Failure Analysis Report

Report Created By Mohamed Sobhy, El-Gammal Industrial

Systems Co.
Report Date 26.2.2018
Customer Nestle

GENERAL INFORMATION

Location 6th October City

VSRT Number Unknown
Serial number [000406H236]
Type Code FC-
102N250T4E54H4TGC3XXSXXXXAXBKCXXXXDX
Type of unit Frequency Converter
Unit identification [--]
information
Tower and Cabinet ID Unknown
Ambient temperature 30°C in a clean environment

PROBLEM DETAILED DESCRIPTION/VERIFICATION

Service info Inspection and Maintenance for FC102

Data logger files Unknown
Fault Situation and Drive not working
environment
Additional information

ROOT CAUSES IDENTIFICATION

When Drive was opened there could be seen that there are effects of dangerous electrical short
circuit Causing damage to many of its components.
CORRECTIVE ACTIONS (from the failed unit’s point of
view)

1- IGBT Dual Module 900A need to be replaced because when be

measured were burned.
2- Power Card 250kW 380-480V also need to be replaced
because it is shorted.
3- Gate Drive Card 400V also need to be replaced because it is
shorted.
4- Heatsink Fan DC 172*51 also need to be replaced because it
is damaged.
5- DC Bus CAP 4700Uf 450V (Quantity 10) also need to be
replaced because it is damaged.
6- IGBT Snubber CAP 1000V 1.5Uf also need to be replaced
because it is damaged.
7- Fuse ultra fast 630A 700V also need to be replaced because it
is damaged.
8-Insulation Motor Terminals D2h/D4h also need to be replaced
because it is damaged.

9-Bus Bar Motor Terminal W phase also need to be replaced

because it is damaged.

10-Cable Power Card to CT D2h/D4h also need to be replaced

because it is damaged.

11-Current Sensor 500Amp LEM also need to be replaced

because it is damaged.
12-Making complete cleaning for the whole drive.

CONCLUSION !!IMPORTANT!!

The Drive parts which was damaged as a result of dangerous

electrical short circuit.
IGBT Module Phase W

Current Sensor 500Amp

 DC Capacitors

Snubber Capacitor
Insulation Motor Terminals

Gate Drive Card 400V