NWL PowerPlus 7.5 Series Troubleshooting Manual For Customer Use Download | Manualshive

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PowerPlus Series 7.5

Troubleshooting Guide

For Customer Use

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Summary of Contents for PowerPlus 7.5 Series

Page 1: ...PowerPlus Series 7 5 Troubleshooting Guide For Customer Use ...

Page 2: ...ries 7 5 PowerPlus Units 20 Setup Instructions using a separate external 120 VAC power source 20 Setup Instructions using the existing incoming 3 phase power source 20 Verifying the gate pulses on the DSP Control Module 21 Verifying the gate pulse signals to the IGBT s for the 28 70 kW units 22 Verifying the gate pulse signals to the IGBT s for the 84 120 kW units 26 Verification of the Gate Signa...

Page 3: ...larm messages that can appear along with their possible cause and solution Undervoltage Occurs when the kVDC is at or below a set value for a user determined period of time indicating a short circuit or high spark rates in the precipitator The undervoltage trip level is adjustable Cause Short circuit or close clearances in the precipitator causing it to spark at low kV levels Solution Perform an o...

Page 4: ...ted properly Solution Recalibrate following instructions in the Calibration section Output Overcurrent Activated if the mADC exceeds its rating by 25 This is a fixed setpoint It can be caused by either the failure to sense a spark arc or incorrect calibration Cause Failure to sense a spark arc Solution Make sure the spark arc sensitivities are properly set Adjust as necessary using an oscilloscope...

Page 5: ...owing Verify the oil circulator internal to the tank is operational Verify that system is properly calibrated and ratings are not being exceeded Enclosure Over Temp activates if the control enclosure temperature exceeds 65C 150F This is a display only alarm and will not trip the unit The Max Duty Cycle will be limited to 80 and the Temperature Limit icon will appear Cause Increase in ambient tempe...

Page 6: ...cond alarm occurs within 5 minutes the unit will trip and stay off until the alarm is manually cleared Cause Incoming line voltage outside of the specified range Solution Change the tap at the power distribution transformer to bring the line voltage within specification Cause Loss of one of the incoming three phase lines Solution Correct the phase loss problem Low DC Bus Voltage Activated if the D...

Page 7: ...ed If not replace motor If it can be re energized determine cause of overheating Main Contactor Fault Activated if the main contactor fails to energize based on the status of the auxiliary contact Since this alarm may have been caused by a low incoming line voltage the PowerPlus will continue to monitor the line voltage for an additional 10 seconds after it trips If the line voltage returns to wit...

Page 8: ...tions or replace contactor or control board if required Gate High Temp Activates if the gate driver chip on the dual gate driver board exceeds 70 o C This trip is wired into the Auxiliary Alarm 1 circuit and is only on the Series 05 and later PowerPlus units This alarm is not applicable to the Series 7 5 units It is only used on Series 5 through Series 7 models Cause Gate driver board fan is not e...

Page 9: ...ary Alarm Activated instantly if any of the customer supplied auxiliary alarm circuit are activated Cause One of the customer supplied auxiliary alarm circuits was activated Solution Check the specific auxiliary alarm circuit and correct the condition Cause Incorrect input to alarm circuit Solution Check the wiring to the auxiliary input and verify that the proper signal is being applied to the in...

Page 10: ...sonant kVdc mAdc SPM Duty Cycle High Input Line H LDC H HDC N HDC N N Low Input Line L HDC L LDC N LDC N N 1 Blown Fuse N HDC or 0 L LDC LDC LDC LDC N 2 or 3 Blown Fuses N L or 0 0 0 0 0 0 100 IGBTs not firing 2 N L or 0 N 0 0 0 0 100 1 IGBT not firing N LDC N LDC LDC LDC LDC N HV tank short N L N H L L 0 100 ESP short or reduced clearance N L N L L L to N 0 to N L to N Codes N Normal L Lower than...

Page 11: ...ct the HV bus from the HV bushing of the Power Plus unit at a point between the HV bushing and the second ground KEEP THE SECOND GROUND CONNECTED TO THE BUS THUS GROUNDING THE PRECIPITATOR SECTION FAILURE TO DO THIS WILL EXPOSE TEST PERSONNEL TO POTENTIALLY LETHAL VOLTAGES There must be at least 8 9 inches of clearance between the HV bushing of the Power Plus unit and the disconnected HV bus to in...

Page 12: ...paired if it failed this test Open circuit test is complete 1 Turn the HV off 2 Lock the Power Plus circuit breaker in the OFF position 3 Use the interlock key to lock the HV Ground Switch in the Ground position 4 Entering through the access port reconnect the HV buss bar to the HV bushing of the PowerPlus unit 5 Remove the ground jumper that was installed on the HV bus bar 6 Cover the HV access p...

Page 13: ...r interlock 8 Unlock the breaker and place it in the ON position 9 At the display panel set the UV trip setting located in the Setpoint menu to 0kV thereby defeating the UV alarm 10 At the display panel set the Mode of control to Manual Mode 11 Go to the METER screen 12 Turn on HV 13 While monitoring the secondary indications slowly increase the duty cycle in increments of approximately 5 The seco...

Page 14: ...the IGBT Modules Use a multimeter to check the resistance across the IGBT connections A label on the side of each IGBT identifies the electrical connections The emitter collector junction should read either open or in the megohms There is a diode mounted in reverse bias to each emitter collector junction so swap your test leads to test in both polarities This junction should also pass a 500V megge...

Page 15: ...e AC resonant capacitors will take various forms depending upon the kW size of the unit On the Series 7 5 models they are a tapped capacitor and may be mounted either in the control enclosure or in the HV tank The quantity of capacitors connected in parallel and the tap configuration is dependent upon the size of the PowerPlus The total capacitance is given in the table below Total PowerPlus Size ...

Page 16: ...from X1 to chassis ground and X2 to chassis ground should show infinite resistance Replacing the IGBT s Once it has been determined that an IGBT is shorted it will need to be replaced The method for replacement of an IGBT will differ somewhat based on the kW rating and the physical layout of the unit On PowerPlus units larger than 70 kW the heat exchanger fan shrouding and protective plexiglass sh...

Page 17: ...Page 15 On units smaller than 70k there is no shrouding The layout of the heatsink will vary based on the kW rating of the unit However the method for the IGBT removal will remain the same ...

Page 18: ...arge white power output wires from the IGBT s being replaced 2 Move the wires out of the way to allow better access to the heatsink components 3 Remove the two bolts connecting the DC bus caps to the input side of the IGBT s ...

Page 19: ...ables is identified or recorded Their exact location is critical to the operation of the unit It is recommended to label each connector in such a manner that you feel confident that it will be re plugged into the proper location at the end of the replacement process 5 Disconnect the green ground wire ...

Page 20: ...ved and discarded The heat sink should then be wiped clean removing any thick build up areas of thermal compound material that may have been left on the heat sink Installation of the IGBT modules is performed in the reverse order 9 Install a new Thermal pad onto the bottom of the new IGBT module The thermal pads have a protective cover on both sides Remove the protective cover from one side and pl...

Page 21: ...ction to the DC bus capacitor assembly 11 Secure the IGBT to the heat sink by re installing the four hex head mounting bolts 12 Re install the green ground wire 13 Reinstall the gate cables into their original locations 14 Reinstall the two bolts that connect the IGBT module to the DC bus capacitor assembly 15 Re install the output bus and the large white power cables to the IGBT module The proces...

Page 22: ... to the ground side of the control transformer thereby causing a short circuit NOTE If the source for the external 120 VAC is from a circuit with GFCI the circuit may trip off This condition will require the alternate configuration using the existing 3 phase power input as described below 4 Set SW3 1 located on the DSP control board in the ON position SW3 1 is the leftmost dip switch on SW3 The sw...

Page 23: ...TP24 Ground 6 Position the cursor on Duty Cycle in the Mode screen 7 Press the ON button on the display and ramp up the duty cycle to 100 8 Verify the pulses displayed on the oscilloscope are as shown in Fig 1A 10 and 1B 100 9 Press the Off button on the display 10 Repeat Steps 4 through 9 with the scope probe connected to TP18 on the I O board of the control module 11 Press the Off button on the ...

Page 24: ...ith each other as shown in Fig 4 5 Press the Off button on the display 6 Change channel 2 scope probe to position B Energize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be out of phase with each other as shown in Fig 5 7 Press the Off button on the display 8 Change channel 2 scope probe to position D Energize unit and ramp up to 100 duty cycle The pulses as observ...

Page 25: ...Page 23 Fig 2 ...

Page 26: ...Page 24 Fig 3 Connect probe to D1 diode as shown for IGBT A D Connect clip to ground screw Connect probe to D4 diode as shown for IGBT B C ...

Page 27: ...Page 25 Fig 4 Pulses at IGBT probe connections at A C Duty Cycle 100 Fig 5 Pulses at IGBT probe connections at A B and A D Duty Cycle 100 ...

Page 28: ...h other as shown in Fig 8 9 Press the Off button on the display 10 Change channel 2 scope probe to position B Energize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be out of phase with each other as shown in Fig 9 11 Press the Off button on the display 12 Change channel 2 scope probe to position D Energize unit and ramp up to 100 duty cycle The pulses as observed o...

Page 29: ...Page 27 Fig 6 ...

Page 30: ...Page 28 Connect probe to D1 diode as shown for IGBT A C F H Connect clip to ground screw Connect probe to D4 diode as shown for IGBT B D E G ...

Page 31: ...Page 29 Fig 7 Fig 8 Pulses at IGBT probe connections at A C E G Duty Cycle 100 Fig 9 Pulses at IGBT probe connections at A B D F H Duty Cycle 100 ...

Page 32: ...gize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be in phase with each other as shown in Fig 12 9 Press the Off button on the display 10 Change channel 2 scope probe to position I Energize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be in phase with each other as shown in Fig 12 11 Press the Off button on the display 12 Change cha...

Page 33: ...s the Off button on the display 27 Change channel 2 scope probe to position L Energize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be out of phase with each other as shown in Fig 13 28 Press the Off button on the display 29 Change channel 2 scope probe to position N Energize unit and ramp up to 100 duty cycle The pulses as observed on the scope should be out of ph...

Page 34: ...Page 32 Fig 10 ...

Page 35: ...ith D4 at the top The leftmost column of boards are turned upside down so D4 is on the bottom Connect probe to D4 diode as shown for IGBT B D E G J L M O The rightmost column of boards are oriented as shown with D4 at the top The leftmost column of boards are turned upside down so D4 is on the bottom Connect clip to ground screw ...

Page 36: ...Page 34 Fig 12 Pulses at IGBT probe connections at A C E G I K M O Duty Cycle 100 Fig 13 Pulses at IGBT probe connections at A B D F H J L N P Duty Cycle 100 ...

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