Project background
As an important strategic asset of RWE Group in North America, Bernard Creek Comprehensive Energy Base in Texas has a total installed capacity of 626 MW (photovoltaic 357 MW+energy storage 269 MW) and an average annual carbon dioxide emission reduction of about 420,000 tons. The project adopts 1500V series inverter architecture and is connected to ERCOT power grid dispatching system. Fault event During Q2, 2025, six centralized inverters in the field triggered the "Error 8042" DC side insulation fault code continuously,which led to the automatic disconnection of the system.According to calculation, the loss of power generation in a single day reached $14,700, which affected the performance rating of PPA agreement.
Technical service
Our emergency response team completed within 5 working days:
1. Root cause analysis: The 27th harmonic resonance on DC side was captured by oscilloscope, which led to misjudgment of insulation monitoring unit.
2. Solution: 2.1 upgrade the inverter DSP control algorithm (V2.3.6 firmware). 2.2 install LC filter device (patent number US202536782A).
3. Long-term measures: deploy AI early warning system to realize fault prediction 72 hours in advance.
Cooperation results
After the implementation of the solution, the MTBF of the equipment was increased to 8500 hours, and RWE has included our company in its short list of core suppliers in North America.