Aug 24

SWITCH变流器模块常见故障总结及原因分析

风电设备维修中心

   一、SWITCH变流器模块损坏常见故障如下:

SWITCH变流器模块维修

  1、模块直流母排绝缘损坏

  常见故障为模块直流母排短路造成器件损坏,母排正负极绝缘垫裂纹,造成母排短路。这种情况属于绝缘材料击穿,可能存在湿度过大凝露引起短路击穿。

  2、门极板损坏

  模块门极板作为IGBT的驱动底层控制板,起到对IGBT门极驱动的作用,同时采集IGBT电流,温度等信号,门极板损坏,经常伴随机组报出过流故障或过温故障。

  3、IGBT短路炸毁

  在模块损坏中,IGBT炸毁大概能占到30%左右,一般伴随着模块内部严重对外壳放电,内部器件损坏严重等现象。

  二、SWITCH变流器模块故障原因分析如下:

  1、直流正负极母排绝缘击穿短路分析

  SWITCH变流器模块内部母排运行电压为DC1050V,其直流正负母排间仅通过绝缘膜进行隔离,结构十分紧凑。母排绝缘层在长时间高温下运行,同时模块并网时正负母排都存在较大的电动力,引起母排间绝缘膜出现裂纹等故障隐患,如隐患没有被及时排除,就可能引起母排间短路放电,引起模块内器件损坏。母排绝缘击穿也可能由于柜体内部凝露引起母排间放电短路。夏季需要严格按照操作规范进行维护。同时加强柜体的密封和除湿工作。在沿海区域,SWITCH变流都加装除湿机进行主动除湿。建议季节变化湿度变化大的风电场通过加装除湿盒进行主动除湿。

  2、驱动板与门极板器件失效分析

  目前容易损坏的板件主要是门极板,门极板是联系驱动板和IGTB的中间采集器件。其直接驱动IGBT门极导通关断,同时又采集IGBT的温度,电流模拟信号。虽然整体电气回路已做了相关隔离。但在驱动板器件失效时,仍然容易引起门极触发异常和采样回路器件烧毁。对于门极板上的器件损坏,初步分析如下:IGBT过温,过流的信号来源于门极板,驱动板对IGBT的信号采集,报出过流过温故障,主要是ASIC板采集的温度,电流信号异常超过保护定值,报出故障。

  3、网侧逆变器过温原因分析

  目前大多数风电场存在网侧逆变器温度高问题,当机组功率达到1200KW左右时,机组频繁报网侧逆变器温度高。该问题经过现场查看故障文件及运行数据。结合内蒙其他风电场也有网侧逆变器过温问题的情况。基本确定网侧逆变器过温是由于模块内部堵塞造成。利用专用清洗液及高压清洗泵,可以对散热器内的堵塞物质进行有效清洗,解决机组变流器过温问题。

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