PCS6000—Preventive maintenance for medium-voltage wind turbine converters CCA2 FR-Q-HX-UL 3BHE057277R0001

　　Checking bolt connections

　　Effort 0 – 2 h

　　1. If not already done for other inspection purposes, shut-down the PCS6000 according to “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Check tightness of power conductor bolt connections:

　　• Make visual checks of the torque markings on the bolts (Fig. 4–1).

　　• If the torque markings on a screw are out of alignment, check torque of screw connection. The required torque is listed in

　　Table 10–2 in section 10.4.1, Correct tightening torques of bolted connections, page 135.

　　• If a connection is loose, tighten the bolt using a torque wrench, then check also the torque of all other connections (the probability is high that if one connection is loose also other connections are loose).

　　• Torque markings of bolts that have been released and/or re-tightened must be cleaned and newly applied.

　　NOTICE The capacitors bushing will be damaged when excessive force is applied.

　　DO NOT exceed the maximum tightening torque when tightening the capacitor terminals. For the appropriate tightening torque of all screws and especially for the screws of the capacitors refer to section 10.4.1, Correct tightening torques of bolted connections, page 135.

　　After completing all work – if no further inspections have to be performed – restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Cleaning

　　The PCS6000 contains components which are sensitive to electrostatic discharge. Electrostatic-sensitive precautions must be applied and suitable tools must be used when cleaning boards and assemblies:

　　▶ Clean with special care using anti-static brushes and a vacuum cleaner.

　　▶ Dirt and dust on the electrical components can cause malfunctions and component failures!

　　▶ DO NOT use compressed air to clean the control system cabinets or converter under any circumstances.

　　▶ Dirt can be spread uncontrollably this way, which could lead to the corresponding malfunctions.

　　▶ DO NOT use alcohol or solvents when cleaning inside the cabinets or any electrical components.

　　Cleaning is necessary if dirt or dust accumulation (also called fouling) occurs within the converter. This could lead to thermally activated accelerated aging, which can be prevented by periodically cleaning.

　　Procedure:

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Clean the room carefully with a vacuum cleaner. In the area around the converter, use a soft nozzle tube in order not to damage any components.

　　3. If necessary, clean the components with a dry cloth.

　　4. Clean all air inlets and outlets of the cabinets.

　　5. Clean the air inlets and outlets on all door and roof fans.

　　6. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Replacing components

　　Replacement means exchange of components as part of the maintenance schedule or as a consequence of performed visual inspection or performance checks.

　　The procedures to replace components are described in chapter 7, Checking control components, page 81 or in chapter 10, Replacing power and cooling components, page 133. The corresponding sections are depicted in the following table.

　　For replacement tasks without a description of the replacement procedure in this service manual, always shut-down the PCS6000 according to “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22 Switch off the corresponding MCB (see electrical diagram) before replacing the component. Restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　DC-link performance check

　　Effort 0 – 2 h

　　The DC-link charging for performance check is performed via the test module of the converter HMI.

　　IMPORTANT! The measurement results are compared to the nominal values in the “PCS6000 Preventive maintenance report”, 3BHS600000 E84.

　　The deviation of the measured values from the nominal values is grouped in 3 categories:

　　– OK: The measurement result is in the expected range.

　　– Monitor: The measurement result is near the limit.

　　The respective component is still OK, but it makes sense to compare previous and future measurements to monitor a trend, as well as to compare similar measurements taken with the same instrument.

　　– Action: The respective component might be faulty and should be replaced.

　　Procedure:

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Close all doors.

　　3. Open DC-link grounding switch.

　　4. Charge the DC link up to +/-500V.

　　5. Record the discharging time from +/-500 to +/-200V.

　　6. Record the discharge time in the Preventive Maintenance Report.

　　7. If the converter is a 2CL system, repeat the test with the second conversation line.

　　8. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　DC-link component check

　　Effort 4 – 8 h

　　The DC-link component check has to be done as described below, if the procedure in section 4.4.5, DC-link performance check, page 56 shows a deviation from the nominal value more than 10%.

　　IMPORTANT! A standard multimeter with capacitance measuring function (up to 10 mF) is required to perform these measurements.

　　The measurement results are compared to the nominal values in the Preventive Maintenance Report. The deviation of the measured values from the nominal values is grouped in 3 categories:

　　– OK: The measurement result is in the expected range.

　　– Monitor: The measurement result is near the limit.

　　The respective component is still OK, but it makes sense to compare previous and future measurements to monitor a trend, as well as to compare similar measurements taken with the same instrument.

　　– Action: The respective component might be faulty and should be replaced.

　　Procedure:

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Double check that the DC-link is grounded (ground switch).

　　3. Remove reinforcement plates and the ASM10 (Auxiliary Supply Module).

　　4. Disconnect the three sets of measurement the wires (1, 2 and 3) which connect the DClink capacitors (C701…C703) to the converter.

　　5. Record the serial number of each capacitor in the Preventive Maintenance Report.

　　6. Measure the capacitance of Grid side Power Module Capacitors (see electrical circuit diagram POMxx).

　　7. Measure the capacitance of Generator side Power Module Capacitors (see electrical circuit diagram POMxx).

　　8. Reconnect the wires/busbars from the converter with the marked tightening torque (see separate sticker on the capacitor) to the capacitors.

　　NOTE – If the tightening torque is not specified on the capacitor, use tightening torque defined under section 10.4.1, Correct tightening torques of bolted connections, page 135.

　　9. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Filter components performance check

　　Effort 2 – 4 h

　　IMPORTANT! A standard multimeter with capacitance measuring function (up to 10 mF) is required to perform these measurements.

　　The measurement results are compared to the nominal values in the Preventive Maintenance Report. The deviation of the measured values from the nominal values is grouped in 3 categories:

　　– OK: The measurement result is in the expected range.

　　– Monitor: The measurement result is near the limit.

　　The respective component is still OK, but it makes sense to compare previous and future measurements to monitor a trend, as well as to compare similar measurements taken with the same instrument.

　　– Action: The respective component might be faulty and should be replaced.

　　The filter components performance check comprises the following 3 parts:

　　– Grid side filter components performance check (see section 4.4.7.1, Grid side filter components performance check, page 59)

　　– Neutral point performance check (see section 4.4.7.2, Neutral point performance check, page 61)

　　– dv/dt filter components performance check (see section 4.4.7.3, dv/dt filter components performance check, page 61)

　　Grid side filter components performance check

　　Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　Double check that the DC-link is grounded (ground switch) and the grid side is grounded (grounding kit).

　　Disconnect the PE wire to -R544:2 in cabinet +A12. (see electrical circuit diagram HFMxx).

　　Measure the resistance of -R544 between -R544:2 (the disconnected pin) and -R544:1.

　　Measure the capacitance between -X541/2:3 and -X541/2:4 (12 capacitors parallel, when grid side grounded).

　　6. Reconnect the removed connection.

　　7. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Neutral point performance check

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Double check that the DC-link is grounded (ground switch).

　　3. Disconnect the wire from:

　　• +A23-R461 pin2

　　• +A23-R462_1 pin1

　　• +A23-R463 pin 1

　　See electrical circuit diagram NCM10

　　4. Measure the capacitance of -C461 between -C461:1 and Ground.

　　5. Measure the resistance of -R461 between -R461:1 and -R461:2.

　　6. Measure the resistance of -R462 (over both two resistances) between -R462_1:1 and Ground.

　　7. Measure the resistance of -R463 between -R463:1 and -R463:2.

　　8. Measure the resistance of -R463 between -R464:1 and -R464:2

　　9. Reconnect the removed connections.

　　10. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　dv/dt filter components performance check

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Double check that the DC-link is grounded (ground switch) and the generator side is grounded.

　　3. Measure the resistance of -R581 and -R582 (connected in series) in cabinet +A11 between -R581:2 and -R582:1.

　　4. Measure the resistance of -R583 and -R584 (connected in series) in cabinet +A11 between -R583:2 and -R584:1.

　　5. Measure the resistance of -R585 and -R586 (connected in series) in cabinet +A11 between -R585:2 and -R586:1.

　　6. (see electrical circuit diagram VFMxx)

　　7. Measure the capacitance between -C581:2 in cabinet +A11 and Ground (7 capacitors parallel when generator side grounded).

　　8. Measure the resistance between -C581:2 in cabinet +A11 and Ground. The measurement is passed when Rmeasured rises to OL (OverLoad).

　　9. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.

　　Functionality and security procedure

　　1. Shut down the PCS6000 according to the “PCS6000 Lockout/tagout procedure”, 3BHS600000 E22.

　　2. Visually check the cable connections to the grid breaker (GRB).

　　3. Check the properly fixation of the contact block of the Local Emergency Button +A40.

　　4. Check whether the maintenance of the GRB has been done according to the manufacturer’s specifications.

　　IMPORTANT! All the points of the following tests have to be confirmed by ticking the corresponding check boxes in the Preventive Maintenance Report.

　　5. Perform the “Local Emergency Button test” according to the procedure given in the

　　Preventive Maintenance Report.

　　During this test the different paths of the GRB open command will be checked. Each path (-X910:5, -X910:8, -X910:9, -X910:11) is tested with the other paths disconnected.

　　For each test case, the GRB must open when the Local Emergency Button +A40 is pressed.

　　6. Perform the “Door interlocking test” according to the procedure given in the Preventive

　　Maintenance Report.

　　During this test the proper function of all door interlocks will be checked.

　　7. Perform the “Grounding isolator interlocking test” according to the procedure given in the Preventive Maintenance Report.

　　WARNING! For the grounding isolator interlocking test, the GRB disconnector must be in test position!

　　• During this test the interlocking function between GRB and DC-link grounding isolator has to be confirmed, ie, the GRB cannot be closed unless the DC-link grounding switch is open and locked; and the DC-link cannot be grounded if the GRB Disconnector is closed or simulated to be “closed” via the HMI button.

　　• If the locking supervision contact is not used, the interlocking has to be confirmed as follows: The GRB cannot be closed if the DC-link grounding isolator is closed, whereas the DC-link grounding isolator cannot be closed if the GRB is closed.

　　8. Perform the “Safety interface to upper level control test” according to the procedure given in the Preventive Maintenance Report.

　　During this test the safety interface communication from the WTC (Wind Turbine Control) to the converter and from the converter to the WTC will be checked.

　　9. Perform the “UPS Supply Check” according to the procedure given in the Preventive Maintenance Report.

　　This test procedure is used to verify the proper functionality of the Uninterruptible

　　Power Supply (UPS).

　　10. After completing all work, restart the PCS6000 according to section 5.4, Start-up after maintenance or troubleshooting, page 70.
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