TO CHANGE IGBT

1) CHECK COMPLETE SANDWICH BUSBAR.

2) CHECK INSULATION OF IT.
3) LENGTH OF GATE EMMITER CABLE SHOULD BE SAME AS PER OTHER MODULE OF INVERTER.
4) CHECK PULSE ON IGBT TERMINAL (IF POSSIBLE AND COMPARE IT WITH OTHER MODULE.)
5) IGBT PULSE SHOULD BE NEAR 1 uSec RISE & FALL TIME AND 2 MICRO SECOND DEAD BAND.
ALSO, IT SHOULD HAVE +15V TO -15V PULSE @ H.ON AND -15V @ H.OFF.
6) DISCONNECT OTHER MODULE.
7) MAKE LS FULL, ON MCCB AND MAKE PANEL IN TEST MODE AND CHECK INVERTER CURRENT
OF CONNECTED INVERTER ON HF-05, VALUE SHOULD BE LESS THAN 3.5 VOLT PEAK.
8) THEN MAKE SURE EVERYTHING IS FINE IF DOUBT RECHECK ON TEST MODE, AND ON MCCB
AND CHECK FOR IT IN RUN MODE.
9) RUN INVERTER FOR 2-3 MINUTES. THEN CHECK VOLTAGE CALIBRATION OF Vcap WITH HV
PROBE, CALIBRATE IT UP TO 900 V, AS IT IS PROBES LIMIT.
10) MAKE SOME CALIBRATION HIGHER THAN ACTUAL. SO, LIMIT COULD BE EASILY PICKED UP.

Changing IGBT
1) Ask for condition of fault, like problem in IGBT while heat off, running, starting or any other
condition.
2) Remove faulty IGBT; also check all IGBT with its gate-emitter capacitance and diode.
3) Check D.C. Blocking capacitor with its capacitance and insulation.
4) If possible check for megger in D.C. sandwich of IGBT Assy.
5) Also check for Water cooled cable for any wear & tear; Caprack Assy megger as guided by
manish Bhai.
6) Check cap-coil Busbar for insulation, do not loose-tight brass nut bolt. (TOP 4 COIL IN
SERIES, last 2 open)
7) Check tightness of other all nut bolt. Check for washer or bolt if there before start.
8) Check with any nipple, Busbar, conducting part near to body; if so, isolate it with Nomex
paper.
9) If time open 3 other inverter and check with only faulty one.
10) Check for Gate resistor of all Driver card of DR-17.
11) Install new IGBT, check for cooler if O’ring and time available.
12) Check for water conductivity. Also see for any insulation failure. Use silica gel.
13) Install IGBT lug cable, and check Pulse, also check deadband of 2uSec & Propogation delay in
different inverter.
14) After checking pulse see that while pressing RESET button pulse stay or goes; if so add relay
and do as per newly prepared drawing.
15) Note all trip setting of all inverter current and capacitor voltage. Trim it to near possible
recommended. Also write down starting freq., FCV gain and Freq gap (start-end).
16) Connect 1 inverter with respect to checking of other inverter open from D.C. as well as a.c.
side open.
17) Make starting Freq of inverter is 33 kHz. Check freq. swapping and start –stop freq. check
with power %. Try for Ls increasing.
18) Charge ACB and make it on, wait for 2 sec, switch panel in test mode, and then press heat
on. Observe Inverter current. It should be near triangle. And at load it should be near sine.
19) If current is in control charge acb and on and press hon with high freq. and 0% power pot.
20) Then gradually reduce power pot, also check inverter current up to safe limit of 380 Amps.
Calibrate inverter with 10 Amps higher setting, so that limit could pick up before actual trip.
21) Run inverter for 5-10 minutes. If noise found in signal use ferrite core or capacitor in trip
section, not in monitoring. But before using capacitor check for all inverter as it will lead to
false failure.
22) Connect all inverters and then repeat process from point 17. Run all inverter for 5-10
minutes.
23) Check capacitor voltage calibration; make 15-20 volts higher than actual, trim the limit level
and trip.
24) Observe panel.
25) Fill table.

26) Top Four coil in series ( 4.4 uHenry)

27) Ls around 14-15 uHenry.
28) Ferrite core in every Feedback with 0.01 uFarad capacitor.
29) Phase limit ADD in picture by Test mode in Normal position instead of Inverter Load mode.
30) Lock Panel to 300kW;
31) Install D.C. voltage setting with new 3-core 0.5 sqmm shielded cable.
To be carry things returnable.

1) 4 Channel CRO.
2) 4-1-10X Probe.
3) 1-HV Probe.
4) LCR meter.
5) Multimeter.
6) Ferrite core.
7) 0.1-0.01 uFarad.
8) IGBT Gate-Emmiter wire.
9) Digital Controller.
10) Keypad-display unit.
11) IGBT O’ring.
12) 3-Core 0.5 sq.mm cable-15 mtr.
13) Tester.
14) Wire stripper.
15) Relay-1 Nos.
Fill count detail sheet from Ketan/Viru Bhai.

Present trip setting

NAME VALUE I/P POINT TRIP POINT O/P DICON

DC VOLT TRIP SET TP-1 TP-3 TP-4
DC CUR TRIP SET TP-5 TP-8 TP-9
INV-1 TRIP TP-19 TP-21 TP-22
INV-2 TRIP TP-23 TP-25 TP-26
INV-3 TRIP TP-27 TP-29 TP-30
INV-4 TRIP TP-31 TP-33 TP-34
START FREQ.
NA
FCV GAIN
Calculated current voltage as per 300KW

POWER 300 KW
A.C. VOLTAGE 415 VOLT
P.F. 0.9 -
EFFI. 0.9 -
A.C. CURRENT 516 AMP

D.C. VOLTAGE 623 VOLT

D.C. CURRENT 619+10% = 670 AMP

INV O/P VOLT 504 VOLT

INV O/P CURR 970+5% =1020 AMP-PEAK
PER INV 255 =~ 270 AMP-PEAK

Recommended trip setting for 300 KW

DC VOLTAGE TRIP SETTING FULL – 11.5-12V

DC CURRENT TRIP SETTING (1000-0.2/1200-0.2) 2.68
INV-1 TRIP 4.5
INV-2 TRIP 4.5
INV-3 TRIP 4.5
INV-4 TRIP 4.5
START FREQ.
FCV GAIN
Calculated current voltage as per 400KW

POWER 400 KW
A.C. VOLTAGE 415 VOLT
P.F. 0.9 -
EFFI. 0.9 -
A.C. CURRENT 688 AMP

D.C. VOLTAGE 623 VOLT

D.C. CURRENT 825+10% = 935 AMP

INV O/P VOLT 504 VOLT

INV O/P CURR 1293+5% = 1360 AMP-PEAK
PER INV 323~340 AMP-PEAK

Recommended trip setting for 400KW

DC VOLTAGE TRIP SETTING FULL – 11.5-12V

DC CURRENT TRIP SETTING 3.8
INV-1 TRIP 5.75
INV-2 TRIP 5.75
INV-3 TRIP 5.75
INV-4 TRIP 5.75
START FREQ.
FCV GAIN

INSTRUMENTS
 1) CRO
2) PROBE
3) HV PROBE
4) MULTIMETER
5) TESTER
6) STRIPER
7) A
8) A
9) A
10) A

COMPONENT

1) GATE-EMMITER WIRE PAIR with Lug – 16 Nos.

2) FERRITE CORE – 5 Nos.
3) 0.1 CAP – 5 Nos.
4) 0.01 CAP – 5 Nos.
5) COIL-CAP BRASS BOLT – 25 Nos.
6) Nomex Paper
7) Heat sink Paste
8) IGBT cooler O-ring
9) HF-05
10) HF-06
11) IGBT + DRIVER CARD