GEH-6727E

1.x MW Doubly-Fed Induction Generator (DFIG)

Electrical Simplified System (ESS) Wind Power Converters
System Guide

August 2019

Non-Public Information
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.
Non-Public Information – This document contains proprietary 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 copied or 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 2019

Issued: November 2012

© 2012 - 2019 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 [email protected]

Document Updates
Update
Revision Description
Location
Overview Updated power range to 1.95 MW.

Throughout
E Replaced instances of UCSA references with controller and UCSx references.
document
Aug 2019
Draining the
Made corrections to the procedure.
Coolant
D Throughout
Miscellaneous updates to fix format, style, trademarks, spelling and other minor changes
Jul 2016 document
Appendix A
C Fuses, Fuse Added a Caution and text in the fuse table notifying the operator that when replacing
Apr 2015 Replacement parallel fuses they must be replaced in sets from the same vendor
Data
B Cover and Removed cover graphic for GE rebranding effort and updated the document footer for GE
Mar 2015 Footers internal use

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 Update
Revision Description
Location
A Updates to include Version C, 1.85 MW ESS power converter and Version D, 1.6e
All sections
Jul 2014 (enhanced) ESS power converter

Nov 2012 N/A Initial release

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Acronyms and Abbreviations
ACLFU AC Line Fuses
ADL Asynchronous Drive Language
AEAA Alternative Energy Application A
AEAD Alternative Energy Application D
AEBI Alternative Energy Bridge Interface
AEBM Alternative Energy Bridge Module
AEDB Alternative Energy Dynamic Brake
AEPS Alternative Energy Power Supply
BPPB Balance of Plant Processor Board Version B
CBC Converter Bridge Cabinet
CCONT Charge Contactor
CFC Converter Filter Cabinet
CT Current Transformer
DB Dynamic Brake
DFIG Doubly-fed Induction Generator
DSP Digital Signal Processor
DSR Design Specific Record
DTA Down Tower Assembly
EGD Ethernet Global Data
ESS Electrical Simplified System
FPGA Field Programmable Gate Arrays
HMI Human-machine Interface
IGBT Insulated Gate Bipolar Transistor
I/O Input/Output
IONet Input Output Network
MACC Multiple Application Converter Control
MCC Main Control Cabinet
NC Normally Closed
NO Normally Open
PDC Power Distribution Cabinet
PIC Programmable Intelligent Computer
PLC Programmable Logic Controller
PLL Phase-locked Loop
PWM Pulse Width Modulator
ROVC Rotor Overvoltage Contactor
SCADA Supervisory Control and Data Acquisition
SDI System Data Interface
TVSS Transient Voltage Surge Suppression
UCSx Universal Controller Stand-alone Version x
UPS Uninterruptible Power Supply
VCO Voltage-controlled Oscillator
WECA Wind DFIGe Converter Interface Version A
WEMA Power Conversion Main Control Module
WEMD Wind Energy MACC DSR ID
WEOR Power Conversion Wired-OR Board

4 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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Related Documents
For further information, refer to the following documents:

Title Doc #
2.5 MW Synchronous (Sync) Generator Wind Converter Maintenance Guide GEH-6669
ToolboxST* User Guide for Mark* Controls Platform GEH-6700
2.x MW Permanent Magnet Generator (PMG) Wind Power Converter System Guide GEH-6726
2.5 MW Wind Converter for Synchronous Generator Product Description GEI-100669
Mark VIe Control Wind DFIGe Converter Interface (WECA) Module Description GEI-100732
Mark VIe Control Wind/Solar Energy Main Control (WEMA) Module Description GEI-100734
Renewables Power Conversion Wired_OR (WEOR) Board Instruction Guide GEI-100764
Renewables Power Conversion Alternative Energy Application D (AEAD) Instruction Guide GEI-100766
Renewables Power Conversion Alternative Energy Application A (AEAA) Instruction Guide GEI-100767
Renewables Power Conversion Alternative Energy Power Supply (AEPS) Instruction Guide GEI-100768
Renewables Power Conversion Alternative Energy Bridge Interface (AEBI) Instruction Guide GEI-100769
Renewables Power Conversion Alternative Energy Dynamic Brake Bridge Interface (AEDB) Module
GEI-100812
Description

GEH-6727E System Guide 5

Non-Public Information
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

6 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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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

GEH-6727E System Guide 7

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Contents
1 Overview ........................................................................................................................................... 11
1.1 Hardware and Software Versions ............................................................................................................. 12
2 Turbine System Architecture ...................................................................................................... 15
2.1 Startup Sequence ................................................................................................................................... 17
2.2 Operation ............................................................................................................................................. 19
3 Mechanical Design......................................................................................................................... 23
3.1 Specifications ....................................................................................................................................... 24
3.2 Components ......................................................................................................................................... 24
3.2.1 Power Distribution Cabinet ............................................................................................................... 25
3.2.2 Converter Filter Cabinet ................................................................................................................... 28
3.2.3 Down Tower Assembly Fan and Airflow Plenum .................................................................................. 31
3.2.4 Main Control Cabinet ...................................................................................................................... 32
3.2.5 Converter Bridge Cabinet ................................................................................................................. 35
3.2.6 Liquid-based Cooling System............................................................................................................ 38
3.2.7 Warmup and Startup Sequence .......................................................................................................... 41
3.2.8 Dynamic Brake Module ................................................................................................................... 43
4 Power Converter Circuit ............................................................................................................... 45
5 Control Hardware ........................................................................................................................... 47
5.1 Multiple Application Converter Control Board ............................................................................................ 50
5.2 Alternative Energy Bridge Interface Board ................................................................................................. 50
5.3 Alternative Energy Dynamic Brake Board .................................................................................................. 51
5.4 Alternative Energy Application D Board .................................................................................................... 51
5.5 Alternative Energy Application A Board .................................................................................................... 52
5.6 Alternative Energy Power Supply ............................................................................................................. 52
5.7 Wind DFIGe Converter Interface Module ................................................................................................... 52
5.8 Power Conversion Main Control Module ................................................................................................... 53
5.9 Power Conversion Wired-OR Board ......................................................................................................... 53
6 Control Software............................................................................................................................. 55
6.1 Protection and Diagnostics ...................................................................................................................... 57
6.2 Communication Interfaces....................................................................................................................... 58
6.3 Rule Engine.......................................................................................................................................... 58
6.4 Download Wizards................................................................................................................................. 58
6.5 Simulator ............................................................................................................................................. 58
6.6 Software Configuration and Monitoring ..................................................................................................... 59
6.6.1 Configuration Parameters ................................................................................................................. 59
6.6.2 Live Data Block Diagrams................................................................................................................ 60
6.6.3 Fault History .................................................................................................................................. 61
6.6.4 Live Data Trend.............................................................................................................................. 62
6.6.5 Capture Buffer................................................................................................................................ 63
7 Maintenance..................................................................................................................................... 65
7.1 Safety Precautions ................................................................................................................................. 65
7.2 Preparing the Equipment ......................................................................................................................... 67
7.3 Maintaining the Equipment...................................................................................................................... 68

8 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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 7.3.1 Cooling System Maintenance ............................................................................................................ 68
7.3.2 Preventative Maintenance ................................................................................................................. 72
7.3.3 Wire Level Maintenance................................................................................................................... 74
7.4 Returning the Equipment to Service .......................................................................................................... 75
8 Troubleshooting ............................................................................................................................. 77
8.1 Rotor Startup Synchronization.................................................................................................................. 77
8.1.1 Pre-synchronization Cell Test ............................................................................................................ 77
8.1.2 Synchronization.............................................................................................................................. 78
8.1.3 Post-synchronization ....................................................................................................................... 78
8.2 Reduced Cooling System ........................................................................................................................ 80
8.2.1 Coolant Temperature Model .............................................................................................................. 81
8.2.2 Heatsink Rise Model ....................................................................................................................... 81
8.3 Low Coolant Level ................................................................................................................................ 82
8.4 Dynamic Brake Startup Test .................................................................................................................... 82
9 Replacement and Ordering.......................................................................................................... 83
9.1 Replacement ......................................................................................................................................... 83
9.1.1 Replacement Procedures................................................................................................................... 83
9.2 Ordering .............................................................................................................................................107
Appendix A Fuses ..............................................................................................................................109
Fuse Replacement Data..........................................................................................................................109
AEPS Power Fuses ...............................................................................................................................110
Appendix B Module Testing............................................................................................................. 111
IGBT Phase Module Testing ...................................................................................................................111
Capacitor Module Testing.......................................................................................................................114

GEH-6727E System Guide 9

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Notes

10 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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1 Overview
This document assumes the This document describes the 1.x MW Doubly-Fed Induction Generator (DFIG) Electrical
reader is familiar with the 1.x Simplified System (ESS) wind power converter. It outlines the different concepts and
MW ESS wind converter components associated with the 1.x MW DFIG ESS power converter, as well as the
products. similarities between products. Additionally, it provides maintenance, troubleshooting, and
replacement procedures.
1.x MW refers to the DFIG
The 1.x MW DFIG ESS power converter is specifically designed to provide excitation
product line that is rated over
and torque control variable speed wind turbine systems with ratings between 1.5 MW and
a range from 1.5 to 1.95 MW
1.95 MW. The DFIG ESS power converter was designed after the original GE DFIG
and includes multiple
power converter (also known as the non-ESS power converter) had been in service for
hardware versions. several years. The 1.x MW DFIG ESS power converter uses conservative power circuit
device ratings and robust control algorithms to keep the wind turbine system online
during severe power system grid disturbances and immediately resume normal operation
when the grid fault clears. Rapid and precise control of excitation and torque allows the
system controller to obtain optimal efficiency in the conversion of wind energy to
electrical energy delivered to the power system grid. Input Output Network (IONet)
communication provides seamless interface to the wind turbine system controller and data
collection system.

1.x MW DFIG ESS Wind Power Converter Cabinet

Overview GEH-6727E System Guide 11

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1.1 Hardware and Software Versions
The 1.x MW DFIG ESS power converters have been factory assembled as one of two
hardware versions (A or D). However, there are four hardware versions of the product: A,
B, C, and D. The hardware version is the last digit in the Software IPN, which is located
on the converter nameplate and displayed in the following figure. Versions B and C are
created by applying a field retrofit kit to version A. The hardware version specifics are as
follows:

• Hardware versions A and B can be used in wind turbines with ratings up to 1.6 MW.
A software version of at least V01.05.02C is required for the 1.6 MW rating with
version A. All software versions that support version B hardware also support 1.5
MW or 1.6 MW operation.
• Version B includes the dynamic brake (DB) functionality, which enhances the power
converter’s performance and robustness to various grid events.
• Version C is the 1.95 MW ESS power converter that has been field upgraded from
version A for 1.95 MW capability and DB functionality.
• Version D is the 1.6e (enhanced) ESS power converter, which is capable of 1.95 MW
ESS at 35°C (95 °F) and includes DB functionality.
Software for the 50 and 60 Hz converters provides various control functions that differ
according to the software release and converter hardware. The 1.x MW DFIG ESS power
converters contain various hardware and software relationships. The following table
displays the correlation between:

• Various available hardware and software versions

• Software Intelligent Part Number (IPN) as found on the Down Tower
Assembly (DTA), required for commissioning of the converter using the
ToolboxST* application

Software IPN Format

1.x MW DFIG ESS Power Converter Hardware and Software Relationships

Hardware Version Software Versions Software IPN Part Numbers
Version A – 50/60 Hz V01.03.05C to DFIGe-1500-5060-A DTA - Any of the following:
(Original 1.x MW ESS converter) V01.xx.yyC 151X1230KA01SA01
151X1230KA01SA03
151X1230KA01SA05
151X1230KA01SA07
Version B – 50/60 Hz V01.06.58C to DFIGe-1500-5060-B DTA - Any of the following:
(Original 1.x MW ESS converter) V01.xx.yyC 151X1230KA01SA01
with DB retrofit kit 151X1230KA01SA03
151X1230KA01SA05
151X1230KA01SA07
With DB retrofit kit:
151X1230KA01PK01
Version C – 50/60 Hz V01.06.58C to DFIGe-1850-5060-C SA09: 151X1230KA01SA09
1.85 MW ESS V01.xx.yyC SA07: 151X1230KA01PK31
SA09 for China
SA07 with DB retrofit kits
Version D – 50/60 Hz V01.07.68C to DFIGe-1850-5060-D 151X1230KA02SA03
1.6e MW ESS V01.xx.yyC

12 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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 Product releases are as follows:

• V01.02.04C - First release

• V01.03.05C - Added full LVRT/ZVRT/HVRT capability
• V01.05.02C - Added power limiter functionality to support 1.6 MW operation
• V01.06.58C - Added enhanced anti-islanding/HVRT capability and support for
versions B and C hardware with DB functionality
• V01.07.68C – Provides support of hardware versions A through D and turbine ratings
between 1.5 MW and 1.85 MW, as well as enhanced grid features

Differences Between Hardware Version A (1.6) and Version D (1.6e)

Cabinet Component Version D (1.6e) Change from Version A (1.6)
Power Distribution Cabinet AC line fuses Upgrade from 350 to 500 A
(PDC) Main breaker Q1 Upgrade from Schneider™ to GE IS EntelliGuard*
TVSS Upgrade to Raycap™ design
Voltage Provision of tie-in voltage to external voltage regulator (with
optional parts kit)
Auxiliary Panel Layout change and provision for Q1 LOTO voltage sensing
Main Control Cabinet DB capability AEDB replaces line AEBI
(MCC) Stop and Idle push-buttons Color change compliance with EN60204-1
Cabinet LOTO New provision for LOTO lockable cabinet
Converter Bridge Cabinet DC link bus bars Provision of connecting points for DB module and DB resistor
(CBC) Line phase C/DB module New combined line phase C/DB module
DB resistor and voltage sensing New DB resistor and voltage sensing cables
cables
DC ground LOTO New provision of dc ground LOTO points
Converter Filter Cabinet Air-cooling Improved air-cooling vents in T2 and L1/L2 shelves, air baffle to
(CFC) L1, and door louver layout
Line inductor L1 Ventilated bracket (new part number)
Distortion resistors Relocated to roof air plenum
DB resistor Inside cabinet mounting
Stator gland plate Blank cover plate and gland installation parts kits for different
markets (provided by GE Wind)
Roof Air plenum enlarged to accommodate relocation of distortion
resistors

Overview GEH-6727E System Guide 13

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 14
ESS Converter

GEH-6727E
Pad Mount Current Main Stator Current Generator
Transformer Transducer Breaker Contactor Transducer
Parallel
(CT1,2,3) (Q1) (K1) (CT4,5,6)
bus bars

Vendor Change

Arc Flash Line Fuse

Fuse (FU1) (ACLFU)
355 A 500 A

†
Airflow
Q5, 1A CCONT CCR Improvements

Line Line Rotor Rotor

Reactor Shunts Shunts Reactor Rotor
TVSS Line DC Link DB Rotor
Distortion Filter (L1) Bridge Bridge (L2) Over-Voltage
Caps Circuit
Contactor
Contactor (ROVC)
(KDF)

Resistor

FB5 Capacitor
200 A
Wire moved

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when Parts Kit
included. Legend
External Voltage
Regulator Optional Parts Kit No Change Required
(Option Package) T2 New Design / Components
Aux Transformer
DTA / Converter Aux Loads Included in Standard Product
(Fans, Pumps, Heaters,
FB4 Contactor Coils, UPS) Not in Converter / DTA Scope

1.6e and 1.6 MW DFIG ESS Hardware Control One-Line Diagram

40 A
Turbine 400/230 V
†
Aux Loads Through the detailed design phase, it
(Top Box, Hoist) will be determined if there are any
conditions under which a DB is not
required.
Turbine 690 V
Aux Loads
FB3 (through Top Box)
80/100 A

1.x MW DFIG Wind Power Converter ESS

2 Turbine System Architecture
The 1.x MW DFIG ESS power converter converts rotational energy of the wind turbine
blade into electrical energy, which is delivered to the utility’s medium voltage (MV)
distribution grid. The system circuit breaker and mid-voltage transformer provide
isolation of the wind turbine system from the utility grid. The stator-synchronizing switch
connects the generator stator to the system bus after synchronization is achieved.

DFIG Generator
The gearbox acts as a speed increaser of approximately 107-72: 1 (depending upon
configuration), converting the blade rotational speed range of approximately 11-20 rpm to
a generator speed range of 800-1600 rpm (60 Hz) or 1000-2000 rpm (50 Hz). For a 60 Hz
power system, the synchronous speed of the generator is 1200 rpm. The nominal
operating point for the system is a generator speed of 1440 rpm, giving a rotor slip
frequency of -12 Hz (-20% super-synchronous). The dynamic range of generator speeds is
800-1600 rpm, giving a dynamic rotor slip frequency range of 20 to -20 Hz (33%
sub-synchronous to -33% super-synchronous). Additional operating points are provided
in the following table.

System Operation Specifications

System Frequency Synchronous Nominal Operating Rotor Slip Rotor Slip (%)
(Hz) Speed (rpm) Point (rpm) Frequency (Hz)
50 1500 1800 -12 -20% super-synchronous
50 1500 1915 -16.8 -27.7% super-synchronous
60 1200 1440 -12 -20% super-synchronous
60 1200 1520 -16.1 -26.7% super-synchronous

Turbine System Architecture GEH-6727E System Guide 15

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 16
GEH-6727E
Blade
bus System bus Stator bus Doubly-fed
System
Gridbus
Induction Generator
Gearbox

•
•
•
MV

switch

Grid
distribution

switch

Grid
Stator sync

System cb

breaker

breaker
System cb
Stator sync
Mid-voltage
transformer Tachometer
Line fuses DFIGe
1.x MW DFIG
ESS Converter Wind turbine I/O packs

Line Rotor

turbine controller:
bus Line side DB Rotor side bus
bridge (optional) bridge IONet
dc 3ac switch

3ac dc
UCSx
Control controller
Filter
contactor ROVC
Grid SCADA
monitor IONet
Line filter switch

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Universal Stand-alone version B (UCSB)
Universal Stand-alone version C (UCSC)

Universal Stand-alone version A (UCSA)

RS-232 serial
ENET ENET proprietary protocol
Laptop
Local HMI Park ENET remote Media conv
ToolboxST
& SCADA Control and SCADA
application

1.x MW DFIG ESS Wind Turbine System One-line Diagram

data collection
Fiber-optic
DVAR control

controllers that run the application-specific code. There are three available forms of the
The Wind turbine controller is part of the Mark* VIe controls product line of stand-alone

1.x MW DFIG Wind Power Converter ESS

 Note The Wind turbine controller is referred to in this document and related help files as
UCSx controller because the controller version used in the control system depends on the
user’s controller version.

The turbine controller performs the following actions:

• Adjusts the orientation of the nacelle (based on wind direction) by setting the
command to the yaw actuators
• Regulates the optimal speed of the blade (based on wind speed and utility power
dispatch) by setting the command to the blade pitch actuators and the torque
command to the power converter
• Sets the volt-ampere reactive (VAR) command to the power converter (based on
utility power factor (PF) dispatch)
• Issues enable and disable commands and collects status and operational data from the
power converter.
• Communicates with the power converter over an IONet data link.
• Has a built-in web server that allows the field technician to access web pages using
Windows® Internet Explorer® to control wind turbine functions. Operational data is
collected across the Ethernet network and logged to a Real Time (RT) server
computer that is typically located at the site's substation.
The 1.x MW DFIG ESS power converter supplies variable frequency 3-phase power to
the generator rotor to provide excitation and control air-gap torque. To provide both
excitation and torque control for the generator, the 1.x MW DFIG ESS power converter is
typically required to handle approximately 30% of the generator total rated power. The
converter is made up of two, four-quadrant Insulated Gate Bipolar Transistor
(IGBT)-based bridges that are coupled by a dc link. The line-side bridge can also be fed
from the system bus and controlled to regulate the intermediate dc link circuit voltage. It
may also be used to supply reactive power directly to the system bus. The rotor-side
bridge is connected to the generator rotor and controlled to regulate the generator rotor
current. This provides the proper amount of excitation to the machine and also controls
the air-gap torque, as follows:

• Real power is supplied to the grid from the generator stator and generator rotor
through the power converter. When the rotor is spinning slower than synchronous
speed (sub-synchronous operation), the power converter moves real power from the
grid and delivers it to the rotor. When the rotor is spinning faster than synchronous
speed (super-synchronous operation), the power converter moves real power from the
rotor and delivers it to the grid.
• Reactive power is supplied to the rotor such that the generator delivers the required
reactive power to achieve the desired net PF delivered to the grid.
• Power applied to the rotor is at slip frequency.

Note The grid monitor performs grid protection functions such as undervoltage,
overvoltage, underfrequency, overfrequency, and excessive power.

2.1 Startup Sequence

The 1.x MW DFIG ESS wind power converter startup sequence is as follows:

• When wind speed is sufficient for wind turbine cut in, the turbine is unfaulted and
grid conditions and permissions exist; the turbine’s main Programmable Logic
Controller (PLC) directs the turbine blades to pitch and start the turbine. When

Turbine System Architecture GEH-6727E System Guide 17

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 generator speed is greater than 800 rpm, and the PLC directs the blades to pitch, the
converter starts.
• The converter control closes Q1 if it is open and allows the dc link to charge. The
converter control starts the line bridge and regulates the dc link.
• The converter starts the rotor bridge and begins to synchronize the generator stator
voltage with the grid voltage. When the voltages are synchronized, the synchronizing
switch (stator contactor K1) is commanded to closed.
• The converter control follows power and VAR commands from the turbine control.

18 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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2.2 Operation
Flux in the generator air-gap induces a supply frequency (emf) in the stator. Es denotes
the stator emf and Ws denotes the stator emf frequency. Additionally, flux in the air-gap
induces a slip frequency emf in the rotor. Er denotes the rotor emf and Wr denotes the
rotor emf frequency. The rotor emf can be expressed in terms of the stator emf as follows:
In this equation, S denotes Er = Es x N x S
rotor slip with respect to the Wr = Ws x S
supply frequency and N
The following graph displays the association of the rotor voltage to the rotor speed for a
denotes the turn ratio between typical 60 Hz DFIG power converter that has a turn ratio of three and synchronous rotor
the stator and rotor.
speed of 1200 rpm.

Normal Operating Nominal Speed

Speed Range (1440 rpm )

Rotor Voltage versus Rotor Speed

The operating speed range for the system is from 800-1600 rpm. Operating at the
extremes of this range results in a rotor slip of ±0.33, rotor emf frequency of ±20 Hz, and
rotor emf size equal to stator emf. With the rotor spinning at a synchronous speed, the
rotor slip is 0, the induced rotor emf size is 0, and the rotor emf frequency is 0 (dc).
To control the current in the generator rotor, the power converter must produce a rotor
converter output voltage that matches the slip frequency emf, which is induced in the
rotor by the flux in the generator air-gap. The rotor power converter cannot operate the
system outside the normal operating speed range because the slip frequency emf that is
induced in the rotor would be too high for the rotor converter to match. The total power
flowing from the DFIG to the grid is comprised of power from both the stator and rotor,
as follows: Pg = Ps + Pr

Turbine System Architecture GEH-6727E System Guide 19

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 Power Flow from DFIG to Grid

Ignoring losses, the total power delivered from the generator to the grid is equal to the
product of the air-gap torque and rotor speed. In the following equation, T denotes the
air-gap torque and Wm denotes the rotor mechanical speed: Pg = T x Wm
The power delivered from the generator stator is equal to the product of air-gap torque
and stator emf frequency: Ps = T x Ws
From these equations, the power delivered by the rotor can be expressed as:
Pr = T x (Wm - Ws)
For rotor mechanical speeds above synchronous speed (super-synchronous), rotor power
is positive (+) and flows from the rotor into the grid. For rotor mechanical speeds below
synchronous speed (sub-synchronous), rotor power is negative (-) and flows from the grid
into the rotor. For a rotor mechanical speed equal to synchronous speed, the rotor power is
0. For a constant stator power of Ps, the association for a rotor speed from 0 – 2400 rpm
is displayed in the following figure.

Power Flow versus Rotor Speed

20 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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 As previously stated, the operating speed range of the actual system is from 800 – 1600
rpm. However, the system cannot deliver a constant power to the grid over this operating
speed range because the generator power that is delivered to the grid is a function of the
power that is extracted from the wind by the turbine blade. The relationship between
generator speed and maximum power that can be delivered to the grid is displayed in the
following figure. The stator and rotor power components are also displayed.

800 rpm 1200 rpm 1110 rpm 1600 rpm

(minimum speed ) (synchronous speed) (nominal speed) (maximum speed )

Grid Power Capability versus Rotor Speed

Turbine System Architecture GEH-6727E System Guide 21

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Notes

22 GEH-6727E 1.x MW DFIG Wind Power Converter ESS

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3 Mechanical Design
The 1.x MW DFIG ESS power converter is supplied in a freestanding cabinet. It is
factory assembled and tested, and intended for indoor mounting.

1.x MW DFIG ESS Power Converter Lineup

Mechanical Design GEH-6727E System Guide 23

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3.1 Specifications
Item Description
Operating temperature (at converter -30 to 45°C (-22 to 113 °F)
inlet temperature) 45 to 50°C (113 to 122 °F) derate 4% per 1°C (1.8 °F)

Derate is determined by current limits and power limits. Refer to the figure, Power
Converter Temperature Derate.
Storage temperature -30 to 65°C (-22 to 149 °F)
Transportation temperature -30 to 70°C (-13 to 158 °F)
Dimensions 2.3 m (7.5 ft) tall without DTA fan or 2.7 m (8.8 ft) tall including DTA fan x 2.3 m
(7.5 ft) x 0.9 m (3 ft) deep
Cabinet enclosures Integrated rigid steel structure made from sheet metal with a minimum 12-gauge
(2.5 mm, 0.1 in) thickness
Paint ANSI™-70 light gray
Protection class CFC and PDC provide IP-21
MCC and CBC provide IP-54

3.2 Components
The major components of the 1.x DFIG ESS power converter are as follows:

• Power Distribution Cabinet (PDC)

• Converter Filter Cabinet (CFC)
• Down Tower Assembly (DTA) Fan and Airflow Plenum
• Main Control Cabinet (MCC)
• Converter Bridge Cabinet (CBC)
• Liquid-based Cooling System (LBCS)

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 3.2.1 Power Distribution Cabinet
The Power Distribution Cabinet (PDC) has five covers, as follows:
Only the bolted covers on the • Synchronizing switch bolted cover
PDC require tools to open. • Circuit-breaker bolted cover with viewable access door
• Service entrance bolted cover
• Hinged auxiliary panel door
• Transient Voltage Surge Suppression (TVSS)
− Bolted cover in 1.6 MW converter
− Hinged panel door in 1.6e MW converter
The following devices are located inside the PDC:

• Grid current sensors (current transformers)

• Synchronizing switch (stator contactor K1)
• AC line fuses (ACLFU)
• Arc flash protection and dc bus charger fuses (FU1)
• TVSS
• Pad mount transformer (PMT) grid cable entry
• DC bus charger
• Main circuit breaker (Q1)
• Grid and stator voltage feedbacks
• Tower power feeders for lighting, hoist, and supply sockets
• Top box and control power feeders

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 Synchronizing switch (K1)

ACLFU
ACFLU
Dc bus charger
Grid and stator
voltage feedbacks

Top
To Box
Box andand
Control
Control power
power feeders
feeders

Tower power
feeders

Main circuit
breaker (Q1)

Grid current sensors

TVSS

Arc flash protection

and dc bus charger
fuses (covered by
cabinet frame)

PMT grid cable entry

1.6 MW PDC Components

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 Q1 load side
voltage sensing
Synchronizing switch (K1)

Top Box and

control power
feeders

ACLFU
x3

Tower power
feeders

Main circuit
breaker (Q1)
TVSS (Raycap)

Arc flash
protection and
DC bus charger
fuses
x3

Grid current
sensors
x3
Grid and stator
voltage fdk

DC bus charger

External voltage
regulator cable
entry (optional)

PMT grid
cable entry

1.6e MW PDC Components

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 3.2.2 Converter Filter Cabinet
The Converter Filter Cabinet (CFC) has four bolted covers that require tools to open. Two
covers are located on the front of the unit and two covers are located on the back. The
following devices are located inside the CFC:

• Distortion filter (DF) resistors

• Distortion filter contactor (KDF)
• DF capacitor
• Stator current sensors
• Control power transformer (PT)
• Rotor overvoltage contactors
• Line reactor
• Rotor reactor
• Air strip heaters
• Coolant pump
• Coolant reservoir
• Coolant heater (located inside the coolant reservoir)
• Stator and rotor cable entry

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 1.6 MW CFC Components

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 Front Back

DB resistor

Distortion filter
resistor (behind
the glastic
insulator)

Control power
transformer

Stator current
sensors

KDF

ROVC

Rotor reactor

Line reator

Stator
connections

Rotor
connections

Strip heaters

Coolant pump

Distortion
filter capacitor

Coolant
reservoir

Stator and rotor

cable entry

1.6e MW CFC Components

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 3.2.3 Down Tower Assembly Fan and Airflow Plenum
The Down Tower Assembly (DTA) airflow plenum is located on top of the main control
cabinet (MCC) and converter bridge cabinet (CBC). It contains the coolant-to-air heat
exchanger. Two ventilation covers with punched louvers are bolted to the front and back
of the plenum, which require tools to remove. Ventilation passages located on top of the
lineup allow the DTA fan to simultaneously force air through the PDC, CFC, air-to-air
heat exchanger, and coolant-to-air heat exchanger.

DTA Fan and Airflow Plenum

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 3.2.4 Main Control Cabinet
The Main Control Cabinet (MCC) has a hinged access door that serves as a mounting
surface for the push-buttons, switches, Uninterruptible Power Supply (UPS), computer
shelf, and document holder. The following devices are located inside the MCC:

• Power Conversion Main Control Module (WEMA)

• Power Conversion Wired-OR Board (WEOR)
• Alternative Energy Power Supply (AEPS)
• UCSx controller
• Power supply T3 for WEMA, UCSx, and Ethernet switches
• UPS
• Ethernet switch 1 for SCADA
• Ethernet switch 2 for IONet
• Control board set
• Power distribution for the following:
− Fans
− Lighting
− Tower hoist
− Optional energy meter
− Supply sockets
− Top Box 400/230 V ac feeder

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 1.x MW MCC Components

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 3.2.4.1 Control Board Set
The control board set consists of the following module and circuit boards:

• Wind DFIGe Converter Interface version A (WECA) module, which includes:

− Multiple Application Converter Control (MACC) main control board
− Wind Energy Main Design Specific Record (DSR) (WEMD) board
− Balance of Plant Processor Board version B (BPPB)
• Alternative Energy Application D (AEAD) board
• Alternative Energy Application A (AEAA) board
• Alternative Energy Bridge Interface (AEBI) #1 line bridge interface board, or for
Version B or greater, hardware (AEDB)
• AEBI #2 rotor bridge interface board

1.6 MW Control Board Set

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 AEAD MACC WECA AEDB (line and DB)

AEAA BPPB WEMD (between AEBI (rotor)

MACC and BPPB)
1.6e MW Control Board Set

3.2.5 Converter Bridge Cabinet

The Converter Bridge Cabinet (CBC) has a bolted cover that requires tools to open.
Located inside the CBC are the following devices:

• Line side converter phase modules

• Rotor side converter phase modules
• DC link capacitor modules
• CBC and MCC circulating fans
• Air-to-air heat exchanger
• Alternative Energy Bridge Modules (AEBM) gate drive boards (includes three on the
line converters and six on the rotor converters)

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 1.6 MW CBC Components

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 Heat exchanger
for liquid cooling

Rotor converter
phase modules
(2 IGBT modules
per heatsink)

CBC/MCC
circulating fans
x3

Line converter phase

modules A and B
(1 IGBT module per
heatsink)

Line converter phase

module C (lower IGBT)
and DB module (upper
IGBT)
(2 IGBT module per
heatsink)

DC capacitor banks
x4

LOTO DC Link

1.6e MW CBC Components

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 3.2.6 Liquid-based Cooling System
The 1.x MW DFIG ESS power converter has a liquid-based cooling system (LBCS). The
following figure illustrates the power converter lineup cooling and heating systems.

LBCS Cooling and Heating System

3.2.6.1 Power Distribution and Converter Filter Cabinet

Cooling
Refer to the section, Down Heat is removed from the PDC and CFC by exchanging the heated internal air with cooler
Tower Assembly Fan and external air. The DTA fan draws external air into the cabinets through louvers on the front
Airflow Plenum. cover of the CFC and the back cover of the PDC. Hot air is expelled from the
compartments through an integrated DTA air exhaust located on top of the lineup. DTA
fan operation is governed by the converter software control. A fan control algorithm
ensures thermal regulation of the ambient temperature inside the cabinets, as well as the
liquid coolant.

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 3.2.6.2 Main Control and Converter Bridge Cabinet Cooling
Heat is removed from the MCC and CBC using both coolant-to-air and air-to-air heat
exchangers. This approach results in very little external air exchange, which minimizes
the chance of contamination of sensitive electronics inside the CBC and MCC.
Refer to the section, Down A self-contained liquid cooling system is used to reject the heat generated by the IGBT
Tower Assembly Fan and switching devices to external air. A vertical submerged pump circulates the coolant from
Airflow Plenum. the liquid reservoir through the IGBT heat sinks to the coolant-to-air heat exchanger and
back to the reservoir. The pump motor, submerged impeller, and reservoir are located in
the CFC. The coolant-to-air heat exchanger is installed inside the DTA airflow plenum,
located on top of the CBC. The DTA fan (mounted on top of the lineup) draws external
air through both the coolant-to-air and air-to-air heat exchangers and exhausts it to the
outside.
Refer to the section, Cooling The coolant is a water/ethylene glycol mixture with an inhibitor that prevents freezing
System Maintenance. under low outside ambient temperatures. The IGBT heat sinks are at ground potential so
the use of deionized water is not required.
The converter software implements a coolant temperature-regulating loop by acting on
the coolant heater, pump, and DTA fan. Liquid coolant is intentionally heated when its
temperature approaches room temperature and is cooled down with forced air when its
temperature increases above 20ºC (68 ºF).
An air-to-air heat exchanger is used to reject the heat generated by the components that
are not cooled by the liquid cooling system. This includes all of the components inside the
MCC and some components inside the CBC (such as dc link capacitors, IGBT gate driver
boards, and dc bus plates). The air-to-air heat exchanger is mounted at the end of the
lineup, sharing contact surface with the MCC and CBC. Three fans inside the CBC
circulate air over the MCC and CBC components, and through the air-to-air heat
exchanger. The overlapping air-to-air heat exchanger and ventilation passages between
the MCC and CBC allow air to flow in a closed loop between these three distinctive
compartments. The CBC internal fans remain powered as long as the control PT is
energized.

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 MCC and CBC Cooling System Components

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 3.2.7 Warmup and Startup Sequence
The 1.x MW DFIG ESS power converter includes a warmup mechanism that establishes
suitable environmental operating conditions inside the cabinets after periods of offline
conditions. Subsequently, a startup sequence is initiated to bring the entire lineup back
online.
Refer to the Mark VIe Control The WEMA, located in the MCC, implements the warmup and startup mechanisms. It
Wind/Solar Energy Main performs functions with relay control circuits, a Programmable Intelligent Computer
Control (WEMA) Module (PIC)® microcontroller chip, and a BPPB processor board running I/O pack firmware.
Description (GEI-100734). Warmup and startup sequences are operational whenever the grid supplies a suitable
voltage level.
The PIC microcontroller and associated relays draw power from the grid lines even when
the rest of the lineup has no power. The PIC modulates the power applied to the heaters
inside the air-to-air heat exchanger plenum to regulate the temperature to 10ºC (50 ºF),
while keeping a minimum temperature increase above ambient for humidity control. This
regulating loop affects temperatures inside the MCC and CBC since air circulates
between them.
During warmup, but before the converter is powered on, the coolant temperature is also
controlled by turning on the coolant heater and pump motor. This action also contributes
to regulating CBC environmental conditions.
Heaters inside the PDC and CFC maintain inner ambient above outside temperature to
avoid condensation. These heaters are permanently energized until the converter
successfully completes its startup sequence.
When the MCC ambient temperature has been heated long enough for the equipment to
be powered, the Environmental OK relay, located on the WEMA, enables the control
power for the following components:

• UPS
• WECA/MACC assembly
• Redundant power path for the PIC
• Power converter dc bus
• Synchronizing stator switch (K1)
• Converter main circuit breaker (Q1)
Subsequently, the UPS provides power to the rest of the control circuit boards inside the
MCC (such as the UCSx controller, SCADA switch, IONet switch, and BPPB processor
board attached to the WEMA). The PIC initiates the startup sequence by powering on the
Environmental OK relay when any of the following conditions are met:

• MCC temperature is above 5ºC (41 ºF) for 70 minutes heat-soak delay time
• MCC temperature is above 45ºC (113 ºF) for 10 minutes
• Pushing and holding the Stop/Reset push-button (located on the MCC door) for 5
seconds
• MCC temperature is above 5ºC (41 ºF) and a toggling watchdog between the PIC and
BPPB is established, which means that the Environmental OK relay can operate
without intentional delay every time the PIC and BPPB communicate successfully
and the surrounding temperatures are above 5ºC (41 ºF)

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 When the Environmental OK relay is energized, only the UCSx controller can drop it out
by accessing the corresponding suicide control bit. When the UCSx controller and
WECA/MACC assembly are online, the MACC board starts regulating environmental
conditions by sending heater control signals (remote mode) to the WEMA through the
IONet interface. When this remote mode is activated, the power converter monitors all
environmental related temperature sensors to determine the best states for all heaters
inside the 1.x MW DFIG ESS converter lineup.
The PIC always remains in control of the MCC heaters, even when the MACC is
remotely regulating the heater operation. The MACC board can only request the PIC to
switch off the minimum duty-cycle of the MCC heaters so that power is saved when heat
is not needed. The MACC generates alarms and faults if the temperatures inside any of
the lineup compartments fall outside of the specifications.

Air and Coolant Heaters Locations

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 3.2.8 Dynamic Brake Module
The Dynamic Brake (DB) module is an optional feature for the 1.x MW DFIG ESS
converter and a standard feature in the 1.6e MW DFIG ESS converter. When installing
the optional DB feature in 1.x MW ESS versions prior to the 1.6e MW version, the
following modifications are required for the MCC, CBC, and CFC:

• Alternative Energy Dynamic Brake (AEDB) line bridge and DB interface board
replaces the AEBI #1 in the MCC

Note The 1.6e MW ESS does not use the AEBE adaptor board. Refer to the figure,
1.6e MW Control Board Set.

• The following devices are added to the CBC:

− DB phase module, which replaces the phase C line module
− Laminated DC bus
− Alternative Energy Bridge Module (AEBM)

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 Note The 1.6e MW ESS DB phase module does not contain the laminated DC bus. Refer
to the figure, 1.6e MW CBC Components.

• The following devices are added to the back upper cover of the CFC:
− DB resistor
− Resistor cover
− Gland plate and wire access hole

Resistor Cover

DB Resistor

Gland Plate and

Access Hole

CBC Devices

Note In the 1.6e MW ESS, the DB resistor is located inside the CFC and the filter
resistor has been moved to the air plenum.

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4 Power Converter Circuit
The 1.x MW DFIG ESS converter power circuit topology consists of two 3-phase IGBT
converter bridges connected by a dc link. The line converter gating is digitally controlled
to regulate the voltage on the dc link. The rotor converter gating is digitally controlled to
produce a variable frequency ac output current to the generator rotor terminals. A rotor
reactor coupled with cable capacitance limits the dv/dt on the generator rotor. A Rotor
Overvoltage Contactor (ROVC) prevents damaging high voltages on the dc link that can
be fed back from the generator stator during faults. A line filter and line reactor trap
current and voltage harmonics generated by the switching events on the line and rotor
converters. Line fuses interrupt damaging fault currents into the power converter.
The dc bus charging circuit charges the dc link capacitors in a current limited fashion
through bridge anti-parallel diodes. The charge contactor (CCONT) connects the line
converter to the line voltage. A hard-wired interlock between the line filter and charging
circuit contactors prevents charging of the dc link when the line filter contactor (KDF) is
closed.
The control power transformer (T2) steps down the line-to-neutral voltage to 230 V ac for
pumps, fans, and noncritical relay logic, which can drop out during line bus voltage dips.
The AEPS is the control power supply. It can be powered redundantly from two sources,
the dc link and T2, to subsequently energize control boards and critical relay logic, which
cannot drop out during line bus voltage dips or dc link failures.

Dynamic Brake
Line Converter (optional for Rotor Converter
1.6 ESS converter)

Main Line Rotor

ACLFU DBR
Breaker Reactor Reactor

Grid Main Rotor

DC
Transformer Bus
Link
LV Connection
Q1 L1 L2
FU1 DC Bus Charging Circuit
CCONT
ROVC

FB4
KDF

Control Power
Transformer (T2)
Primary 690 V ac
Secondary 400/230 V ac

Line Filter
Control
Power Feed

1.6e and 1.6 MW DFIG ESS Power Converter Circuit Diagram

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 The converter power output is dependent on the configuration in the specific turbine
design. Each turbine has power capability curves that show the maximum power
produced for a given grid voltage and power factor.
Current limits begin to reduce from 35°C (95 °F) and higher. This may limit power
depending on the grid voltage and power factor. Power limits begin at 45°C (113 °F) and
are a linear slope from turbine rated power to 1309 kW at 50°C (122 °F). Power is rapidly
reduced above 50°C (122 °F) to 0 kW at 55°C (131° F). The converter will shut down at
55°C (131 °F).

Power Converter Temperature Derate

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5 Control Hardware
The MCC contains the circuit boards that make up the Digital Signal Processor
(DSP)-based digital control. The following modules and circuit boards contain the control
and protection features for the 1.x MW DFIG ESS power converter:

• Multiple Application Converter Control (MACC) Board

• Alternative Energy Bridge Interface (AEBI) Board
• Alternative Energy Dynamic Brake (AEDB) Board
• Alternative Energy Application D (AEAD) Board
• Alternative Energy Application A (AEAA) Board
• Alternative Energy Power Supply (AEPS)
• Wind DFIGe Converter Interface Module (WECA)
• Power Conversion Main Control Module (WEMA
• Power Conversion Wired-OR Board (WEOR)

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 1.6 MW ESS Control Hardware One-line Diagram

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 DB Res Vfb

1.6e MW ESS Control Hardware One-line Diagram

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5.1 Multiple Application Converter Control Board
The Multiple Application Converter Control (MACC) contains the DSP and memory
subsystems that run the line converter and rotor converter control algorithms. Several
Field Programmable Gate Arrays (FPGA) provide the logic to interface the DSP with the
following:

• Pulse Width Modulator (PWM) gate control and protection logic for the IGBT
switches
• Counters for current, voltage, and temperature voltage-controlled oscillator (VCO)
feedbacks
• Counters for tachometer feedback
• Discrete logic inputs and outputs
• RS-232C serial communications interface
• Dual port memory arbitration for communication with the WECA

5.2 Alternative Energy Bridge Interface Board

Refer to the Renewables Power The Alternative Energy Bridge Interface (AEBI) provides the bridge interface function
Conversion Alternative Energy between the MACC and the power converter. Two AEBI boards are required: the first
Bridge Interface (AEBI) (AEBI #1) interfaces with the MACC to the line converter, while the second (AEBI #2)
Instruction Guide interfaces with the MACC to the rotor converter. Each AEBI provides a galvanically
(GEI-100769). isolated interface for the following:

• IGBT gate drive signals from the MACC:

To replace an AEBI, refer to
the section, Replacing an AEBI − Phase A upper and lower
or AEDB. − Phase B upper and lower
− Phase C upper and lower
• IGBT protection indications to the MACC:
− Desaturation by monitoring the IGBT collector to emitter voltages
− Overcurrent by monitoring the phase current through the shunt voltage
− Excessive rate of change of current by monitoring the phase current through the
shunt voltage
• VCO feedback signals to the MACC:
− Converter phase currents: Ia, Ib, Ic
− Converter line-to-line voltages: Vab, Vbc
− Converter dc link voltage, V dc
− IGBT base plate temperature per module

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5.3 Alternative Energy Dynamic Brake Board
Refer to the Renewables Power The IS200AEDBH#A Alternative Energy Dynamic Brake Bridge Interface (AEDB)
Conversion Alternative Energy board, combined with Dynamic Brake (DB) and battery charger functions, enables
Dynamic Brake Bridge communication between the Multiple Application Converter Control (MACC) and the
Interface (AEDB) Module Insulated Gate Bipolar Thyristor (IGBT) bridge. The AEDB provides a galvanically
Description (GEI-100812). isolated interface for all signals.
The AEDB replaces the AEBI #1 when the DB option is installed. It provides the same
To replace an AEDB, refer to
functions for the line converter as AEBI #, plus a bridge interface to the DB IGBT
the section, Replacing an AEBI
module and battery voltage. Refer to the section, Dynamic Brake (DB) Module.
or AEDB.

5.4 Alternative Energy Application D Board

Refer to the Renewables Power The Alternative Energy Application D (AEAD) provides the interface function between
Conversion Alternative Energy the MACC and application-specific inputs/outputs (I/O). It provides a galvanically
Application D (AEAD) isolated interface for the following:
Instruction Guide
• General use relay outputs rated for 240 V ac or 24 V dc, 10 A normally open (NO)
(GEI-100766).
and 5 A normally closed (NC) contacts:

To replace an AEAD, refer to − Stator sync switch close command (quantity 1)

the section, Replacing an − System circuit breaker undervoltage trip command (quantity 1)
AEAD. − Grid monitor link to safety string, rated for 24 V dc and 30 mA (quantity 1)
• Dedicated relay outputs for the internal power converter use rated for 240 V ac or 24
V dc, 10 A NO and 5 A NC contacts:
− KDF close command (quantity 1)
− Rotor overvoltage contactor open command (quantity 2)
− Liquid cooling pump motor run command (quantity 1)
− DTA fan run command (quantity 1)
• General use contact inputs rated for 24 V dc, 30 mA:
− KDF status (quantity 1)
− System circuit breaker bell alarm (quantity 1)
− Spare (quantity 2)
• Special use power enable inputs rated for 24 V dc, 30 mA:
− Tower safety chain (quantity 1)
• Voltage feedback VCO to the MACC (rated ±856 V full scale input):
− Grid line-to-neutral voltages Van, Vbn, and Vcn (quantity 3)
• CT feedback VCO to the MACC (rated for 30 V full scale input):
− Grid phase currents: Ia, Ib, Ic (quantity 3)
• Thermistor input VCO to the MACC (rated for 5 V full scale input):
− Type J thermistor with resistance of 10 kA at 25ºC (77 ºF) sensing air
temperature inside cabinets, inlet air temperature, and coolant temperature
(quantity 4)

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5.5 Alternative Energy Application A Board
Refer to the Renewables Power The Alternative Energy Application A (AEAA) provides the interface function between
Conversion Alternative Energy the MACC and generator stator specific inputs. The AEAA provides a galvanically
Application A (AEAA) isolated interface for the following:
Instruction Guide
• Voltage feedback VCO to the MACC (selectable for 12 or 1400 V full scale input):
(GEI-100767).
− Generator stator line-to-line voltages V ab, V bc (quantity 2)
To replace an AEAA, refer to • Current transformer feedback VCO to the MACC (rated for 30 V full scale input):
the section, Replacing an − Generator stator phase currents: Ia, Ib, Ic (quantity 3)
AEAA.

5.6 Alternative Energy Power Supply

Refer to the Renewables Power The Alternative Energy Power Supply (AEPS) converts dc link input power derived from
Conversion Alternative Energy the bridge into multiple output power (voltages) required for power conversion control
Power Supply (AEPS) systems. The AEPS supplies dc bus power to the following components:
Instruction Guide
• Control and isolated power to the MACC
(GEI-100768).
• Interface and contactor power to the AEAA
To replace an AEPS, refer to • Isolated bridge power to the AEBI
the section, Replacing an
AEPS.

5.7 Wind DFIGe Converter Interface Module

Refer to the Mark VIe Control The Wind DFIGe Converter Interface (WECA) module provides an I/O pack interface for
Wind DFIGe Converter the DFIG ESS power converter to the IONet where the UCSx controller and additional
Interface (WECA) Module I/O packs are connected. This communication channel allows the sharing of data between
Description (GEI-100732). the MACC and the rest of the system for control, monitoring, and diagnostic purposes.
The WECA exchanges pages of I/O signals with the UCSx controller using the Ethernet
To replace WECA module, Global Data (EGD) protocol.
refer to the section, Replacing
Communication with the ToolboxST application is also provided through the use of
a WECA.
Asynchronous Drive Language (ADL) messages imbedded in the System Data Interface
(SDI) protocol. Power converter faults and alarms are passed to the UCSx controller as
I/O pack diagnostic alarm messages.

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5.8 Power Conversion Main Control Module
Refer to the Mark VIe Control The Power Conversion Main Control (WEMAH1) is part of the ESS wind turbine. The
Wind/Solar Energy Main WEMA controls the hardware in the MCC, communicates to the Mark VIe controller, and
Control (WEMA) Module is configured using the ToolboxST application. The WEMA’s PIC microcontroller handles
Description (GEI-100734). cabinet temperature control in conjunction with the wind turbine startup.
The WEMA has the following inputs and outputs for controlling the MCC hardware:
To replace a WEMA module,
refer to the section, Replacing • 9 relay outputs
a WEMA. • 27 digital inputs
• 3 solid-state relay outputs
• 2 analog thermistor temperature sensor inputs

5.9 Power Conversion Wired-OR Board

Refer to the Renewables Power The Renewables Power Conversion Wired-OR (WEOR) board distributes a second power
Conversion Energy (WEOR) supply source to the AEPS. The AEPS typically derives power from the power bridge dc
Instruction Guide link. As voltage is not located on the power bridge, the WEOR supplies a 460 V ac
(GEI-100764). control voltage transformer feed, which is primarily used for startup and other situations.

To replace a WEOR, refer to

the section, Replacing a
WEOR.

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Notes

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6 Control Software
The overall goal for the 1.x MW DFIG ESS power converter is to regulate the torque in
the generator and the net power factor (PF) presented to the grid by the generator and
power converter. The generator torque reference and grid reactive power are commanded
from the UCSx controller over the IONet communication interface. The MACC contains
the processors that run the control algorithms for the power converter.
The rotor converter control regulates the generator torque and stator PF. The control is
implemented in a rotating frame of reference that is oriented such that the x-axis current is
in phase with the rotor voltage, which produces real power, and the y-axis current is in
quadrature with the rotor voltage, producing reactive power. A rotor angle is used to
demodulate the current and voltage feedbacks from ABC into XY and rotate voltage
commands from XY back into ABC. The rotor angle is derived from a tachometer-based
rotor position feedback and a stator voltage based phase-locked loop (PLL).
The torque reference is used to calculate the rotor x-axis current reference. The grid
reactive power is used to calculate the rotor y-axis current reference. Assuming the line
converter and distortion filter (DF) are operating at a net unity PF, the rotor y-axis current
is calculated to operate the generator stator at the desired grid PF. If a rotor current limit is
encountered that makes it unable to fully satisfy the grid PF angle reference through the
generator stator, the line converter is employed to make the y-axis line current through a
spillover reference in an attempt to fulfill the grid PF reference.
The line converter control regulates the voltage on the dc link. The control is
implemented in a rotating frame of reference that is oriented such that the x-axis current is
in phase with the line voltage, which produces real power, and the y-axis current is in
quadrature with the line voltage thus, producing reactive power. A line voltage angle
demodulates current and voltage feedbacks from ABC into XY and rotates voltage
commands from XY back into ABC. The line voltage angle is derived from the line
voltage-based PLL.
A dc link voltage regulator commands the line x-axis current reference. The line y-axis
current reference is normally zero. A non-zero current to the line converter can result
from activation of the spillover y-axis current reference from the rotor converter control.
A power trim function regulates the power output at the transformer secondary so that the
measured grid monitor power divided by the generator’s shaft angular speed, is equal to
the torque command received from the USCA controller.

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 Note AEBI-1 in the following figure provides an alternative to the AEDB.

MACC Software Control

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6.1 Protection and Diagnostics
The protection philosophy for The 1.x MW DFIG ESS power converter continually tests for abnormal conditions and
the power converter is to alarm generates a diagnostic whenever a problem is detected. A diagnostic can be an alarm or
abnormal conditions but only trip.
trip when operating with the
Alarm indicates an abnormal condition that requires attention but does not shut down the
abnormal condition would
power converter.
result in equipment damage.
Trip indicates an abnormal condition that shuts down the power converter or prevents it
from starting. Trips can occur instantaneously (for example, no intentional delay is
applied) or delayed with a preceding alarm.
The power converter control provides protection from, but is not limited to, the following:

• Converter overcurrent and overvoltage

• Stator overcurrent and overvoltage
• IGBT desaturation
• IGBT overtemperature
• Coolant overtemperature and undertemperature
• DC bus overvoltage
• Ground fault
• DF verification
• Cable overload protection
Grid monitor functions are provided to ensure grid quality at the point of connection for
the power converter and the rest of the power system. Some of the grid monitor
protections provided by the power converter include:

• Excess power flow detection

• Reverse power flow detection
• Undervoltage and overvoltage detection
• Voltage peak detection
• Voltage asymmetry detection
• Underfrequency and overfrequency detection
Detailed diagnostic information is available using the ToolboxST application. The
converter control also sends diagnostic signals to the UCSx controller over the IONet
communication interface.

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6.2 Communication Interfaces
The power converter provides the following serial communication interfaces:

• IONet is the control and diagnostic interface to the UCSx controller. The ControlST*
Software Suite and WorkstationST* applications gain access to power converter data
using this interface.
• RS-232C is the direct serial communications on the MACC board for the
ToolboxST application.

6.3 Rule Engine

An embedded rule engine calculates all of the control settings based on the generator
equivalent circuit parameters and other customer-specific inputs, such as grid frequency.

6.4 Download Wizards

Refer to the ToolboxST User The power converter and ToolboxST application provide user friendly interface elements
Guide for Mark Controls called Download Wizards, which consist of a series of dialog boxes that lead users
Platform (GEH-6700), the through specific tasks. The most common wizards include:
sections, Creation Wizard and
• Wind DFIG commissioning
Download Wizard.
• Product version upgrade
• Cell test
• Capture buffer setup
• Grid monitor setup

6.5 Simulator
An embedded system simulator models the 1.x MW DFIG ESS power converter, grid bus,
and operation of the line and rotor converters. The only hardware required to run the
simulator is a MACC board. The simulator runs at about one half the speed of real time
and is very useful in evaluating steady state operating points and transient system
behaviors.

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6.6 Software Configuration and Monitoring
The 1.x MW DFIG ESS power converter is configured and monitored using the
ToolboxST application, which runs on a Microsoft Windows-based computer. The
computer communicates with the UCSx controller over the Ethernet directly to the power
converter over the IONet. The UCSx controller is the access point to the IONet where the
power converter and I/O packs make diagnostic data available.
An automatic recording of the power converter operation can be created using the
WorkstationST application. This application runs as a service or application on
Windows-based computers and communicates with the UCSx controller over the Ethernet
to obtain information concerning the power converter as required.

6.6.1 Configuration Parameters

Configuration parameters are stored in non-volatile memory on the MACC board. The
ToolboxST application enables the user to view and modify these parameters. Typical
system parameters that must be set during commissioning include:

• Grid frequency
• Software IPN
• Generator equivalent circuit parameter values from the generator data sheet.
Predefined parameter settings for VEM®, Hitachi®, ABB®, and other generators are
embedded in the converter control software and are selectable through the
Commissioning Wizard.
• Ethernet communication settings for the UCSx controller (such as IP address and
subnet mask) are set based on network assignments particular to the installation site.

Generator Parameters

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 6.6.2 Live Data Block Diagrams
Refer to the section, Fault The ToolboxST application displays block diagrams that represent various aspects of the
History . control algorithms, including live data. The fault list displays the faults that are monitored
by the application.

Note Variable and parameter helps are not accessible from animated drawings.

Live Data Block Diagram

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 6.6.3 Fault History
Refer to the ToolboxST User The power converter provides non-volatile diagnostic memory that is used to maintain
Guide for Mark Controls fault history and capture buffer information in the event of a loss of control power. During
Platforms (GEH-6700), the the startup initialization process, the fault history and capture buffer are restored to the
section Active Fault List. state just before the loss of control power.
The ToolboxST application displays a list of active faults in the power converter and a
history list of the last 100 faults that have occurred. It provides detailed documentation on
each fault to facilitate troubleshooting.

Fault History List

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 6.6.4 Live Data Trend
Refer to the Trender for the The Trender is a component of the ToolboxST application that collects live data from the
ToolboxST Application power converter and presents it in an oscillograph display. User selectable signals display
Instruction Guide with sample rates as fast as 25 ms.
(GEI-100795).
➢ To trend the power converter startup
1. From the Settings tab, expand Pre-Defined Trends.
2. Double-click Default Trends.
3. Verify that all Traces are checked.
4. Click Online/Offline to start the trend.
5. Refer to the following figure for the start trend sequence.

1. The turbine control accelerates the

Line DC bus voltage generator to minimum operating speed .
(V dc)
2. The line converter MA closes and the
line PLL locks .
Line AC current (A rms)
3. The line converter regulates the
nomical dc link voltage .

Line AC frequency (Hz) 4. The rotor converter applies dc

excitation to the rotor:
a. Check rotor resistance .
Line AC voltage (V rms) b. Check stator voltage magnitude .
c. Check stator voltage frequency .
d. Check stator voltage phase .

Rotor current 5. The rotor converter applies ac

(A rms) excitation to the rotor to synchronize the
stator voltage to grid voltage .
Rotor voltage
(V rms) 6. The stator sync switch closes .

7. The excitation is commanded through

the stator and rotor current drops to
Speed feedback (rpm)
zero :
a. Check stator CT magnitude .
Torque reference input (pu) b. Check stator CT phase .

8. Resume excitation through the rotor.

Torque feedback (pu)
9. Enable the torque regulator.

Grid power (kW)

Grid reactive power (kVAR)

Stator current (A rms)

Power Converter Startup Trend

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 6.6.5 Capture Buffer
The capture buffer records The ToolboxST application uploads and displays high-speed capture buffer data from the
4,096 samples of up to eight power converter. It contains the logic to automatically re-arm the capture buffer after
user-selectable signals, with manual capture buffer uploads. The power converter provides the following logic to
sample rates as fast as 350 μs. automatically re-arm the capture buffer:

• If MACC startup, re-arm the capture buffer when the power converter is not in a
stopped state and no fault is present.
• Else after any capture buffer upload, re-arm the capture buffer when the power
converter is not in a stopped state, no fault is present, and 15 seconds have passed
since upload.
• Else all other times, re-arm the capture buffer when the power converter not in a
stopped state, no fault is present, and the default re-arm delay of 2,880 minutes (48
hours) has expired.

Capture Buffer Data

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Refer to the WorkstationST The WorkstationST application can automatically upload the capture buffer data and live
Alarm Viewer Instruction trend data from the power converter through the Ethernet connection. Included with this
Guide (GEI-100620). data is a record of any faults that occurred during the data capture interval. The data is
uploaded and archived to the computer hard drive without user interaction. The archived
data files are viewed with the Trender and Alarm Viewer.

Running Capture Buffer

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7 Maintenance
This section provides the following maintenance procedures for the 1.x MW DFIG ESS
power converter, as well as the procedure to return it to service after maintenance has
been performed:

• Safety Precautions
• Preparing the Equipment
• Maintaining the Equipment
• Returning the Equipment to Service

7.1 Safety Precautions

With power applied, this equipment contains a
potential hazard of electric shock or burn. The
nominal voltage of the mains of this equipment is
690 V ac and the dc link voltage is approximately
1075 V dc.

Warning Voltage measurement equipment and safety

equipment/procedures for this application should be
used. Refer to IEC-1010 and UL-3111.

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 per local site’s safety policy and practices
Warning before performing any adjustments, servicing, or
other acts requiring physical contact with the circuit
boards, electrical components or wiring.

Wear appropriate hearing protection when working

around this equipment.
Warning
Acoustic Noise Levels
Equipment Distance Noise Level
81.1 dBA average
Front of the converter filter cabinet 1 m (3 ft)
83.3 dBA maximum
80.7 dBA average
Back of the converter filter cabinet 1 m (3 ft)
82.3 dBA maximum

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

Although less toxic than other commonly used

coolant mediums, ethylene glycol is highly
conductive to electrical current. This property
creates a hazard to any electrical component the
coolant comes in contact with.

Although easily cleaned up, the coolant can soak in

to porous circuit boards, plastic, and laminations,
causing stray electrical currents that may not cause
immediate failure, but can severely affect equipment
Warning operational lifetime. Coolant that evaporates or is
wiped up can leave a powdered residue that is also
conductive. Take precautions to prevent any coolant
from leaking onto circuit boards, terminal strips,
fuses, or inductor components before disconnecting
hoses.

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

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 remove.

While working on the module replacement, do not

set any tools, hardware, rags, (on the top of the
capacitor bank modules). These things could have
coolant on them or this coolant could be on hands
Caution that are touching parts of the module. Any coolant
on the module could cause major equipment
damage.

Be sure to place all tools, hardware, and rags outside

of the cabinet while working on the equipment.

Follow all fastener torque requirements listed.

Caution

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7.2 Preparing the Equipment
➢ To prepare the equipment for maintenance
1. Follow all instructions provided in the section, Safety Precautions.
2. Verify that all power sources to the equipment have been disconnected in accordance
with the site's lockout tagout (LOTO) procedures.
3. Wait at least 20 minutes before opening any cabinet doors to allow the dc link
capacitors to discharge to <50 V peak.
4. Open the MCC door and locate the WEOR board in the lower right area of the
cabinet.
5. If applicable, remove the protective shield if holes are not provided.
6. On the WEOR board, connect a meter between fuses FU4 and FU5 and measure the
dc link voltage. The voltage should be <5 V.

If the voltage is not <5 V, do not proceed with

maintenance. Contact the nearest GE sales or
service office, or an authorized GE sales
representative.
Warning
7. Perform the intended maintenance procedures.

WEOR Board DC Link Voltage Measuring Points

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7.3 Maintaining the Equipment
Before performing any maintenance procedures, follow all safety precautions and
preparation procedures. Refer to the sections, Safety Precautions and Preparing the
Equipment.

7.3.1 Cooling System Maintenance

Refer to the figure Cooling and The liquid-based cooling system (LBCS) controls the 1.x MW DFIG ESS power
Heating System for the coolant converter IGBT temperature. Heat that is generated by the operating IGBTs is transferred
paths. to the coolant by the heatsinks and released into the air by the heat exchanger. The control
software implements an algorithm to ensure thermal regulation of the liquid coolant.

Equipment Needed for Cooling System Maintenance

Item Measurement Quantity
Antifreeze N/A As needed
Refractometer with ethylene glycol scale N/A 1
Utility Pump 9 lpm at 9 m (~2.4 gpm at 30 ft) 1
Drain / Mix container 19 liters (~5 gallons) 3
Graduated Mix container 0.94 liters (0.25 gallons) 8 quart capacity 2
Hose 1: pump to drain/mix container 9 mm (0.35 in) minimum ID 1
Hose 2: pump to power converter reservoir 9 mm (0.35 in) minimum ID with male garden hose connector 1
Cloth N/A As needed

7.3.1.1 Cooling System Specifications

Capacity
Item Measurement
Liquid cooling system capacity 14.2 liters (3.75 gallons)
Liquid reservoir capacity 45.4 liter (12 gallons)

Coolant Concentration
Item Description
Coolant Mixture of 50% water and 50% inhibited ethylene glycol antifreeze (GE part number 151X1220PX01PC01, 3.8
liters [1 gallon]) (50/50) by volume.

Products that conform to these specifications are Valvoline™ Zerex™ G-05 and BASF™ Glysantin™ G-05.
New coolant concentration can be controlled by volume measurement using 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 provides freeze protection to -34°C (-30 °F)
55% concentration provides freeze protection to -40°C (-40 °F)

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 7.3.1.2 Checking the Coolant Level
➢ To check the coolant level
1. Remove the front bolted cover of the Converter Filter Cabinet (CFC).
2. Locate the pressure regulator installed on the top of the reservoir (refer to the
following figure). 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.

Cooling System Components

3. Unscrew the pressure regulator to open the top of the reservoir.
4. Place the dipstick located on the right sidewall, beside the reservoir, inside the tank
and let it rest on the edge of the regulator opening.
5. Remove the dipstick and read the coolant level from the dipstick-graduated surface.
The dipstick has three marks, as displayed in the following figure. Make sure the
liquid level never exceeds the maximum pump marks, depending on the state of the
pump motor.

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 Cooling System Diagram
6. Following EHS procedures, clean the dipstick and any coolant spills with a clean, dry
cloth.
7. Hang the dipstick back on the right sidewall.
8. Properly dispose of all coolant waste.
9. Screw the pressure regulator back in the reservoir’s opening.
Refer to the section, Returning 10. Secure the CFC cover in place.
the Equipment to Service.
11. Return the equipment to service.

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 7.3.1.3 Filling the Converter Cooling System
➢ To add coolant to the power converter

Although less toxic than other commonly used

coolant mediums, ethylene glycol is highly
conductive to electrical current. This property
creates a hazard to any electrical component the
coolant comes in contact with. Although easily
cleaned up, the coolant can soak in to porous circuit
boards, plastic, and laminations, causing stray
electrical currents that may not cause immediate
failure, but can severely affect equipment
operational lifetime.
Caution
Coolant that evaporates or is wiped up can leave a
powdered residue that is also conductive. Take
precautions to prevent any coolant from leaking
onto circuit boards, terminal strips, fuses, or
inductor components before disconnecting hoses.

Note The power converter uses a 50/50 mixture of ethylene glycol (Valvoline Zerex
G-05 or BASF Glysantin G-05) and demineralized water. Refer to the section, Cooling
System Specifications.

1. Remove the CFC front bolted cover.

2. 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.
3. Unscrew the pressure regulator to open the top of the reservoir.
4. Insert the garden hose that is connected to the utility pump outlet through the
reservoir opening.
5. Mix the required amount of coolant in a container and submerge it in the hose that is
connected to the utility pump inlet.
6. Apply power to the utility pump and let the coolant flow into the reservoir.
7. When the mixture container is empty, remove the hose from the reservoir.
Refer to the section, Checking 8. Check the coolant level.
the Coolant Level.
9. Screw the pressure regulator back in the reservoir’s opening.
10. Following EHS procedures, clean any coolant spills with a clean, dry cloth.
11. Properly dispose of all coolant waste.

Refer to the section, Returning 12. Secure the CFC cover in place.
the Equipment to Service. 13. Return the equipment to service.

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 7.3.1.4 Draining the Coolant
➢ To drain coolant from the reservoir
1. Remove the CFC front bolted cover.
Refer to the figure, Cooling 2. Locate the pressure regulator installed on the top of the reservoir. Press the button on
System Components. 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.
3. Unscrew the pressure regulator to open the top of the reservoir.
4. Insert the garden hose that is connected to the utility pump inlet through the reservoir
opening.
5. Position the hose that is connected to the utility pump outlet inside the drainage
container.

Note Allow the cooling system to drain into the reservoir for a minimum of 30 minutes
before operating the utility pump.

6. Apply power to the utility pump and let the coolant flow out of the reservoir.
7. Turn off the utility pump and remove the hose from the reservoir when the drainage
operation is complete.
8. Screw the pressure regulator back in the reservoir’s opening.
9. Following EHS procedures, clean any coolant spills with a clean, dry cloth.
10. Properly dispose of all coolant waste.
Refer to the section, Returning 11. Secure the CFC cover in place.
the Equipment to Service.
12. Prior to placing the system back in service, fill the system with coolant by following
the instructions in the section, Filling the Converter Cooling System .
13. Returning the equipment to service.

7.3.2 Preventative Maintenance

The 1.x MW DFIG ESS power converter is designed to operate with minimal operator
interaction or maintenance. The following checks are needed to ensure continued
availability and performance to specification over the converter life.

Note Most parts are designed to last throughout the converter’s lifetime. Parts that fail
need to be replaced and reported to determine if component reliability problems have
developed, or if any additional preventative maintenance checks are required.

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 7.3.2.1 Annual Maintenance
Check the coolant concentration ethylene glycol/water after 12 months of converter
operation.

➢ To check the coolant concentration

1. Using a digital refractometer, check the coolant concentration for a 50/50 ethylene
glycol/water mixture.
2. If the coolant concentration is incorrect, add distilled water or 50/50 ethylene
Refer to the procedure, Filling
glycol/water mixture to restore the solution of ethylene glycol to a range of 51 to
the Converter Cooling System.
47% (volume).
3. Replenish the coolant tank level to full.

7.3.2.2 Six-month Maintenance

Refer to the procedures, Perform the following maintenance after six months of converter operation:
Checking the Coolant Level
• Check the coolant level in the reservoir and replenish as needed.
and Filling the Converter
Cooling System. • Inspect the cooling system for leaks and repair as needed.

7.3.2.3 Five-year Maintenance

Replace the coolant to renew the corrosion inhibitors in the coolant at five-year (40,000
run-hours) intervals. Refer to the procedures, Draining the Coolant and Filling the
Converter Cooling System.

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 7.3.3 Wire Level Maintenance
Wiring levels can be categorized into as many as four levels. This level separation is used
to segregate potentially noisy wiring from sensitive wiring. The wire levels are defined as
follows:

• Level 1, Low (most noise sensitive)

− Analog values up to 50 V dc
− Digital values up to 15 V dc
• Level 2, Medium - Analog values > 50 V dc, with < 28 V ac ripple
• Level 3, High
− DC switching > 50 V dc
− Analog values > 50 V dc, with > 28 V ac ripple
− AC power up to 230 V using #12 AWG or smaller wire
• Level 4, Power
− AC/DC buses
− AC feeders or dc power circuits, #10 AWG or larger wire
A minimum of three groups must be used to keep noisy wiring away from sensitive
wiring. More than three groups may be used if desired, but if only three groups are used,
the following separation needs to be implemented:

• Group 1
− Two cables going to the WECA module tachometer and Ethernet
− One shielded cable used for the tachometer
• Group 2
− All wiring to and from the MCC
− Six wires for the grid current transformer (CT) inputs grouped together in
twisted pairs
− Six wires for the stator CT inputs grouped together in twisted pairs
− Individual digital inputs wired with twisted pairs, except the main breaker, Bell
Alarm, which should use a shielded twisted pair
− Individual digital outputs wired with twisted pairs
− Individual thermistor sensor inputs wired with twisted pairs
− Four wires for the 690 V grid voltage feedback grouped together in a twisted
bundle
− Three wires for the 690 V stator voltage feedback grouped together in a twisted
bundle
− Three wires for the 400/230 V auxiliary power feed grouped together in a twisted
bundle
• Group 3
− Main 690 V power cables to line converter
− Main 690 V power cables to the rotor converter

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7.4 Returning the Equipment to Service
➢ To return the power converter to service after maintenance has been
performed

Note This procedure should be not be performed unless the procedure, Preparing the
Equipment has been completed.

1. Follow all instructions provided in the section, Safety Precautions.

2. Verify that all maintenance procedures have been completed.
3. Verify that all tools have been removed from the equipment.
4. Verify that all test leads and connections have either been removed or carefully
secured to prevent contact with energized components or buswork.
5. Close and bolt all covers in place.
6. Close the MCC door.
7. Following all LOTO procedures, reconnect the power sources to the power converter.

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Notes

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8 Troubleshooting
Refer to the help file, Wind-DFIG ESS Help, for the faults that may be generated while
operating the 1.x MW DFIG ESS power converter. Fault descriptions, possible causes,
and solutions are provided in the help file for troubleshooting.

8.1 Rotor Startup Synchronization

The rotor startup sequence The 1.x MW DFIG ESS power converter is started by a power converter connected to the
begins after the line converter rotor circuit through brushes and slip rings. To go online with the power converter, the
has started gating and is stator voltage must first be matched to the line voltage, and then a contactor is closed to
regulating the dc link to its connect the stator to the line. Subsequently, the power, torque, and power factor (PF) can
setpoint. be controlled through the rotor circuit.
This section provides the sequence used by the converter control to achieve the voltage
match and check for various fault conditions, including:

• Pre-synchronization Cell Test

• Synchronization
• Post-synchronization

8.1.1 Pre-synchronization Cell Test

The ROVC is also known as When the power converter is not operating, the ROVC shorts the rotor. When the rotor
the crowbar contactor. converter is commanded to start, it runs a cell test to verify that the rotor bridge IGBT’s
are operating correctly. Current is circulated through inductor L2 and the ROVC by
applying short pulses that exercise all possible current conduction paths. (Refer to the
elementary diagram, sheet CFC/4, for these locations.)
If the cell test is successful, relays K3 and K4 on the AEAD board (refer to the
elementary diagram, sheet MCC/14, for these locations) are picked up to energize the coil
of the ROVC. (K3 will drop out after a short delay to insert a power-economizing resistor
in the ROVC coil circuit).
The rotor converter runs the cell test again to verify that the ROVC is no longer shorting
the rotor. With an open stator, the rotor impedance is very high; therefore, very low
current should result from the pulses applied by the cell test.

Note For the purpose of this test, the rotor impedance is considered to be an open circuit.

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 8.1.2 Synchronization

8.1.2.1 Rotor Connection

The rotor is excited with dc current with the full magnetizing current commanded to
phase A, and a 50-50 split between phases B and C. The rotor voltage is compared to the
product of the measured currents and the expected rotor resistance.

8.1.2.2 Stator Voltage Feedback

While dc excitation is applied to the rotor, the presence of stator voltage feedback is
verified. If voltage is present, the stator PLL will lock on to its frequency. The frequency
is determined by the generator speed: 40 Hz at 800 rpm, 60 Hz at 1200 rpm, and so forth.
A failure to lock is most likely due to a severe unbalance in the stator voltage feedbacks,
as a result from a missing phase.
If the stator cables have the wrong phase rotation, or the stator voltage feedbacks have a
pair of wires that are incorrectly placed, the PLL frequency will be negative. The PLL
frequency is compared to the tachometer speed indication. The correct frequency in Hz is
the speed in rpm divided by 20. If the stator voltage feedbacks were connected to some
other voltage source other than the stator, this relationship would not be observed. After
the PLL has locked, a stator voltage regulator is enabled, which attempts to match the
stator voltage magnitude to the line voltage magnitude.

8.1.2.3 Rotor Phasing

The rotor excitation is switched from dc to the frequency required to match stator
frequency to line frequency. For example, at 800 rpm, 20 Hz must be applied to the rotor
to get 60 Hz on the stator. At 1000 rpm, 10 Hz is applied, and so forth. The stator PLL
frequency is compared to the line frequency. At this point, the tachometer zero position
(the tachometer marker position relative to the rotor) is adjusted to make the stator phase
match the line phase. Once both stator voltage magnitude and phase are matched to the
line, the stator can be closed onto the line. Given the cell tests that have passed prior to
this, a failure to continue here may result from very erratic line conditions that will
prevent synchronization.

8.1.3 Post-synchronization
After synchronization is complete, the sync-breaker/contactor is commanded to close by
the AEAD relay K2 (refer to elementary diagram, sheet MCC/14 for this location). After
an appropriate delay (nominally 0.25 seconds), a reactive current equal to rated
magnetizing current is commanded on the stator circuit that normally results in near zero
current on the rotor. The status of the stator sync-breaker/contactor and proper operation
of stator current feedback (CTs) (refer to the elementary diagram, sheet MCC/17) are
verified as follows:

• Stator current magnitude should be balanced and equal to the magnetizing current
based on the applied voltage and generator magnetizing inductance.
• Stator current phase should lag the line voltage by 90°.

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 The following figure displays a waveform of a normal phase relationship between the
stator voltage and currents. Stator voltage is compared to the commanded value. If the
voltage magnitude error increased larger than an appropriate threshold during CT testing,
and the condition remained for 0.25 seconds nominally, the stator sync-breaker/contactor
has failed the closing operation. This stator voltage error indicates that magnetizing
current could not flow in an opened stator circuit.

Converter Stator CT Trend

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 8.1.3.1 Wiring Errors
When wiring errors exist, the synchronizing switch may be closed out of phase with the
line and result in very high stator current. The rotor bridge is turned off, which may also
cause a dc link overvoltage that will lead to a crowbar fault shutdown. A crowbar fault
will cause the rotor bridge to be gated on to short the rotor terminals simultaneous to the
drop out of the synchronizing switch and the ROVC. Shorting the rotor circuit will likely
cause very high current to flow in the stator and/or the rotor current to get high enough to
saturate the rotor converter’s current feedback transducers.

8.2 Reduced Cooling System

The 1.x MW DFIG ESS power converter implements algorithms that monitor the
performance of the LBCS while the power converter is running. This monitoring logic
will detect a LBCS that performs poorly, but it will not indicate the cause of the problem.
Many different factors can impair the LBCS from effectively extracting heat losses
generated in the power converter and transferring it into ambient temperature. Some
possible factors for reduced cooling include:

• Defective fan
• Defective pump
• Contaminated coolant
• Bad thermal coupling between heat sinks and IGBT modules
• Low coolant level
• Obstructed heat exchanger
• Obstructed coolant path
• Obstructed air passage
• Poor voltage quality
The power converter firmware detects a degraded LBCS using two models:

• Coolant Temperature Model

• Heatsink Rise Model

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 8.2.1 Coolant Temperature Model
The coolant temperature model is a mathematical approximation of the self-contained
LBCS, liquid-to-air heat exchanger, and DTA fan, which predicts coolant temperature
when the power converter is running.

Coolant Temperature Model

The predicted temperature is subtracted from a measured version of the coolant

temperature to obtain an error quantity. This error is passed to a level detection routine
that annunciates the reduced cooling system alarm, when the error rises above the
threshold. The threshold is 5°C (41 °F) when the inlet air temperature is above
0°C (32 °F), and can increment up to 15°C (59 °F) when inlet air temperature decreases
below 0°C (32 °F).

8.2.2 Heatsink Rise Model

The heatsink rise model is a mathematical approximation of the thermal impedance
between the location of an IGBT Resistance Temperature Detector (RTD) and the liquid
coolant flowing through the corresponding heatsink when the power converter is running.
The output of this model is the temperature difference between the RTD and coolant.

Heatsink Rise Model

The predicted heatsink temperature rise, plus a 50°C (40 °F) margin, is compared to a
measured version (maximum of all IGBT modules). If the measured temperature rise is
larger than the conditioned calculation, the reduced cooling system alarm is generated.

Note The heatsink temperature imbalance alarms can be accompanied by a reduced

cooling system alarm, which indicates that a particular IGBT module is not being cooled
properly as opposed to the entire system.

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8.3 Low Coolant Level
Refer to the section, Cooling The control software detects low coolant level based on the fact that insufficient
System Maintenance. circulating liquid conducts to an abnormal heatsink temperature rise, which is detected by
the cooling system monitoring logic. The coolant pump can be damaged if it operates for
extended periods of time under low coolant conditions, especially when the motor is
starting to rotate and the impeller’s bushing is not submerged in liquid. To avoid this
situation, the impeller has been surrounded by a cylindrical container that momentarily
offsets the real reservoir level and the level recognized by the pump assembly.
If the total coolant volume is reduced to 5.25 ±0.5 gallons (about half of the reservoir),
the volume inside the cylindrical pump is drawn in by the impeller faster than the rest of
the coolant, and a considerable amount of air is introduced in the system as well. The
mixture of coolant and air, now circulating through pipes and heatsinks, causes IGBT
base plates to rise above coolant temperature at unacceptable levels. The situation
eventually surfaces as a reduced cooling system alarm.
When the pump stops, liquid drains back into the reservoir and fills the pump again. A
common level stabilizes above the impeller’s bushing and below the hole indicated by a
yellow circle in the following figure. The pump can safely start again since the bushing is
properly lubricated, while operators are aware of the reduced cooling condition. The
following figure displays the pump assembly, including the cylindrical pump installed
around the impeller.

Pump Assembly

8.4 Dynamic Brake Startup Test

A Dynamic Brake (DB) startup test is performed each time the power converter starts for
units that are Version B or greater. After the Q1 breaker and DF are closed, the DB circuit
is activated for about 60 msec. During this time, the value of the DB resistor is measured.
If the measured value is outside of the allowed tolerance, a trip fault is given; otherwise,
the normal startup sequence continues.

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9 Replacement and Ordering
9.1 Replacement
Printed circuit boards may contain static-sensitive components. Therefore, GE ships all
replacement boards in anti-static bags. When handling boards or board components, make
sure to store them in anti-static bags or boxes and use a grounding strap (per the following
Caution criteria).

To prevent component damage caused by static

electricity, treat all boards 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
Caution potentially energized equipment and are at a
normally grounded workstation.

This equipment contains a potential hazard of

electric shock, burn, or death. Ensure that all
Lockout/Tagout procedures are followed prior to
replacing terminal boards. Only personnel who are
adequately trained and thoroughly familiar with the
Warning equipment and the instructions should install,
operate, or maintain this equipment.

9.1.1 Replacement Procedures

Troubleshooting should be done at the system component level. The failed system
component (least replaceable part) should be removed, returned to GE, and replaced with
a known good spare. Do not attempt to repair system components.

To prevent electric shock, turn off power to the

equipment, then test to verify that no power exists in
the board before touching it or any connected
circuits.
Warning

To prevent equipment damage, do not remove,

insert, or adjust board connections while power is
applied to the equipment.
Caution

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 Replacement of the terminal board requires full
reconfiguration of the changed component using the
ToolboxST application. For this reason, it is
generally preferable to replace only the I/O pack
unless the terminal board is known to be the point of
Attention failure.

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 9.1.1.1 Replacing an IGBT Phase Module

With power applied, this equipment contains a

potential hazard of electric shock or burn. Only
adequately trained personnel who are thoroughly
familiar with the equipment and the instructions
Warning 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. Ensure that all power sources to
the equipment are turned off, then discharge and
ground the equipment per local site’s safety policy
and practices before performing any adjustments,
Warning services, or other acts requiring physical contact
with the circuit boards, electrical components, or
wiring.

Due to the large amount of energy passing through

the converter, failure to properly reinstall shields or
to completely latch doors and covers compromises
these safeguards and places the operator at high risk
within the enclosed environment of the turbine
Warning tower. Understand and follow the safety procedure
and warning labels.

Handle phase modules carefully. Do not allow them

to be supported only by the ac bus work at each end.
Take special care with phase A modules as they have
an additional module/IGBT on the backside of the
generator (top) heatsink. Do not set the module
Caution down on top of the boards.

Before performing any maintenance procedures,

follow all safety precautions and preparation
procedures. Refer to the sections, Safety Precautions
and Preparing the Equipment.
Attention

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 Tools and Equipment Needed for Replacement
Tool/Equipment Measurement Quantity
Voltmeter N/A 1
Blue hose (GE part number 278A2175PUP1)† N/A 1
Blue hose stepless ear clamp (GE part number 305A6482P5)† N/A 6
Blue hose swing jaw clamp (GE part number PDMH1020HOSECLP)† N/A 2
Hose mender (plastic or brass) 10 mm (3/8 in) 1
Small diagonal cutters N/A 1 pair
Cloth rags N/A 3
Drip tray 350 ml (~12 oz) 1
Pincer hose clamp tool (GE part number 305A6482P2) N/A 1
Torque wrench 4 - 25 Nm (30 - 200 in-lb) range 1
minimum
Wrenches 17 mm (11/16 in) 2
14 mm (9/16 in) 2
10 mm (3/8 in) 1
8 mm (5/16 in) 1
Plastic cable ties 152 mm (6 in) 15
Large plastic sheet N/A 1
†These items are supplied with replacement parts kits:
151X1220BR01PK01 and 151X1220BR02PK01 for converter model 151X1220KA01SA01
151X1228BR01PK01 and 151X1228BR02PK01 for converter model 151X1228KA02SA01

Phase Module Location Replacement Parts Kit

Bridge Phases Phase Module Part Number† Replacement Parts Kit Number†
1 (Line) A, B, or C 151X1220BR01SA01 151X1220XX01PK01
2 (Rotor) A, B, or C 151X1220BR02SA01 151X1220XX02PK01
†Phase module and module kit part numbers may have a letter on the end of the number indicating assembly revision. When
ordering the replacement parts kit, indicate the full part number as displayed on the phase module label.

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 ➢ To remove the phase module
1. Remove the CBC front bolted cover, observing the path of all cable and hose
connections to the module.

Installed Phase Module

2. Obtain a large sheet of plastic and lay it across everything below the IGBT module
that will be replaced. Tape the plastic, if necessary, to completely cover every
component below the IGBT module. This is done to protect all of the components
from the coolant, which could damage the components, as well as to block any loose
hardware that might be dropped during this process. The hardware will fall onto the
plastic and will be much easier to find than if it were to drop lower into the cabinet.
3. Open the drain back valve. (2.x only)
4. Open the clamps that secure gate leads. Observe the tie points and orientation of each
cable for correct re-attachment when connecting them to the new IGBT module. Tie
each of the gate lead cables out of the way while performing the remainder of this
procedure.
5. Disconnect the gate leads that are connected to P1 and P2 and tie them out of the way
using plastic cable ties.
6. If replacing the Rotor Bridge A2 or B2 phase module, disconnect the gate leads
connected to P5 and P6 directly underneath the phase module. This protects the pins
in these connectors during the following steps.
7. Using a 14 mm (9/16 in) wrench, disconnect the buswork from the shunts (refer to
the previous figure).

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 8. Using a 10 mm (3/8 in) wrench, remove all nuts and washers from DC bus on the left
side of phase module. Count all nuts and washers as they are being removed to
confirm that hardware is not left inside the converter. If a line IGBT module is being
removed, there are 6 nuts and 6 washers. If a rotor IGBT module is being removed,
there are 12 nuts and 12 washers.
9. Using an 8 mm (5/16 in) wrench, remove the two rear phase module mounting bolts
from the underside of the steel mounting bracket.
10. Loosen the two front phase module mounting bolts. These will be removed later to
provide additional support when removing the hoses.
11. Using a blue hose swing-jaw clamp, clamp both phase module inlet and outlet hoses.
Tighten them by hand to prevent the flow of coolant during replacement. Attach the
swing-jaw clamps as close to the hose barbs as possible (within 100-130 mm [4-5
in]) to minimize the amount of coolant on the heatsink side of the clamps.
12. Position the drip tray and cloth rags beneath the hose barbs to catch all coolant leaks
from the heatsink and hoses (approximately 350 ml, 12 oz).
13. Lifting the clamp strap past the barb with a pair of small, sharp diagonal cutters or
small screwdriver, release and remove the stepless ear clamps from the inlet and
outlet hoses and discard them. The hose and clamps may be rotated for better access.
The following figure displays the stepless ear clamp removal process.

Note The drip tray and cloths used to protect devices under the connections are not
shown for clarity.

Stepless Ear Clamps

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 Note The hose on the outer pipe is connected to the bottom of the heatsink and the hose
on the inner pipe is connected to the top of the heatsink. This is important when the hoses
are connected to the replacement IGBT module.

14. Disconnect the phase module outlet (top) hose from the hose barb. Pull the hose off
the end of the hose barb and let it drain into the drip tray.
15. Disconnect phase module inlet (bottom) hose from the hose barb. Pull the hose off
the end of the hose barb and let it drain into the drip tray.
16. Attach a short piece of blue hose between the inlet and outlet hose barbs to prevent
coolant from draining out of the heatsink during phase module removal.
17. Insert a barbed plastic or brass hose mender between the two hoses.
18. Remove the two front phase module mounting bolts from underside of the steel
mounting bracket.
19. Remove the phase module by sliding it to the right to avoid the studs from the DC
Link bus and then pulling the module forward, out of the enclosure.
20. Once the phase module has been removed, place a tag on the module saying it may
contain coolant within the heatsink.

Do not disconnect the short piece of blue hose that is

attached between the inlet and outlet hose barbs.

Do not allow any coolant to leak, drip, or spill out of

Caution either hose barb.

21. Using a 14 mm (9/16 in) wrench, remove the buswork from the module.
22. Drain any remaining coolant from the heatsink. Clean coolant may be reused.
23. Close the drain back valve. (2.x only)
24. Install the replacement phase module.

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 ➢ To install the phase module
1. 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 front of the nuts, the
insulation will be in the electrical joint when the module is assembled to the DC Link
bus.

DC Bus Nuts

2. Using a 14 mm (9/16 in) wrench, connect the buswork to the IGBT module and
torque the fastener to 19 Nm (168 in-lb).
3. Install the replacement phase module by sliding it into the enclosure on the steel
mounting plate, then pulling it to the left so that all studs extend through the slots in
the DC Link bus.
Refer to the procedure To 4. Install all nuts and washers that were removed with the replaced phase module onto
remove the phase module. the studs on the DC bus. Do not tighten them at this time. Count all nuts and washers
as they are being installed to confirm that all hardware is installed correctly. If a line
IGBT module is being installed, there are 6 nuts and 6 washers. If a rotor IGBT
module is being installed, there are 12 nuts and 12 washers.
5. Install all four mounting bolts that were removed with the replaced module into the
threaded inserts in the fiberglass support channels of the phase module. Do not
tighten them at this time.
6. Using a torque wrench and 10 mm (3/8 in) wrench, torque the fasteners that were
installed in step 5 to 3.5 Nm (32 in-lb).

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 Do not tighten the fasteners tighter than 3.5 Nm (32
in-lb). Over tightening could break off the posts that
connect the module to the DC Link.
Caution
7. Using an 8 mm (5/16 in) wrench, tighten the fasteners that were installed in step 6.
These are not electrical connections so they do not need to be tightened to a specific
torque requirement. These should be greater than finger tight and should attach the
module securely.
8. Using a 14 mm (9/16 in) wrench and fasteners, connect the buswork to the shunt bus.
Torque the fasteners to 19 Nm (168 in-lb).
9. Re-connect the inlet and outlet hoses to the new heatsink as follows:
a. Inspect the end of the inlet (bottom) hose for damage that may have occurred. If
the hose appears to be damaged, cut off the portion of the hose under the
replaced ear clamps.
b. Slide the two stepless ear clamps onto the inlet hose as displayed in the
following figure.

Inlet Hose with Stepless Ear Clamps

c. Insert the hose over the inlet hose barb, pressing the end of the hose up against
the front of the heatsink.
d. Using a pincer hose clamp tool, crimp the two stepless ear clamps as displayed
in the following figure. There should not be a gap in the crimp area.

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 Note Make sure that both stepless ear clamps are crimped within 3 mm (0.12 in)
from the end of the heatsink so as to not miss the end of the inlet hose barb.

Sliding the Stepless Ear Clamps onto the Inlet Hose

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

f. When both inlet and outlet hoses are fully clamped, remove the swing-jaw
clamps from both hoses.
g. Inspect the hoses for leaks.
Refer to the procedure To 10. Re-connect all connectors disconnected during the removal of the phase module.
remove the phase module.
11. Secure the gate leads by installing the cable clamps in the same manner as they were
found before they were removed.
12. Remove the protective plastic cover.
13. Run the pump for approximately 1 minute, then check for leaks.
14. Fill the reservoir to the maximum pump off level.

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 ➢ To inspect the converter after replacing an IGBT phase module
1. Verify that all modules, hoses, and cables are correctly positioned and oriented.
2. Make sure that no water hoses were damaged during removal and installment
procedures.
3. Verify that the clamps have been crimped.
4. Verify that the hoses are not kinked. Make sure the inside bend radius on the hoses is
greater than 38 mm (1.5 in).
5. Run the pump and check for leaks.
6. Make sure that all bolted connections that were loosened are re-torqued properly.
Verify that all cable connectors are secure.
Refer to the figure, Cooling 7. Verify that the coolant is at the maximum pump off dipstick level in the reservoir.
System Diagram
8. Verify that all foreign matter such as tools, parts, hardware, and temporary hose
clamps used for replacement have been removed from the power converter.
Refer to the section, Returning 9. Return the equipment to service.
the Equipment to Service..

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 9.1.1.2 Replacing a Capacitor Module
Before performing any maintenance procedures, follow all safety precautions and
preparation procedures. Refer to the sections, Safety Precautions and Preparing the
Equipment.
Capacitor module part The following table lists the tools recommended to replace a single dc link capacitor
numbers may have a letter on module (GE part number 151X1220BC01SA01).
the end of the number
Tools Needed for Replacement
indicating a revision of the
module. When ordering the Tool Measurement Quantity
replacement parts kit, indicate Voltmeter N/A 1
the full part number as Torque wrench 4 - 25 Nm (30 - 200 in-lb) range minimum 1
displayed on the module label. Wrench 10 mm (3/8 in) 1

➢ To remove the capacitor module

1. Remove the CBC front bolted cover. Observe the path of all wire connections to the
module. The following figure displays an installed dc capacitor module. Notice the
two red wires attached to the top bus (+) and bottom bus (-) of the dc link.

DC Link Capacitor Module

2. If replacing a capacitor module with wires connected, using a 10 mm (3/8 in) wrench,
disconnect the red wires connected to studs at the top right of the capacitor module.
3. Using a 10 mm (3/8 in) wrench, remove all nuts and washers from dc bus on the right
side of the capacitor module.
4. Using a 10 mm (3/8 in) wrench, remove the three capacitor module mounting bolts
from the mounting base.

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 5. Remove the capacitor module by sliding module to the left to clear the studs from the
dc link bus and then pulling it forward, out of the enclosure. Take care to not damage
the wiring as the module is being removed.
6. Install the replacement capacitor module.

➢ To install the capacitor module

1. Verify that the nuts on the studs in the dc bus protrude through the insulation, as
displayed in the following figure.

Note If the insulation sits on the front of the nuts, the insulation will be in the electrical
joint when the module is assembled to the dc link bus.

Nuts on the Capacitor Module

2. Install the replacement phase module by sliding it into the enclosure on the steel
mounting plate, then pulling it to the right so that all studs extend through the slots in
the dc link bus.
Refer to the procedure, To 3. Install all nuts and washers that were removed with the replaced capacitor module
remove the capacitor module. onto the studs on the dc bus. Do not tighten them at this time.
4. Install all three mounting bolts that were removed with the replaced capacitor module
through the holes in the fiberglass base of module. Do not tighten them at this time.
5. Using a torque wrench and a 10 mm (3/8 in) socket, torque the mounting bolts to 3.5
Nm (32 in-lb).
6. Using a 10 mm (3/8 in) wrench, tighten all nuts and washers.
Refer to the procedure, To 7. Re-connect all wires that were disconnected with the replaced capacitor module.
inspect the converter after
8. Inspect the DFIGe power converter.
replacing a capacitor module.

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 ➢ To inspect the converter after replacing a capacitor module
1. Verify that all replaced assemblies are correctly positioned and oriented.
2. Ensure that all bolted connections that were loosened are re-torqued properly.
3. Verify that all foreign matter such as tools, parts, and hardware used for maintenance
have been removed from the power converter.
Refer to the section, Returning 4. Secure the CBC cover in place.
the Equipment to Service.
5. Return the equipment to service.

9.1.1.3 Replacing an AEAA

➢ To replace an AEAA
1. Perform lockout tagout (LOTO) procedures for the equipment.
2. Verify that the MCC has been completely de-energized.
3. Remove all of the fast-on connectors and the two green terminal strips from the
AEAA. The wires should remain on the terminals as the entire terminal strips are
removed from the board.

Note Not all connections to the green terminal strips are displayed in the following
figure. An AEAA board will have many more wires on the terminals.

AEAA Hardware
4. Unscrew the four mounting screws and two standoffs for the AEAA. The four
mounting screws are located in the corners of the board and the two standoffs are
positioned in the middle, along the top and bottom of the AEAA board.

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 5. Slide the AEAA board to the left to disconnect it from the MACC board. Separate the
D-sub connector from the MACC board.
6. Remove the AEAA board from the MCC.
7. Place the new AEAA board inside the MCC and slide the D-sub connector to the
right to attach it to the MACC board.
8. Attach the four mounting screws and two standoffs that were removed in step 4 to
properly secure the AEAA board.
9. Reconnect all of the fast-on connectors removed in step 3 and the two green terminal
strips in the same locations. Examine the AEAA board closely to make sure there are
no disconnected fast-on connectors or terminal strips.
10. Verify that all foreign matter, such as tools, parts, and hardware used for
maintenance, has been removed from the cabinet.

9.1.1.4 Replacing an AEAD

➢ To replace an AEAD
1. Perform lockout tagout (LOTO) procedures for the equipment.
2. Verify that the MCC has been completely de-energized.
3. Remove all of the fast-on connectors and three green terminal strips from the AEAD.
The wires should remain on the terminals as the entire terminal strips are removed
from the board.
4. Unscrew the four mounting screws and two standoffs for the AEAD board. The four
mounting screws are located in the corners of the board and the two standoffs are
positioned in the middle, along the top and bottom of the AEAD board.
5. Slide the AEAD board down to disconnect it from the REBF (or MACC). Separate
the D-sub connector from the REBF (or MACC).
6. Remove the AEAD board from the MCC.
7. Place the replacement AEAD board inside the MCC and slide the D-sub connector
up to attach it to the REBF (or MACC).
8. Attach the four mounting screws and two standoffs that were removed in step 4 to
properly secure the board.
9. Reconnect all of the fast-on connectors and two green terminal strips that were
removed in step 3 in the same locations. Examine the AEAD board closely to make
sure there are no disconnected fast-on connectors or terminal strips.
10. Verify that all foreign matter, such as tools, parts, and hardware used for
maintenance, has been removed from the cabinet.

Note Not all connections to the green terminal strips are displayed in the following
figure. An AEAD board will have additional wires on the terminals.

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 Mounting screw Green terminal strip

Fast-on
connector

D-sub
connector

Part number label

AEAD Hardware

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 9.1.1.5 Replacing an AEBI or AEDB
➢ To replace an AEBI or AEDB
1. Perform lockout tagout (LOTO) procedures for the equipment.
2. Verify that the Main Control Cabinet (MCC) has been completely de-energized.
3. Remove all of the fast-on connectors and harnesses from the AEBI or AEDB board.
4. Unscrew the six mounting screws and two standoffs for the AEBI or AEDB board.
There are four mounting screws located along the top or bottom of the board and two
screws located along the opposite edge. The two standoffs are positioned along the
top and bottom corners of the AEBI or AEDB board.

The two middle screws on the top are nylon screws.

Do not use a nut driver to remove the screw in the
bottom right corner of the board. A nut driver could
rub against the component located next to the screw
and could damage it. Use a screwdriver to remove
Caution the screw.

5. Slide the AEBI or AEDB board up to detach the D-sub connector from the MACC.
6. Pull the board out from behind all of the cables that are hanging in front of the board.
7. Carefully place the new AEBI or AEDB board behind all of the harnesses without
scraping the plugs against any of the components on the board.
8. Slide the new AEBI or AEDB board down into the correct D-sub connector on the
MACC.
9. Attach the six mounting screws and two standoffs that were removed in step 4 to
properly secure the AEBI or AEDB board. Be sure to put the nylon screws along the
top in the middle two screw locations.

Do not use a nut driver to install the screw in

the bottom right corner of the board. This could
damage the adjacent components.
Caution
10. Reconnect the two fast-on connectors on the top right of the board removed in step 3
in the same locations. Make sure the label of the left and vertical stab matches the
label of the cable being connected. Perform the same check on the right and
horizontal stab.
11. Reconnect all of the harnesses that were removed in the same locations from where
they were removed in step 3. Each harness has the location labeled to ensure that
each plug is connected correctly.
12. Examine the AEBI or AEDB board closely to make sure there are no disconnected
harnesses, cables, or plugs.
13. Verify that all foreign matter, such as tools, parts, and hardware used for
maintenance, has been removed.

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 Mounting screw

Mounting screw
D-sub connector
AEDB Hardware

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 9.1.1.6 Replacing an AEPS
➢ To replace an AEPS
1. Perform lockout tagout (LOTO) procedures for the equipment.
2. Verify that the Main Control Cabinet (MCC) has been completely de-energized. The
AEPS is positioned face down, mounted under the other control boards inside the
MCC.
3. Remove all of the fast-on connectors and harnesses from the AEPS.
4. Unscrew the five mounting screws and one mounting nut for the AEPS. There are
four screws located in the four corners of the AEPS, one screw in the mid-upper area,
and one nut located in the mid-lower area.
5. Pull the board off the post in which the mounting nut was attached and remove the
AEPS from the MCC.
6. Carefully place the new AEPS in the cabinet so the post for the mounting nut goes
through the hole and the rest of the standoffs line up with the holes in the board.
7. Attach the five mounting screws and one mounting nut that were removed in step 4
to properly secure the AEPS.
8. Reconnect all of the harnesses and fast-on connectors removed in step 3 into the
same locations.
9. Examine the AEPS closely to make sure there are no disconnected harnesses or
fast-on connectors.
10. Verify that all foreign matter, such as tools, parts, and hardware used for maintenance
has been removed from the cabinet.

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 Mounting screw Mounting screw Mounting screw

Mounting screw Mounting nut Mounting screw

AEPS Hardware

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 9.1.1.7 Replacing a WECA
➢ To replace a WECA

Note The WECA consists of a MACC board mounted with a BPPB and a WEMD.
Replace the WECA as an assembly.

Refer to the Renewables Power 1. Remove all connections to the WECA and BPPB boards, including the attached
Conversion Alternative Energy AEAD and AEAA boards.
Application A (AEAA)
Instruction Guide Note The cables connected to the AEAD and AEAA boards do not need to be removed
(GEI-100767).
while the D-sub connectors are detached.

Refer to the Renewables Power

Conversion Alternative Energy 2. From the AEAD board, unscrew the four mounting screws (located in the corners of
Application D (AEAD) the board) and two standoffs. Refer to the figure, AEAD Hardware.
Instruction Guide 3. Once all AEAD mounting hardware is removed and the board is supported only by
(GEI-100766). the attached cables, slide the AEAD to the left to separate its D-sub connector from
the WECA.
4. From the AEAA board, unscrew the four mounting screws (located in the corners of
the board) and two standoffs. Refer to the figure, AEAA Hardware.
5. Once all AEAA mounting hardware is removed and the board is supported only by
attached cables, slide the AEAA board to the left to separate its D-sub connector
from the WECA.
6. From the WECA, unscrew the six mounting screws located in the four corners of the
WECA board and one in the middle along the left and right sides of the board.

WECA Hardware

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 7. Slide the WECA assembly to the left to separate the two D-sub connectors that are
attached to the AEBI boards (located on the right top and on the right bottom).
8. Remove the WECA assembly from the Main Control Cabinet (MCC).
9. Insert the replacement WECA assembly inside the MCC and slide the two D-sub
connectors to the right to attach the MACC board to the AEBI boards.
10. Install the six mounting screws that were removed in step 6 to properly secure the
WECA assembly.
11. Re-attach the AEAD D-sub connector that was removed in step 3 onto the WECA
assembly.
12. Re-attach the four mounting screws and two standoffs that were removed in step 2 to
properly secure the AEAD board.
13. Re-attach the AEAA D-sub connector that was removed in step 5 onto the WECA.
14. Re-attach the four mounting screws and two standoffs that were removed in step 4 to
properly secure the AEAA board.
15. Connect all of the cables that were removed from the WECA assembly into their
original positions.
16. Visually inspect the WECA, AEAD, AEAA , and AEBI boards closely to make sure
there are no disconnected harnesses, cables, or plugs.
17. Verify that all foreign matter such as tools, parts, and hardware used for maintenance
have been removed from the power converter.
Refer to the section, Returning 18. Return the equipment to service. (This includes powering up and downloading the
the Equipment to Service. applicable software (firmware/parameters) to this board before actual operation of the
converter.

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 9.1.1.8 Replacing a WEOR
➢ To replace a WEOR
1. Perform lockout tagout (LOTO) procedures for the equipment.
2. Verify that the MCC has been completely de-energized.
3. Remove the fast-on connectors from the WEOR board.
4. Unscrew the five mounting screws for the WEOR board. There are four screws
located in the corners and one screw in the center of the board, as indicated by the red
circles in the following figure.
5. Remove the WEOR from the MCC.
6. Place the new WEOR inside the MCC in the same position as the one that was
removed.
7. Secure the board in place using all five mounting screws that were removed in step 4.
8. Reconnect all of the fast-on connectors removed in step 3 in the same locations.
9. Examine the WEOR board closely to make sure there are no disconnected fast-on
connectors.
10. Verify that all foreign matter such as tools, parts, and hardware used for maintenance
have been removed from the control cabinet.
11. Close the cabinet door and follow normal startup procedures.

WEOR Hardware

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 9.1.1.9 Replacing a WEMA
➢ To replace a WEMA
Refer to the ControlST 1. Verify that the replacement WEMA is compatible with one being replaced by
Upgrade Instruction Guide comparing the model numbers on the faceplates. The model number begins with an
(GEI-100694). IS220W prefix. Most times the numbers will match, but sometimes newer revisions
are used to replace older WEMAs.
Refer to the BPPC I/O
2. Lockout tagout the converter MCC and isolate the power source.
Upgrade V05.01.05 Instruction
Guide (GEI-100847). 3. Verify that the 230 V ac is removed from J5 at the top of the WEMA.
4. Disconnect the Ethernet connection to the processor board.
5. Disconnect the Mate-N-Lock and Mini Mate-N-Lock fast-on connectors.
6. Disconnect the green terminal board connections TB1 to TB4.
7. Unscrew all 19 mounting screws on the edges and middle of the board (14 screws are
located in the corners and sides of the board, and there are 5 in the inner surface).
8. Carefully remove the old WEMA from the MCC (record the location of the clear
cover standoffs).
9. Place the replacement WEMA board inside the MCC.
10. Re-attach all 19 mounting screws that were removed in step 2 to properly secure the
WEMA board.
11. Reconnect all of the fast-on connectors that were removed in step 1, positioned in the
same locations as they were found.
12. Verify that all foreign matter such as tools, parts, and hardware used for maintenance
have been removed from the power converter.
13. Return the equipment to service.

WEMA Hardware

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9.2 Ordering
Prior to ordering a replacement part for a GE product, the following items should be
understood:

• How to accurately identify the part

• If the part is under warranty
• How to place the order

Note Renewals and spares (or those not under warranty) should be ordered by contacting
the nearest GE Sales or Service Office, or an authorized GE Sales Representative.

Control system electronics are identified by a 12-character alphanumeric part number and
a single revision letter.

Serial number

First 12 characters
of the part number
On the replacement part , the revision letter
will be the same or a higher letter.

Example
When ordering, be sure to include the following items:

• Complete part number and description

• Serial number
• Material List (ML) number (The ML number is provided on the data nameplate.)

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Notes

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Appendix A Fuses
Fuse Replacement Data

When replacing parallel fuses, always replace them

in sets. All fuses in that set must be from the same
vendor.
Caution
Fuse Description Vendor Part #
FU1A, B, C Fuse-NH, type 355 A 690 V, size 2, gG/gL SIBA 2021213.355
For 1.6 MW DTA ESS:
SIBA 2066031.350
350 A 690 V PSC fuse
FERRAZ SHAWMUT 6.9URD31TTF0350
(parallel fuses per phase from same vendor)
ACLFU1, 2, 3
For 1.6e MW DTA ESS:
SIBA 2067132.500
500 A 690 V PSC fuse
FERRAZ SHAWMUT 6.9URD32TTF0500
(parallel fuses per phase from same vendor)
FB1 Fuse-NH, type 200 A 690 V, size 1, gG/gL SIBA 2021113.200; Equivalent fuse type
FB2 Fuse-NH, type 100 A 690 V, size 00, gG/gL SIBA 2020913.100; Equivalent fuse type
FB3 Fuse-NH, type 80 A 690 V, size 00, gG/gL SIBA 2020913.80; Equivalent fuse type
SIBA 2047713.40;
FB4 Fuse-NH, type 40 A 690 V, size 000, gG/gL
FERRAZ SHAWMUT NH000GG69V40 (1C647)

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AEPS Power Fuses

Note Shunt on JP1 must be IN if the AEPS is on the thread converter and must be OUT
if it is in the CMC.

Fuse Description Rating Status Indicator Power Distribution Test Points

FU1 600 V
Feed from DC Link None E1, E2 None
FU11 5A
P48B = TP1
None 48 V dc local supply None None None
PCOMB = TP2
External bulk capacitance for 24
None None None E3, E4 None
V dc control supply MACC
250 V DS2 (green off) = FU4 P1 (AEPS ) to J7 P24A = TP4
FU4 24 V dc control supply to MACC
1.5 A blown (MACC) PCOMA = TP5
24 V dc isolated Tach supply to 250 V DS1 (green) off = FU5 P1 (AEPS ) to J7 IP24 = None
FU5
MACC 0.5 A blown (MACC) I24COM = TP6
5 V dc isolated Serial Port supply 250 V DS5 (green off ) = FU8 P1 (AEPS ) to J7 IP5A = None
FU8
to MACC 0.5 A blown (MACC) I5COMA = TP7
5 V dc isolated CANbus supply to 250 V DS6 (green) off = FU9 P1 (AEPS ) to J7 IP5B = None
FU9
MACC 0.5 A blown (MACC) I5COMB = TP8
P18A1 (AEPS ) to P18
(AEAA)
250 V P24C = None
N24 V dc control supply to AEAA, DS3 (green) off = FU7 P18A2 (AEPS ) to P18
FU7 1A N24C = None
AEAC, and AEAB blown (AEAC)
2 Ag PCOMC = TP3
P18A1 (AEPS ) to P18
(AEAB)
P18A1 (AEPS ) to P18
(AEAA)
P24 V dc control supply to AEAA, 250 V P24C = None
DS4 (green) off = FU6 P18A2 (AEPS ) to P18
FU6 AEAC, and AEAB 2A N24C = None
blown (AEAC)
Littlefuse© PN 225002 2 Ag PCOMC = TP3
P18A1 (AEPS ) to P18
(AEAB)
P4A2 (AEPS) to J4
P24 V dc control supply to AEAA, (AEAA)
250 V
FU2 AEAC, and AEAB P4A1 (AEPS) to J4
8A None None
FU3 Bussmann© PN MDL_8A (AEAC)
TD
Littlefuse PN 313008 P4A1 (AEPS) to J4
(AEAB)
25 kHz supply to AEBD (used in
250 V P2B1 (AEPS) to P2 AC1 = None
FU10 thread converters only) None
2A (AEDB) AC2 = TP9
Littlefuse PN 229002
25 kHz supply to AEBI (used in AC1 = None
250 V P2B2 (AEPS) to P2
FU12 thread converters only) None
2A (AEBI)
Littlefuse PN 229002 AC2 = TP9

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Appendix B Module Testing
IGBT Phase Module Testing
When an IGBT phase module’s integrity is in question, perform a phase module test.

➢ To test the IGBT phase module

1. For a rotor converter module, carefully check the cables going from the upper
Alternative Energy Bridge Module (AEBM) to the lower AEBM.
2. Verify that all pins are properly seated in all of the cable connectors by pulling on
them lightly. Make sure no pins are being pushed out the back of the cables.
3. Verify that all hardware is properly torqued or tightened.
Refer to the procedure, To 4. Remove and disconnect the IGBT phase module.
remove the phase module.

Do not disconnect the blue hoses. They should

remain connected for this test.

Caution
5. Remove the phase module from the shelf and place it in a safe location for
examination.

Do not to damage the blue hoses or accidentally

loosen them from the heat sinks while removing it
from the shelf.
Caution

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 6. Check the following values to confirm that the module has not been damaged:
a. Measure resistance between the following points and verify that it is within the
Refer to the figure, IGBT
acceptable range (refer to the following table):
Phase Module for the location
of these points. • P1-3 to P1-4
• P1-5 to P1-6
• P2-3 to P2-4
• P2-5 to P2-6
Resistance Acceptable Range

Converter Module Measurement Range

Line 1.0 KΩ ±20 Ω (327 to 342)

Rotor 500 Ω ±10 Ω (510 to 490)

IGBT Phase Module

b. Measure resistance between the following points and verify that it is within the
acceptable range of 334 Ω ±7 Ω (327 to 342):

• P5-1 to P5-3
• P6-1 to P6-3
c. Measure resistance between P1-7 to P1-8 and verify that it is within the
acceptable range of 4.7 Ω (10°C, 50 °F = 9K) (40°C, 104 °F = 2.9K).

Note Resistance is measured using a Resistance Temperature Detector (RTD) so

temperatures will vary.

d. Using a DVM, check the following (on 20 MΩ scale):

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 • Phase A+ to Phase A AC: Diode one way - Reverse leads to read OPEN
• Phase A- to Phase A AC: Diode one way - Reverse leads to read OPEN
• Phase B+ to Phase B AC: Diode one way - Reverse leads to read OPEN
• Phase B- to Phase B AC: Diode one way - Reverse leads to read OPEN
• Phase C+ to Phase C AC: Diode one way - Reverse leads to read OPEN
• Phase C- to Phase C AC: Diode one way - Reverse leads to read OPEN
• Phase A+ to P5-1: Conducts one way - Reverse leads to read OPEN
• Phase B+ to P5-1: Conducts one way - Reverse leads to read OPEN
• Phase C+ to P5-1: Conducts one way - Reverse leads to read OPEN
• Phase A AC to P6-1: Conducts one way - Reverse leads to read OPEN
• Phase B AC to P6-1: Conducts one way - Reverse leads to read OPEN
• Phase C AC to P6-1: Conducts one way - Reverse leads to read OPEN
e. Check the desaturation (DSAT) circuit as follows:

• Phase A+ to P1-1: Read as two diodes - Reverse leads to read OPEN

• Phase A AC to P2-1: Read as two diodes - Reverse leads to read OPEN

Note The pins on the plugs are numbered starting at 1 on the left.

Refer to the procedures, To 7. If the phase module fails any of these tests, replace the IGBT phase module.
remove the phase module and Disconnect the blue hoses and completely remove the module. If the module passes
To install the phase module. all of the tests, re-install the original phase module.
8. Inspect the IGBT phase module and the DFIGe power converter. Refer to the
procedure, To inspect the converter after replacing an IGBT phase module.

Appendix B Module Testing GEH-6727E System Guide 113

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Capacitor Module Testing
When a capacitor module’s integrity is in question, perform a capacitor module test.

➢ To test the capacitor module

1. Disconnect both of the fast-on connectors from each of the three discharge resisters.
The following figure displays one of the discharge resisters and the fast-on
connectors.

Note The following figure displays a capacitor module that has been removed from the
cabinet. The three capacitors at the bottom are connected in series. The three capacitors at
the top are also connected in series, but they are connected in parallel with the three at the
bottom. When testing the three series capacitors at the bottom, the other three series
capacitors at the top that are connected in parallel will also tested.

Removed Capacitor Module

2. Disconnect both of the fast-on connectors from each of the three discharge resisters.
3. Using a handheld meter in the ohmmeter position, measure the resistance across each
Refer to the procedures, To
of the three series capacitors, individually. Verify that the resistance is within the
remove the capacitor module
acceptable range of 16.5 KΩ ±5% (15.675 to 17.325 KΩ).
and To install the capacitor
module. 4. The ohmmeter will charge the capacitor, therefore, when the ohmmeter is initially
connected across the capacitor, the resistance will be low. Verify the capacitor slowly
Refer to the procedure, To charges to greater than 1 MΩ of resistance. If it does not, check the battery in your
inspect the converter after DVM, and if OK, replace the capacitor module.
replacing a capacitor module.
5. If the module fails any of these tests, replace it with a new capacitor module. If the
module passes all tests, re-install the original module.
Refer to the section, Returning
the Equipment to Service. 6. Inspect the capacitor module.
7. Return the equipment to service.

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