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Rectifier Blowing off

Created by: GrantForeman at: 5/18/2012 3:45 PM (10 Replies)

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5/18/2012 3:45 PM	Rate (0)
GrantForeman Posts: 14 Rating: (1)	Hi, we have a Masterdrive 6SE7032-1EG60 which has blown the Rectifier off the front card as per the attached photo. What can cause this, as this is the second card that has blown up. Thanks in advance Attachment 005_PCC.jpg (644 Downloads)
GrantForeman Posts: 14 Rating: (1)
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5/18/2012 3:47 PM	Rate (3)
Graeme Platinum Expert Joined: 6/4/2008 Last visit: 11/25/2025 Posts: 1521 Rating: (327)	Hi, I have seen this exact thing thing before. The cause was found to be the Braking resistor itself was shorted by metal dust. It could also be the same if the Dynamic braking unit is shorted. Suffice to say, it may also be the main rectifier itself, check this out with a diode checker. Regards, Graeme

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5/18/2012 3:49 PM	Rate (1)
Gary.Hare Posts: 101 Rating: (8)	Please check you're brake chopper as if this fails short circuit then the braking resistor will be in circuit constantly increasing the load on the rectifier causing catastrofic failures.
Gary.Hare Posts: 101 Rating: (8)
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5/18/2012 4:00 PM	Rate (0)
GrantForeman Posts: 14 Rating: (1)	Thanks guys, the brake unit is showing a short circuit, Ihad not even consider the brake unit, as the drive was not running and I thought the only time it was active was when the drive was in regen, Thanks again, great advice. I have an emergency card tomorrow, hopefully, then the drive will work fine once the brake unit is replaced. Grant.
GrantForeman Posts: 14 Rating: (1)
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5/18/2012 4:05 PM	Rate (3)
Graeme Platinum Expert Joined: 6/4/2008 Last visit: 11/25/2025 Posts: 1521 Rating: (327)	Great news, by the way, double check the pre-charge resistor, as this could have been stressed (overtemp) (You mentioned this is the third card (twice blown before)? Depending on your drive, build version, the pre-charge resistor will be a long tube down the right hand side, or two resistor modules at the top right next to the card that is blown. Basically, the reason why the rectifier is blown is that during pre-charge, the small rectifier is used to "pre-charge" the capacitors gently through the pre-charge resistor, if there is a short circuit across the capacitors caused by the DBR, the small rectifier is overloaded and "POP" Regards, Graeme

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5/18/2012 5:00 PM	Rate (0)
GrantForeman Posts: 14 Rating: (1)	Disaster, we have done as you said and checked the resistor as well, it was falling to pieces, and all the wires was burned. See the photo.There is no part number on this device, how do I know what to order? Thanks. Attachment Charge Resistor.JPG (634 Downloads)
GrantForeman Posts: 14 Rating: (1)
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5/18/2012 5:03 PM	Rate (2)
Graeme Platinum Expert Joined: 6/4/2008 Last visit: 11/25/2025 Posts: 1521 Rating: (327)	Hi, Ouch, um ok, what is the build revision of your drive, please see the attachment, there will be a lable somewhere on the frame where the red circled version is shown. With this I can generate a list of parts for this drive. I think you may have to dig a little deeper here, there may be more damage that you can see. Regards, Graeme Attachment Build_rev.JPG (544 Downloads)

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5/18/2012 5:04 PM	Rate (0)
GrantForeman Posts: 14 Rating: (1)	Nice one, could you wait please I know it's Friday afternoon, but I will run down to the plant room and find out. Thanks.
GrantForeman Posts: 14 Rating: (1)
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5/18/2012 5:29 PM	Rate (0)
GrantForeman Posts: 14 Rating: (1)	Hi, the version on the sticker shows E, What do you mean, that there could be more damage? I don't think I can get this resistor by tomorrow, my boss is just telling me to order it. Thanks
GrantForeman Posts: 14 Rating: (1)
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5/18/2012 5:48 PM	Rate (3)
Graeme Platinum Expert Joined: 6/4/2008 Last visit: 11/25/2025 Posts: 1521 Rating: (327)	Hi, please find attached the parts list for this drive and revision. What I mean is that you should check over the rest of the drive, as this fault is quite severe. I think is is reasonably safe to assume that the IGBT section is ok, as this fault seems is related to the pre-charge, but I definately think you need to strip the drive back to the thyristors and check over them. You can use a multimeter on ohms range to check these. But I would perform a complete health check once you have your replacement parts. Refer to the following links: Test procedure for testing thePCC card and Thyristors in Master drive units Fault F028 Testing the IGBT (This also describes thyristor testing) Regards, Graeme Attachment 6SE7032-1EG60.pdf (686 Downloads)

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