Delta PCS100 Manuel utilisateur
100kW Power Conditioning System (PCS)
Maintenance Manual
Version: 1.0.0
Maintenance Manual i
Copyright
The ownership and all intellectual property rights of this Maintenance Manual (this “Manual”), including
but not limited to the content, data and figures contained herein are vested by Delta Electronics, Inc.
(“Delta”). The Manual can only be applied to operation or use of the product. Any disposition,
duplication, dissemination, reproduction, modification, translation, extraction or any other usage of the
Manual is prohibited without first obtaining Delta’s written permission. As the product will be developed
and improved continuously, Delta may modify or update the Manual from time to time without any
notice. Delta will do its best to keep the Manual updated and maintain the accuracy of the Manual.
Delta disclaims any kinds or forms of warranty, guarantee or undertaking, either expressly or implicitly,
including but not limited to the completeness, accuracy, non-infringement, merchantability or fitness for
particular purpose or usage.
Copyright © 2019 Delta Electronics, Inc. All Rights Reserved.
Maintenance Manual ii
TABLE OF CONTENTS
Hardware Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Enclosure Front and Side Sections . . . . . . . . . . . . . . . . . . . . . . . 2
Internal Enclosure Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Enclosure Rear Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Rear Compartment Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
General Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Preventive Maintenance Guidelines. . . . . . . . . . . . . . . . . . . . . . 14
Guidelines for Cleaning and General Inspection . . . . . . . . . . . . 16
Guidelines for Cable Maintenance. . . . . . . . . . . . . . . . . . . . . . . 16
Guidelines for Power Component Maintenance. . . . . . . . . . . . . 16
Guidelines for Air Filter Maintenance. . . . . . . . . . . . . . . . . . . . . 16
Guidelines for General Maintenance . . . . . . . . . . . . . . . . . . . . . 17
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Powering off the PCS100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Rear Door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Safety Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
AC and DC Switch Handles . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ventilation Fan for DC-Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Maintenance Manual iii
LCD Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
LCD Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Auxiliary Heat Exchanger Power Board (G Board) . . . . . . . . . . 62
Switch Indicator for Door State (Door Sensor). . . . . . . . . . . . . . 64
DC Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
AC Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fuse for AC Surge Protection (AC SPD Fuse). . . . . . . . . . . . . . 72
AC Surge Protector (AC SPD) . . . . . . . . . . . . . . . . . . . . . . . . . . 75
DC EMI Filter Board (F Board). . . . . . . . . . . . . . . . . . . . . . . . . . 78
AC EMI Filter Board (E Board). . . . . . . . . . . . . . . . . . . . . . . . . . 80
Interface Board (J Board). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
DC Surge Protector (DC SPD). . . . . . . . . . . . . . . . . . . . . . . . . . 85
AC Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
DC Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
AC Main Contactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
AC Softstart Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DC Main Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
DC Softstart Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
IGBT Driver Board (B Board) . . . . . . . . . . . . . . . . . . . . . . . . . . 116
IGBT Driver Adapter Board (A Board) . . . . . . . . . . . . . . . . . . . 119
DC Cap Board (D Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Module Control Board (M Board) . . . . . . . . . . . . . . . . . . . . . . . 128
System Control Board (S Board) . . . . . . . . . . . . . . . . . . . . . . . 132
Module Sampling Board (R Board) . . . . . . . . . . . . . . . . . . . . . 137
System Sampling Board (H Board) . . . . . . . . . . . . . . . . . . . . . 140
Ventilation Fan for Auxiliary Power . . . . . . . . . . . . . . . . . . . . . 144
Auxiliary Power Board (P Board) . . . . . . . . . . . . . . . . . . . . . . . 147
Auxiliary Transformer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Maintenance Manual iv
Air Intake Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Ventilation Fan Module-IGBT. . . . . . . . . . . . . . . . . . . . . . . . . . 157
Ventilation Fan Module-Choke. . . . . . . . . . . . . . . . . . . . . . . . . 162
B Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
A Board Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
AC Filter Module (C Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
IGBT Heatsink (HSK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Maintenance Manual v
Conventions
General Conventions
The following conventions are used in this manual:
Typographical Conventions
The following typographical conventions are used in this document:
Italics
Indicates book titles.
Constant width
Indicates computer output shown on a computer screen, including menus, prompts, responses to
input, and error messages.
Constant width bold
Indicates commands or information literally entered by a user on the computer. Variables contained
within user input are shown in angle brackets (< >).
Indicates directory, file, path, and program/process names.
Bold italics
Indicates keyboard keys that are pressed by the user.
Note:
Indicates additional information that is relevant to the current process or procedure.
WARNING!
Warning information appears before the body of text indicting a hazardous situation, which if
not avoided, could result in death or serious injury.
CAUTION!
CAUTIONS APPEAR BEFORE THE TEXT IT REFERENCES. CAUTIONS APPEAR IN CAPITAL LETTERS TO
EMPHASIZE THAT THE MESSAGE CONTAINS VITAL HEALTH AND SAFETY INFORMATION.
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Maintenance Manual vi
About to this Manual
Version Control
Table 1: Version Control
Rev. Change Description Date
1.0.0
Maintenance Manual vii
Purpose
This manual provides includes safety guidelines, detailed instructions for the maintenance and
troubleshooting of the Delta PCS100.
Target Audience
This manual is intended for customers intending to maintain and troubleshoot these products. Installers
should be certified technicians or electricians.
Manual Organization
This manual includes information covering the following areas:
Front Matter: Safety, regulatory, convention and important information used throughout this
manual and on the device.
Chapter 1. Hardware Introduction: Overview of the system, including features, specifications,
and physical descriptions.
Chapter 2. Preventive Maintenance: Overview of guidelines and information for the mainte-
nance of equipment and consumable components.
Chapter 3. Maintenance: Processes required to repair field serviceable.
Maintenance Manual viii
Maintenance Flowchart
Figure 1. Maintenance Flowchart
Start
Complete
Turn off PCS100
via host server
Turn off the AC/DC
disconnect switch on
the front panel
Service the
front cabinet
Open the
front panel
Close the front panel
(Make sure the front
panel is correctly
secured)
Follow the Maintenance
Manual to service PCS
(Note: Attentive to the
inner power warnings.
Areas below QSU1 and
QSU2 are still powered
and should be protected
with shields.)
YES
Open the
rear panel
Close the rear panel
(Make sure the rear
panel is correctly
secured)
Follow the Maintenance
Manual to service the
rear cabinet of PCS
(Note: Attentive to the
inner power warnings.)
NO
Maintenance Manual ix
Safety Instructions
Warnings
WARNING!
Read all the instructions before using this product.
WARNING!
This device should be supervised when used around children.
WARNING!
The PCS100 must be grounded through a permanent wiring system or an equipment
grounding conductor.
WARNING!
Do not install or use the PCS100 near flammable, explosive, harsh, or combustible
materials, chemicals, or vapors.
WARNING!
Turn off input power at the DC SPD before installing or cleaning the PCS100.
WARNING!
Use the PCS100 only within the specified operating parameters.
WARNING!
Never spray water or any other liquid directly at the wall mounted control box. Never spray
any liquid onto the charge handle or submerge the charge handle in liquid. Store the charge
handle in the dock to prevent unnecessary exposure to contamination or moisture.
WARNING!
Stop using and do not use the PCS100 if it is defective, appears cracked, frayed, broken, or
otherwise damaged, or fails to operate.
WARNING!
Do not attempt to disassemble, repair, tamper with, or modify the PCS100. The PCS100 is
not user serviceable. Contact Tesla for any repairs or modification.
WARNING!
When transporting the PCS100, handle with care. Do not subject it to strong force or impact
or pull, twist, tangle, drag, or step on the PCS100, to prevent damage to it or any
components.
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