Siemens Robicon GH180 MV Drives DC-Link Capacitors Refurbish, Repair, Replace
Siemens Robicon GH180 MV Drives DC-Link Capacitors Refurbish, Repair, Replace
GEN IV Cell DC Bus low faults
Hi Expert house,
We are having GEN IV air cooled VFD with 9 cells w/o cell bypass
4.16 KV input, 100 Amps cell rating.
Since last two years we received at least 4-5 time Cell DC Bus low warning. Each time we checked and found blown fuse. Strangely all are coming on TRAFO SECONDARY delta side phase
A2, B2 and C2. cells. We checked the faulty cells with external VARIAC and found drawing abnormal current with a typical 5 % of rated voltage indicating cell internal Capacitors/semiconductor fault.
Questions are
1. Is there any aging for these power cells even with INPUT MV ON always
2. We have total 3 air-cooled drives and occurring problem in one drive only? Any thing to cehck.
3. Why the cell faults occurring only on Phase L2..
Thanks
Hi N. Vijay,
Check all the transformer secondary voltages for the A2, B2 and C2 cells. Compare the voltages against some other cells that are not experiencing any issues. There could be a transformer secondary winding issue.
For the ageing of components in the cells the dc link electrolytic capacitors have a service life time. It is dependent on several factors. Worst cast scenario for a GEN IV drive is 10~12 years in a heavy duty environment ie average operating temperature = 35°C, operating hours > 8500 hours/yr, full load.
N Vijay
Hi Will
Thanks for immediate response. How to measure secondary voltages live. Are there any test points like VMA, VMB, VMC (TP 5, 6 and 7) for motor voltage. Will it reflect @ VIA,VIB nd VIC , I mean TP 1,2 and 3. Shall I monitor cyclic variation through Debug tool these values...
Regards,
Vijay
Hi N. Vijay,
There are no PCB test points for the transformer secondary voltages or any feedback to the debug tool. To measure the secondary voltages there are a few options. One option with the drive isolated is that you can remove the necessary covers and connect up the required meters with the leads coming out of the drive to the meters. Put the covers back on energise the drive to get your readings. Measure the 3 phase to phase voltages for each cell experiencing issues and compare against some cells that are not having issues. This will be a good start to find out if the transformer is causing the DC Bus Low faults.
Good morning Will
OK. Let me check the practicability as LTT norms should allow to charge MV with doors open..
One more question is that in case if it is TRAFO issue what is confusing is that the removed cell shown internal fault. I mean during external checking through 3 phase Variac, the removed cells drawing abnormal current even at 2% nominal voltage. Shall we consider as effect of TRAFO secondary cause.
.Once we replace the fuse and cell, it is running without any issue
Thanks
N Vijay
Hi N. Vijay,
When you inspected the failed cells did you notice anything visually? Were the rectifier diodes in good condition? How did the DC link caps look? A shorted diode on the rectifier section of the cell could cause possibly cause a low DC link voltage if this blows a fuse and a phase is lost. This would also explain the high current when using a variac direct. If you still have the failed cells check the 3 phase rectifier with a meter. Its a process of elimination. Things to check;
Transformer secondary voltages
Cabling or bus work from secondaries to cell
Cell rectifier
DC link capacitors
IGBTs
Cell control board and cable loom to DC link
Keep us posted on what you find
small correction it is phase L1 not L2.
One more thing I forgot is that Phase L1 to DC BUS -ve shown low ohmic value, indicating rectifier fault.
So my question is it is purely cell related issue OR
TRAFO secondary also can cause Rectifier fault (Drawing more current etc...)
Regards,
Vijay
It is good practice to measure the transformer secondary voltage in this case. Once you have that information then you can figure out if the issue is caused by the transformer, cell, or even a combination of both.
To test the cell outside of the drive after repair you can use a portable cell tester similar to what is shown in this video
Individual Cell Load Test Video
Hi Will
Good morning,
We are having planned shutdown and want to measure the voltages. But is it possible after connecting brought out leads, cells can be pushed back intact. OR shall I perform this test without power cells.
Will it work if MV trip interlock from VFD is bypassed or not?
Regards,
N Vijay
You can do the test with the power cells out. You will get "link faults" with the power cells out but this shouldn't have any effect on the MV trip interlock.
Remember to conduct a detailed risk assessment for this work and put any controls in place to mitigate the risks from any identified hazards.
Siemens Sinamics GH180 Robicon Perfect Harmony Power Cell Load Test
Thanks Will
We are doing JSA too before attempting the job. We don't have panel rear door access. My impression was that "Cell DC Bus low" is warning but Cell link fault is a trip interlock to MV breaker too. that is the reason for my query.
Regards,
N Vijay
Hi Will
We did the test with MV ON and measured the power cell side AC input voltages of all phases and found normal without any variations.
Might be coincidence then to have power cells of one particular phase to have alarms.
Removed defective power cells checked and found rectifier in phase 1 faulty.(internal short circuit)
Replaced the rectifier block semikron and tested with variac found ok.
Thanks
N Vijay
dear colleagues,
we have a problem each day our drive GH180 trip by cell by pass fault,we check parameter of drive we remark that fast bypass ID 2600 is disable.
if we put ID 2600 enable we will not trip??please we need your advise.
best regards,
Motor derating
Hello everybody
We need connecting a Siemens motor 1500HP / 3578 RPM / 183AMP / 4000V to a perfect harmony drive 900HP / 4160V / 125AMP (output).
What do I need to consider and how can I do the derating in the motor in order to setup it correctly in the VFD?
The app is a centrifugal pump.
Thanks for your support
Need help to provide reactor information and connection to power cell
Hi Peter,
The attached table from section 7.9 of the Gen3 Startup and Advanced Manual 902232 V3.0 details the reactor sizes recommended to be used with the Siemens PCT.
If you want to verify your proposed setup put everything into modelling software such as Spice or PSIM. The model will tell you expected currents etc for different reactor and output voltage combinations.
The idea is to use minimal power cell output voltage but achieve high current limited only by the reactor or power cell current rating. The low voltage used on the power cell output means the power requirements on the supply will be minimal. Remember the output frequency of the power cell will be locked to 50 or 60Hz.
Regards,
will4
Nuclear power has at least three waste streams that may impact the environment: Spent nuclear fuel at the reactor site (including fission products and plutonium waste) Tailings and waste rock at uranium mining mills. Releases of ill-defined quantities of radioactive materials during accidents.
Hi,
we have in custommer factory Robicon GH180
6SR3102-5GJ46-0FG0-Z
G32+G47+G91+K31+K68+K73+M35+M42+M64+N50+P82+Q84+T25+U02+U11+V10+Y10
Custommer need critical spares for this drive.
Inside is NXG2-Rack 10000313.00 (6SR0960-0CB10-0AA0) but if I check in PDM it is "Product is no longer orderable", Substitution is 6SR0960-0CB21-0AD0. My question is, is it fully compatible or we must change other pars such as Input/Output board, PCA signal Conditioning board.
THX Krystof
PH GH180 6SR41022FB370FF0-Z keypad for display parameter
Hello! We have 7 frequency converters, all do not have a display with a keyboard, there is no LCD monitor backlight, how can I connect it separately from NXG to check it
p/n: A5E02669580
GH 180 VFD Time synchronization with Remote PLC
Dear All,
Customer want to synchronize GH 180 VFD time and dates with their SCADA system. Is there possible way to do it? Seek your advice. Thanks,
Regards,
Peter
Hi Peter,
This is possible by setting the clock time of the drive at regular intervals. The clock time can be set using the parameter read / write functionality of the drive which is detailed in the parameter read / write appendix of the communications manual.
The medium voltage drive is battery powered: refurbish, repair, replace or roll the dice?
As we have recently outlined, there are many factors that affect the life of medium voltage VFD power units. Through careful design and planning (or preventive maintenance plan), your electrical equipment can be used for a long time. However, all electronic devices have a clear reality: eventually, they will all fail. Many maintenance managers find that their question is: "What should I do to extend the life of a medium voltage drive?" Depending on your budget, time frame, and downtime, there are several different answers to this common question.
Based on our 100 years of experience in installing, repairing and replacing electronic products, we can accurately predict when the medium voltage power unit is approaching or exceeding its service life. The service life of electrolytic capacitors existing in many different types of power batteries is about 7-10 years. If your power battery approaches or exceeds this time range, you can reasonably assume that it needs attention.
The maintenance manager has four options to maintain the medium voltage drive power unit:
Refurbishment-before failure
Repair-when they fail
Replacement-when they fail
Roll the dice-do nothing and hope for the best
Refurbish
If your medium voltage drive has not failed, it is recommended to refurbish it. Refurbishment involves replacing all electrolytic capacitors on all circuit boards and the electrolytic capacitors of the DC bus. It is usually cheaper to replace all circuit cards in the power unit with the latest version instead of replacing capacitors at the component level. If your battery uses oil-filled capacitors, they may also need to be replaced depending on their age.
If you are currently running a medium voltage drive and plan to continue using it for the foreseeable future, then refurbishment is a good choice for you. However, if the medium voltage drive is planned to be replaced soon, refurbishment is not a worthwhile investment. Refurbished medium voltage power unit is the cheapest of these four options. In many cases, spending money to refurbish now can help you avoid spending money on repairs or replacements in the future. Refurbishing drives requires shutting them down, so this should be done during planned downtime.
repair
If your medium voltage drive power unit has failed, repair is a viable option. Our RobiconPerfectHarmony recommends that customers have a spare medium voltage power battery in case of failure. This allows you to quickly resume operation. After replacing the damaged unit with the spare unit, it can be repaired and then retained as a new spare unit. If you don't have spare parts available, then when the MVD drops and the manufacturer's batteries are out of stock, repair may still be the most time-saving option. Since no new power units are manufactured for your specific drive, there are situations where you are forced to use repair options. Fortunately, RobiconPerfectHarmony is well-equipped to repair medium-voltage power batteries (even old ones)! If you need repair urgently, please call our battery repair hotline for immediate help.
replace
If your battery fails and you can still buy replacement parts, then this is a viable option, especially when time is tight. Although the initial cost of buying a brand new battery is the highest, it can save you money in terms of downtime costs. Most medium voltage variable frequency drives have a modular design that allows you to replace the power battery in just 30 minutes, which can save thousands of dollars in downtime. Unfortunately, for many customers whose medium-voltage VFD equipment of RobiconPerfectHarmony is outdated, battery replacement is not a viable option because new batteries are no longer produced. Therefore, RobiconPerfectHarmony can protect many of the refurbished and tested power batteries in the inventory from the outdated medium voltage VFD. If your drive is no longer in production and needs a replacement power call, please call us to see if it is in stock.
Roll the dice (do nothing)
The "do nothing" option is an option that many people choose to adopt. Sometimes this option is chosen due to a tight budget. Some people choose this option because they have already developed a plan to replace the medium voltage VFD as soon as possible. If the drive is about to be replaced completely, it is logical to roll the dice and hope that your medium voltage drive will run before it can be replaced, which is of course logical. If there is no plan to replace the drive itself, then the "do nothing" approach can have disastrous consequences for your business.
Compare options
RobiconPerfectHarmony's evaluation of these options is based on years of experience in installation, repair and preventive maintenance on medium voltage drives. Our team goes to discuss various options and how each option affects our customers. This simple comparison table demonstrates the results of our discussion.
Maintenance comparison table of medium voltage drive power unit
Drive failure occurs, please be prepared
Medium voltage VFDs are highly reliable, but there are still some factors that can cause failures. The drive has failed. This is not an IF problem, but time. Preparation through refurbishment, repair or new units can relieve stress and reduce downtime. Most RobiconPerfectHarmony customers are in a highly competitive industry because the downtime has caused a huge loss to its reputation and bottom line. Don't let battery failure become your company's competitive disadvantage!
RobiconPerfectHarmony is here to help you
We have seen a lot. We have repaired a lot. We invite you to contact us to discuss the best option for your company. You can call our dedicated MVD cell repair hotline to contact experts. No one can be better at driving than RobiconPerfectHarmony.
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