GEH-6777C

Brilliance* Solar
1275 kVA Photovoltaic (PV) Inverter
Operation and Maintenance Guide
August 2016

SAVE THESE INSTRUCTIONS - This manual contains important

instructions for the Brilliance Solar Photovoltaic (PV) Inverter that
must be followed during installation and startup.

GE Internal
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and GE makes no warranty as to the accuracy of the information included herein. Changes, modifications,
and/or improvements to equipment and specifications are made periodically and these changes may or may not be reflected
herein. It is understood that GE may make changes, modifications, or improvements to the equipment referenced herein or to
the document itself at any time. This document is intended for trained personnel familiar with the GE products referenced
herein.
GE may have patents or pending patent applications covering subject matter in this document. The furnishing of this
document does not provide any license whatsoever to any of these patents.
GE Internal – This document is proprietary. It contains information that belongs to the General Electric Company and is
furnished to its customer solely to assist that customer in the installation, testing, operation, and/or maintenance of the
equipment described. This document or the information it contains shall not be reproduced in whole or in part or disclosed to
any third party without the express written consent of GE.
GE provides the following document and the information included therein as is and without warranty of any kind,
expressed or implied, including but not limited to any implied statutory warranty of merchantability or fitness for
particular purpose.
For further assistance or technical information, contact the nearest GE Sales or Service Office, or an authorized GE Sales
Representative.

Revised: August 2016

Issued: January 2014

© 2014 - 2016 General Electric Company.

___________________________________
* Indicates a trademark of General Electric Company and/or its subsidiaries.
All other trademarks are the property of their respective owners.

We would appreciate your feedback about our documentation.

Please send comments or suggestions to [Link]@[Link]

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 Document Updates
Revision Update Location Description
C Throughout the Miscellaneous updates to fix format, style, trademarks, spelling and other minor
Aug 2016 document changes
Added Warning: Opening the DC disconnect switch (Q2 - SAPC) and the AC
main circuit breaker (Q1- GPC) does not fully de-energize the breaker’s input
B Maintenance with
terminal bus work. Before opening either the SAPC or GPC cabinets, the DC
Apr 2016 Equipment De-energized
source from the PV array and the AC source from the transformer must be
de-energized at their source.
Chapter, Preventative
Added the section, IGBT Phase Module Replacement containing the steps to
Maintenance and
A replace damaged IGBT phase modules.
Replacement
Jan 2015
Appendix A IGBT Phase Added Appendix A containing the steps to confirm IGBT phase module
Module Test assembly health for Bench testing.
Jan 2014 N/A Initial release

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Title Document
ToolboxST* User Guide for Mark* Controls Platform GEH-6700
Brilliance Solar 1275 kVA PV Inverter Installation Guide GEH-6776
Brilliance Solar 1275 kVA PV Inverter Operation and Maintenance GEH-6777
Mark VIe Control Analog Input/Output (PAIC) Module Description GEI-100576
Mark VIe Controllers UCCx and UCSx Instruction Guide GEI-100665
Power Conversion Main Control Module (WEMA) Module Description GEI-100734
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GEH-6777C Operation and Maintenance Guide 3

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 Acronyms and Abbreviations
AEPS Alternative Energy Power Supply

BPPB Balance of Plant Processor Board version B

CBC Converter Bridge Cabinet

CEC California Energy Commission

CFC Converter Filter Cabinet

DMM Digital Multi-meter

DVM Digital Voltmeter

EGD Ethernet Global Data

E-Stop Emergency Stop

FPGA Field Programmable Gate Array

GFDI Ground Fault Detector Interrupter

GPC Grid Power Cabinet

HMI Human-machine Interface

IGBT Insulated Gate Bipolar Transistor

MACC Multiple Application Converter Control

MCC Main Control Cabinet

MPPT Maximum Power Point Tracker

MVP Moisture Vapor Proof

PIC Programmable Intelligent Computer

PPE Personal Protective Equipment

PV Photovoltaic

RNC Rigid Non-metalic Conduit

RTD Resistive Temperature Device

SAPC Solar Array Power Distribution Cabinet

SCADA Supervisory Control And Data Acquisition

SECA Solar Energy Converter I/O Module

UCSA Unit Controller Stand Alone

VCO Voltage-controlled Oscillator

WEMA Power Conversion Main Control Module

WEOR Power Conversion Wired-OR Board

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Safety Symbol Legend

Indicates a procedure or condition that, if not strictly observed, could result in

personal injury or death.
Warning

Indicates a procedure or condition that, if not strictly observed, could result in damage
to or destruction of equipment.

Caution

Indicates a procedure or condition that should be strictly followed to improve these

applications.

Attention

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Control System Warnings

To prevent personal injury or damage to equipment, follow all equipment safety

procedures, Lockout Tagout (LOTO), and site safety procedures as indicated by
Employee Health and Safety (EHS) guidelines.
Warning

This equipment contains a potential hazard of electric shock, burn, or death. Only
personnel who are adequately trained and thoroughly familiar with the equipment
and the instructions should install, operate, or maintain this equipment.
Warning

Isolation of test equipment from the equipment under test presents potential electrical
hazards. If the test equipment cannot be grounded to the equipment under test, the
test equipment’s case must be shielded to prevent contact by personnel.

To minimize hazard of electrical shock or burn, approved grounding practices and

Warning procedures must be strictly followed.

To prevent personal injury or equipment damage caused by equipment malfunction,

only adequately trained personnel should modify any programmable machine.
Warning

Always ensure that applicable standards and regulations are followed and only
properly certified equipment is used as a critical component of a safety system. Never
assume that the Human-machine Interface (HMI) or the operator will close a safety
critical control loop.
Warning

Opening the DC disconnect switch (Q2 - SAPC) and the AC main circuit breaker (Q1-
GPC) does not fully de-energize the breaker’s input terminal bus work. Before
opening either the SAPC or GPC cabinets, the DC source from the PV array and the
AC source from the transformer must be de-energized at their source.
Warning

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 Contents
1 Overview ............................................................................................................................................. 9
1.1 Equipment and Material .......................................................................................................................... 10
1.1.1 Safety Equipment............................................................................................................................ 10
1.1.2 Typical Maintenance Tools ............................................................................................................... 10
1.1.3 Control System Hardware................................................................................................................. 11
2 Web-based HMI Control Operation ............................................................................................ 13
2.1 Home Page........................................................................................................................................... 13
2.2 Control and Status ................................................................................................................................. 14
2.2.1 Password Panel............................................................................................................................... 14
2.2.2 Basic PV Control Panel .................................................................................................................... 14
2.2.3 Grid Status Panel ............................................................................................................................ 15
2.2.4 PV Array Panel ............................................................................................................................... 15
2.3 Main Menu........................................................................................................................................... 16
2.3.1 Alarms and Logs............................................................................................................................. 17
2.3.2 Inverter Control .............................................................................................................................. 19
2.3.3 Performance Data I/O and Variables ................................................................................................... 24
2.3.4 Site Conditions I/O and Variables....................................................................................................... 25
2.3.5 Array Sub-combiner I/O and Variables ................................................................................................ 26
2.4 Control Panel Status Bar ......................................................................................................................... 27
2.5 Trending .............................................................................................................................................. 28
3 Configuration and Troubleshooting .......................................................................................... 29
3.1 System Parameters................................................................................................................................. 29
3.1.1 Forced Variables ............................................................................................................................. 33
3.1.2 Utility Interconnection Voltage, Frequency Trip Limits, and Trip Times .................................................... 35
4 Preventative Maintenance and Replacement.......................................................................... 39
4.1 Inspection and Maintenance Schedule........................................................................................................ 40
4.2 Maintenance Record............................................................................................................................... 41
4.3 Maintenance Procedures ......................................................................................................................... 41
4.3.1 Maintenance with Equipment Energized ............................................................................................. 43
4.3.2 Maintenance with Equipment De-energized ......................................................................................... 45
4.3.3 Dust Removal ................................................................................................................................ 49
4.3.4 Mechanical Connections................................................................................................................... 50
4.3.5 Wire and Cable Inspection ................................................................................................................ 52
4.3.6 Board and Module Cleaning.............................................................................................................. 52
4.3.7 Cooling System Scheduled Maintenance ............................................................................................. 52
4.3.8 Power Circuit Breaker Inspection ....................................................................................................... 57
4.3.9 Safety Chain Operation Inspection ..................................................................................................... 58
4.3.10 Fan and Blower Replacement ............................................................................................................ 58
4.3.11 Coolant Pump Replacement .............................................................................................................. 60
4.3.12 IGBT Phase Module Replacement...................................................................................................... 70
4.3.13 Fuse Replacement ........................................................................................................................... 84
4.3.14 Return the Inverter to Service ............................................................................................................ 86
Appendix A IGBT Phase Module Test ............................................................................................. 89

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Notes

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1 Overview
This document provides instructions for inverter operation, recommended preventive
maintenance, component replacement, and general parameter configuration and
troubleshooting procedures for the Brilliance* Solar 1275 kVA Photovoltaic (PV)
Inverter.

Inverter Control Cabinet (Front View)

Inverter Control Cabinet with Doors Open (Front View)

Overview GEH-6777C Operation and Maintenance Guide 9

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1.1 Equipment and Material
Check boxes should be marked Verify that the following equipment and materials are available for the procedures in this
to verify that equipment is on document:
hand.

1.1.1 Safety Equipment

□ Site-specific safety/confined space manual
□ Appropriate Personal Protective Equipment (safety boots, safety glasses, hard-hat,
high voltage gloves, face shield, safety jacket)
□ High voltage ac/dc detector (with an insulated pole of appropriate length)
□ Locks and tags
□ Danger and caution tape
□ Protective grounding cables and grounding stick

1.1.2 Typical Maintenance Tools

□ High quality tools, including screwdrivers and pliers, designed specifically for
working with electrical wiring systems
□ Socket set (metric and standard)
□ Hex wrench set (metric and standard)
□ 1-inch adjustable wrench
□ Torque wrench
□ Electrical tape
□ Clean dry cloth
□ Soft-bristled brush (such as a paintbrush)
□ Isopropyl alcohol and citrus-based cleaner
□ Digital meter
□ High-voltage voltmeter
□ Megger tester (capable of dc testing from 500 V up to 5 kV)
□ Vacuum cleaner with non-metallic nozzle and finely woven, high efficiency filter
□ Fuse puller
□ Replacement components including fuses, wires, cables, fans, and hardware
□ Static-charge wrist straps

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 1.1.3 Control System Hardware
Solar Inverter Circuit Boards
Catalog (Part) Number Board/Module Cabinet
IS200AEAAH2B Alternative Energy Application A (AEAA) MCC
IS200AEAD Alternative Energy Application D (AEAD) MCC
IS200AEBIH2B Alternative Energy Bridge Interface (AEBI) MCC
IS210AEPSG1B Alternative Energy Power Supply (AEPS) MCC
IS220UCSA Universal Controller Stand Alone (UCSA) MCC
IS200WEMAH2A Power Conversion Main Control Module (WEMA) MCC
IS200WEOR Power Conversion Wired-OR Board (WEOR) MCC
IS215SECA Solar Energy Converter Module (SECA) (MACC and processor board) MCC
IS220PAIC Analog Input/Output Module (PAIC) (optional) SAPC

Overview GEH-6777C Operation and Maintenance Guide 11

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Notes

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2 Web-based HMI Control Operation
This section provides details that may be useful when using the web-based
Human-machine Interface (HMI) for local or remote inverter operation and maintenance.
The HMI provides password protected access to inverter operational functions including
start up, shut down, and fault reset, as well as with mode selection and setpoint
adjustment. The HMI also provides data collection and display capability.

2.1 Home Page

The Solar Inverter Home Page provides the following operations:

• Live data trends

• Control and status indicators, including site conditions (temperature, irradiance,
wind, and such)
• Inverter control
• Array and grid status monitoring
• Alarms, faults, and event messages
• Parameter configuration and modification

Live Data Display in Trend Form

Navigation :

Alarms Basic Control

and Logs

Inverter Control

Performance Key Grid

Data Status Signal

Site
Conditions
Key PV Array
Array Status Signal
Subcombiner
(current )
Password Entry for
Active alarms, Web Operation
faults, warnings ,
or events

Solar Inverter Home Page

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2.2 Control and Status
Panel refers to a section of the The control and status buttons (located on the right panel of the home page) enable certain
home page that contains operations and display the status of the inverter, grid, and PV array.
buttons, displays, and
navigation tools.
2.2.1 Password Panel
A password is required to activate buttons and change the setpoint of the inverter.

A password is required for PV inverter control and

setpoint configuration. Only a validated password
grants full control of the web page. The access status
to the system (locked or unlocked) is displayed on
the status bar. Refer to section, Control Panel Status
Attention Bar.

➢ To log on to the inverter control system: from the Password panel, enter a
valid password.

Password Panel

2.2.2 Basic PV Control Panel

The PV Control panel provides six buttons for inverter operation as displayed in the
following figure.

Note Control buttons are only active after a password has been validated. Refer to the
section, Password panel.

Starts the Inverter when in

Stop or Maintenance mode
Shuts down the
Inverter for
Stops the Inverter when in maintenance
Running, SunFree, Curtailed,
Starting, or Sleeping mode.
Enables SunIQ* setpoints
and indicates when
Automatic Solar Control
Resets system alarms mode is active (red)
and faults

Enables Inverter control

using Web-based HMI and
indicates when Manual
mode is enabled (red)

PV Control Panel Features

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 [Link] Manual Mode
Manual mode enables the operator to control the inverter using the HMI.

Note When the inverter is switched from Automatic to Manual mode, the last active
setpoints value from plant control remain active until the operator changes them in the
inverter Op Controls panel.

➢ To enable Manual mode: from the PV Control panel, select the Manual button.

Verify that the button is Red before

performing any manual operation.

2.2.3 Grid Status Panel

The Grid Status panel displays Inverter grid-related variables.

Voltage of grid Current feed

into grid

Reactive power
Real power
feed into grid
feed into grid

Power factor

Grid Status Panel

2.2.4 PV Array Panel

The PV Array panel displays the status of PV array variables.

DC voltage

DC current

Power

PV Array Panel

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2.3 Main Menu
These functions and data The Main menu provides navigation details for the control functions and data panels. It
panels may also be accessed aligns on the left side of the web page, and contains five main function categories. Select
from the Home Page. any item on the Main menu to display the related panels.

Main Menu

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 2.3.1 Alarms and Logs
The Alarms and Logs option on the Main menu enables the operator to view and control
the following:

• Command and event log

• Active alarms
• Operational data log

[Link] Cmd & Event Log

➢ To display and export a command and event log: from the Main menu
Alarms and Logs option, select Cmd & Event Log to display the Command &
Event Log panel.

Data field

Click Export to Excel to

From the Configuration panel, select the time export the log details .
span and click Go to update the data field.

Command & Event Log

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 [Link] Active Alarms
The Active Alarms panel displays when alarms are active and provides a description of
each alarm for troubleshooting.

➢ To display active alarms: from the Main menu Alarms and Logs option, select
Active Alarms.

Date and time when the alarm occurred Alarm description

Active Alarms Panel

[Link] Operational Data Log

The Operational Data Log panel displays items from the operational data record, which
To display the data as a chart, contains 1 second or 5 minute average values of key variables.
export the data to Excel and
➢ To display and export an Operational Data Log: from the Main menu, select
use the Chart tool. Refer to the
Operational Data Log.
figure, Cmd & Event Log.

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 2.3.2 Inverter Control
The Invert Control option on the Main menu enables the operator control the following:

• Override plant control

• I/O and variables

[Link] Op Controls
The Ops Controls panel enables the operator to override plant control and manually adjust
setpoints.

➢ To display the Op Controls panel: from the Main menu Inverter Control
option, select Op Controls.

Op Controls Panel

Refer to the procedure, Manual The inverter Op Controls panel is active only when the inverter is in Manual mode. If the
Mode. operator attempts to adjust a setpoint while the inverter is in Automatic mode, the
following message displays.

Click OK and place the

inverter in Manual mode .

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 The following Op Controls procedures are available:

• Adjust the maximum Power Limit

• Adjust the Power Ramp rate
• Adjust the Power Factor (Pf) Control
• Adjust the VAR Control setpoint

➢ To adjust the maximum power limit

1. Make sure the inverter is in Manual mode.
2. From the Op Controls panel, enter the value of the setpoint in the Power Limit
field.

Click the arrow to

apply the value.

The power limit setpoint must be

in the range of 1 to 1000 kW. If it
is not, this message display .

Click OK and enter a value that is

within the acceptable range.

Note The Curr val box displays real-time feedback from the inverter. To verify that the
Power Limit setpoint is active, make sure the value displayed in the Curr val box is in line
with the setpoint.

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 ➢ To adjust the power ramp rate
1. Make sure the inverter is in Manual mode.
2. From the Op Controls panel Power Ramp option, click Enable.

The red light beside Enable indicates Enter

Enter the desired
value for the
that the Power Ramp rate setpoint
value for and click the
the setpoint
adjustment is enabled. arrow.
and click the arrow.

The power ramp rate setpoint must

Inverter Power Ramp rate response
be in the range of 0 to 1000 kWs.
can be governed by the Maximum If it is not, this message displays .
Power Point Tracker (MPPT)
rather than the Power Ramp setting. Click OK and enter a value that is
within the acceptable range .

Note The Curr val box displays real-time feedback from the inverter. To verify that the
Power Ramp rate setpoint is active, make sure that the value displayed in the Curr val box
is in line with the setpoint.

The inverter can provide ➢ To adjust the power factor (Pf) control
reactive power control in either 1. Make sure the inverter is in Manual mode.
Power Factor (Pf) mode or
VAR control mode. 2. From the Op Controls panel Power Pf Control option, click Enable.

The red light beside Enable

Enter the value for the
indicates that the Power Pf
setpoint and click the arrow.
Control rate adjustment is
enabled.

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 The power Pf control rate setpoint
must be in the range of 0.9 to -1.
If it is not, this message displays .

Click OK and enter a value that is

within the acceptable range .

Note The Curr val box displays real-time feedback from the inverter. To verify that the
Power Pf Control setpoint is active, make sure the value displayed in the Curr val box is
in line with the setpoint. Additionally, the calculated VAR Control value is updated and
displayed in the Curr val box in the VAR Control area.

➢ To adjust the VAR control setpoint

1. Make sure the inverter is in Manual mode.
2. From the Op Controls panel VAR Control option, click Enable.

The red light beside Enable

indicates that the VAR Enter the value for the
Control rate adjustment is setpoint and click the arrow.
enabled.

The VAR control setpoint must be in

the range of -1000 to 1000 kVAR .
If it is not, this message displays .

Click OK and enter a value that is

within the acceptable range .

Note The Curr val box displays real-time feedback from the inverter. To verify that the
VAR Control setpoint is active, make sure the value displayed in the Curr val box is in
line with the setpoint.

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 [Link] I/O and Variables
➢ To display the I/O and Variables panel: from the Main menu, Inverter
Control option, select I/O & Variables to display the inverter control inputs and
outputs variables tables.

Inverter Control I/O and Variables Tables

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 2.3.3 Performance Data I/O and Variables
These tables include all of the calculated values for inverter performance.

➢ To display the performance data I/O and variables: from the Main menu
Performance Data option, select I/O & Variables to display the inverter
performance inputs and outputs variables tables.

Inverter Control Performance Data I/O and Variables Tables

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 2.3.4 Site Conditions I/O and Variables
➢ To display the site conditions I/O and variables: from the Main menu Site
Conditions option, select I/O & Variables to display the environment, grid, and
PV array status information tables.

Inverter Control Site Conditions I/O and Variables Tables

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 2.3.5 Array Sub-combiner I/O and Variables
➢ To display array sub-combiner I/O and variables: from the Main menu
Array Subcombiner option, select I/O & Variables to display the array
Subcombiner Inputs and Outputs data tables.

Inverter Control Array Subcombiner I/O and Variables Tables

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2.4 Control Panel Status Bar
The Control Panel Status bar aligns on the bottom of the web page and displays inverter
system information.

Monitor Control mode icon indicates when

the operator is locked out (locked) or SunIQ version info /Help file
can perform control commands (unlocked) Timout indicator
System Timestamp

Inverter ID icon
Connection Status between
web page and controller Model Number

Inverter Real Inverter Array Total Produced

Power (kW) Voltage (V dc) Power (MWh)

Control Panel Status Bar Features

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2.5 Trending
The Trending bar graph displays inverter control or site condition variables in real time. It
updates every second to display current data for the selected variable until the Pause
Each monitored variable has a button is selected. Data collection continues in the background while the trend graph is
minimum and maximum value paused. When the trend graph is resumed, it displays the real-time data plus the data
for display resolution. collected during the pause period.

From the drop down menu, From the Duration menu, adjust the
select either InverterControl timeframe. Options include 1, 5, 15, Click Pause to freeze the trend graph
or SiteConditions . 30, or 60 minutes). or Resume to restart trending.

In the bar graph,

click any y-axis
to index.

Trending Features

InverterControl trending includes:

• Array Voltage (V dc)

• Real Power Output (kW)
• Reactive Power Output (kVar)
SiteConditions trending includes:

• PV Array Temp (°C)

• Irradiance (W/m2)
• Array Voltage (V dc)
• Real Power Output (kW)

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3 Configuration and Troubleshooting
Refer to the ToolboxST User The ToolboxST* application is used to configure, troubleshoot, and tune for
Guide for Mark* Controls commissioning the inverter, as needed. It features Microsoft® Windows®-based menus,
Platform (GEH-6700), the block diagrams, dialog boxes, and wizards on a computer-based interface.
chapters related to Power
Conversion Control.
3.1 System Parameters
The ToolboxST application enables the user to view and modify system parameters.

➢ To modify parameters

Note This procedure requires ControlST Software Suite V04.04 or higher.

1. From the ToolboxST application File menu, select Open System and select the
system file to display the System Editor .

Double-click the controller .

Configuration and Troubleshooting GEH-6777C Operation and Maintenance Guide 29

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 From the View menu, select
Control Constants to display the
Solar Control Constants Editor .

Double-click a parameter to modify and display the Send Value dialog box .

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 Enter the Next value
and click Send & Close.

The Not Equal symbol displays for the parameter that was modified.

2. From the Component Editor, click Build to rebuild the Mark VIe controller.
3. Click Download to download the new configuration settings.
4. Verify that the Not Equal symbol is removed.
Parameters may also be modified using the Watch Window feature. The Watch Window
feature displays variables in a stand-alone window. The variable Parameter_Setting
contains all of the parameter information.

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 Parameter_Setting Watch Window

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 3.1.1 Forced Variables
➢ To view forced variables

From the View menu,

select Forced Variables.

The Forced Variables

on Solar window displays
the variable name, value,
and description.

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 [Link] Ambient Temperature and Altitude Derating
When external ambient temperature changes, the inverter control derates output power on
a defined slope.

Note The following tables and charts are valid for up to 1000 meters.

1 MW Ambient Temperature and Output Power Derating

Ambient Temperature Output Power Derating
From 50 to 55°C (122 to 131 °F) Power will linearly derate to 1100 kW
From 55 to 60°C (131 to 140 °F) Power will linearly derate to 0 kW

Ambient Derating

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 Note For UL™ 1741 applications (applies to 1 MW Inverter only), utility interactive
inverters must respond to abnormal changes in grid voltage and frequency. UL 1741, with
the IEEE™ 1547 standard, defines the abnormal voltage and frequency ranges and the
default times for an inverter to cease exporting energy to the grid during an abnormal
condition. These standards also allow the ranges and times to be field adjustable for large
output power inverters.

3.1.2 Utility Interconnection Voltage, Frequency Trip

Limits, and Trip Times
Two sets of voltage and frequency ranges, and clearing times are displayed in the
following table. The values in the left side of the table are the default settings when the
inverter ships from the factory. The values in the right side of the table are the field
adjustable settings.

Utility Interconnection Voltage and Frequency Trip Limits with Trip Times
Factory Default Settings Field Adjustable Settings
Voltage Range (% of 480 V ac) Clearing Time (sec) Voltage Range (% of 480 V ac) Clearing Time (sec)
V < 50 0.16 0 < V < 80 0.16 to 1
50 ≤ V < 88 2.0 0 < V < 90 1 to 2
110 < V < 120 1.0 105 < V ≤ 110 0.5 to 1
V ≥ 120 0.16 110 < V ≤ 120 0.16 to 0.5

Frequency range (Hz) Clearing Time (sec) Frequency range (Hz) Clearing Time (sec)
> 60.5 0.16 60.2 to 63 0.16 to 300
< (59.8 to 57.0) 0.16 57 to 59.8 0.16 to 300
< 57.0 0.16 57 to 59.8 0.16

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 ➢ To adjust utility interconnection voltage/frequency trip limits and times

From the System Editor , double -click the Power

Conversion control to display the Component Editor.

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 From the Settings tab Tree View, expand Application
Settings , and select Standard Interconnect.

For UL 1741 applications, adjust the trip setting and trip times within limits.

For non-UL 1741 applications, set the Stdlnter Connect Tool Value to No
to disable the voltage and frequency trip limits and times .

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Notes

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4 Preventative Maintenance and
Replacement
Preventative maintenance is the detection and correction of conditions that may cause
future equipment malfunction. Recommended preventive maintenance includes
inspections for damage and wear, tests, and cleaning of equipment at regular intervals.

This equipment contains a potential hazard of

electric shock or burn. Only adequately trained
persons who are thoroughly familiar with the
equipment and the instructions should maintain this
equipment.

To prevent electric shock while servicing the

Warning equipment, personnel must understand and follow
all safety requirements for working around
dangerous voltages.

Opening the dc disconnect switch (Q2 - SAPC) and

the ac main circuit breaker (Q1- GPC) does not fully
de-energize the breaker’s input terminal bus work.
Before opening either the SAPC or GPC cabinets,
the dc source from the PV array and the ac source
Warning from the transformer must be de-energized at their
source.

Preventative Maintenance and Replacement GEH-6777C Operation and Maintenance Guide 39

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4.1 Inspection and Maintenance Schedule
For maximum benefit, preventive maintenance must be performed at scheduled intervals
by a qualified technician. The required frequency for each procedure depends on the
following:

• How often the equipment is used

• Ambient environmental conditions

Frequency Method Inspection and Maintenance Items

After initial 6 Visual Check all equipment, components, subassemblies, wiring, and insulation system.
months of inspection Check enclosure integrity (presence of corrosion, door seals, and such).
operation, then Check the IGBTs and inverter control boards for discoloration.
annually Check the power capacitors for signs of damage.
thereafter Check the appearance and cleanliness of the cabinet, ventilation system, and insulated
surfaces.
Check for corrosion on all terminals and cables.
Check the fuses in the inverter and combiner for signs of heating.
Check the condition of heaters (look for signs of over heating).
Check the condition of both the ac and dc surge suppressors.
Check the coolant level and condition and top off if necessary.
Refer to the section, Coolant Level Check.
Check the operation of status lights.
Refer to the section, Operation of Exterior Status Lights and Replacement.
Clean the air filters and replace as needed.
Refer to the procedure, Air Filter Cleaning and Replacement.
Check fan operation and for presence of noise or vibration.
Check the operation of all safety devices, including the E-Stop circuit and Ground Fault
Detector Interrupter (GFDI).
Refer to the section, Safety Chain Operation Inspection.
Operation Check nuts, bolts, screws and connectors for tightness and heat discoloration.
check Refer to the section, Mechanical Connections.
Inspect the breaker, including manually charge, close, and trip/contact inspection.
Annually Operation Check nuts, bolts, screws and connectors for tightness and heat discoloration.
check
Inspect breaker, including manually charge, close, and trip/contact inspection.

Refractometer Using a refractometer with an ethylene glycol scale, verify that the coolant concentration is
still within the 50/50 requirement. Flush and replace the entire coolant if it is not 50/50.

Every 5 years Component Check blower and fans operation, temperature, and for presence of noise and vibration.
check and Replace as needed.
replacement Refer to the section, Blower and Fan Inspection.

Check coolant pump operation, temperature, and for presence of noise and vibration.
Replace as needed.

Every 10 Component Perform a coolant flush and refill coolant.

years replacement Refer to the procedure, Add Coolant.

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4.2 Maintenance Record
Keep a detailed record of maintenance (such as a log book) for every inverter. This record
serves two purposes:

• Verifies that equipment is routinely checked

• Aids troubleshooting and prevention of equipment failure by providing a history of
equipment maintenance and problems

4.3 Maintenance Procedures

Print this section to use as a These procedures describes the operation check and component replacement
record of completed requirements. The procedure to check for wear and damage through visual inspection is
preventative maintenance. by comparison to the equipment when new.

With power applied, this equipment contains a

potential hazard of electric shock or burn. The
nominal voltage of the mains of this equipment is
480 V ac and the DC Link voltage can be up to 1000
V dc.

Warning Only adequately trained persons who are

thoroughly familiar with the equipment and the
instructions should maintain this equipment.

To prevent electric shock while servicing the

equipment, personnel must understand and follow
all safety requirements for working around
dangerous voltages.

Voltage measurement equipment and safety

Warning equipment/procedures for this application should be
used. IEC-61010 and UL-3111 are possible sources
of information.

With power applied, the cooling fans and heaters

may operate without warning.

Make sure that all power sources to the equipment

are turned off, then discharge and ground the
equipment before performing any adjustments,
Warning servicing, or other acts requiring physical contact
with the circuit cards, electrical components or
wiring.

Wear appropriate hearing protection when working

around this equipment.

Acoustic noise levels are as follows:

1 m (3.3 ft) from front of enclosure: 77 dBA average

Warning
1 m (3.3 ft) from back of enclosure: 78 dBA average

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 Read and follow all safety warnings and instructions
provided on the coolant container.
Warning

Use a small step ladder or platform for reaching

equipment that is at or above 2 m (6.6 ft) high.
Warning

Opening the dc disconnect switch (Q2 - SAPC) and

the ac main circuit breaker (Q1- GPC) does not fully
de-energize the breaker’s input terminal bus work.
Before opening either the SAPC or GPC cabinets,
the dc source from the PV array and the ac source
Warning from the transformer must be de-energized at their
source.

To prevent equipment damage, take care to prevent

loose fasteners from falling into the equipment.
Keep all fasteners in a secure location for use when
installing the replacement phase module.
Caution

To prevent equipment damage, do not allow coolant

to be spilled on circuit boards, other electrical
components, or electrical insulation. The coolant
contains conductive material and is difficult to
Caution remove.

While working on the module replacement, do not

set any tools, hardware, rags, etc. on the top of the
capacitor bank modules. These things could have
coolant on them or this coolant could be on hands
that are touching parts of the module. Any coolant
on the module could cause major equipment
damage.
Caution
While working on the equipment, be sure to place
all tools, hardware, and rags outside of the cabinet.

To prevent equipment damage, follow all fastener

torque requirements listed.

Caution

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 4.3.1 Maintenance with Equipment Energized
The following maintenance requires the inverter to be energized. Perform these
procedures at the beginning of the preventative maintenance schedule.

[Link] Air Filter Cleaning and Replacement

The air filters supplied on the inverter are designed to provide efficient filtering and
airflow to the internal components for up to one year. The filters should be inspected at
regular intervals and replaced as necessary. The filter element should be replaced if the
integrity of a filter is compromised in any way, such as holes or deformation that allow
ingress of unfiltered air. All air filters are replaceable from the outside of the inverter.
Clean the air filters if the following issues are detected:

• Excessive dirt buildup is present

• Inverter thermal diagnostics indicate high or rising temperatures

➢ To clean the air filters: follow the cleaning instructions imprinted on the side of
the filters and observe proper air flow direction indicators.

Note Air filters are located outside the CFC on both the back and front side of the
inverter.

➢ To replace CFC air filters

1. Disengage the louver hood clips, and lift the louver hood to expose the filter. The
filter is located behind the air louvers.
2. Pull directly up on the filter and remove it.
3. Install the new filter into the slot vacated by the removed filter. The filter does not sit
flush with the louvers; it will protrude 10 mm (0.5 in).
4. Lower the louver hood and re-engage the louver clips.

➢ To replace Grid Power Cabinet (GPC) and Solar Array Power Distribution
Cabinet (SAPC) air filters
The vent hood does not need to 1. Reach under the filter hood and lift the filter up.
be removed to replace the GPC
2. Pull the bottom of the filter forward and then down to dislodge it from the filter
or SAPC air filters.
bracket.
3. Install the new filter by sliding it into the filter hood from the bottom and into the
space vacated by the removed filter.
4. Ensure that the filter is seated properly and the sheet metal lip holds the bottom in
place.
5. Repeat the replacement procedure for the second filter.

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 [Link] Blower and Fan Inspection
Walk around the unit and listen for abnormal noises that could be related to malfunction
of the blower or cooling fans. Verify that the fans are operating by placing your hand
under the roof eave in front of each fan exhaust.

[Link] Operation of Exterior Status Lights and Replacement

There are three status lights (LEDs) on the door of the MCC. The following table
describes the indication of each LED.

Lens Color Indication

Green Inverter Online
Yellow Inverter Standby Mode

Red Inverter Faulted

The lights glow dimly to indicate that the LED is operational. The light glows brightly to
indicate an active status. If a light is not dimly illuminated, the LED must be replaced.

➢ To replace an LED: remove the lens cap and pull outward on the bulb.

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 4.3.2 Maintenance with Equipment De-energized
Certain maintenance procedures require that the inverter be de-energized before
maintenance can be safely performed.

This equipment contains a potential hazard of

electric shock, burn, or death. Only personnel who
are adequately trained and thoroughly familiar with
the equipment and the instructions should install,
Warning operate, or maintain this equipment.

➢ To de-energize the inverter

1. Review safety and work precautions.
2. Open the MCC door and locate the three control switches on the upper left side.

Turn the Maintenance

switch to the Yes position.

Maintenance Switch

Opening the dc disconnect switch (Q2 - SAPC) and

the ac main circuit breaker (Q1- GPC) does not fully
de-energize the breaker’s input terminal bus work.
Before opening either the SAPC or GPC cabinets,
the dc source from the PV array and the ac source
Warning from the transformer must be de-energized at their
source.

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 3. De-energize both the dc disconnect switch (Q2-SAPC) and the ac main circuit
breaker (Q1-GPC). Verify that all power sources to the equipment have been
disconnected according to the relevant lockout tagout procedures.
4. Wait at least 20 minutes before opening any enclosure doors to allow the DC Link
capacitors to discharge to < 50 V pk.
5. Locate the Power Conversion Wired-OR (WEOR) board in the lower right area of the
enclosure. Carefully remove any protective shield.
6. On the WEOR board, measure the DC Link voltage by connecting a probe between
fuses FU4 and FU5 using the access holes provided in the protective shield.

WEOR Board

Do not proceed until the DC Link voltage is less

than 5 volts.
Warning

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 7. Open the Converter Bridge Cabinet (CBC) door (located behind the MCC).
8. Visually inspect the power converter without touching any part of the converter.

If obvious damage to IGBT modules, circuit

boards, DC Link capacitors or the DC Link bus
structure is present, STOP! Do not proceed.
Contact the nearest GE sales or service office, or
Attention an authorized GE sales representative.

9. From the CFC, short the DC Link by connecting a ground cable to chassis ground.

Ground Cable in CFC

10. From the CBC, apply grounds to the DC Link positive and negative bus.

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 Ground Cables in CBC

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 4.3.3 Dust Removal
Dust buildup on components can increase operating temperature, which reduces their
normal operating life. Dust on standoff insulators can collect enough moisture to produce
a current path to chassis ground. Dust (especially metallic dust) on wire surfaces can
cause tracking between connector pins. Tracking is usually capacitive in nature and
involves a buildup of electrical charge along the wire surface, which can cause
intermittent problems that are hard to find.

Dust buildup on electrical components and wiring

can damage components and cause mis-operation.

Caution
➢ To remove dust from the control components
1. Clean standoff insulators with a clean dry cloth. Do not use any solvents.
2. Using a fine-filtered vacuum cleaner with a non-metallic nozzle, remove dust and dirt
from wiring and electrical components.
3. Examine the parts for pitting or other signs of metal deposits on insulation or
insulated parts. If parts are pitted, do not reuse.

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 4.3.4 Mechanical Connections
Check nuts, bolts, screws and connectors for tightness and heat discoloration. Vibration
during equipment operation can loosen mechanical and electrical connections and cause
intermittent equipment failure. Additionally, dust and moisture in loose connections can
cause loss of low-level signals at terminal boards and thermal runaway at bus
connections.

➢ To check connections
1. Check all hardware and electrical connections by attempting to move the device/wire,
and tighten if needed.
2. Tighten or replace any loosened crimp-style lugs.
3. Tighten or replace all loose or missing hardware.
4. Inspect circuit boards for correct seating, and verify that all plugs, wiring, and bus
connectors are tight.
5. Inspect equipment and component surfaces for signs of moisture or moisture damage.
If present, the surface should be wiped clean and replaced if necessary.
6. Inspect the door gasket for wear or damage and replace if necessary.
7. Verify that the four pairs of weep holes in the base of the CFC cabinet are free from
obstruction.

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 [Link] Torque Requirements for General Hardware

To prevent component damage caused by static

electricity, treat all boards and devices with
static-sensitive handling techniques. Wear a wrist
grounding strap when handling boards or
components, but only after boards or components
have been removed from potentially energized
Caution equipment and are at a normally grounded
workstation.

To prevent equipment damage, do not remove,

insert, or adjust board connections while power is
applied to the equipment.
Caution
Mechanical Hardware
Torque Nut Side Torque Bolt Side
Hardware Designation x Pitch
Nm ft-lbs Nm ft-lbs
M5x0.8 2.8 2.1 3.4 2.5
M6x1.0 9.5 7 11.4 8.4
M8x1.25 22 16 26 19
M10x1.5 34 25 41 30
M12x1.75 95 70 114 84
M16x2 196 144 236 174

Electrical Hardware
Torque Nut Side Torque Bolt Side
Hardware Designation x Pitch
Nm ft-lbs Nm ft-lbs
M6x1.0 5.4 4 6.5 4.8
M8x1.25 11 8.1 13 9.6
M10x1.5 19 14 23 17
M12x1.75 47 35 57 42
M16x2 95 70 114 84

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 4.3.5 Wire and Cable Inspection
Wires and cables with damaged insulation are dangerous when carrying electricity. They
can also intermittently short, causing equipment malfunction and failure.

➢ To inspect wires and cables

1. Check all wires and cables for fraying, chipping, nicks, wear, or rodent damage.
2. Check all wires and cables for signs of overheating or carbonization.
3. Repair minor low voltage insulation damage with a good grade of electrical tape. If a
damaged cable carries high voltages, replace the cable.
4. Replace any cables or wires that have more than mild damage.

4.3.6 Board and Module Cleaning

The MCC and CBC are air-cooled by an internal air-to-air heat exchanger. The internal
circuit boards are not exposed to external environmental conditions.

➢ To clean circuit boards/modules: if fine dust has settled on the boards or

modules, use a vacuum cleaner with non-metallic nozzle.

4.3.7 Cooling System Scheduled Maintenance

The liquid cooling system controls the power converter IGBT temperature. Heat
generated by the IGBTs operation is transferred to the coolant by the heatsinks and
rejected to air by the heat exchanger. The converter’s control software implements an
algorithm to ensure thermal regulation of the liquid coolant.
The power converter cooling The liquid cooling system capacity is 14.2 liters (3.75 gallons). The liquid reservoir
system is designed to last the maximum capacity is 45.4 liters (12 gallons). Required scheduled maintenance for the
life of the product with proper cooling system includes:
maintenance.
• Coolant Level and Condition Check
− Check the coolant level in the reservoir and replenish as needed.
− Perform the procedures in the sections, Coolant Level Check and Add Coolant.
− Inspect the cooling system for leaks and repair as needed.

• Coolant Replacement
− Completely replace the coolant to renew the corrosion inhibitors in the coolant.
− Perform the procedures in the sections, Drain Coolant and Add Coolant.

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 Equipment Required for Maintenance
Description Part Number Quantity
Antifreeze 151X1220PX01PC01 As required
Refractometer with ethylene glycol scale N/A 1
Utility Pump ~ 9 lpm at 9 m (2.4 gpm at 30 ft) NA 1
Drain/Mix container ~ 18.9 l (5 gal) N/A 3
Graduated Mix container: 7.6 l capacity (8 qt) N/A 2
Hose 1: pump to Drain/Mix container 9 mm (3/8 in) min ID N/A 1
Hose 2: pump to power converter reservoir 9 mm (3/8 in) min ID with N/A 1
male garden hose connector
Cloth N/A As required

Coolant Concentration
Item Description
Coolant Mixture of 50% water and 50% inhibited ethylene glycol antifreeze GE part number 151X1220PX01PC01.
This part number is for 1 gallon. Products that conform to this drawing are Zerex™ G-05 or BASF™ G05.

New coolant concentration can be controlled by volume measurement using a refractometer with an
ethylene glycol scale. Coolant concentration in a power converter is best determined with a refractometer
with an ethylene glycol scale.
Water Distilled water

Potable water is not recommended due to the variation in

mineral and chemical content variation.

Caution
Antifreeze 50% concentration of antifreeze provides freeze protection to -34ºC (-30 ºF).
55% concentration of antifreeze provides freeze protection to -40ºC (-40 ºF).

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 [Link] Coolant Level Check
➢ To measure the coolant level
Refer to the procedure, To 1. Verify that the inverter has been properly de-energized.
de-energize the inverter.
2. Open the front doors of the CFC.
3. Locate the pressure regulator installed on the top of the reservoir. Press the button on
top of the pressure regulator to release any pressure that may have built up inside the
tank. Verify that the regulator is set to ±1.5 psi.

Reservoir and Other Cooling System Components

4. Unscrew the pressure regulator by hand to open the top of the reservoir.
5. Remove the dipstick from the right sidewall beside the reservoir and place it inside
the tank. The dipstick should rest on the edge of the regulator opening.

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 6. Remove the dipstick and read the coolant level from the graduated surface. The
dipstick has three marks, as displayed in the following figure. Make sure the liquid
level does not exceed the Max Pump marks, depending on the state of the pump
motor.

RESERVOIR
VENT HOSE
LIQUID
TO PRESSURE
LEVEL CHECK
RELIEF VALVE
AND FILL PORT Reservoir vent hose to
Liquid level check pressure relief valve
and fill port

368. 503
368.503 mm
[14.51in)
(14.51
MAX PUMP OFF
Max Pump OFF
310. 083mm
310.083
[12.21] in)
(12.21
MIN
Min PUMP
PumpOFF OFF
OR
Or
MAX PUMP ON
Max Pump ON
249. 123
249.123 mm
[9.81]
(9.81 in)
MIN
Min PUMPON
Pump ON

7. Clean the dipstick and any coolant spills with a cloth. Return the dipstick to the right
sidewall. Dispose of all waste coolant and used cloth rags per site environmental,
health, and safety (EHS) procedures.
8. Screw the pressure regulator back in the reservoir’s opening hand tight. Close and
secure the CFC doors.

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 [Link] Add Coolant
➢ To add coolant
1. Open the front doors of the CFC.
2. Locate the pressure regulator installed on the top of the reservoir. Press the button on
top of pressure regulator to release any pressure that may have built up inside the
tank. The regulator is set to ±1.5 psi.
3. Unscrew the pressure regulator to open the top of the reservoir. Insert the hose
connected to the utility pump outlet into the reservoir opening.
4. Mix the required amount of coolant in a container.
5. Place the hose connected to the utility pump inlet in the coolant mix.
6. Power the utility pump to pump coolant into the reservoir. Turn off the utility pump
and remove the hose from the reservoir when the mixture container empties.
Refer to the section, Coolant 7. Check the coolant level.
Level Check.
8. Screw the pressure regulator back in the reservoir’s opening.
9. Clean up any coolant spills with a cloth. Dispose of all waste coolant and used cloth
rags per site EHS procedures.
10. Close and secure the CFC doors.

[Link] Drain Coolant

➢ To drain coolant
1. Open the front doors of the CFC.
2. Do not operate the coolant pump for at least 30 minutes to let the system drain into
the reservoir.
3. Locate the pressure regulator installed on the top of the reservoir. Press the button on
top of pressure regulator to release any pressure that may have built up inside the
tank. The regulator is set to ±1.5 psi.
4. Unscrew the pressure regulator by hand to open the top of the reservoir. Place the
hose connected to the utility pump inlet through the reservoir opening.
5. Place the hose connected to the utility pump outlet into the drainage container.
6. Power the utility pump to pump the coolant from the reservoir. Turn off the utility
pump and remove the hose from the reservoir when the drainage operation is
complete.
7. Screw the pressure regulator back in the reservoir’s opening.
8. Clean up any coolant spills with a cloth. Dispose of all waste coolant and used cloth
rags per site EHS procedures.
9. Close and secure the CFC doors.

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 4.3.8 Power Circuit Breaker Inspection
➢ To inspect ac and dc power circuit breakers
Refer to the procedure, To 1. Verify that the inverter has been properly de-energized.
de-energize the inverter.
2. Inspect the enclosure. The enclosure should be clean and dry. All covers and trip
pieces should be in place.
3. Check for cracks in the molded case. Any circuit breaker with a cracked molded case
should be replaced because its ability to withstand short-circuit interruption stresses
is reduced.
4. Check for signs of overheating. Visually inspect electrical components for
discoloration. This may indicate overheating. If there is no evidence of overheating
or loose connections, do not disturb or re-torque connections.
5. Clean the circuit breaker. Remove any buildup of dust, dirt, grease or moisture from
circuit breaker surfaces with a lint-free dry cloth or vacuum cleaner. Do not use
compressed air. Use caution when using detergent-based cleaners or solvents: these
may deteriorate faceplate labels, and insulation materials. Clean contact surfaces of
circuit breaker terminals and terminal pads or bus bars with a nonabrasive cleaner.
Abrasive cleaners will remove plating, resulting in joint deterioration.
6. Exercise circuit breaker mechanism: Manually charge the operating spring to ensure
that mechanical linkages are free. Verify that the spring charge/discharge indicator is
functioning properly. Press the Close button and confirm the status indicator is
functioning properly. Trip the circuit breaker with the Push-to-trip button. Repeat
to ensure operability. If the circuit breaker does not trip, or if it does not reset after
tripping, it must be replaced.
7. Check the contact gap by first removing the screws securing the arc chutes and then
lifting the arc chutes from the breaker case.

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 4.3.9 Safety Chain Operation Inspection
Before returning the inverter to service, check the operation of all safety devices,
including the E-Stop circuit and Ground Fault Detector Interrupter (GFDI).

➢ To check the E-Stop circuit

1. Remove the factory-installed jumper between terminal board points. The E-Stop
factory-installed jumper is between terminal board points X6.2-1(2) and X6.2-2(2).
2. Perform the procedure, Return the Inverter to Service. The inverter should trip on a
safety string fault.

➢ To check the GFDI

1. Remove the GFDI fuse located in the SAPC cabinet.
2. Perform the procedure, Return the Inverter to Service. The inverter should trip on a
GFDI blown fuse fault.

4.3.10 Fan and Blower Replacement

➢ To replace the CBC air circulation fans (FAN 2, 3, 4)
Refer to the procedure, To 1. Verify that the inverter has been properly de-energized.
de-energize the inverter.
2. Verify that all connectors to the fan assembly to be replaced are correctly labeled and
disconnect them.
3. Remove the four mounting M4 Keps™ nuts.
4. Remove the fan.
5. Ensure the replacement fan has LEXAN* installed exactly as it was on the fan being
replaced.

Note The LEXAN must remain installed on the replacement fan.

6. Reorient the new fan in place and secure with new Keps nuts to replace those
removed in step 3. Tighten in accordance with the table, Torque Requirements for
General Hardware.
7. Reconnect all connectors removed in step 2. Tighten each nut to 0.5 Nm (4 in-lb).

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 ➢ To replace the GPC or SAPC ventilation fan

Note Strictly follow all safety precautions and lockout tagout procedures.

Refer to the procedure, To 1. Verify that the inverter has been properly de-energized.
de-energize the inverter.
2. Verify that all connectors to the fan assembly to be replaced are correctly labeled and
disconnect them.
3. Remove the eight mounting M6 Keps nuts that hold the fan plenum in place.
4. Remove the entire plenum and fan assembly.
5. Remove the four self-tapping screws that hold the fan to the plenum.
6. Remove the fan.
7. Reorient the new fan in place and secure with the screws removed in step 5. Tighten
in accordance with the table, Torque Requirements for General Hardware.
8. Reorient the new plenum and fan assembly in place and secure with new Keps nuts
to replace those removed in step 3. Tighten in accordance with torque requirements.
9. Reconnect all connectors removed in step 2. Tighten each nut to 0.5 Nm (4 in-lb).

➢ To replace the CFC blower

Removal and replacement of the blower will require

at least two people for lifting due to its weight.

Attention
1. Verify that all connectors to the blower assembly are correctly labeled and disconnect
them.
2. Remove the fourteen M6 bolts holding the blower transition duct to the CFC wall.
3. Remove the twelve M8 Keps nuts holding the blower assembly to the roof, taking
care to support the blower as the nuts are loosened.
4. Remove the entire blower and transition duct.
5. Remove the twenty M6 bolts holding the transition duct to the blower.
6. Install the transition duct onto the new blower using the hardware removed in step 5.
Tighten in accordance with the table, Torque Requirements for General Hardware.
7. Reorient the new blower and transition plenum assembly into place and install using
new Keps nuts to rplacce those removed in step 3. Tighten in accordance with torque
requirements.
8. Reattach the transition plenum using the hardware removed in step 2. Tighten in
accordance with torque requirements.
9. Reconnect all connectors removed in step 1. Tighten to 1.7 Nm (15 in-lb).

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 4.3.11 Coolant Pump Replacement
Required Materials
Quantity Material (M) Number Description
1 107W8971P001 Replacement pump
1 107W9037G001 Pump replacement kit – series units (gaskets,
connectors, grommet, and so forth)

➢ To replace the coolant pump

Refer to the procedure, To 1. Verify that the inverter has been properly de-energized and grounded.
de-energize the inverter.
2. Verify that all connectors to the pump assembly to be replaced are correctly labeled
and disconnect them.
3. Open the CFC cabinet door on the front side of the inverter to access the pump
assembly.
4. Before disconnecting any of the system hoses, release the pressure in the system by
pressing the pressure regulator release button.

Pressure Regulator Release Button

5. Disconnect all wiring to the pump.

6. Remove the door sill across the reservoir to access the bolts securing the reservoir as
well as the connections to the heater and temperature switch.

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 7. Remove the R-C suppressor from the reservoir lid by cutting the attachment zip ties.

8. Remove the wiring from the temperature sensor, temperature switch, and fluid heater.

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 9. Remove any wiring clips that could be damaged during the removal of the reservoir.
10. Remove the reservoir and then move all wiring out of the way.
11. Wait 15 to 30 minutes after the converter cooling pump has been shut down before
removing hoses. This will minimize the amount of coolant that will drain from the
system after the hoses are disconnected.
12. Remove all red hoses connected to the top of the reservoir. Catch all residual coolant
in a drip pan. Minimal coolant will drain from these hoses if the system has been shut
down 15 to 30 minutes.
13. Remove the four bolts that mount the reservoir to the CFC cabinet.

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 14. Verify all obstructing components are removed (wiring clips, ground tap, and so
forth).
15. Slide the reservoir out of the cabinet and onto supporting blocks.
16. Remove the 14 mounting bolts holding the reservoir cover and pump subassembly to
the reservoir.

17. Remove the pump subassembly from the reservoir.

Note Allow the coolant in the pump to drain into the reservoir as the pump subassembly
is removed.

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 18. Carefully remove the inlet hat from the pump.

19. Remove the pump subassembly from the reservoir lid by removing the four mounting
bolts.
20. Clean the mounting and reservoir sealing surfaces in preparation for reassembly.
Take care not to contaminate the coolant while cleaning the reservoir sealing surface.
21. Install the lid gasket and lid to the new subassembly.

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 22. Install the new subassembly and the four mounting bolts.

23. If an inlet hat is not supplied with the replacement pump, clean the original hat and
install it on the new pump. Remove only the required pump housing bolts. Not all
pump housing bolts should be removed. Avoid any separation between the pump
housing and base joint.

If the pump housing is completely removed from the

pump base, the pump seal can be damaged or
pinched and will result in future converter cooling
pump trips.
Caution
24. Remove any debris before reassembling the system. Take care not to contaminate the
coolant.
25. Install the reservoir lid gasket on the reservoir.

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 26. Install the pump subassembly into the reservoir and loosely attach all mounting bolts.

27. Once all bolts are hand tight, torque the bolts to 12.4 Nm (110 in-lb).
28. Slide the reservoir back into the cabinet and reattach the assembly to the base.
29. Apply weatherproof sealant to the bottom of the door sill and reattach to the base.
30. Remove the cover from the electrical junction box and connect all pump wiring.
a. Install the supplied wiring grommet into the appropriate hole in the side of the
motor junction box.
b. Cut the supply wires directly behind the original stab connectors.
c. Route the supply wires through the supplied grommet and into the motor
junction box.
d. Cut the supply wires approximately 0.13 m (5 in) from the housing and strip
approximately 0.01 m (0.38 in) of the insulation from the end of each wire.
e. Cut the joining wires in the motor electrical junction box approximately 0.13 m
(5 in) from the housing and strip 0.01 m (0.38 in) of insulation from the end or
each wire.

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 f. Connect the wires as displayed in the figure, Wire Connection. Twist the defined
wire ends together and install the crimp connectors. Crimp the splice connectors
and test for an adequate connection by gently pulling on the wires.
g. Install the cover on the electrical junction box.

Take care when positioning the wires in the

electrical junction box to ensure the wires are not
damaged by the cover.
Attention

Wire Connection

31. Reconnect all sensor wiring and reattach the R-C suppressor.

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 32. Connect the two coolant hoses to the reservoir as displayed in the following figures.
One hose goes from the heat exchanger to the reservoir, while the second hose goes
from the bridge/manifold to the pump outlet on the reservoir.
a. Install each hose to its fitting with a minimum overlap of 2 in (50 mm).
b. Install two clamps on each hose with the clamp screws 180° apart. Place one
clamp 0.2 in (5 mm) from the end of the hose and the other clamp 0.2 in (5 mm)
from the first.
c. Torque all clamps from 2.5 to 3 Nm (22 to 27 in-lb).

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 Use the specified coolant only – Zerex G-05.

Attention
33. With the pump turned off, check the coolant level on the dipstick.
34. Verify that the coolant level reaches the top notch on the dipstick.
35. If the coolant level is below the top notch, fill the system to the appropriate level.
36. Inspect the area for any tools and materials left in the cabinet.

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 4.3.12 IGBT Phase Module Replacement
In the event of a failed component in any of the IGBT phase modules, the entire phase
module must be replaced. This section provides the steps required to replace damaged
IGBT phase modules.
IGBT phase module replacement is required when any of the following conditions are
observed:

• Base plate or junction temperatures are erratic and are not tracking properly, and
cooling system flow to and from the phase have been verified
• IGBT fails the cell test
• IGBT fails catastrophically

Description Unit GE Part Number Salem Part Number

IGBT phase module 700 kW, 1 MW, 1.25 MW, 1.3 MW 107W8805P001 151X1241BR02SA01

[Link] Safety and Work Precautions

With power applied, this equipment contains a

potential hazard of electric shock or burn. The
nominal voltage of the mains of the Inverter is 480 V
ac.

Only adequately trained persons who are

Warning thoroughly familiar with the equipment and the
instructions should maintain this equipment.

To prevent electric shock while servicing the

equipment, personnel must understand and follow
all safety requirements for working around
dangerous voltages.

Voltage measurement equipment and safety

Warning equipment / procedures for this application should
be used. IEC-61010 and UL-3111 are possible
sources of information.

With power applied, the cooling fans and heaters

may operate without warning.

Make sure that all power sources to the equipment

are turned off, then discharge and ground the
equipment before performing any adjustments,
Warning servicing, or other acts requiring physical contact
with the circuit boards, electrical components or
wiring.

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 Wear appropriate hearing protection when working
around this equipment.

Acoustic noise levels are as follows:

1 m (3.3 ft) from front of enclosure: 77 dBA average

Warning
1 m (3.3 ft) from back of enclosure: 78 dBA average

Read and follow all safety warnings and instructions

provided on the coolant container.
Warning

To prevent equipment damage, take care to prevent

loose fasteners from falling into the equipment.
Keep all fasteners in a secure location for use when
installing the replacement phase module.
Caution

To prevent equipment damage, do not allow coolant

to be spilled on circuit boards, other electrical
components, or electrical insulation. The coolant
contains conductive material and is difficult to
Caution remove.

While working on the module replacement, do not

set any tools, hardware, rags, and such. on the top of
the capacitor bank modules. These things could
have coolant on them or this coolant could be on
hands that are touching parts of the module. Any
coolant on the module could cause major equipment
damage.
Caution
While working on the equipment, be sure to place
all tools, hardware and rags outside of the cabinet.

To prevent equipment damage, follow all fastener

torque requirements listed.

Caution

Preventative Maintenance and Replacement GEH-6777C Operation and Maintenance Guide 71

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 [Link] Prepare Equipment for Maintenance
Prepare the inverter to safely perform maintenance using the following procedures. Once
the following steps are completed, the power inverter will be ready for maintenance.

# Step Verified Initials

1 Review the Safety and Work Precautions. Yes
Open the MCC door and locate the three control switches on the upper left side.

Turn Maintenance
Switch to Yes.

2 Yes

MCC Cabinet

Opening the dc disconnect switch (Q2 - SAPC)

and the ac main circuit breaker (Q1- GPC) does
not fully de-energize the breaker’s input terminal
bus work. Before opening either the SAPC or
GPC cabinets, the dc source from the PV array
3 Yes
Warning and the ac source from the transformer must be
de-energized at their source.

De-energize both the dc disconnect switch(Q2-SAPC) and the ac main circuit breaker
(Q1-GPC). Verify that all power sources to the equipment have been disconnected according
to the relevant lockout tag out procedures.
Wait at least 20 minutes before opening any enclosure doors to allow the DC Link capacitors
4 Yes
to discharge to < 50 V peak.
5 Locate the Wind Energy OR Board (WEOR) in the lower right area of the enclosure. Yes

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 # Step Verified Initials
From the WEOR board, measure the DC Link voltage by DMM between fuses FU4 and FU5
(as indicated in the following photo) using the access holes provided in the protective shield.
Do not proceed until the DC Link voltage is less than 5 V.

6 < 5 V dc

DC Link voltage
measuring points

WEOR Board
7 Open the Converter Bridge Cabinet (CBC) door. The CBC is located behind the MCC. Yes
Visually inspect the power inverter without touching any part of the inverter.

If obvious damage to IGBT modules, circuit

8 boards, DC Link capacitors or the DC Link bus Yes
structure is present, perform replacement and
clean up procedure.
Attention

Preventative Maintenance and Replacement GEH-6777C Operation and Maintenance Guide 73

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 # Step Verified Initials
From the CFC, short the DC Link by connecting a ground cable to chassis ground.

9 Yes

From the CBC, apply grounds to the DC Link positive and negative bus.

10 Yes

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 [Link] Required Equipment
The following table lists the tools and materials recommended to perform IGBT phase
module replacement.

Description Part Number Quantity

DMM N/A 1
Blue hose 278A2175PUP1 0.30 m (1 ft)
Blue hose stepless ear clamp 305A6482P5 6
Small diagonal cutters N/A 1 pair
Cloth rags N/A 3
Pincer hose clamp tool 305A6482P2 1
Torque wrench, 4 to 25 Nm (30 to 200 in-lbs)
NA 1
range minimum
Wrenches, 17 mm (5/8 in) NA 2
Wrenches, 14 mm (9/16 in) NA 2
Wrench, 10 mm (3/8 in) NA 1
Wrench, 5/16 in (8 mm) NA 1
Plastic cable ties, 191 mm (75 in) 218A4335P2 15

[Link] IGBT Phase Module Removal

Non-blown IGBT Phase Module Removal
Perform the following steps to remove an IGBT phase module that is not blown.

Non-blown IGBT Phase Module Removal

# Step Verified Initials
1 Review the section, Safety and Work Precautions. Yes
2 Perform the procedure, Prepare the Equipment for Maintenance. Yes
Open the Converter Bridge Cabinet (CBC). Observe the path of all cable and hose
connections to the module. The following figure displays an installed phase module.

3 Yes

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 Non-blown IGBT Phase Module Removal (continued)
# Step Verified Initials
Open the clamps that secure the gate leads. Take note of tie points and orientation of each
cable so they can be reattached correctly when connecting them to the replacement IGBT
4 Yes
module. Tie each of the gate lead cables out of the way while performing the rest of the
procedure.
Disconnect gate leads connected to P1 and P2 on the phase module to be replaced and tie
5 Yes
them out of the way using plastic cable ties.
Disconnect the gate leads connected to P5 and P6 on the phase module directly beneath
the phase module to be replaced. This action will help protect the pins in these connectors
6 during the following steps. Yes
If replacing the line phase B module, make sure to disconnect the thermal switch
from heat sink.
Disconnect braided cables from the shunt bus shown above using a 14 mm (9/16 in)
7 Yes
wrench.
Remove all nuts and washers from dc bus on left side of phase module using a 10 mm (3/8
in) wrench. Make sure to count all nuts and washers as they are being removed to confirm
8 Yes
that hardware is not left inside the inverter. There will be 12 nuts and 12 washers to be
removed.
Remove the two rear phase module mounting bolts from underside of steel mounting
bracket using 8 mm (5/16 in) wrench. Loosen the two front phase module mounting bolts.
9 Yes
The two front mounting bolts are only loosened in this step and are later removed to provide
additional support when removing the hoses.
Remove the clamps from the inlet and outlet hoses and discard. These clamps are released
by lifting the clamp strap past the barb with a pair of small, sharp diagonal cutters or small
screwdriver. The hose and clamps may be rotated for better access. The following figure
displays the stepless ear clamp removal process. The hose on the right is connected to the
bottom of the heatsink and the hose on the left is connected to the top of the heatsink. This
is important when the hoses are connected to the replacement IGBT module.

10 Yes

Remove the two front phase module mounting bolts from the underside of the steel
11 Yes
mounting bracket.
Remove the phase module by first sliding the module to the right to clear the studs from the
12 Yes
DC Link bus, and then pulling forward, out of the enclosure.

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 Non-blown IGBT Phase Module Removal (continued)
# Step Verified Initials
Once the phase module has been removed, place a tag on the module saying it may contain
coolant within the heatsink. Be careful not to disconnect the short piece of blue hose that is
13 Yes
attached between the inlet and outlet hose barbs. Be careful not to allow any coolant to leak,
drip or spill out of either hose barb.
14 Using a 14 mm (9/16 in) wrench, remove the bus-work from the module. Yes
15 Drain any remaining coolant from the heatsink. Yes
16 Install the IGBT Phase Module. Yes

Blown IGBT Phase Module Removal

Perform the following steps to remove a blown IGBT phase module.

# Step Verified Initials

1 Perform all steps in the table Non-blown IGBT Phase Module Removal. Yes
Verify that any damaged components, such as burnt wiring harnesses, shunts, circuit
2 boards, DC Link capacitors, or the DC Link bus structure, are removed from the inverter Yes
cabinet.
Clean the cabinet using a non-conductive cleaner, non-metal scratch pad (nylon), and a
3 Yes
paper towel.
4 Verify that there is no carbon mark inside the inverter after cleaning. Yes

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 [Link] IGBT Phase Module Installation
The following table contains a preliminary procedure for the installation of an IGBT
phase module assembly. This procedure assumes proper completion of IGBT Phase
Module Removal.

Note Make sure to replace all damaged connectors and components that were
disconnected during the removal procedure.

# Step Verified Initials

1 Review the section, Safety and Work Precautions. Yes
Verify that the nuts on the studs in the dc bus protrude through the insulation as displayed in
the following figure. If the insulation sits on the face of the nuts, the insulation will be in the
electrical joint when the module is assembled to the DC Link bus.

2 Yes

Connect the bus-work to the IGBT module using a 14 mm (9/16 in) wrench and torque the 19 Nm (168
3
fastener. in-lbs)
Install the replacement phase module by sliding it into the enclosure on the steel mounting
4 Yes
plate, then pulling it to the left so that all studs extend through the slots in the DC Link bus.
Install all fasteners previously removed onto the studs on the dc bus. Do not tighten at this
time. Count all nuts and washers as they are being installed to confirm that all hardware is
5 Yes
installed correctly. There should be 12 nuts and 12 washers to be installed on the IGBT
phase module.
Install all four fasteners removed previously into the threaded inserts in the steel hex posts
6 Yes
of the phase module. Do not tighten at this time.
Torque the fasteners installed in step 5 using a torque wrench and 10 mm (3/8 in) wrench.
3.5 Nm
7 Do not tighten fasteners tighter than 3.5 Nm (32 in-lbs) as over tightening could break the
(32 in-lbs)
posts off that connect the module to the DC Link.
Tighten the fasteners installed in step 6 using a 8 mm (5/16 in) wrench. These are not
8 electrical connections so they do not need to be tightened to a specific torque requirement. Yes
These should be greater than finger tight and should attach the module securely.
Connect the braided cable using all fasteners removed in step 7 to the shunt bus with a 14
9 Yes
mm (9/16 in) wrench. Torque the fastener.

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 # Step Verified Initials
Re-connect the inlet and outlet hoses to the new heatsink as follows:

a. Inspect the end of inlet (bottom) hose for any damage. If damage is detected, cut
off the portion of the hose under the old clamps.

b. Slide the clamps (qty 2) onto inlet hose in the orientation displayed in the following
figure.

c. Insert the hose over the inlet hose barb, pressing the end of the hose up against
the front face of the heatsink.

d. Crimp the clamps using the pincer hose clamp tool as displayed in the following
figure. The crimp area of a properly crimped clamp should have no gap. Verify that
both clamps are crimped within 1 1/4 in (32 mm) from the end of the heatsink so as
to not miss the end of the inlet hose barb.

10 Yes

e. Repeat steps a through d on the outlet (top) hose.

f. When both inlet and outlet hoses are fully clamped, remove the swing jaw clamps
from both hoses.

g. Inspect for leaks.

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 # Step Verified Initials
Re-connect all connectors and components that were disconnected or replaced during the
11 Yes
removal procedure.
Secure the gate leads by installing cable clamps in the same manner as they were before
12 Yes
removal.
13 Remove the protective plastic cover that was previously installed. Yes
14 Dispose of all waste materials per site EHS procedures. Yes
15 Secure the CBC cover back in place. Yes
16 Proceed to the procedure, Inspection Points. Yes

[Link] Inspection Points

Prior to placing the IGBT phase module back into service, perform the following steps to
inspect the inverter after replacement. This procedure assumes proper completion of
IGBT Phase Module Installation.

# Step Verified Initials

1 Review the section, Safety and Work Precautions. Yes
2 Verify that all replaced modules, hoses, and cables are correctly positioned and oriented. Yes
Verify that the water hoses were not damaged during removal and re-insertion.
Verify that the clamps have been crimped and the hoses are not kinked.
3 Yes
To prevent hose kinks, the inside bend radius on the hoses must be > 38 mm (1.5 in).
After the pump has run, check for leaks.
Verify that all bolted connections that were loosened are properly re-torqued and cable
4 Yes
connectors are secure.
Run the pump for about 1 minute. Check for leaks. Fill the reservoir to the MAX PUMP OFF
5 Yes
level. Perform the procedures, Coolant Level Check and Coolant Refill.
Verify that all foreign matter, such as tools, parts, hardware, and temporary hose clamps
6 Yes
used for replacement, have been removed from the power inverter.
7 Perform the procedure, Return Equipment to Service Yes

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 [Link] Coolant Level Check and Refill
Coolant Level Check
Perform the following steps to check the coolant level.

Acceptable
# Step Initials
Range
1 Review the section, Safety and Work Precautions. Yes
2 Perform the procedure, Prepare the Equipment for Maintenance. Yes
3 Open the front doors of the CFC. Yes
Locate the pressure regulator installed on the top of the reservoir. Press the button on the
top of pressure regulator to release any pressure that may have built-up inside the tank. The
regulator is set to ±1.5 psi. The following figure displays the reservoir and other cooling
system components.

Pump Motor

4 Pressure Gauge Yes

Pressure Regulator

Reservoir

Unscrew the pressure regulator to open the top of the reservoir. Remove the dipstick from
5 the right sidewall beside the reservoir and place it inside the tank. The dipstick should rest Yes
on the edge of the regulator opening.

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 Acceptable
# Step Initials
Range
Remove the dipstick and read the coolant level from the graduated surface. The dipstick has
three marks as displayed in the following figure. Verify that the liquid level does not exceed
the Max Pump marks, depending on the state of the pump motor.

Liquid Level Reservoir Vent Hose to

Check and Pressure Relief Valve
Fill Port

6 Yes

368.503 mm
(14.51 in)
Max Pump Off
310.083 mm
(12.21 in)
Min Pump Off
or Max Pump On
249.123 mm
(9.81 in)
Min Pump On

Clean the dipstick and any coolant spills with a cloth. Return the dipstick to the right
7 sidewall. Dispose of all waste coolant and used cloth rags per site environmental, health, Yes
and safety (EHS) procedures.
Screw the pressure regulator back in the reservoir’s opening. Close and secure the CFC
8 Yes
doors.

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 Coolant Refill
Perform the following steps to add a small amount of coolant.

Acceptable
# Step Initials
Range
1 Open the front doors of the CFC. Yes
Locate the pressure regulator installed on the top of the reservoir. Press the button on the
2 top of pressure regulator to release any pressure that may have built-up inside the tank. The Yes
regulator is set to ±1.5 psi.
Unscrew the pressure regulator to open the top of the reservoir. Insert the hose connected
3 Yes
to the utility pump outlet into the reservoir opening.
4 Mix the required amount of coolant in a container. Yes
5 Place the hose connected to the utility pump inlet in the coolant mix. Yes
Power the utility pump to pump coolant into the reservoir. Turn off the utility pump and
6 Yes
remove the hose from the reservoir when the mixture container empties.
7 Check the coolant level. Yes
8 Screw the pressure regulator back in the reservoir’s opening. Yes
Clean up any coolant spills with a cloth. Dispose of all waste coolant and used cloth rags
9 Yes
per site EHS procedures.
10 Close and secure the CFC doors. Yes
11 Return equipment to service. Yes

[Link] Return Equipment to Service

Perform the following steps to return the inverter to service after performing maintenance.
This procedure assumes that all maintenance procedures in this document have been
performed and completed.

Acceptable
# Step Initials
Range
1 Review the section, Safety and Work Precautions. Yes
Check the following:
• All maintenance procedures have been completed.
2 • All tools have been removed from the equipment. Yes
• All test leads and connections have been removed or carefully secured to prevent
contact with energized components or bus work.
3 In the CBC and CFC, remove the ground cable connections installed previously. Yes
4 Close the CBC by bolting its cover back in place. Also, close the MCC access door. Yes
The power inverter is now ready to have power sources reconnected. Follow the relevant
5 Yes
LOTO procedures to reconnect the power sources.

Preventative Maintenance and Replacement GEH-6777C Operation and Maintenance Guide 83

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 4.3.13 Fuse Replacement
This section provides the fuse tables for each inverter cabinet. The diagrams illustrate the
location and type for each fuse in the inverter.

SAPC CPC (Front) MCC

Refer to
Detail A
FU1-3
Liquid -Air
Heat Exchanger
WEMA

A ir-Air Heat Exchange r

AEPS
(Refer to
FU101-114 Detail B )
(Optoinal)
WEOR
(Refer to
Detail C )
Refer to Detail D FU18 FU19

FU9 FU6 FU2

FU5 FU7 FU3
FU8
FU9 FU4
FU12
FU8
FU10
FU11
FU1
FU12
FU11
Spare
Detail B
Detail A IS210AEPS (Rotated 90°)
(Cover Not Shown)
FU2

FU1 FU2
FU3
FU1
FU4 FU5 FU6 FU3
FU5

FU4
Detail D
Detail C
(Located on Table)
IS200WEOR
Inverter Fuses

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 Solar Array Power Cabinet (SAPC)
Fuse Name Fuse Description Vendor Part Number or Equivalent
FU8-9 5 A, 1000 V FERRAZ DCT5-2
FU11-FU12 10 A, 1000 V FERRAZ DCT10-2
FU101-FU114† 400 A, 1000 V FERRAZ A150X400-4
† Optional — provided with subcombiner option

Converter Bridge Cabinet (CBC)

Fuse Name Fuse Description Vendor Part Number or Equivalent
CDCFUP 10 A, 700 V FERRAZ A70QS10–14F
CDCFUN 10 A, 700 V FERRAZ A70QS10–14F

Converter Filter Cabinet (CFC)

Fuse Name Fuse Description Vendor Part Number or Equivalent
FU1–6 100 A, 600 V FERRAZ A60X100–4TA
FU20–22 5 A, 600 V BUSSMANN™ LP-CC-5

Grid Power Cabinet (GPC)

Fuse Name Fuse Description Vendor Part Number or Equivalent
FU15–17 60 A, 600 V FERRAZ A60X100–4TA
630 A, 700 V
ACLFU1–9 FERRAZ A070URD33LI0630
ac line fuses

Main Control Cabinet (MCC)

Fuse Name Fuse Description Vendor Part Number or Equivalent
IS200AEPS
FU1, FU11 5 A, 600 V FERRAZ A070GRB05T13
8 A, 250 V
FU2, FU3 BUSSMANN™ MDL-8
Time Delay
FU4 2 AG; 1.5 A, 250 V LITTELFUSE™ 22501.5MXP
FU5, FU8, FU9 2 AG; 0.5 A, 250 V LITTELFUSE 225.500P
FU6 2 AG; 2 A, 250 V FERRAZ SMG2
FU7 2 AG; 1.0 A, 250 V LITTELFUSE 225001P
2.0 A, 250 V
FU10, FU12 LITTELFUSE [Link]
SLOW BLOW
FU18, FU19 3 A, 600 V BUSSMANN LP-CC-3
IS200WEOR
0.5 A, 600 V
FU1 BUSSMANN FNQ-R-1/2
FNQ-R
2.0 A, 250 V
FU2 LITTELFUSE [Link]
SLOW BLOW
FU3 0.5 A, 250 V BUSSMANN MDL-1/2
FU4, FU5 5 A, 600 V FERRAZ A070GRB05T13
IS200WEMA
0.315 A, 250 V;
FU1 LITTELFUSE 218.315
5X20 MM
3.15 A, 250 V;
FU2, FU3 BUSSMANN GDC-3.15
5X20 MM

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 4.3.14 Return the Inverter to Service
➢ To return the converter to service after maintenance has been performed
1. Review all safety and work precautions.
2. Check the following:

• All maintenance procedures have been completed.

• All tools have been removed from the equipment.
• All test leads and connections have either been removed or have been carefully
secured to prevent contact with energized components or buswork.
3. Remove the ground cables that short the DC Link positive and negative bus in the
CBC to chassis ground in the CFC.

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 4. Close the CFC and CBC doors.
5. The power converter is now ready to have power sources reconnected. Follow the
relevant lockout tagout procedures to reconnect the power sources.
Refer to the figure, 6. In the MCC, turn the Maintenance switch to the NO position.
Maintenance Switch.
7. Close the MCC door.
8. From the web-based HMI application, verify startup status.
9. Verify power has returned to the inverter.

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Notes

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Appendix A IGBT Phase Module Test
If there is any doubt of IGBT phase module functionality for a Brilliance Inverter, the
entire phase module must be tested. This section provides the steps to confirm IGBT
phase module assembly health for Bench testing.

Before performing the bench tests, remove the IGBT

module from the inverter.

Attention

Appendix A IGBT Phase Module Test GEH-6777C Operation and Maintenance Guide 89
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 Bench Testing
# Step Verified Initials
In the event that an IGBT module’s integrity is in question and it needs to be tested, verify
the following check points:

a. Perform a visual inspection of the following:

i. Check the components for any physical damage.

ii. Check for any spilled coolant on the IGBT, heatsink and AEBM.
iii. Check the coating condition on the AEBM.
1 Yes
b. Verify that there is no loose hardware on the assembly.

c. Carefully check the cables going from the upper AEBM to the lower AEBM.

d. Verify that all pins are properly seated in all of the cable connectors by pulling on
them lightly. All cables must be attached for this test, otherwise it will result in an
inaccurate reading.

e. Verify that no pins are being pushed out the back of the cables.
Once the IGBT module is on the bench, check the following values to confirm that the
module has not been damaged. The location of these points is provided in the following
figure (pins on the plugs are numbered starting at 1 on the left).
Fluke™ 87 digital multi-meters (DMM) must be used for all resistance and diode
measurements. All measurements are taken in parallel with both units (top and bottom)
connected, not individually.

2 Yes

1105 Ω
Measure resistance between the following points:
(±22 Ω)
• P1-3 to P1-4
[1083
3 • P1-5 to P1-6
to 1127]
• P2-3 to P2-4
(use
• P2-5 to P2-6 bottom AEBM)

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 Bench Testing (continued)
# Step Verified Initials
Measure resistance between the following points: 369 Ω (±7.4 Ω)
4 • P5-1 to P5-3 [361.6 to
• P6-1 to P6-3 376.4]
Measure resistance between the following points:
• P5-1 to P5-3 4.7 KΩ
5 • P1-9 to P1-10 (use bottom
This is a RTD so it will vary with temperature AEBM)
(for example, 10°C ~ 9 kW, 20°C ~ 5 kW, 40°C ~ 3 kW)
Using the Diode Function on the DVM, verify the following:

a. For upper (top) IGBT:

i. Phase A+ (BLK) to AC (RED) reads 0.28 to 0.35 V.

Reverse leads to read OPEN.

ii. Phase A– (RED) to AC (BLK) reads 0.28 to 0.35 V.

Reverse leads to read OPEN.

iii. Phase A+ (BLK) to P5-1 (RED) reads 0.4 to 0.6 V.

Reverse leads to read OPEN.

iv. AC (BLK) to P6-1 (RED) reads 0.4 to 0.6 V.

6 Reverse leads to read OPEN. Yes

b. For Lower (bottom) IGBT:

i. Phase A+ (BLK) to AC (RED) reads 0.28 to 0.35 V

Reverse leads to read OPEN.

ii. Phase A– (RED) to AC (BLK) reads 0.28 to 0.35 V.

Reverse leads to read OPEN.

iii. Phase A+ (BLK) to P5-1 (RED) 0.4 to 0.6 V.

Reverse leads to read OPEN.

iv. AC (BLK) to P6-1 (RED) reads 0.4 to 0.6 V.

Reverse leads to read OPEN.
Using the Diode Function on the DVM, verify DSAT circuit as follows:
• Phase A+ (BLK) to P1-1 (RED) reads 0.8 to 1.1 V.
7 Reverse leads to read OPEN. Yes
• AC (BLK) to P2-1 (RED) reads 0.8 to 1.1 V.
Reverse leads to read OPEN.
8 Place IP-stamp on Module’s ID nameplate. N/A

Appendix A IGBT Phase Module Test GEH-6777C Operation and Maintenance Guide 91
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Notes

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