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sunday matembo
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Join Date: Jan 2012
Posts: 24

How to Test the Following Electronics Cards-01

06/06/2012 10:42 AM

We are running HydroPowerPlant having 2machines with 34Mw each as shown pictur←

We normally facing some indications available in machine display unit known as SACCO.We as maintenance Teams we conclude some times these kinds of abnomalities probably due to misbehavior of some Electronics cards attached to our Voltage Regulator/Excitationsystems (Pulse Trasformer cardYXU 169E ,TriggerPulseUnitCard DSTS 101,SupervisonCard DSTS 102,GeneratorVoltageMeasurementCard DSTY W120,GridVoltageMeasurementCard DSTY W120,CurrentMeasurementCard DSTY W111 and TriggeringPulseAmplifier {WEIDMULLER} ) which needs further detailed tests.

PulseTransformerCard YXU 169E When is not connected to ckt.

But below is the same card while connected to circuit.

As shown above this card(green) receive supply from from TriggerPulseUnits( DSTS101 card as shown below +unit resistance 12 attached by small pins of WhiteRubber{reffer to above picture} )and supply different fuses {metallic type above} before reched to 6 ThyristorConverter(SCR)Limbs below it with yellow manufacture stamps each for Triggering and provides waveform required.

Figure above shows DSTS 101 before connected to circuit

And after connected to circuit as it can be shown in figure below

Above card E27.1 is DSTS 101 -Which is TriggerPulseCard and those wires /cables are connected to above said 12 resistance before taken by White Rubber to PulseTransformerCard YXU 169 E and just below that Card E27.1 there Card E27.2-Known as SuperVisionCard DSTS 102 THEY ARE SHAPELY EQUIVALENT some sort of connection but different application as per their names.

SOME OTHER CARDS ARE

Above figure no.1 from LEFTis CurrentMeasurementCard DSTY W111,secondly GeneratorVoltageMeasurementCard DSTY W120 and LAST GridVoltage MeasurementCard DSTY W120.

Below diagram is TriggeringPulseAmplifierCard(WEIDMULLER)

So general look of VOLTAGE REGULATION PANEL IS AS SHOWN BELOW

Its my hopeful that, we have prenty of expertise and experienced peoples in this Wonderful Website .We normally use suggetion from this site for Troubleshoots ,SO COULD SOMEONE TELLS ME HOW TO TEST THOSE MENTIONED ELECTRONICS CARDS as per standard requirements (PulseTransformerCard,TriggerPulseCard,SuperVisionCard,Current & VoltageMeasurementsCards,TriggerPulseAmplifierCard<WEIDMULLER> ects) as per shown picture.

Based on facts that DSTS 101 supply signal to→12 Triggering resistors through white rubber ribbon→Pulse Transformer Card YXU 169 E→6Fuses{Mettalic in coloursee 3 picture from top}→6 ThyistorsConvertor /SCR{With yellow stamps each see 3 picture from top}→TRANSFORMER and circuit goes on.

Practical Detailed and Several suggestions will be highly appreciated.

Best Rgds

Sunday-Hydro Maintenance Engineer

"SO MANY TRIES MAKE THINGS PERFECT"
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JohnDG
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#1

Re: How to Test the Following Electronics Cards-01

06/06/2012 11:08 AM

I suggest you contact the manufacturer.

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Randall
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#2

Re: How to Test the Following Electronics Cards-01

06/06/2012 11:31 AM

If you have the circuit diagrams for the cards: approach a local test company to design tests for them. If not you have to refer back to the manufacturer/designer.

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PeterT
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#3

Re: How to Test the Following Electronics Cards-01

06/06/2012 1:29 PM

If you are only experiencing occasional, seemingly "random" or intermittent problems, I wouldn't suspect your circuit boards as the likely problem as much as the interconnections between them, or else their environment. The need to develop detailed test procedures for each board is probably more expense than it is worth. You would be better off to put your maintenance efforts into checking things such as the following:

1. Are all the interconnecing cables fully plugged in and the connectors tight? Is there any vibration that could cause connectors to come loose, and what can be done to reduce the vibration or to assure that the connectors stay tight despite the vibration?

2. Are the connectors making firm, tight contact on all conductors or connection pins & sockets within the connector?

3. Are all terminal screw or compression connections tight? Is there any corrosion on any connections or components?

4. Is the enclosure clean inside, or is dust & dirt collecting on electronic components, heat sinks, ventilation fans or openings, etc.?

5. Is the temperature in the enclosure staying within acceptable limits? This relates to #4. Heat will affect the characteristics of many electronic components, and either throw them out of tolerance or even destroy them. If temperature is not within range, then you must improve ventilation or provide additional temperature control (cooling, air conditioning, etc.).

6. Is the humidity in the enclosure under control, or is it humid or wet? Water is another thing that does not mix well with electricity.

7. Are the power supply voltages within the manufacturer's specified limits for proper operation of the equipment?

I would suggest that paying attention to details such as the above list will save you many headaches and much money that you would spend on repairs or replacements when boards fail. You have a very nice looking facility, as far as the photos show. Keep taking good care of it and it will operate well for you for a long time.

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SolarEagle
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#4
In reply to #3

Re: How to Test the Following Electronics Cards-01

06/06/2012 3:49 PM

I have to agree with PeterT here, just shooting from the hip I would suspect a moisture problem, or heat/ventilation issue...I would add an IR profile of each component as this can expose temp issues that are being created for whatever reason....

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sunday matembo
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#5

Re: How to Test the Following Electronics Cards-01

06/07/2012 3:16 AM

I think our cards seems to be in good condition physical appearence but if we could have any kinds of corrosion,dust,dirty etc we could have been started with it as first suspect but the probs is we have multi burning of cards which appeared several times per year and we always enjoy festive of EXCITATION EQUIPMENT FAULTS which leads to SEVERAL MACHINE DOWNTIME.Likewisely humidity and temperature/heat as nothing to do with machines due technology used to design panel....we have ventilating fans and device to sense if temp exceeded the design limit to multifanction cards.More ever when we trace back and check for supply signals of corresponding input and output to the cards it seems meaningful as refered to commersional reports.The big Question is Why??? there frequently burning of cards while supply and protective system is OK .
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PeterT
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#6
In reply to #5

Re: How to Test the Following Electronics Cards-01

06/07/2012 8:09 AM

Then the next thing that comes to mind is to investigate whether you have good, solid grounding of all the cabinets, equipment, boards, power supplies, etc., and proper transient suppression on signal cables.

Voltage differences between components that are expected to be at the same potential are a recipe for failures.

Transients on the power supplies or on signal cables are often caused by improper shielding, cables laid in parallel that shouldn't be, arcing due to poor connections, etc.

You need to do some troubleshooting to determine what is the cause of your cards failing. They generally don't fail just from normal use. There is something causing the failures, and you need to find it and eliminate it.

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Randall
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#7

Re: How to Test the Following Electronics Cards-01

06/08/2012 4:59 AM

Where is the control room located relative to the water flow and generators?

Could it be subject to a lot of vibration?

Routine maintenance which includes removing all the cards and applying contact cleaner may help.

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JohnDG (1); PeterT (2); Randall (2); SolarEagle (1); sunday matembo (1)

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