Last edited 5 years ago
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Public:Replace HV cascade

Template:Infobox bms


  1. Basic Info

If the HV cascade is damaged or we need to replace it for some other reasons, please follow this information carefully!

File:E27 Location of the cascade.png
Location of the cascade


  1. Instructions
  • Take out the 230V fuse and wait 5 min if the generator was switched on before to let the capacitors discharge
  • Switch off the 24V supply of the generator
  • Remove the polarity switch knobs.
  • Remove the plexi glass cover, one screw is behind the warranty seal of Heinzinger. It is okay to break the seal in this case, but we need to inform Heinzinger later on
  • Mark the HV cable connections with a marker or a piece of tape. The connections are all pluged in, but we will get problems if they are not fully inserted. To avoid this, this marking will help you later to check if they are fully plugged in again.
  • The HV cascade will be usually send back for repair, so handle it with care
  • Write the date and your name on the HV cascade as well as the reason you take it out


File:E27 Marking of HV cables at the plug connections.png
Marking of HV cables at the plug connections


  • Disconnect all plugs, the signal plugs are screwed in! It is not easy to open some on them, but possible
File:E27 Signal plugs disconnected.png
Signal plugs disconnected
File:E27 HV plugs disconnected.png
HV plugs disconnected
File:E27 Grounding disconnected.png
Grounding disconnected
  • Open all screws fixing the HV cascade, take care of the weight and make sure the cascade is not dropping onto something in the generator
  • Install the new cascade and reconnect all cables, make sure not to mix up the HV cables
  • Make sure all HV cable plugs are fully inserted
File:E27 Reconnected HV cables.png
Reconnected HV cables
File:E27 Not correct plugged in HV cable.png
Not correct plugged in HV cable!!


  • Make sure these cables are bended as shown in the Figure 8. Cable distance between the wires must be equally from the coil to the cascade
File:E27 Correct cable route.png
Correct cable route
File:E27 Wrong cable route.png
Wrong cable route

There were some cases of wrong labeling reported. Regardless of the labels X1 and X2 of the original cascade, never cross the cables! They must be as parallel as possible.

  • When reinstalling the polarity switches, make sure they point to the correct direction. You can see the polarity at the small limit switches activated by the screw at the shaft.
File:E27 Polarity switches.png
Polarity switches
File:E27 Find correct position of polarity switches.png
Find correct position of polarity switches
  • Contact EEP and PM project manager after you replaced the cascade and send it back to BMS. Please provide following information:
Project name and number
Who replaced the cascade
Serial number of the generator


If you have any questions, problems happen or unclear, please inform: EECIbn@brueckner.com