTION) TB21
(DC CABLE CONNECTION) TB22

1
TB25
6
Figure 1-7 Left Rear Panel
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Product Description
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.
B22
SH21 (HOT!) CW-BUP
Controlled by thermostat
Figure 1-8 Left Internal Fan Panel
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Interior Components
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).
K21-AUX
C B A
1
5L3 3L2 1L1 K21-AUX 10
6T3
C B A R13 RTB21 DB3
K21
4T2 2T1
R12
T1-TB DB1
T1
F54,55,56,57,59,60
Figure 1-9 Left Main Panel Assembly Table 1-3 lists the control voltage and circuit functions of these voltages and protective fuses. Table 1-3 Voltages and Protective Fuses on Left Main Panel
Reference Designation F54, F55 F56 F57 F59, F60 Control Voltage 24 Vac 115 Vac 230 Vac Circuit Function Voltage for the CCU2 circuit board and 24 Vdc internal power. Voltage for internal fans and contactor coil power supply. Voltage for internal space heaters. Voltage for matrix fan motors.
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Product Description
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.
CT12
CCU2
Figure 1-10 CCU2 Circuit Board Panel and CT Panel
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Interior Components
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. 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.
DC Current Transducer
CT11 +DC CABLE CONNECTION TB11
DC CABLE CONNECTION TB12

1
TB15
6
CT13 C
Figure 1-11 Right Rear Panel
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Product Description
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.
B12
SH11 (HOT!)
Controlled by a thermostat
Figure 1-12 Right Fan Panel
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Interior Components
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 113 on page 116 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 114.
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Product Description
K11-AUX
A B C
2T1 4T2
1L1
A B C
K11
3L2
6T3 K11-AUX
5L3
1 R14
TB14
TB5
10
C2
DB2 RTB11
SW1
TS11
F51,52,53
Figure 1-13 Right Main Panel Assembly Table 1-4 Components on Right Main Panel Assembly
Component F51 F52 F53 TB14 SW1 TS11 SSR11 SSR12 SSR21 C2 DB2 TB5 K11 RTB11 116 Description 690 volt reference fuse 690 volt reference fuse 690 volt reference fuse AC voltage divider Enable/Disable selector switch Adjustable thermostat for the space heaters Solid state relay used to interface the contactor coils to the CCU2 circuit board Solid state relay used as an auxiliary control for the space heaters Solid state relay used to interface the contactor coils to the CCU2 circuit board Capacitor Diode bridge External control circuit terminal block Line contactor DC Power supply for the contactor coils 152874
Interior Components
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.
L21
Figure 1-14 Left Inductor 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.
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Product Description
TB23 A B C
LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS TB10-GND ALL GROUNDING CONNECTIONS
Figure 1-15 Left AC Connection Ground Bus
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Interior Components
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.
.
L11 PFC11
Figure 1-16 Right Inductor 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.
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Product Description
TB13 A B C
LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS
GROUND TO TB10-GND
Figure 1-17 Right AC Connection
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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 22 Unpacking the Inverter Enclosure on page 22 Moving InstructionsForklift on page 22 Moving InstructionsLifting Straps on page 23 Mounting Instructions on page 24 Connecting the DC Generator Cables on page 29 Connecting the AC Power and Ground Cable on page 211 Phasing on page 211 Control Wiring on page 214 Turbine Control Unit (TCU) to Inverter Communication on page 215
Installation
Equipment Storage
Inverter enclosures Matrix fan assemblies Store the inverter enclosures in a clean, dry location until the enclosures are ready for installation in the tower. 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 Enclosure

Do 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.
WARNING
The approximate weight of each inverter enclosure is approximately 6500 lbs.
WARNING: Physical injury

Attempting 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.
Moving InstructionsForklift
CAUTION: Equipment damage
Before lifting the inverter enclosure, verify that all of the front access doors are securely attached with the appropriate hardware and all of the cabinets bolts and screws are securely in place.

Do not attempt to use the top heatsink matrix brackets to lift the inverter enclosure. Lift from the bottom of the inverter enclosures only.
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 23 for forklift points. 3. Keep the doors closed and latched when moving the inverter enclosures.
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Moving InstructionsLifting Straps
Moving InstructionsLifting Straps

Before lifting the inverter enclosure, verify that all of the front access doors are securely attached with the appropriate hardware and all of the cabinets bolts and screws are securely in place.

When using the lifting straps, the fan assemblies must not be installed.
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.
Forklift locations
Recommended locations for lifting straps
Figure 2-1 Inverter Enclosure Lifting Locations

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Installation
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

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.
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 .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 25 for mounting hole size and locations.
Important: Anchoring hardware is not provided with the inverter enclosures.
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Back
Front
Side
Back
2 .75 Mounting Holes on left side: 1 in front and 1 in back
2 .75 Mounting Holes on right side: 1 in front and 1 in back
Figure 2-2 Mounting Hole Locations 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.
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Installation
Mounting the Matrix Fan Assemblies WARNING: Risk of injury

The 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.

Be careful not to drop the housing or damage the heatsink cooling fins.
Left and right matrix fan assemblies Outer matrix edge mounting bolts
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. 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 -20 .50 L
The 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.
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Connecting plate with mounting bolts
Slotted holes on housing
Outer edge mounting bolts
Figure 2-3 Mounting Right Matrix Fan Assembly to Cabinet 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.
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Installation
Figure 2-4 Matrix Fan Cable Fitting 3. Secure the cable compression fitting to the enclosure.
Figure 2-5 Matrix Fan Power Cable Quick Disconnect Terminals 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.
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Connecting the DC Generator Cables
Connecting the DC Generator Cables

CAUTION: Reverse polarity damage
Before 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.
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.
Positive (+) DC cable connection
Negative () DC cable connection
Figure 2-6 DC Cable Entry Covers on the Back of the Inverter Enclosure
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Installation
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.
DC cable entry
1 3 2
Figure 2-7 DC Cable Connections on Left and Right Side of CW 2.5 MW Inverters Figure 2-8 DC Cable Components (.66 hole for 5/8 bolt size; quantity 4)
Feature Description 1 3 Positive (+) DC cable connection Negative () DC cable connection Feature Description 2 4 Positive (+) DC cable connection Negative () DC cable connection

Before 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 ().
4. Terminate the cables and attach to the bus bars carefully observing polarity. See Figure 2-7.
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Connecting the AC Power and Ground Cable
Connecting the AC Power and Ground Cable

To 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.
A B C .66 HOLE FOR 5/8 BOLT SIZE (QTY: 6) 3/8 THREADED HOLE (QTY: 4) GN AC & GROUND CABLE ENTRY
Figure 2-9 Making Left AC Connections and Ground Bus Connection
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Installation
C .66 HOLE FOR 5/8 BOLT SIZE (QTY: 6) A B
AC CABLE ENTRY
Figure 2-10 Making Right AC Connections 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 Shield

A safety shield will be installed in each unit, one per door. See Figure 2-11 on page 213.
Important: The safety shield should only be installed once the CW 2.5 MW Inverters
have been unwrapped and installed.
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.
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Installing the Safety Shield
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
Control Wiring
Each 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 optisolated solid state switches (FETs) rated at 2 amps, 60 volts maximum. It is suggested that a relay is utilized to interface with the TCU.

Positive (+) must be connected to positive (+). Negative () must be connected to negative ().
CAUTION
Do not connect this circuit to 115 Vac.
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.
TB5
1 2 3 4 5 6 7 8 9 10 (+) () (+) ()
Fault interlock
External shutdown switch Jumper if not used
Figure 2-12 External Fault and Stop Interlocks
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Turbine Control Unit (TCU) to Inverter Communication
Turbine Control Unit (TCU) to Inverter Communication

Communication 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.
Communication signal to/from TCU via Opto-cable Tx/Rx
U1002 Tx
Figure 2-13 Connection between CCU2 Board and TCU
U1001 Rx
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216
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 32 Equipment Required on page 32 Taking Measurements Overview on page 33 Visual Inspection on page 33 Grounding on page 34 690 Volt Utility Connections on page 34 Preparing to Energize the Inverters on page 34 Power On Tests on page 37 Downloading Operational Software on page 37 E-Stop Circuit Check on page 38 Matrix Test, Generators Idle on page 38 Matrix Test, Generators Operating on page 39 Full Operation Test on page 310
Commissioning
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.
Important: Two inverter enclosures are utilized in each CW 2.5 MW Power

Conversion System. This procedure applies to each one.

Perform this procedure in dry conditions.
WARNING: Lethal voltages

The 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 moisture

If 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.
Equipment Required
The 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 set
The test equipment must be rated to at least 700 Vac and 1000 Vdc.
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Taking Measurements Overview
Taking Measurements Overview

Use 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 Inspection
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. 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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Commissioning
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.
Grounding
Verify the ground connection has been made to the ground bus bar connection at the bottom of the enclosure.
690 Volt Utility Connections

To 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

Do not open the inverter enclosure doors without applying parking brake and rotor lock.

If 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.

The inverter enclosures contain high voltages: 115 Vac, 230 Vac, 690 Vac and 1400 Vdc.

The 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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Preparing to Energize the Inverters
Two Inverter Enclosures

Important: Two inverter enclosures are utilized in each CW 2.5 MW Power
Conversion System. This procedure applies to each one.
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.
K11-AUX
A B C
2T1 4T2
1L1
A B C
K11
3L2
6T3 K11-AUX
5L3
1 R14
TB14
TB5
10
C2
DB2 RTB11
SW1
TS11
F51,52,53
Figure 3-1 Enable/Disable Selector SW1 2. Check the heater thermostat. It should be set to a low value, approximately 40 F. 3. Close and latch both upper compartment doors.
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Commissioning
4. Connect the external computer containing the GUI program to the GUI test port at the front of the enclosure. See Figure 3-2.
Figure 3-2 External GUI Connection 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
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Power On Tests
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 Software

To 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 File S/W Version are the same. 5. Return to the initial GUI program.
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Commissioning
E-Stop Circuit Check

To 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 Idle

Before 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 51 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 81. 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
Matrix Test, Generators Operating

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

Any time the generators are operating, DC bus voltage is present.
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.
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Commissioning
Full Operation Test

WARNING: Flying debris
Wear 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.
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.
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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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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 42 System Operation on page 46
Operation
Theory of Operation
The 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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Theory of Operation
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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Operation
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. Table 4-1 LVRT Line Voltage Limits and Time Delay
Line Voltage Limits (% of nominal) 100% thru110% 110% thru 120% 120% thru 130% 130% and Above 100% thru 90% 90% thru 10% 10% and below Time Delay Before Drop Out Nominal Operation 5 Seconds 0.5 Seconds Instantaneous Nominal Operation 5 Seconds 5 Seconds
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.
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Theory of Operation
Clipper Windpower Liberty Wind Turbine Transient Voltage Ride-Through Characteristics
Turbine remains online in this area
Clipper Windpower Liberty Wind Turbine Transient Frequncy Ride-Through Characteristics
Turbine remains online in this area
Figure 4-3 Transient Voltage and Frequency Ride-Through Characteristics
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Operation
System Operation
In 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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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 52 GUI Elements and Features on page 510 GUI Data Logging Set Up Window- Fields Selection on page 513 Graphs Screen on page 516 Downloader Window on page 519 Troubleshooting Window on page 522 Fault Analysis and Fault History Window on page 525 General Procedures on page 536 Choose Parameter Window on page 537
GUI
Main Window of the GUI

The 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-byside 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.
1 2
3 5 7 9 11
4 6 8 10 12
13 14 16 15
17
18
19
21
23
20
22
24
Figure 5-1 Main Window of the GUI
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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 1 3 Inverter #3 and 4 Features 2 4
Description Title Bar identifies the inverters as #1, 2, 3 or 4. Menus provide access to different functions of the software program. There are four submenus: File Menu (see page 54) CommPort Menu (see page 56) Tools Menu (see page 57) Help Menu (see page 58) Toolbar (see page 59) Inverter Operating States (see page 46) Fault Conditions (see page 83) Software Version (see page 58) Data Boxes and Parameter Labels, LM (Left Matrix) (see page 510) Data Boxes and Parameter Labels, RM (Right Matrix) (see page 510) Status Bar (see page 510) Shutdown Button (page 510) Clear Fault Button (see page 510) 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.
5 7 9 11 13 15 17 19 21 23
6 8 10 12 14 16 18 20 22 24
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GUI
File Menu
The File Menu provides four selections: Set Colors, Message Rate, Select Database and Exit (F12). See Figure 5-2.
Figure 5-2 File Menu
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.
Figure 5-3 Choose Color Window 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.
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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.
Figure 5-4 Message Rate Window 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.
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
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.
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GUI
CommPort Menu
The CommPort menu offers three functions: Connect, Disconnect and Properties.
Figure 5-5 CommPort Menu
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 5-6 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
Figure 5-7 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 511.)
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 522.)
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 WindowFields Selection on page 513.)
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GUI
Downloader (F6)
Use Downloader to open the Downloader window for downloading software into the CCU2 board. (See Downloader Window on page 519.)
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 525.)
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 536.)
Help Menu
The Help Menu provides three options: Contents, Technical Support, and About.
Figure 5-8 Help Menu
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.
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Toolbar
The 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 Icons Table 5-2 Toolbar Icons and Descriptions
Icon Icon Name CommPort Properties Description 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. 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. 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. Clicking Troubleshooting opens the TroubleShooter window. You can then view information about the inverter's current fault and clear faults. Clicking Data Logging opens the GUI Data Logging Set Up window. You can then manage a data logging session. Clicking Downloader opens the Downloader window. You can then download software into the CCU2 board. See Troubleshooting Window on page 522. For more information See CommPort Properties window on page 56.
Read/Write
See Read/Write by ID# Window on page 511.
Shutdown
Troubleshooting
Data Logging
See GUI Data Logging Set Up Window- Fields Selection on page 513. See Downloader Window on page 519. See Fault Analysis and Fault History Window on page 525. See General Procedures on page 536.
Downloader
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. General Procedures Clicking General Procedures opens the General Procedures window. You can then perform commissioning, maintenance, and other procedures.
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GUI
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 537.
Figure 5-10 Data Boxes and Parameter Labels
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.
Figure 5-11 ShutDown and Clear Fault Buttons
Status Bar
The Status Bar shows information about the connection to the CCU2 board including CommPort settings, board response status, and connection duration.
Figure 5-12 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.
Figure 5-13 Read/Write by ID# Window
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.
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GUI
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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GUI Data Logging Set Up Window- Fields Selection
Data Logging Set Up Window
Figure 5-14 Data Logging Set Up Window - Custom Fields Logging data Default mode Custom Fields mode You can log the data being received from the CCU board from the Data Logging Set Up window in two different ways. In the default mode, the parameters being logged are fixed in the CCU2 board software and the file produced is a comma delimited one. 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).

To 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.
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GUI
Figure 5-15 GUI Data Logging Set Up Window - Fixed Fields 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 537.
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 button or Go button to start the logging process. Clicking the Stop button will interrupt or halt the logging process. Pause
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.
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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 on 10/05/2000 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 516) 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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GUI
Graphs Screen
This screen allows you to display data which was previously logged using the Data Logging Set Up window.
Figure 5-17 Graphs Screen 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.
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Graphs Screen
Figure 5-18 Graph View 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 dont 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.
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GUI
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.
Figure 5-19 Data View 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.
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Downloader Window
Downloader Window
The 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.
Figure 5-20 Downloader Window To download software: 1. Click Select File. A window appears with a list of different software versions. See Figure 5-21.
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GUI
Figure 5-21 Save As Window 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 5-22 Downloader Window with Status Information
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Downloader Window
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. OR If 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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GUI
Troubleshooting Window
The 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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Troubleshooting Window
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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Figure 5-24 Working in Off Line Mode
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.
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Fault Analysis and Fault History Window

The 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 Clearing fault analysis data Viewing status of the data log 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. To clear the fault analysis data from non-volatile memory, on the Tools menu Tools, select Delete 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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GUI
Figure 5-25 Fault Analysis and Fault History Screen 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.
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Figure 5-26 Save As Window 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.
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GUI
Figure 5-27 shows the screen in the process of retrieving data.
Figure 5-27 Retrieving Fault History 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.
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Figure 5-28 Graph View 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.
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GUI
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.
Figure 5-29 Data Table View You can display the data in graph form again by clicking the selecting Show Graphs from the Tools menu. button or by
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.
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Figure 5-30 Save As Window
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.
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GUI
Figure 5-31 Save As Window 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 533 shows the screen in the process of retrieving the fault history data.
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Figure 5-32 Retrieving Fault History 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.
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GUI
Figure 5-33 Print Window 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.
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Figure 5-34 Typical Fault History File 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.
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General Procedures
The 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.
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 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.
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Choose Parameter Window
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.

The 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.
Figure 5-36 Choose Parameter 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.
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GUI
Figure 5-37 Choose Parameter 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.
Figure 5-38 Select Configuration 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 537. You can also select different colors for the main screen elements to be saved with this configuration (see File Menu on page 54 for choosing colors).
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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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GUI
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Flow Charts
Chapter 6, Flow Charts, provides the flow charts which display the high level software logic information.
Flow Charts
Flow Chart 1 of 3
Lmatrix_idle( ) 0 LM state = Idle LM goal state =Idle. Red LED OFF. Green LED ON. NO System faulted? YES NOTE: Right matrix flow chart is identical to left matrix flow chart located in this page. K11 is used instead of K21.
switch matrix OFF Open K21. Red LED ON.Green LED OFF.
LM state = Idle LM goal state =Idle. switch matrix OFF.
System faulted? NO
YES
LM state = faulted. LM goal state =Idle. switch matrix OFF.
Lmatrix_faulted( ) 3 YES
LM state = faulted. LM goal state =Idle.
YES System IDLE AND L Matrix Test requested by GUI? YES
System faulted?
NO
L Matrix Test canceled by GUI?
NO
Lmatrix_matrix_test( ) 4
NO
Mask DC bus undervoltage fault. Open K21. LM State = Matrix Test. Switch matrix ON. YES
NO
System READY AND L Matrix DC BUS > VDC_PRE_LOW AND L Matrix Current Command requested by GUI Or TCU 0x01?
YES
Current Cmd = 35. Close K21. Set settling timer.
System faulted? Lmatrix_ready( ) 1
NO
L Matrix set to IDLE by GUI OR E-Stop open?
YES
Current Cmd = 0. Switch Matrix OFF. Open K21.
NO
NO Current Cmd = 0. Switch Matrix OFF. Open K21. YES NO L Matrix set to IDLE by GUI OR E-Stop open?
L Matrix DC BUS >= DCBUS_REF YES
Check for DC bus Low.
NO
System faulted? YES
Perform current control on left side matrix according to input from GUI.
Lmatrix_manual_Icmd( ) 2
Switch matrix ON.
Figure 6-39 Flow Chart 1 of 3
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Flow Chart 2 of 3
Flow Chart 2 of 3
NOTES: Boot up J1 PIN1-2 will be open if the system is faulted. J1 PIN3-4 will be open if the system is faulted (temporary addition because J1 1-2 hardware damaged on board)
Lmatrix_idle( )
sys_initializing( ) 0
Rmatrix_idle( )
J1 PIN11-12 will be open if the system is faulted on a fault other than TWIN_INVERTER_FAULT. Before opening K21, the L matrix current command is set to zero and the L matrix is switched OFF.
Initialize all states and goal states to Idle.
Before opening K11, the R matrix current command is set to zero and the R matrix is switched OFF. K21 and K11 will open if any fault occurs.
Close J1 pin1-2
sys_idle( ) 1
Set all states and goal states to Idle.
NO
System faulted?
YES
GREEN LED OFF RED LED ON
The matrix current command is set to zero automatically when exiting current command mode.
K21 will open if L matrix enters Matrix Test mode. System faulted? NO YES Enable/disable switch closed? J2_pin1to2 LM goal state = Matrix Test AND/OR RM goal state = Matrix Test NO YES YES LM goal state = Idle. RM goal state = Idle. sys_ready( ) 2 YES System goal state = Idle. sys_faulted( ) 3 K11 will open if R matrix enters Matrix Test mode.
System faulted? NO
YES
GUI request L or and R matrix test? NO
E-Stop is closed?
LM goal state = Idle. RM goal state = Idle.
NO

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Flow Charts
Flow Chart 3 of 3
Main( )
c_int02( ) Interrupt @ 5700 Hz
Set D2A outputs.
WriteD2A( )
Do_Rmatrix_DC_Icmd( ) YES
Reset interrupt 2 watchdog timer. Keep Two AC cycle counter. Keep frequency test counter. bootSystem( ) Check FPGA fault register.
Do_data_logging( ) R matrix state = Manual I Cmd?
NO
checkForFaults( )
R_matrix_test( )
Verify boot source. Initialize all variables. Test memory, copy flash to RAM and execute from RAM. Clear faults. Initialize hardware.
Check limits, trigger software faults. Add fault to fault history log. Do state machine sanity check. NO Open J1 pin1-2.
YES
read_CCU_inputs_a2d( )
R matrix state = Matrix Test?
NO
Read all A2D converters inputs. YES
while(TRUE)
System faulted?
Mask DC bus undervoltage fault. Set system state = Faulted. Set system goal state = Idle.
Do_Rmatrix_DC_Icmd( ) line_volt_freq_calc( ) YES
Do serial communication. Alternate serial port #1 and #2. Check connector J2 inputs.
Check limits, trigger software faults.
Do Line signal transformation, filtering and calculations.
checkForFaults( ) matrixes_power_calc( )
L matrix state = Manual I Cmd?
NO
E-Stop is closed?
YES
Set system goal state = Ready.
YES
NO Set system goal state = Idle. L matrix state = Matrix Test? NO YES
R matrix state = Matrix Test? NO Set R Matrix goal state = Idle.
Do Left matrix side power calculation. Do Right matrix side power calculation.
L_matrix_test( )
YES
L matrix state = Matrix Test?
NO
Set L Matrix goal state = Idle.

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Fault Conditions
Chapter 7, Fault Conditions, provides a list of fault conditions which may appear on the GUI.
CW 2.5 MW Inverters Fault Conditions

Fault 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 0000 F000 Fault Title No Faults Download Software (H) or (S) or Both Fault Description No fault conditions are detected. 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. (S) (S) None None The current system state is not a legal state. Interrupt c_int02 (5700 Hz) did NOT occur before checkForFaults ( ) function was called 1000 times. Condition Before Checking
Triggered
0001 0002
State Machine Failure Interrupt Timeout
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Fault Conditions

Fault Number 0010 Fault Title External Disable Inductors Compartment High Temperature (H) or (S) or Both Fault Description (S) This fault is set by the user by shutting down the inverter from the GUI At least one of the matrixes is in Ready or Manual Current Command state. None CCU connector J2 pin 7-8 is not getting 15 Vdc. The Temperature switch is open. Condition Before Checking
Triggered
0015
(S)
0029
(S) Serial Communication Timeout In Programming (S) Mode
No message has been received from TCU (through a serial port U1001 & U1002) for more than 150 milliseconds. 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. The software wrote and read from static memory and the result of the reading did NOT agree with the data written to it. 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. 300 milliseconds have passed and there is no response from SEEPROM.
0040
None
0042
Bad Memory
(S)
During boot_sys ( ) function called only once during system power up.
None
0043
SEEPROM Write Error SEEPROM Timeout
(S)
None
0028
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Fault Number 0080 0120 Fault Title Left Ripple Current Line Frequency Low (H) or (S) or Both Fault Description (S) (S) Line voltage greater than (AC_LINE_R MS * SQRT2 * 0.5) Condition Before Checking
Triggered User settable, default 300A. Troubleshooting inspect the rectifier circuit. Line frequency has been less than 57 Hz for one second.
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.
0220 0130
Line Frequency High Line AC Voltage Too Low Line AC Voltage Too High
(S) (S)
0230
(S)
Ripple Currents also shows up None Line frequency has been greater than 63 Hz for one second. sometimes when the DC bus gets System passed The line voltage is less than 10% of Nominal AC for 5 sec. shorted. When the DC bus gets OR the Initialize The line voltage is less than 90% of Nominal AC for 5 sec. shorted, voltage state dips down, current System passed The line voltage is between +10% and +20% of Nominal AC goes up and it for 5 seconds. the Initialize essentially looks state. OR The line voltage is between +20% and +30% of Nominal AC like a big ripple is about to happen. for 500 milliseconds.
OR The line voltage is greater than +30% of Nominal AC volts instantaneous.
0155
Left Matrix State Machine Failure Left Matrix Control Failure to Turn Off
(S)
None
The current left matrix state is not a legal state.
0156
(S)
None
After disabling the left matrix, the software reads from the matrix controller that the matrix is NOT off.
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Fault Conditions

Fault Number 0256 Fault Title Left Matrix Control Failure to Turn On Left Matrix DC Bus Voltage Low (H) or (S) or Both Fault Description (S) Condition Before Checking None
Triggered After enabling the left matrix, the software reads from the matrix controller that the matrix is NOT on. Hardware (CCU) detects that the DC bus voltage is less than 848 volts DC. OR Software detects that the left matrix DC bus is less than Vdc_PRE_LOW (900) volts DC.
0157
(H/S)
Matrix is ON (for hardware check) AND Matrix state is NOT Matrix Test. OR Matrix state is NOT Idle. None
0257
Left Matrix DC Bus Voltage High
(H/S)
Hardware (CCU) detects that the left matrix DC bus voltage is more than 2014 volts DC. OR Software detects that the left matrix DC bus voltage is more than DCBUS_MAX_VOLT (1950) volts DC. The temperature read from the left matrix at CCU-J7 pins 4-5 is less than 49 F (45 C). The temperature read from the left matrix at CCU-J7 pins 4-5 is greater than 176 F (80 C).
0158
Left Matrix Temperature Sensor Error Left Matrix OverTemperature
(S)
None
0258
(H/S)
None
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Fault Number XX66 Fault Title Left Matrix Gate Drive Fault (H) or (S) or Both Fault Description (S) Condition Before Checking None
Triggered 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. Hardware (CCU) detects that the left matrix current phase A is greater than 1142 amps peak. (0877) AND, OR Hardware (CCU) detects that the left matrix current phase B is greater than 1142 amps peak. (1077) AND, OR Hardware (CCU) detects that the left matrix current phase C is greater than 1142 amps peak. (2077).
XX77
Left Matrix Overcurrent Fault
(H/S)
None
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Fault Number XX77 Fault Title Left Matrix Overcurrent Fault (H) or (S) or Both Fault Description (H/S) Condition Before Checking None
Triggered Software (CCU) detects that left matrix current phase A is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (0177) AND, OR Software (CCU) detects that left matrix current phase B is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (0277) AND, OR Software (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 Right Matrix State Machine Failure Right Matrix Control Failure to Turn Off
(S)
None
Software detects that the left matrix DC bus current is more than DCBUS_MAX_CURRENT (1000) amps DC. The current right matrix state is not a legal state.
01AA
(S)
None
01AB
(S)
None
After disabling the right matrix, the software reads from the matrix controller that the matrix is NOT off.
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Fault Number 02AB Fault Title Right Matrix Control Failure to Turn On Right Matrix DC Bus Voltage Low Right Matrix DC Bus Voltage Low Right Matrix Temperature Sensor Error Right Matrix Over Temperature (H) or (S) or Both Fault Description (S) Condition Before Checking None
Triggered After enabling the right matrix, the software reads from the matrix controller that the matrix is NOT on. Software detects that the right matrix DC bus is less than Vdc_PRE_LOW (900) volts DC.
01AC
(S)
Matrix is NOT in Idle or Matrix Test Mode. None
02AC
(S)
Software detects that the right matrix DC bus voltage is more than DCBUS_MAX_VOLT (1950) volts DC. The temperature read from the right matrix at CCU-J7 pins 67 is less than 49 F (45 C). The temperature read from the right matrix at CCU-J7 pins 67 is greater than 176 F (80 C).
01AD
(S)
None
02AD
(S)
None
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Fault Number XXBB Fault Title Right Matrix Gate Drive Fault (H) or (S) or Both Fault Description (H) Condition Before Checking None
Triggered 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. Hardware (CCU) detects that right matrix current phase A is greater than 1142 amps peak. (08CC) AND, OR Hardware (CCU) detects that right matrix current phase B is greater than 1142 amps peak. (10CC) AND, OR Hardware (CCU) detects that right matrix current phase C is greater than 1142 amps peak. (20CC).
XXCC
Right Matrix Overcurrent Fault
(H/S)
None
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Fault Conditions

Fault Number XXCC Fault Title Right Matrix Overcurrent Fault (H) or (S) or Both Fault Description (H/S) Condition Before Checking None
Triggered Software (CCU) detects that the right matrix current phase A is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (01CC) AND, OR Software (CCU) detects that the right matrix current phase B is greater than (RATED_CURRENT * 1.44) 835 amps RMS. (02CC) AND, OR Software (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 Right Ripple Current
(S)
None
Software detects that the right matrix DC bus current is more than DCBUS_MAX_CURRENT (1000) amps DC. User settable, default 300A. Troubleshooting inspect the rectifier circuit.
00DE
(S)
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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.
Troubleshooting
Before You Start Troubleshooting

In 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.

Never attempt to perform these procedures with the CW 2.5 MW Inverters operating.

Do not use a voltmeter with a voltage rating below 2500 volts when working on the DC bus related circuits.

The 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.

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 Inspection
Before 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.
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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 Conditions
Fault 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 37.
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 threephase 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 SW1 7. Using an ohmmeter, check the temperature sensor circuit for an open lead. Refer to the schematic diagram (see Figure B-2 on page B3). 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.
CAUTION
When removing and installing fiber optic connectors, pull off and push on with the connector only. Do not pull on the fiber cable.
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.
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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. OR Less 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 531.) 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 seconds Or Between +20% and +30% of nominal for 500 milliseconds Or Greater 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 531.) 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. Or CCU2 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, GUIFault History on page 531). 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.

The 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.
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. Or CCU2 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 531). 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.
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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 836.
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 835. 3. If the fan seems to be operating normally, check the temperature sensor per the procedure Matrix Temperature Sensors on page 836.
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 831. 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 831. 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 831. 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 38. 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:
Fault Code 0877 1077 2077 Phase Phase A Phase B Phase C
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 830. 3. Verify proper operation of the current transformers CT22 and CT23. Refer to the procedure Current Transducers on page 824. 4. Verify proper operation of the high voltage driver board as described High Voltage Driver Board on page 831. 5. Replace the CCU2 circuit board.
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Troubleshooting
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 830. 3. Verify proper operation of the current transformer CT21. Refer to the procedure described in Current Transducers on page 824. 4. Verify proper operation of the high voltage driver board as described in High Voltage Driver Board on page 831. 5. Replace the CCU2 circuit board.
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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 531). 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 531.) 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.
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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 836.
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 835. 3. If the fan seems to be operating normally, check the temperature sensor per the procedure described in Matrix Temperature Sensors on page 836.
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. Table 8-1 Device Detecting the Right Matrix Gate Driver Fault
Fault Code 01BB 02BB 04BB 08BB 10BB 20BB Device Detecting the Fault Phase A+ Phase A Phase B+ Phase B Phase C+ Phase C
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.
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Troubleshooting
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 831. 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 831. 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 831. 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 38. 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:
Fault Code 08CC 10CC 20CC Phase Phase A Phase B Phase C
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 830. 3. Verify proper operation of the current transformers CT12 and CT13. Refer to the procedure described in Current Transducers on page 824. 4. Verify proper operation of the high voltage driver board as described in High Voltage Driver Board on page 831. 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 830. 3. Verify proper operation of the current transformer CT11. Refer to the procedure described in Current Transducers on page 824. 4. Verify proper operation of the high voltage driver board as described in High Voltage Driver Board on page 831. 5. Replace the CCU2 circuit board.
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Troubleshooting
230/120/22 Vac Control Power

In 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.

Never attempt to perform these procedures with the inverter running. Make certain the generators are locked and cannot turn.


The 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.
The following sections describe how to check the various control voltages within the inverter enclosure.
690 Vac Utility Voltage CAUTION

Use a voltmeter with an AC volts rating of at least 1000 Vac.
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 116.) 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.
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230/120/22 Vac Control Power
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 19, Left Main Panel Assembly on page 111. 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.

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.

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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Troubleshooting
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 Supplies

There 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
4. Connect the negative lead of the DVM to an AGND terminal (Analog Ground) on the CCU2 board.
CAUTION
Take care to not short any components on the CCU2 circuit board with the test leads.
5. Check the voltages.

Test Point +15 V DRV Reading +14.5 to 15.5 Vdc
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 831 for troubleshooting information. 6. If the voltage is OK, proceed with checking the other onboard power supplies.
Test Point (+)5 Vdc (+)15 Vdc (-)15 Vdc Reading +4.5 to 5.5 Vdc +14.5 to 15.5 Vdc 14.5 to 15.5 Vdc
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.
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Troubleshooting
Contactor Control Circuit

There are two contactors in the inverter enclosure: K21 for the left side inverter K11 for the right side inverter
The 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 104.
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Space Heaters
Space Heaters
The 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 Fans
The 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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Troubleshooting
Current Transducers
There 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 B4 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.

Be careful not to short any components on the CCU2 circuit board with the test leads.
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 burden resistor. Transducers CT11 and 21 have a 30.1 burden resistor. These resistors can be measured in circuit (without disconnecting any wires). 9. Measure with respect to CCU2 (AGND) terminal.
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Filter Capacitor
Filter Capacitor
If 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.
CAUTION: Wire damage

When 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.
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.
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.
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.
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Troubleshooting
Matrix
Figure 8-1 Power Electronic Converter 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.
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Matrix
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 boards 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 matrixs 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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Troubleshooting
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 boards P1 connector. b) If some of the green LEDs are on and some are Off, replace the high voltage 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.
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Matrix Test
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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Troubleshooting
IGBT Checks
Basic 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.

Remove all power. Make certain the generators are stopped and cannot rotate. Wait 30 minutes for the bus voltage to discharge.
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 M 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 M or higher. 3. A reading of less than 1 M 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.
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High Voltage Driver Board
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 830.

The 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.
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 828. b) If all 6 green LEDs are not On or if any of the yellow LEDs are On, continue 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 820.
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Troubleshooting
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 9 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 834.
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Matrix Damage
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 1012. 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 828.
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Troubleshooting
Fiber Optic Cables

Remove all power. Make certain the generators are stopped and cannot rotate. Wait 30 minutes for the bus voltage to discharge.
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.

Do not pull on the fiber optic cable.
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.
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Matrix Fans
Matrix Fans
This 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 circuits 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.
WARNING: Personal injuryrotating fan blade

Do not attempt to check fan voltage at the motor with the fan operating.
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.
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Troubleshooting
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 k. a) If the measurement shows a resistance less than 2.5 k 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 k, 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 sensors connector: P2, Pins 2 to 4. At an ambient temperature of 68 F (20 C), the resistance should be around 2 k. The resistance of the sensor increases with the temperature.
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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 92 Removing All Power and High Voltage on page 92 Upper Compartments on page 92 Lower Compartments on page 93 Cable Glands on page 93 Ground/Power Terminations on page 93 Electrical Connections on page 93 Heatsinks and Fans on page 93 Gate Drive Fiber Optic Cables on page 93
Maintenance
Equipment Required
The following equipment is required to perform maintenance: Small slotted screwdriver Ratchet handle Socket set Wrench set Hex wrench set Ohmmeter

Remove 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.

Removing All Power and High Voltage

To 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 Compartments
Visually 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.
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Lower Compartments
Lower Compartments
Remove 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 Glands
Visually 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 Terminations
Verify 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 Connections
Visually 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 Fans

Visually 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 Cables

Verify 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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10
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 102 Before You Start Replacing Components on page 103 Replacing the CCU2 Board on page 104 Replacing the Current Transducer (CT) Modules on page 106 Replacing the Line Contactors on page 108 Replacing the Solid State Relays (SSR) on page 109 Replacing the Control Transformer on page 1010 Replacing the Matrix Fan Assembly on page 1011 Replacing the Matrix Assembly on page 1012 Replacing the Matrix Sub-Assemblies on page 1019 Replacing the Inductor on page 1020 Replacing the Fuses on page 1023 Replacing the Internal Fans on page 1024 Replacing the Lower Magnetics Compartment Fans on page 1025 Replacing the Wiring Harness on page 1026
Equipment Required
The 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

Before beginning any component replacement procedures, turn off power. See Removing All Power and High Voltage on page 92. 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.

Allow 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
Before You Start Replacing Components

In 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.

Never attempt to perform these procedures with the inverter running.

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.

Review the system schematic for the installation to verify that all available energy sources are de-energized. See Appendix B, Drawings on page B1.
Identifying Components for Replacement

All 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 B7. 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 B8.
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Replacing the CCU2 Board

If 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 B7 to locate the CCU2 board (Item # 1). Then refer to Table B-1 on page B8 to for detailed information on the component.
CAUTION: CCU2 Compatability Check

There 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.
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 92.

Grasp 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.
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.
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.
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.
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Replacing the CCU2 Board
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.

Grasp 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.
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.
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Replacing the Current Transducer (CT) Modules

To replace the current transducer modules, see Figure B-6 on page B7 to locate the current transducer CT module (Item 2). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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
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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Replacing the Line Contactors

To replace the line contactor, see Figure B-6 on page B7 to locate the two line contactors, K11 and K21 (Item # 3). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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)
Replacing the Solid State Relays (SSR)

To replace the solid state relay components, see Figure B-6 on page B7 to locate the solid state relays (Items # 4 and #5). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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 Transformer

To replace the control transformer, see Figure B-6 on page B7 to locate the transformer (Item # 6). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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
Replacing the Matrix Fan Assembly

To replace a matrix fan assembly, see Figure B-6 on page B7 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 B8 for detailed information on the component.

Verify that the 690 Vac power is off and that the DC bus voltage is fully discharged. Make sure that the turbine generators cannot rotate.
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 92. 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.
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Replacing the Matrix Assembly

There 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.
Fan Motor Fan Venturi Fan Housing Heatsink Maxtrix Cover Insulated Gate Bi-Polar Transistors (IGBTs) Laminated Bus DC Filter Capacitors High Voltage Driver Board Power
Figure 10-2 Power Electronics Matrix - Left Side

Verify 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 injury

The 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.
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To replace a matrix assembly, see Figure B-6 on page B7 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 B8 for detailed information on the component.
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.
Additional Equipment Required

In addition to the Equipment Required on page 102, 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)
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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 92. 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 1011.) 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.
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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 1011. 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 38. b) Then with generators operating. See Matrix Test, Generators Operating on page 39. 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.
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Replacing the Heatsink Assembly

There 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 1012.
FAN MOTOR
FAN VENTURI
FAN HOUSING
HEATSINK MATRIX COVER LAMINATED POWER BUS INSULATED GATE BI-POLAR TRANSISTORS (IGBT)
DC FILTER CAPACITORS
HIGH VOLTAGE DRIVER BOARD
Figure 10-3 Heatsink Assembly

In addition to the Equipment Required on page 102, the following equipment is required to complete this procedure: 3/16 inch Allen wrench suitable for use with socket set
WARNING: Personal injury

Removal and replacement of a heatsink assembly requires two personsone working at the front and one working at the rear of the inverter enclosure.

Verify 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.
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Replacing the Heatsink Assembly
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 92. 3. At the top of the enclosure, remove the matrix fan assembly, with housing. (See Replacing the Matrix Fan Assembly on page 1011.) 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 1019. 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.
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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 1019.) 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 38, first with generators idle, then with generators operating. See Matrix Test, Generators Operating on page 39. 12. Operate the inverter under TCU control and check for proper inverter operation. Check operation of the matrix fan.
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Replacing the Matrix Sub-Assemblies
Replacing the Matrix Sub-Assemblies

Removing the High Voltage Driver Board CAUTION: Wire damage
Grasp 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.
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 92. 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 dont 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 38.
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1019
Replacing the Inductor

To replace an inductor, see Figure B-6 on page B7 to locate the left and/or right inductor (Item #13). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 for detailed information on the component.

In addition to Equipment Required on page 102, additional equipment may be required to complete this replacement procedure: Portable chain hoist or equivalent Chain

Verify 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 injury

The inductors weigh more than 1300 lbs. Exercise caution during this procedure to avoid personal injury.
Removing an Inductor
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 #00010144 have inductors with copper windings installed. Units with serial numbers ranging from #0145onward have inductors with aluminum winding installed. The aluminum inductor is much smaller than the copper inductor. All replacements will be the aluminum inductor type.
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 92. 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.
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Replacing the Inductor
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 WARNING: Personal injury

The inductors weigh more than 1300 lbs. Exercise caution during this procedure to avoid personal injury.
Units with serial numbers ranging from #00010144 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 shrouds 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.

When installing the cables onto the inductor, be careful not to bend or deform the inductor terminals.
5. Apply the anti-corrosion compound to the inductor mounting tabs. See Figure 10-4 and follow the three steps described.
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1021
Step 1: Apply a thin layer of anti-corrosion compound to the top surface of the inductor mounting tab.
Cable Cut-away Inductor Cut-away Inductor Mounting Tab
Step 2: Apply a thin layer of anti-corrosion compound to the bottom surface of the inductor mounting tab. Step 3: Clean out excess anti-corrosion compound from the mounting hole to prevent the compound from transferring to threads of the bolt.
Cable Cut-away
Figure 10-4 Hardware Stack Up and Application of Anti-Corrosion Compound at Aluminum Inductors 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 B1. 8. Install the thermal switches in the protective tubes in the inductor core. 9. If installing a replacement inductor in units #00010144, secure a tie wrap 5 inches above the sensors to prevent the sensor from sliding down the protective tube beyond its designed location.
Important: The replacement inductor should have the protective tubes already
installed. If not, contact Xantrex for further instructions. See Contact Information on page ii.
10. Replace the enclosure cover plate.
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Replacing the Fuses
Replacing the Fuses

To remove and replace the fuses, see Figure B-6 on page B7 to locate the correct fuse (Items #12, 15 or 17). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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 . 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.
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Replacing the Internal Fans

To replace an internal fan, see Figure B-6 on page B7 to locate the left and/or right internal fan (Item #19). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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.
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Replacing the Lower Magnetics Compartment Fans
Replacing the Lower Magnetics Compartment Fans

To replace a lower magnetics compartment fan, see Figure B-6 on page B7 to locate the left and/or right fan (Item #19). Then refer to Table B-1, Assembly Description for Component Replacement on page B8 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 92. 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.
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Replacing the Wiring Harness

Before 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 92. 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.
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Specifications
Appendix A, Specifications, provides the electrical and environmental specifications for the CW 2.5 MW Inverters.
Specifications
Electrical Specifications
Rated Power, Continuous at 50 C Ambient Inverter DC input Voltage Maximum Transient DC Voltage Inverter Pre-Charge Method Nominal AC Voltage and Frequency Operational AC Voltage Tolerance Operational AC Frequency Tolerance Efficiency, DC Input to AC Output Power Quality Inverter Switching Frequency Inverter AC Current Rating (Each Inverter) Individual Inverter Power Factor Individual Inverter Protective Functions 4 650 kW Inverter 900 to 1400 Vdc 2014 Vdc Inverter Pre-Charge via Generator Operation 690 Vac, 60 Hz 690 10% Continuous 60 Hz 3 Hz 97%, Minimum at Rated Power IEEE 519, PCC is 2.5 MW 690 V Transformer Connection 1.6 kHz 650 kW 0.95 Lead or Lag Power Transistor De-Sat Detection Adjustable Current Limit (Software) Utility Fuse Protection Over-Current Protection Over-Voltage Protection Matrix Over-temperature Protection Fiber-optic Link, Bi-Directional White Polyester Urethane Powder Coat Fan Cooled - Main Inverter heatsink to dissipate heat outside enclosure. 30 years 98 dB Max., ISO 9614 A-Weighted Scale 90 dB Max., Single Pronounced Tone
Power Transistor Gate Drive Interface Finish Cooling Design Life Audible Noise
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Environmental Specifications
Environmental Specifications
Operating Temperature Range Non-Operating Temperature Range Altitude Relative Humidity 40 C to 50 C 40 C to 50 C 0 to 2000 meters above sea level 0 to 100% condensing
Physical Specifications
Inverter Enclosure Width Height Depth (front to back) Weight 80 inches 113 inches 30 inches 6500 lb
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A3
Specifications
CW 2.5 MW Inverter Enclosure Dimensions

80" 30" 0.75 Clearance Hole Quantity 4
26"
113"
76" VIEW A-A
Note: All dimensions are in inches.
Figure A-1 CW 2.5 MW Inverter Enclosure Dimensions
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Drawings
Appendix B, Drawings, provides detailed information on the system schematics of the CW 2.5 MW Inverters.
Drawings
Schematic Diagram of Main Power Distribution
Figure B-1 Schematic Diagram of Main Power Distribution

B2 152874
Schematic Diagram of Control Power Distribution
Schematic Diagram of Control Power Distribution
Figure B-2 Schematic Diagram of Control Power Distribution

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Drawings
Schematic Diagram of CCU2 Circuit Board
Figure B-3 Schematic Diagram of CCU2 Circuit Board
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Left Side Component Designators
Left Side Component Designators

6
3RD ANGLE PROJECTION
3
CC
2
REVISIONS
REV A DESCRIPTION ECO 5197 AUT GB DATE 02-28-06
1
CHK'D BILL FOSTER ENG DOUG BLODGETT MFG BRAD SMITH QA MICHAEL SARGENT
LEFT SIDE
D
CT21 TB21 (+DC CABLE CONNECTION)
(-DC CABLE CONNECTION) TB22

1
TORQUE CHART VALUE DESIGNATOR 50 FT LBS TB21 TB22 50 FT LBS
TB25
6
C B22 A CT23 C CT22

C
K21-AUX 5L3 3L2 1L1 K21-AUX 1 10 6T3
C SH21 B A R13 RTB21

1 8
B A
K21
4T2 2T1
(HOT!)
CW-BUP
R12
T1-TB
DB1
DB3
CONTROLLED BY THERMOSTAT
T1
F54,55,56,57,59,60
L21
TB23 A B C
C (CONNECT 3 POWER)
TORQUE CHART DESIGNATOR VALUE TB23 50 FT LBS TB10 50 FT LBS
2
A
(LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS) TB10-GND (ALL GROUNDING CONNECTIONS)
FUSE CHART VALUE DESIGNATOR F54 15A, 600V F55 15A, 600V 15A, 600V F56 F57 10A, 500V 10A, 500V F59 F60 10A, 500V
COPYRIGHT 2004 XANTREX TECHNOLOGY INC.. THIS DOCUMENT IS THE PROPERTY OF XANTREX TECHNOLOGY INC., AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT, WITHOUT THE EXPRESS WRITTEN PERMISSION OF: XANTREX TECHNOLOGY INC.
CONFIDENTIAL INFORMATION OF XANTREX TECHNOLOGY INC.
TOLERANCES: (UNLESS OTHERWISE SHOWN)

TITLE:
X.XX .02
X.XXX .010
ANGLES 1.0
TM
COMPONENT DESIGNATORS, LEFT, CW2.5 MW

DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN
AUT
G. BELTRAN
DES
02-28-06
SCALE:
SIZE
DWG No.
NTS
152891
SHT
A
OF
REV.
Figure B-4 Left Side Component Designators

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Drawings
Right Side Compartment Designators

6
3RD ANGLE PROJECTION
2
REVISIONS
CC REV A B C DESCRIPTION ECO 5197 ECO 6260 ECO 6991 AUT GB GB G. BELTRAN DATE 02-28-06 09-07-07 01-30-09
1
REG BILL FOSTER BILL FOSTER N/A ENG DOUG BLODGETT ANTONIO MANTILLA CHARLES STAUFFER MFG BRAD SMITH VAL ARTMAN VAL ARTMAN MFG MICHAEL SARGENT N/A EMMANUEL BOSOMPRA
RIGHT SIDE
D
TB11
CT11
TORQUE CHART DESIGNATOR VALUE TB11 50 FT LBS TB12 50 FT LBS
(+DC CABLE CONNECTION)
(-DC CABLE CONNECTION) TB12

1
TB15
6
CT13 C
A
C
K11-AUX 2T1 4T2 6T3 K11-AUX 1L1
A B C SH11 B12
C
B C
K11
3L2 5L3
CT12 A
1 R14 SSR11 SSR12 SSR21
TB5
10
C2
C11 C12 1 C21 1
TB14
6
(HOT!)
F11,12,13
LVRT CCU2
B
DB2 RTB11
SW1
TS11 CONTROLLED BY THERMOSTAT
F51,52,53
B
L11 PFC11 TB13 A B C
DESIGNATOR TB13
VALUE 50 FT LBS
(CONNECT 3
POWER)
(LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS)

2 1 4 3 6 5
FUSE CHART DESIGNATOR VALUE F11 63A, 690V F12 63A, 690V F13 63A, 690V F51 10A, 690V F52 10A, 690V F53 10A, 690V
COPYRIGHT 2004 XANTREX TECHNOLOGY INC.. THIS DOCUMENT IS THE PROPERTY OF XANTREX TECHNOLOGY INC., AND SHALL NOT BE REPRODUCED, COPIED, OR USED AS THE BASIS FOR THE MANUFACTURE OR SALE OF EQUIPMENT, WITHOUT THE EXPRESS WRITTEN PERMISSION OF: XANTREX TECHNOLOGY INC.
CONFIDENTIAL INFORMATION OF XANTREX TECHNOLOGY INC.
(GROUND TO TB10-GND)
TOLERANCES: (UNLESS OTHERWISE SHOWN)

TITLE:
X.XX .02
X.XXX .010
ANGLES 1.0
TM
COMPONENT DESIGNATORS, RIGHT, CW2.5 MW

DIMENSIONS ARE IN INCHES UNLESS OTHERWISE SHOWN
AUT
G. BELTRAN
DES
02-28-06
SCALE:
SIZE
DWG No.
NTS
152892
SHT
C
OF
REV.
Figure B-5 Right Side Component Designators

B6 152874
Component Replacement Model
Component Replacement Model

2 2 CT21 2 CT11
CT13
19
B12 2 9
10
F11-13
2 CT23 CT22
11 12 3X
1 19
B22 CW-BUP
CT12
PFC11 CCU2 B23-25 3 22 B13-15
21 K21
3 L21 T1 20 L11
6 6X 16 3X 17 3X 18 3X 19 13 13 19 3X
SSR11,12,21
F51-53 14 2X 4 5 15 3X
Figure B-6 Clipper 2.5 MW Inverter Component Replacement Model

152874 B7
Component Replacement List for CW 2.5 MW Inverters
Component Replacement List for CW 2.5 MW Inverters

Table B-1 provides a detailed list of the components which are identified in Figure B-6 on page B7.
Item Quantity Reference Designator Xantrex Part No. Description
1 2
1 6
3 4 5 6 7 8 9 10 11 12 13 14 15 16
2 2 1 1 1 1 1 1 1 3 2 1 3 6
CCU2 110-0821-01-02 PCB Assembly, LVRT CCU2 board, tested CT11, 12, 13, 21, 22, 1-151988-02 Current transducer, 1000 A Hall Effect, 100 A/s DC to 150 kHz 23 bandwidth, 3 kVac PCB mount; Operating temperature range: 10 to +85 C K11, 21 1-151786-01 Contactor, 3 Pole, 750 A, 120 Vac SSR 11, 21 1-151495-01 Solid state relay, 12 A, 200 Vdc, UL Rated SSR 12 1-112129-01 Solid state relay, 10 A, 240 Vac, Crydom D2410 T1 1-152861-01 Transformer, 4.5 kVA,1 Pole, 690 V/115230 V, 22 V, 50/60 Hz N/A 1-152916-01 Left matrix fan assembly N/A 1-152915-01 Right matrix fan assembly N/A 1-152767-01 Left matrix assembly, 1200 A, 2500 V N/A 1-152767-02 Right matrix assembly, 1200 A, 2500 V F11, 12, 13 054-2005-02 Modular fuseholder, 600 Vac, 100 A, 22 mm (D) 58 mm Fuse DIN rail mount, UL/CSA/IEC F11, 12,13 054-0030-02 Fuse, 63A, 690 Vac 22D x 58mm, 2s@500A 0.2s@800A 4.7W-LOSS 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 A F51, 52, 53 054-2005-01 Modular fuseholder, 40 A, 600 Vac, 14 mm (D) 51mm Fuse DIN rail mount, UL/CSA/IEC F51, 52, 53 054-0028-01 Fuse, 10 A, 690 Vac, 14 mm (D) 51mm, 2s@40 A 0.1s@80 A, 1.5W-Loss F54, 55, 56, 57, 59, 1-151523-01 Fuseholder, 1 Pole, TCHSAF, Class CC 60
Table B-1 Assembly Description for Component Replacement
152874
B8
Component Replacement List for CW 2.5 MW Inverters Item Quantity Reference Designator Xantrex Part No. Description
17 18 19 20 21
3 3 8 1 1
F54, 55, 56 F57, 59, 60 B12, 13, 14, 15, 22, 23, 24, 25 C2 PFC11
1-150772-09 1-150772-08 1-151024-01 1-112340-01 015-0050-04
Fuse, 15 A, 600 Vac, FNQ-R-15 Control fuse, 10 A, 500 Vac Fan, 225SQX80,115 V Cap, Elect, 3300 F, 450 Vdc Cap FLM, 3 24.9 F, 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 CW, Backup power board, 24 V, output
22
C2W-BUP
1-152863-01
Table B-1 Assembly Description for Component Replacement
152874
B9
B10
Glossary
Appendix C, Glossary, provides a list of acronyms used in this Manual.
Glossary
Acronyms
Acronym CB CCU CT DSP DVM EMI EEPROM GUI IGBT LVRT MW PC PF PLC PWM RFI RTD SEEPROM SSR TCU Definition Circuit Breaker Converter Control Unit Current Transformer Digital Signal Processing Digital Volt Meter Electro-Magnetic Interference Erasable Programmable Read-Only Memory Graphical User Interface Insulated Gate Bipolar Transistors Low-voltage Ride-through Mega watt Personal Computer Power Factor Programmable Logic Controller Pulse Width Modulated Radio Frequency Interference Resistance Temperature Detector Serial EPROM Solid State Relay Turbine Control Unit
C2
152874
Index
A
AC and ground cable entry, illustrated 211 AC connections left 211 right 211 AC phases, troubleshooting 827 receiver 827 fiber optic connector, gray transmitter 827 fuses, replacing 1023
G
ground bus connections hole diameter and quantity 211 illustrated 211 grounding 34
C
CCU2 circuit board connecting to TCU 215 downloading software 37 resetting out of download mode 521 circuit breaker locking out vii safety warning v clear fault button, illustrated 510 commissioning defined 31 General Procedures window 59 CommPort Menu functions 56 illustrated 56 CW 2.5 MW Inverters orientation of 14
I
inductor, replacing 1020 inverter enclosure mounting holes 25 storage of 22 inverter switching frequency 16
K
key location 25
L
left AC connection, hole diameter 211 line contactor, replacing 108 line-side fiber optic connections 104 lockout and tag vii, 82
D
DC cable components, hole diameter and quantity 210 DC cable connections, illustrated 210 DC cable entry covers 29 DC connection, negative illustrated 29 DC connection, positive illustrated 29 DC generator cables, connecting 29
M
matrix assembly, replacing 1019 matrix fan assembly storage of 22 weight of 26
E
E-Stop push button 214
O
outer matrix edge mounting bolts 26
F
fan shroud extension, to install 1021 fan shroud, when to modify 1021 faults, explanations 83 fiber optic connector, blue
P
personal safety vi
Q
quick disconnect terminals, illustrated 28 IX-1
152874
Index
S
safety features 13 personal vi serial number location 1020 short circuit, troubleshooting 827 shutdown button, illustrated 510 software, downloading rate 521 solid state relays, replacing 109
T
TCU, described 215 transformer, replacing 1010 turbine control unit function of 12
W
wiring harness, replacing 1026
X
Xantrex web site iv
152874
IX2
Xantrex Technology Inc.

1 800 670 0707 Tel toll free North America 1 360 925 5097 Tel direct 1 360 925 5143 Fax direct customerservice@xantrex.com www.xantrex.com
152874
Printed in USA

Xantrex 1.3 MW Power Inverter Manual

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Installation, Operation & Maintenance Manual

CW 2.5 MW Wind Turbine Generator Power Conversion System

CW 2.5 MW Wind Turbine Generator Power Conversion System

About Schneider Electric

Exclusion for Documentation

Date and Revision

Document Part Number

Product Part Number 1-152859-01 Contact Information

About This Manual

About This Manual

Important Safety Instructions

WARNING: High voltage

WARNING: Lethal voltage

WARNING: Shock hazard

WARNING: Shock hazard

WARNING: High voltage

WARNING: Shock hazard

WARNING: Limitations on use

WARNING: Shock hazard

Before Servicing the CW 2.5 MW Inverters

Taking Measurements Safely

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

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

1 3 5 Upper Left Compartment 7 9

2 4 6 Upper Right Compartment 8

Lower Left Compartment

Lower Right Compartment

Power Electronics Matrixes

Figure 1-4 Power Electronics MatrixLeft Side

Table 1-2 describes the components in the compartments.

Upper Left Compartment 1 3 5 7 Lower Left Compartment 9 11

Upper Right Compartment 2 4 6 8 Lower Right Compartment 10 14 12 15

Upper Left Compartment

Left Panel and Left Rear Current Transducers (CTs) Panels

Figure 1-6 Current Transducers (CT) Panel

CT21 (+DC CABLE CONNECTION) TB21

(DC CABLE CONNECTION) TB22

Figure 1-7 Left Rear Panel

Left Internal Fan Panel

SH21 (HOT!) CW-BUP

Figure 1-8 Left Internal Fan Panel

Left Main Panel Assembly

5L3 3L2 1L1 K21-AUX 10

C B A R13 RTB21 DB3

Upper Right Compartment

LVRT CCU2 Circuit Board Panel and Rear CT Panel

Figure 1-10 CCU2 Circuit Board Panel and CT Panel

CT11 +DC CABLE CONNECTION TB11

DC CABLE CONNECTION TB12

Figure 1-11 Right Rear Panel

Right Internal Fan Panel

Right Main Panel Assembly

Lower Left Magnetics Compartment

Figure 1-15 Left AC Connection Ground Bus

Lower Right Magnetics Compartment

LUGS CAN BE BOLTED TO FRONT & BACK OF BUS BARS

Figure 1-17 Right AC Connection

Unpacking the Inverter Enclosure

WARNING: Physical injury

CAUTION: Equipment damage

Moving InstructionsLifting Straps

Moving InstructionsLifting Straps

CAUTION: Equipment damage

Recommended locations for lifting straps