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ABB Ltd 3BHS249852 E04 Page 1 of 65

BORDLINE M180 AC Auxiliary Converter

Type: AL D715 C01

Operation & Maintenance Manual

Document Number 3BHS249852 E04

Release Version & Date Rev.0, 30th Jan 2009


Notice

The information in this document is subject to change without notice and should not be construed as a commitment by ABB Ltd. This document has been prepared and checked with great care. If however it still contains errors, then the user is asked to report these to ABB and ABB assumes no responsibility for any errors that may appear in this document.

In no event shall ABB Automation Technology Products be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Automation Technology Products be liable for incidental or consequential damages arising from use of any software or hardware described in this document.

This document and parts thereof must not be reproduced or copied without written permission from ABB and the contents thereof must not be imparted to a third party nor used for any unauthorized purpose.

Software & hardware described in this document were furnished under a license/contract and may be used, copied or disclosed only in accordance with the terms of such license/contractual agreements.

Copyright 2009 ABB Ltd.

All rights reserved.


Table of Contents

Chapter 1 - Safety Precautions.................................................................................................................. 6 1.1. General ............................................................................................................................................ 6 1.2. Introduction ..................................................................................................................................... 6 1.2.1 Responsibility .................................................................................................................................. 6 1.3. Safety Instructions ........................................................................................................................... 6 1.4. Safety & Protection Concept ........................................................................................................... 7 1.5. General Notes on Safety .................................................................................................................. 7

Chapter 2 - Introduction............................................................................................................................ 9 2.1 Purpose of Document ...................................................................................................................... 9 2.2 Tareget Group & Required Qualifications ...................................................................................... 9 2.3 Manual Contents.............................................................................................................................. 9 2.4 Contact Details .............................................................................................................................. 10

Chapter 3 - Equipment Description........................................................................................................ 11 3.1 Brief Description ........................................................................................................................... 11 3.2 Block Diagram............................................................................................................................... 12 3.3 Electrical Schematics..................................................................................................................... 13 3.4 Mechanical Drawing ..................................................................................................................... 13 3.5 Arrangement of Components......................................................................................................... 14 3.6 Control Power Supply ................................................................................................................... 16 3.7 Control Electronics ........................................................................................................................ 16 3.8 Control Board Description............................................................................................................. 17 3.9 Control Electronics Block Diagram .............................................................................................. 18

Chapter 4 - Mechanical Construction .................................................................................................... 19 4.1 Mechanical Arrangement .............................................................................................................. 19

Chapter 5 - Cooling System..................................................................................................................... 20 5.1 Cooling Concept ............................................................................................................................ 20 5.2 External Ventilation....................................................................................................................... 20 5.3 Internal Ventilation........................................................................................................................ 20 5.4 Power Supply for Cooling Fans..................................................................................................... 20

Chapter 6 - Electro Magnetic Compatibility ......................................................................................... 21 6.1 EMC Concept ................................................................................................................................ 21

Chapter 7 - Power & Control Interface ................................................................................................. 22 7.2 Power Wiring................................................................................................................................. 22 7.3 Control Wiring & Interface ........................................................................................................... 24

Chapter 8 - Converter Operation ........................................................................................................... 25 8.1 Self Test......................................................................................................................................... 25 8.2 Preparation for establishing communication with PC ................................................................... 26 8.3 IP Address Configuration .............................................................................................................. 27


8.4 Verifying Communication State.................................................................................................... 28 8.5 Bordline View Configuration & Startup .................................................................................... 30 8.6 Converter Operating Sequence...................................................................................................... 32 8.7 Sequence Control (State Machine) ................................................................................................ 32 8.8 Description of Operating Sequence............................................................................................... 33

Chapter 9 - Functional Description ........................................................................................................ 34 9.1 Input Passive Unit.......................................................................................................................... 34 9.2 IGBT based active front end rectifier ............................................................................................ 35 9.3 IGBT based output Voltage Source Inverter ................................................................................. 36 9.4 Voltage Limiting Unit ................................................................................................................... 36 9.5 Battery Charger ............................................................................................................................. 37

Chapter 10 - Battery Charging Characteristics ...................................................................................... 38 10.1 Charging Characteristics................................................................................................................ 38

Chapter 11 - Display & Diagnostics.......................................................................................................... 39 11.1 Introduction ................................................................................................................................... 39 11.2 Pilot Lamp Indication ................................................................................................................... 39 11.3 LCD ............................................................................................................................................... 40 11.3.1 Parameter Display ......................................................................................................................... 40 11.3.2 Fault Display ................................................................................................................................. 41 11.4 Earth Fault Bypass......................................................................................................................... 42 11.5 Service Access............................................................................................................................... 42 11.6 Bordline View Diagnostic Tool.................................................................................................. 42 11.7 Bordline View User Interface..................................................................................................... 43 11.8 Bordline-View : Transient Recorder .......................................................................................... 44 11.9 Bordline-View : Transient Recorder data interpretation ............................................................ 44

Chapter 12 - Protections ............................................................................................................................ 45 12.1 Protection concept ......................................................................................................................... 45 12.2 Protection zones............................................................................................................................. 45 12.3 Trips............................................................................................................................................... 46 12.4 Fault Classification........................................................................................................................ 46 12.5 Protection Zones............................................................................................................................ 47 12.6 Faultwords & limits ....................................................................................................................... 49 12.6.1 Zone 1 Input circuit .................................................................................................................... 49 12.6.2 Zone 2 U21 (4QS) ...................................................................................................................... 49 12.6.3 Zone 3 DC link ........................................................................................................................... 50 12.6.4 Zone 4 U22 (VLU) ..................................................................................................................... 50 12.6.5 Zone 5 U23/U22 Inverter (WR) ................................................................................................. 50 12.6.6 Zone 6 U23/U22 Inverter Gate Driver (WR) ............................................................................. 51 12.6.7 Zone 7 U24 Full bridge DC/DC converter (BL) ........................................................................ 51 12.6.8 Zone 8 Battery output circuit...................................................................................................... 51 12.6.9 Zone 9 Main Control .................................................................................................................. 52 12.6.10 Zone 10 Temperature sensor alarm ............................................................................................ 52

Chapter 13 - Electrical & Mechanical Installation ................................................................................. 53 13.1 Installing the Converter inside Locomotive .................................................................................. 53 13.2 Electrical Connections................................................................................................................... 54


Chapter 14 - Commissioning..................................................................................................................... 55 14.1 Preparation for Commissioning..................................................................................................... 55 14.1 .1 Visual Checks............................................................................................................................ 55 14.1.2 Wiring............................................................................................................................................ 55 14.2 Commissioning.............................................................................................................................. 55

Chapter 15 - Maintenance Instructions.................................................................................................... 56 15.2 General Maintenance Work........................................................................................................... 56

Chapter 16 - Repair Instructions .............................................................................................................. 57 16.1 Service Concept............................................................................................................................. 57 16.2 Requirements for Carrying out Repairs on the Vehicle................................................................. 57 16.2.1 Looking for Faults with the Converter Installed............................................................................ 57 16.2.2 Replacement of the Defective Components .................................................................................. 57 16.3 Requirements for Repairs Carried out Outside the Vehicle .......................................................... 58 16.3.1 Replacement of the Defective Components .................................................................................. 58 16.3.2 Looking for Faults in Converter which is not Installed................................................................. 58 16.4 Procedure on the Occurence of a Fault in the Converter............................................................... 58 16.4.1 Safety Precautions ......................................................................................................................... 58 16.4.2 Converter Reset ............................................................................................................................. 59 16.5 Request for Fault Diagnosis & Replacement of Parts ................................................................... 59 16.6 Packing and Shipment ................................................................................................................... 60 16.7 Name Plate..................................................................................................................................... 60

Chapter 17 - Packing, Transportation & Storage ................................................................................... 61 17.1 Packaging Information .................................................................................................................. 61 17.1 .1 Packaging Instructions for Returned Components .................................................................... 61 17.2 Transportation................................................................................................................................ 61 17.2.1 Lifting & Moving the converter .................................................................................................... 61 17.2.2 Power Modules .............................................................................................................................. 61 17.3 General Storage Conditions........................................................................................................... 61

Chapter 18 - Technical Data...................................................................................................................... 62 18.1 Input Data ...................................................................................................................................... 62 18.2 Output Data ................................................................................................................................... 62 18.2.1 AC output ...................................................................................................................................... 62 18.2.2 DC output ...................................................................................................................................... 62 18.3 Communication,Display & Signalisation ...................................................................................... 63 18.4 Mechanical Data ............................................................................................................................ 63 18.5 General Data .................................................................................................................................. 63 18.6 Environmental Specifications........................................................................................................ 64 18.7 Test Voltages ................................................................................................................................. 64

Chapter 19 - Additional Documentation .................................................................................................. 65 19.1 Annexures...................................................................................................................................... 65


Chapter 1 -Safety Precautions

1.1. General

Experience & familiarity with full implementation of safety regulations, safety instructions and warnings stated in this manual are essential for safe installation, commissioning as well as for safety during operation, maintenance and servicing of BORDLINE M180 AC auxiliary converter.

Only qualified personnel having specialist knowledge required to correctly interpret and implement the safety requirements & instructions presented in this manual should be allowed to work on the converter.

Fleet operator/owner must ensure that all the specified technical & environmental conditions are fulfilled.

1.2. Introduction

1.2.1 Responsibility

Customer or fleet operator of is responsible for ensuring that every person involved with the installation, operation or maintenance of this equipment has read and understood the safety regulations stated below and the safety notes given in the individual chapters. In particular the fleet operator is responsible for the safety and training of personnel and prevention of material damage.

The fleet operator is also responsible for compliance with the applicable general regulations concerning work safety, the safety regulations for working on low voltage electrical installations and the specific safety regulations imposed by the application.

It is the customers or owners responsibility that all persons involved in the installation, operation and maintenance have completed an appropriate course of training and have thoroughly read and understood this manual.

When working with the static converter, all persons must comply with the appropriate regulations and with the notes on safety contained in this operating manual.

Modifications and constructional changes to converter by fleet operator/owner are not allowed unless authorized and approved by ABB. Maintenance staff of fleet operator/owner must ensure that the converter is in fully serviceable state during its operating lifetime.

1.3. Safety Instructions

Safety instructions always appear at the beginning of a section and/or in the context of instructions which may involve potentially hazardous situations. The notes on safety have been divided into the following five categories:


DANGER!

This symbol indicates an immediate and imminent hazard which can lead to serious bodily injury or death.

WARNING!

This symbol indicates a potentially hazardous situation, which if not avoided, could result in death or serious injury.

CAUTION!

This symbol indicates a potentially hazardous situation, which if not avoided, may result in minor or moderate injury.

NOTE!

This symbol indicates a situation which could lead to damage, one in which either the product or objects in its immediate vicinity could be damaged & as attention to refer other information.

IMPORTANT!

This symbol is used to indicate notes on use and other useful information. It may not be used to indicate dangerous or potentially harmful situations.

1.4. Safety & Protection Concept

NOTE! : Converter is designed with safety devices, required as per design, which allow safe installation and risk free operation of equipment if it is used correctly and in agreement with this manual. However certain residual risks can still remain, and in particular where notes on safety contained in this manual are ignored.

1.5. General Notes on Safety

When working on the static converter it should be remembered that it is anelectrical equipment with potential hazards to life and property if safety regulations are not followed correctly. Therefore user must strictly comply with all the electro-technical safety regulations when handling it.

!


DANGER! :

When input voltage is switched on, any contact with inside parts of the converter can be fatal!

If you have to remove the cover of the converter to carry out maintenance or repair work, then make sure that you follow the instructions given below: DANGER!

The following safety regulations must be complied with before starting any work on the static converter :

Disconnect or fully isolate input & output connections. Make sure the converter cannot be switched ON again. Wait for minimum 5 minutes to allow trapped energies in capacitors

are fully discharged, before proceeding for any work inside the converter.

Check for presence of voltages with suitable test equipment before touching or accessing any component.

Isolate/Insulate any parts which are live.

WARNING!

There is a risk of short-circuiting if any of the live terminals come into contact with metallic objects such as wrist watches, rings, tools etc. Make sure locomotive battery is disconnected!

CAUTION!

An earth strap must be connected between the users wrist and the frame of a unit while accessing control electronic boards. Control electronics could otherwise be destroyed by static electricity.

Watch out for sharp edges when the converter is open.

!


Chapter 2 -Introduction

2.1 Purpose of Document

This operating manual pertains to BORDLINE M180 AC static converter type AL D715 C01 and is intended to document the purpose, the type of use, operation and maintenance and the technical details of the converter.

The following terms are interchangeably used at different places in this manual to signify BORDLINE M180 AC static converter of type AL D715 C01:

static converter auxiliary converter converter equipment

2.2 Tareget Group & Required Qualifications

The AL D715 C01 operating manual is aimed at the following target groups:

assembly and commissioning staff operating staff maintenance staff

The term "staff" refers to technical personnel (in accordance with EN 292) who have special mechanical and electrical skills required to commission/operate/service similar equipment.

2.3 Manual Contents

This operating manual for the type AL D715 C01 converter contains detailed information on:

Description of converter Installation & Commissioning Operation & Maintenance Diagnostics &Troubleshooting Packing & Transport Replacement of components


2.4 Contact Details

Please contact us at the following for any questions or comments on this manual and for technical problems encountered during operation & maintenance of converter.

Contact Address:

ABB Ltd,

Dept: ATDP, Power Electronics Systems,

Traction Converters,

Plot no: 5&6, 2nd Phase, Peenya Indl.Area,

Bangalore 560058, Karnataka

Contact Information:

Telephone : +91 2294 9409/9583

Facsimile : +91 2294 9389

24 hrs Helpline : +91 99014 90130

Email Id : [email protected]


Chapter 3 -Equipment Description

3.1 Brief Description

BORDLINE M series air cooled static converters are compact, rugged units for use as onboard auxiliary power supplies in rail vehicles. Bordline M180 AC static converter is housed in a single cubicle with H type construction suitable for onboard mounting in different types of conventional single phase (tap-changer type) locomotives.

BORDLINE M180 AC static converter is equipped with Power Electronic Building Blocks (PEBB), which is the new paradigm for designing high reliability static power conversion systems. These PEBB modules together with their hardware managers provide an optimum solution for the high-speed control requirements of demanding power electronic systems.

The main controller, PEC 800, is realized with a digital system architecture based on microcontrollers & FPGA, offering powerful computational resources as well as communication interfaces, enabling ease of operation and interaction.

Control signals together with state variables measurements and various commands are transmitted through and across hierarchies using common communications protocol, which enables PnP capabilities to the system, exuding in modularity, re-configurability and reusability.

Input supply from the two auxiliary windings (a0-a1 & a7-a8) of traction transformer are separately wired to the converter and connected in parallel inside the converter and connected to an IGBT based single phase full bridge converter which converts the single phase AC input into a regulated DC voltage, draws near sinusoidal input current and operates at unity power factor (Cos Phi) for its entire operating range.

DC link is connected to an IGBT based three phase voltage source inverter, which generates three phase sine weighted output of 415 V, 50 Hz output. This PWM output is delivered to auxiliary loads through a sine filter, which filters out the switching current ripple and ensures output voltage distortion is maintained below 10 %.

Operation of converter in presence of an earth fault is provided to enable the loco pilot clear the section in case of earth fault in the middle of a section, in any of the auxiliary loads. Inverter will first trip on earth fault in the event of an earth fault in any one of the phases of auxiliary load. However earth fault trip can be bypassed for a period of 45 minutes by enabling the earth fault bypass switch provided in the converter front panel.

DC link of 180 kVA static converter is also connected to a IGBT based switch mode type battery charger which generates 110 Vdc required for charging vehicle battery & powering the DC loads in the locomotive. 110 Vdc output is galvanically isolated from the input AC supply of static converter & its AC output.

Bordline M180 converter has been designed to conform to IEC 61287 and other applicable standards for rolling stock converters, as far as they are relevant to this type of equipment. An EMC concept was specifically developed for this equipment, and also existing guidelines which were formulated by EMC specialists from ABB have been complied with.


3.2 Block Diagram


3.3 Electrical Schematics

Electrical schematic (3BHS249852 ZAB E03) of Bordline M180 AC static converter is provided as annexure to this manual.

3.4 Mechanical Drawing

Dimensional drawing (3BHS248948_E05) of Bordline M180 AC static converter is provided as annexure to this manual.


3.5 Arrangement of Components

The following photographs show the arrangement of various components inside the converter. The figures show only the most important components and elements.

Swing door display Control Cabinet Internal fan Additional capacitor bank

Axial fan

Terminal chamber

Battery charger

Input choke Sine filter choke Power modules


Fig : Rear Side View

Centrifugal fan Access for PM inspection


3.6 Control Power Supply

Bordline M180 AC static converter requires 110 Vdc supply for its control electronics and is derived from vehicle battery (Vbatt + & Vbatt-). This 110 Vdc supply from vehicle battery is fed to the converter via connecter X15 and MCB S 971 , provided inside the converter and is fed to power supplies G956 & G957 through a bridge rectifier, which provides reverse polarity protection for the control electronics. The total power consumption of electronics is approximately 250 W.

Power supply G956 generates+ 15 V, 4A & + 5 V, 5.5 A outputs for powering the main control electronics, current & voltage transducers, LCD & LED pilot lamps.

Power supply G957 generates 2 x 24 V, 2.2 A outputs for powering gate drive cards of all power modules. (PM1 & PM4).

The power supply unit can bridge short interruptions of less than 10 ms to ride through short time interruptions/sags during normal operation. Converter stops all the control signals if the break in power supply is longer than 10 ms. Converter control stops all the control signals and protects the converter safely, if the external 110 Vdc power supply from vehicle battery is disconnected for any reason for more than 10 ms while converter is in operation.

Refer to electrical schematics 3BHS249852 ZAB E03 to check the connections and wiring of control power supply.

3.7 Control Electronics

The Bordline Compact Converter Control PP D114 is a control platform for power converters in traction applications. It is built modularly and can be made up with multiple boards in different combinations based on application requirement. The core is the main controller AC 800 PEC, which is a modular high speed programmable control device from ABB and is the optimum solution for combining the high-speed control requirements of power electronics applications and low-speed process control tasks. The backplane consists of the CCC Base Board XV D824, which also hosts digital and analog IOs required for basic converter applications. More application interfaces and IOs can be added with the CCC Extension board XV D825, which can be plugged directly to the XV D824. A general purpose digital interface is available on the XV D824 where a wide range of communication interfaces can be adopted.


Fast, time-critical control and I/O tasks are programmed by means of MATLAB/Simulink and integrated into the control environment as a Simulink I/O unit. These fast control tasks and configuration of the PEC 800 specific fast I/O's are programmed by means of MATLAB/ Simulink and Real Time Workshop (RTW). High Speed time-critical, hardware- specific functions such as pulse-width modulators, pulse logic with associated protective functions, fast analog and binary inputs and outputs, etc are implemented in FPGA and programmed in VHDL. This board also has an Ethernet and RS232 port for system configuration, diagnostics and vehicle bus communication. Additional potential free relay contacts are available for indications, alarms and for remote signalling purposes. The driver electronics of the converters convert the information from the control electronics into trigger signals and is also responsible for the protection of the power semiconductors.

3.8 Control Board Description

The following boards are used in the BORDLINE M180 AC static converter (Refer section 3.9 for block diagrams of major boards & electrical schematic for interconnection between boards):

Type (Designation) Name Functional description

XV D824 (U31) Compact converter control

- Houses FPGA

- Interfaces for V & I transducers.

- Digital I/Os

- NTC Temperature sensors

- Service connection

- CAN LCD display

- Gate drivers

XF D151 (U33) CAN converter board

Converts CAN optical pulses from XV D824 to electrical signals for LCD

UF D827 (U32) Optical extension board

Interfaces between XV D824 and (GD D830 & XF D151)

GD D830 (U51-U58) Dual IGBT gate driver

- Current & DC link voltage measurement

- Vce saturation detection

- Overcurrent

- DC link overvoltage

- Gate output short circuit /overload

- Top/bottom switch interlock

- DC link short circuit detection

- Soft turn-ON & turn-OFF

ECOMOT100(U41) LCD dispaly LCD display

Table: Control boards description


3.9 Control Electronics Block Diagram

Fig. : Control hardware block diagram

Fig. :: Compact converter control XV D824 (U31) with interfaces


Chapter 4 - Mechanical Construction

4.1 Mechanical Arrangement

The converter is built with mild steel into a cabinet for onboard mounting inside locomotive and is mechanically partitioned into two compartments of different ingress protection (IP) categories. One compartment, with ingress protection level of IP 65, contains mainly the power modules of the entire converter in four heatsinks, control electronics, auxiliary power supplies for control electronics, switchgears and a cooling fan for internal air circulation. Higher ingress protection level of this compartment protects the components from external environmental factors, thereby enhancing their reliability.

The second compartment, with ingress protection level of IP 21, mainly contains the input inductor, output sine filter, power & control terminals for interfacing the converter with the vehicle and an axial fan for cooling. Apart from the above the converter is also provided with an LCD unit for parameter & fault data display, pilot lamps to indicate the status of the converter and an ETHERNET interface for service & diagnostics.

In order to have ease of replacement, the input converter and output inverter power modules are made identical. The complete converter contains four power modules. One PEBB module contains the active front end rectifier, two modules contain the inverter & voltage limiting unit and one power module contains the battery charger.

Detailed dimensional drawing of Bordline M180 AC converter is given in drawing 3BHS248948_E05.


Chapter 5 - Cooling System

5.1 Cooling Concept

The cooling of power modules and the converter is realized by means of forced air circulation with four fans. Thermal monitoring devices are provided on different converter components to monitor the temperatures and to protect them from thermal overloads.

5.2 External Ventilation

External air is sucked from the backside of the converter by a centrifugal fan (E951) and forced through the heat sinks of converter & inverter power modules (PM1- U21 to 23) via an air duct at the bottom. An axial fan (E952) is used for cooling input inductor (L701), sine filter inductor ( L705 707), battery charger power module (PM4 U24), power & control terminal interfaces (X1 to X11) and input fuse (F981).

5.3 Internal Ventilation

Two centrifugal fans (E953 & E954) are used to cool the components inside the IP 65 chamber and to maintain uniform temperature inside the power module and control electronics compartment by circulating the air inside the IP 65 chamber.

5.4 Power Supply for Cooling Fans

All fans derive their supply (3 Phase, 415 V, 50 Hz) for their operation from inverter AC output and are provided with a common manual motor starter for overload & short circuit protection. Refer to Sec.3.3 Electrical Schematics for fan connections and Sec 14 Arrangement of Components for location of different fans.

Fan Operation E951 Air inlet @ the back of converter behind the PM 1 modules.

Air outlet from the heat sink of U22. Velocity of air at heat sink outlet should be minimum 10m/s

E952 Air inlet @ left side of the converter under display swing door. Air outlet @ front of the converter above H cutout. Velocity of air at heat sink outlet should be around 4 -5 m/s

E953 Blows air into the control cubicle E954 Blows air into the PM1 module chamber

IMPORTANT! : Please verify & ensure correct rotational direction of fan

and check velocity of air at outlets are as below while commissioning the converter for the first time or after repair work was done on the converter.


Chapter 6 - Electro Magnetic Compatibility

6.1 EMC Concept

Bordline M180 converter has been designed to conform to the EMI/EMC requirements outlined in IEC 61287 and other applicable standards for rolling stock converters, as far as they are relevant to this type of equipment. An EMC concept was specifically developed for this equipment, and also existing guidelines which were formulated by EMC specialists from ABB have been complied with.

The converter output is provided with midpoint grounded sine filter which eliminates the common mode voltage at inverter output, to protect the motor insulation. With the sine filter the maximum increase in the ripple voltage, which overlays the fundamental output voltage is also limited to < 10V/us.

Further, internal return of the HF interference currents to the source by means of Y capacitors minimizes the emissions given off by the cables.


Chapter 7 - Power & Control Interface

7.2 Power Wiring

Bordline M180 AC static converter is designed for operating with a nominal voltage of 380/415 V. Therefore input supply from the auxiliary windings (a0-a1 & a7-a8) of traction transformer should be separately wired to the converter. Bus bar terminals are provided inside the converter terminal assembly for power cable terminations as given below. Input Terminals : X1 to X4 : Suitable for connecting 120 sq.mm cable with M-16 Bolt. DC Output Terminals : X5 to X8 : Suitable for connecting 10 sq.mm cable with M-6 Bolt. AC O/p Terminals : X9 to X11 : Suitable for connecting 120 sq.mm cable with M-16 Bolt. Power Earth : X12 : Suitable for connecting 120 sq.mm cable with M-16 Bolt.

DC Output Terminals AC O/p Terminals Input Terminals Power Earth

Control Interface


Following modifications needs to be carried out/ensured on the locomotive, before connecting power cables to transformer auxiliary windings or to the converter. Input power connections should be as per fig. given below

Auxiliary windings (a0 a1) & (a7 a8) MUST NOT be connected together. Link provided in the transformer to connect a1 & a7 terminals in series must be REMOVED.

Midpoint grounding of 1 uFD (0.47 uFD x 2) filter capacitors provided across auxiliary windings MUST BE REMOVED and capacitors should be connected as shown in fig. below

RC surge suppressor provided across transformer auxiliary windings MUST be connected as below to avoid overheating of resistors due to switching frequency ripple current.

Fig : Input power connections


7.3 Control Wiring & Interface

The following inputs/outputs are delivered or received by the converter from vehicle control, as control interfaces. Terminal blocks suitable for 12 nos x 1.5 to 4 sq.mm cables is provided inside the converter terminal assembly for these interfaces.

Converter Terminal (X15)

Signal Description

1 & 21 110 Vdc battery voltage for control power supply

3 & 42 DI - START command from locomotive control system

7 & 83 DO - NO-NC, INVERTER ON feedback to locomotive control system

9 & 103 DO - NO-NC, CONVERTER TRIP feedback to locomotive control system

13 & 143 DO - NC-NO, CHBA TRIP feedback to locomotive control system

1Reverse polarity protected (77 140 V DC), 2NO contact from vehicle control

3All contacts rated for 4A, 110V DC

DI Digital Input, DO Digital Output


Chapter 8 - Converter Operation

8.1 Self Test

PP D114 compact converter control is equipped with four system status LEDs (V1900 to V1903) that are placed on XV D824A CCC Base Board. These four LEDs indicate different device states and the status of control electronics can be interpreted without additional hardwired connections by monitoring their indicating status. 110 Vdc supply to control electronics should be switched ON and the LEDs status should be monitored during the self test/booting process as given below. Converter is ready for operation and application software can be downloaded only after successful completion of this test. Green LEDs 2, 3 & 4 will glow permanently on successful completion of self test/boot up process. Any other status indication point to potential problems with control electronics and appropriate action shall be taken as per the status matrix given below.

LED No Color Marking Status and Meaning in Running State LED_1: V1900 Red F(ault) LED is turned OFF.

LED may be turned ON to indicate a severe system fault. LED is SW controlled. Fault, indicates error in PP D103A Software

LED_2: V1901 Green R(un) LED is turned ON if FPGA is configured. LED is turned OFF if the FPGA is cleared. LED is SW controlled. Run/Config Done, indicates that the FPGA configuration in PP D103 is done successfully

LED_3: V1902 Green P(ower) LED is turned On. LED is turned OFF if supply is out of range. LED is HW controlled. Power OK, indicates that the local power supervision on the PP D103 has not detected any errors

LED_4: V1903 Green S(upervisor) LED is turned ON. LED is turned OFF if any operating condition is out of range. LED is SW controlled.

On successful completion of SELF TEST, SI unit OK LED on the converter front panel will glow.


8.2 Preparation for establishing communication with PC

To establish communication with the converter and to view the converter status, parameters, fault data etc with Bordline View Maintenance Tool the following requirements/preparations are necessary. 1. A computer with Bordline View Software installed in it. Refer to the screen shot attached

below to check whether the required software is properly installed in the service PC.

2. Authorization for the users account to change IP Address of the PC used for service. 3. Crossover Ethernet Cat. 5 cable to connect the computer with the controller. Verify the cable

as per the pin out configuration given below.

From Connector 1 Pinout

To Connector 2 Pinout

1 3 2 6 3 1 4 none 5 none 6 2 7 none 8 none


4. Necessary project (.prj) & variable (.var) files are copied into the respective folders. Go to Windows Explorer and verify presence of project specific .prj & .var files as shown in screen shot below.

NOTE! : Refer to BORDLINE View maintenance tool users manual, 3BHS221602 ZAB E01, Rev. A, attached as annexure to this document, for further details. Please contact ABB if the user does not have .var & .prj files.

8.3 IP Address Configuration

Before connecting the service PC to RJ 45 ETHERNET interface, following settings have to done as per the procedure below.

Setup the Ethernet connection in the PC to a fixed IP-Address. Administrator rights on the PC are required to do these changes.

To change TCP/IP-settings go to Windows Start-menu/Settings/Control Panel/Network Connections/LAN (Click on LAN).

Click on Properties tab in the LAN Status window. In the LAN Properties window select Internet Protocol (TCP/IP) and then click on the

Properties button.

Select Use the following IP address option and set the IP-address to 10.10.1.102 and Subnet-mask as 255.255.0.0 as shown below,


Fig.: PC IP Settings

8.4 Verifying Communication State

1. Interconnect service PC (TCP/IP port) and the converter (front panel RJ 45 harting

connector) with an Ethernet cross over cable.

2. Switch ON control electronics power supply and wait till control electronics self check & booting processes have completed.

3. Go to Windows Start menu, Click on RUN.


4. Type cmd and press OK to open MS DOS command prompt.

5. Type ipconfig and check the IP setting of service PC as shown in screen shot below. IP Address & Subnet Mask values should be same as those set by the user as per instructions in sec 27.


6. Type ping 10.10.1.101 and check whether the reply from PEC 800 controller is received and there is no loss of data as shown is screen shot below.

7. Successful completion of stage 6 completes the tasks required to establish and verify communication between service PC and the converter.

8.5 Bordline View Configuration & Startup

BORDLINE View maintenance tool is required to monitor converter parameters and download fault data. This software tool runs under Windows 2000/XP on a standard PC. Configuration : Interconnect service PC (TCP/IP port) and the converter (front panel RJ 45 harting

connector) with an Ethernet cross over cable.

Switch ON control electronics power supply and wait till control electronics self check & booting processes have completed.

Establish communication between converter and service PC as per the instructions in sec 27, 28 & 28.

Before starting Bordline View copy project specific variable list file (IR_180kVA_H_Test.var) in the following directory: Program Files\AbbMaintTool\VarLists and project file (IR_180kVA_H_Test.cfg) into the following directory: Program Files\AbbMaintTool\Projects


Startup : Start Bordline View application and select the corresponding project (IR_180kVA_H_Test) from the Project List and setup from the Setup List. Different setups are available for different tests.

Fig.: Bordline View setup selection

Fig Bordline View user interface


8.6 Converter Operating Sequence

All control and monitoring functions are dealt with by the control electronics, which is fitted with a processor. As the control power supply is switched ON, the control electronics goes through self-tests and initialization routines and then the control software application is started. When the input voltage is within the operating limits, converter starts automatically if START signal from vehicle control is present. On receipt of START command, pre-charging contactor is closed to charge the DC link through a current limiting resistor. Main contactor is closed, as soon as DC-Link is charged to a pre-set value and charging contactor is opened. After synchronization with the input supply, Battery charger modulation is started and grid control for input 4QC is started. Shortly afterwards AC & DC output will be available at the inverter and battery charger output terminals and DC link voltage limiting unit (VLU) will be initialized and kept ready. In case of a trip either the particular output sections are stopped or the entire converter except VLU will be stopped based on the nature of trip and will remain in that state till the fault is cleared or the reset button is pressed. For details of trips refer to section [12.3]

The operating status of the converter at any moment is displayed by an LCD provided on the front panel along with LED pilot lamps. In-addition three potential free relay outputs have been provided for on-vehicle signalization/interfacing with vehicle control.

8.7 Sequence Control (State Machine)

The sequence control (State Machine) through the central processor on the full unit instrument and control takes place as shown in the following diagram.The state machine is based on the hierarchy of states as shown in the diagram. TRIP1 states are highest in hierarchy, then are STOP states and then ON states.

Initial

InitReset

Normal

Standby

Trip1 OnInhibit Test_Mode

ResetTrip

ON

Fig : State Machine


8.8 Description of Operating Sequence

The following notes describe the main operating sequence:

Initial State:

Initial condition after control power supply is switched ON. Initialization of SW parameters is carried out and converter automatically changes from this

condition to the Init Reset condition. Init Reset:

If input voltage is in operating range and if external START command is active, the state machine moves to Normal condition.

Normal State:

In this state SW and HW are initialized. The starting sequence begins pre-charging, start of the BL, 4QC & WR Unit switches to Standby condition if start signal drops out or if input voltage is outside the

operating range If a fault occurs, which requires the complete unit to be stopped or on failure of supply

voltage the State Machine automatically switches to Trip1 state. Standby State:

Modulation of IGBTs are stopped and contactors opened. If the external start signal is present and the input voltage is within the operating range the

auxiliary converter changes to the Normal condition. If an error occurs the State Machine switches to condition Trip1 state

Trip1 State:

All power sections are stopped and contactors opened The condition automatically changes from Trip1 to On Inhibit state.

On Inhibit State:

In this condition all the power sections and the charging IGBT are open After a severe failure, one which does not allow the converter to be restarted, this condition is

no longer left If a restart of the converter is allowed (resettable trip) then the auxiliary converter

automatically switches to the Reset Trip condition. Reset Trip:

A general Trip Reset is carried out From this condition the State Machine switches to Normal state.


Chapter 9 - Functional Description

9.1 Input Passive Unit

The input passive unit consists of a pre-charging unit and a filter inductor. Pre-charging unit is used to charge the DC link capacitors as soon as START command is received and the input filter inductor limits the input current distortion, due to switching frequency ripple current generated by the input converter.

Fig.2 : Input Passive Unit

The pre-charging unit consists of a charging contactor and a charging resistor. The charging contactor is turned on as soon as the input voltage is sensed and is within operating range and the START signal from vehicle control is active. The charging resistor ensures reduces the capacitor charging current to an acceptable value for the power semiconductors. After the DC link is charged to a preset value, the main contactor is closed and the charging contactor is opened. The charging contactor is also opened if there is a command to stop the converter either internal (due to trips, for example) or external (if Start is disabled). The charging switch is then switched ON when the following conditions are fulfilled: Input voltage is in the operating range, input voltage is more than a minimum threshold & External Start signal is enabled. Main contactor is switched ON, when the DC-Link is charged and the start command from vehicle control is active. The main contactor is opened when there is as STOP command generated internally from the converter (due to trips, for example) or external (if START is disabled).


9.2 IGBT based active front end rectifier

The input four quadrant active front end rectifier is realized based on single phase full bridge topology, utilizing IGBTs as the switching device. The input 4QC is actively pulse width modulated and together with the DC link filter capacitors generate a regulated DC-link voltage for the output voltage source inverter.

Fig.3: Input 4 Quadrant Converter

The input 4QC starts automatically if the input voltage lies within the working range, after pre-charging is completed and if the internal/external STOP signal is not active. SPWM is used for modulating the input 4QC converter with unipolar switching. Use of SPWM modulation with unipolar switching results in ripple frequency doubling effect (better THD for same Fsw) at the input and reduces the voltage jumps from +Udc to Udc to 0 to +/ Udc, when compared with bipolar switching. Input rectification with active front end converter has many advantages over conventional rectifiers, Viz., UPF operation at the Input, reduced harmonic distortion, constant DC link voltage irrespective of supply voltage fluctuations c and the inherent capability to regenerate power back to the source. The DC link capacitors are sized for absorbing the second harmonic ripple current and to ensure sufficient ride through capacity.

The input 4QC converter converts the input AC voltage into a regulated DC link voltage. The references and pulses for input 4QC are enabled by the state machine.


9.3 IGBT based output Voltage Source Inverter

The output voltage source inverter (VSI) is realized with a three phase half bridge topology utilizing IGBTs as the switching device. VSI is connected to the DC link and sine pulse width modulated to generate a three phase sine weighted PWM output of 415V (Line to Line) & 50 Hz output at its terminals. The topology of the output VSI is given below.

Fig.4 : Three Phase Voltage Source Inverter

The output of the voltage source inverter is connected to a sinusoidal LC-filter to filter the switching frequency ripple current. The resultant waveform at the output of sine filter is nearly devoid of high frequency components and can be directly connected to standard three-phase motors without shielded supply leads. Voltage distortion at sine filter output is less than 10 % and the dV/dT of output voltage is below 10 V/s, which results in lower stresses on the motor insulation. Output voltage regulation is implemented as an open loop control, with compensation for variation in DC link voltage & sine filter voltage drop. Inverter switching pulses are generated in the PLD, based upon the modulation index and reference frequency. The three-phase output voltage (therefore the modulation index) and reference frequency are fixed references. Over current limitation is a function implemented in the PLD. The peak output current is limited to a threshold of 350 A for 5 s and the inverter is switched OFF if the time threshold is exceeded.

9.4 Voltage Limiting Unit

An active switch (IGBT) based fast over voltage protection system, called voltage limiting unit (VLU), is provided on the DC link to protect the power semiconductors and DC link capacitors against DC link over voltage due to supply side transients or load regeneration. In-addition VLU is also used to discharge the DC link fast if the converter is stopped due to external stop command. The scheme of VLU is shown below,


Fig.5: Voltage Limiting Unit

In case of DC link over voltage, VLU is operated for a specified band of DC link voltage range and the duty cycle of the switch is varied linearly from 0 and 1 based on actual value of DC link voltage within the band. If fast DC link discharge is required then the duty cycle is set to 1.

9.5 Battery Charger

The Battery charger converts the DC-Link voltage to a controlled DC output required by the vehicle battery & DC loads with galvanic isolation. The scheme of the battery charger is given below.

Fig.6: Battery Charger

The input full bridge inverter generates a pulsating high frequency AC output and its duty cycle is varied based on the battery charge state and the charging characteristic curve. The output of the this inverter is connected to a step down transformer, which provides galvanic isolation between the input and output as well as voltage level transformation and a full bridge diode rectifier is connected to the transformer secondary to rectify the AC voltage. An LC filter at the output of the diode rectifier smoothens the DC output voltage. Charging current of the battery is measured and is limited to the maximum allowable battery charging current by reducing the DC output voltage. The battery charger switches over to Boost/ Trickle charging mode based on the current drawn by the battery and its charge state.


Chapter 10 - Battery Charging Characteristics

10.1 Charging Characteristics

Battery charger provided in Bordline M180 AC static converter charges the battery based on three stage IUoU charging characteristic with Boost & Trickle modes. This type of controlled charging will ideally help in preventing overcharging, over heating & loss of electrolyte in the battery and hence will have a positive impact on the usable life of batteries. Charging characteristics of the battery charge is given below.

Fig.24: Battery Charging Characteristic On completion of pre-charging, battery charger modulation is started. Battery charger controller initially commands the charger to deliver a constant output voltage of 109.5 V (U) and monitors the current drawn by the battery. If the current drawn by the battery is more than 4 A then the battery charger switches over to Boost Charge Mode, as this indicates that the battery is not fully charged. Under this condition the battery charger controller increases the charger output voltage reference beyond 109.5 V, till the current limit of 8 A is reached. As the battery gets charged, boost charge voltage is increased gradually, with maximum current limit of 8 A, till it reaches 114.5 V (Uo). Once Boost Charge voltage is reached, a constant voltage of 114.5 Vdc is applied continuously till the battery current falls below 3 A. Battery charger switches over to trickle charge mode from Boost charge mode, when battery current falls below 3 A and will charge the battery at a constant voltage of 109.5 V. Monitoring, adjustment of reference values & set points are based on battery charge state and is done at a fast dynamic rate by the battery charger controller.


Chapter 11 -Display & Diagnostics

11.1 Introduction

11.2 Pilot Lamp Indication

LED lamps are provided on the converter front panel swing door to indicate the status in of the converter. Details of the lamps and remarks on their operation are given below.

Description LED Remarks

SI unit OK Green ON when unit has no fault

Input voltage in range Red OFF when input voltage is within operating range

Internal fault Red ON during internal fault

External fault Red ON during external fault (see section 23.5)

CHBA OK Green ON when battery charger unit is working

I/P not in range Internal fault External fault Earth fault bypass

SI unit OK CHBA OK Service port

LCD


11.3 LCD

The converter is fitted with a LCD display on the display door for displaying important system parameters and faults.

Fig 29: LCD display unit

11.3.1 Parameter Display

The following information are displayed on the LCD (as per RDSO REPORT No. RDSO/2007/EL/IR/0126 Rev0) and the same can be accessed by pressing function keys as mentioned below.

Key Display on LCD (Remarks) F1 Input voltage XXX V

Input current XXX A F4 Output voltage XXX V (Line line voltage, phase 1)

Output current XXX A (Phase 1 current) F5 Output voltage XXX V (Line line voltage, phase 2)

Output current XXX A (Phase 2 current) F6 Output voltage XXX V (Line line voltage, phase 3)

Output current XXX A (Phase 3 current) F2 CHBA voltage XXX V (Battery voltage)

CHBA current XX A (Battery charging current) DC current XX A (Sum of DC load and charging current)

F3 (Status of the converter)


11.3.2 Fault Display

In the event of a fault in the system, the parameter display will be replaced by the fault display on the panel. The following messages (as per RDSO REPORT No. RDSO/2007/EL/IR/0126 Rev0), will be displayed on the LCD in the case of respective faults. For faults which do not come under the list as per RDSO REPORT No. RDSO/2007/EL/IR/0126 Rev0, the fault message will be as per text under column protection function in section 23.4. Fault message1 Remarks Input fuse failure In case the input fuse blows Input voltage high Input voltage exceeds upper limit Input voltage low Input voltage drops below lower limit DC link current high -NA- DC link voltage high DC link voltage exceeds upper limit DC link voltage low DC link drops below lower limit Output current high High output AC current persisting Output voltage high -NA- Output voltage low -NA- Earth fault Earth fault at input/output of SIV Single phase fault Unbalance/single phasing at the output Blower fault Failure of cooling blower CHBA fault Battery charger fault Input current high High input AC current persisting Rectifier fault Input rectifier fault Inverter fault Inverter fault Chopper fault Voltage limiter unit fault Over temperature Over temperature in rectifier/inverter Power supply fault -NA- Chopper current high Voltage limiter unit overcurrent fault CHBA current high Battery charger current limit exceeded CHBA voltage high Battery voltage exceeding upper limit CHBA voltage low Battery voltage drops below lower limit CHBA temp high Battery charger over temperature

1Alongwith the fault message, another message as per section 23.4 under column protection function will also be displayed in the next line for further information on the location of the fault. The messages persist until the esc button is pressed and the parameters are displayed. For actual resetting of the fault, the Reset pushbutton has to be pressed.


11.4 Earth Fault Bypass

Push button has been provided on the display door to manually bypass earth fault protection to enable loco pilot clear the section in case of earth fault in the middle of a section, in any of the auxiliary loads.

Inverter will first trip on earth fault in the event of an earth fault in any one of the phases of auxiliary load. This earth fault trip can be bypassed for a period of 45 minutes by enabling the earth fault bypass switch provided in the converter front panel. E/f bypassed message will be displayed on the LCD status screen if this option is enabled.

CAUTION! : Careful analysis should be done, with record of

observations, by the loco pilot or vehicle operator before bypassing earth fault protection.

It is NOT RECOMMENDED to RESET the converter and continue to operate the converter after the first 45 minutes of operation in earth fault bypass mode.

For further operation under an earth fault, the loco Pilot or vehicle operator is advised to investigate & identify the location of fault and operate the loco only after isolating the faulty motor as per RDSO instructions.

11.5 Service Access

TCP/IP protocol is used for communication with PEC 800 controller and a RJ 45 Harting connector has been provided on the converter front panel swing door for service access. CAT 5 ETHERNET cross over cable should be used to communicate between service laptop & PEC 800 controller.

11.6 Bordline View Diagnostic Tool

BORDLINEView is used for diagnostics on the vehicle with a PC. Several faults, warnings and actual process and status values like input voltage are displayed. In addition, resetting of trips & downloading of fault data is performed with the diagnostic tool.

Service access can be obtained using a standard PC/laptop connected to a standard interface on the display door. Current operating data is also displayed using the BORDLINE diagnostic tool for on-line monitoring.


11.7 Bordline View User Interface

The maintenance tool BORDLINE-View displays detailed information on the operating condition of the auxiliary converter. If a malfunction occurs the program BORDLINE-View, installed on the standard PC, can be used to display additional data to help resolve the problem

Fig: Bordline-View user interface 1 Status indication of the converter 2 Message window for faults and warnings 3 Indication of actual values, e.g voltage, current, temperature

1

2

3


11.8 Bordline-View : Transient Recorder

The BORDLINE M180 converter is provided with a transient recorder facility which greatly eases troubleshooting and fault diagnosis. The functioning is as follows:

The occurrence of a fault (see section) triggers the transient recorder. The transient recorder writes two TR (transient recorder) files into the FLASH

memory of the main controller (U31).

The recording of TR files in the FLASH memory is on FIFO (first in first out) basis. The FIFO buffer size is for 50 faults i.e 100 TR files.

Each TR (transient recorder) file contains 1000 data samples (500 pre- & 500 post- events) of predefined signals, parameters & internal status codes. The sampling time for data logging is 300us. The TR files can be directly converted into EXCEL filtes with BORDLINE diagnostic tool for troubleshooting & post-fault analysis. Service access can be obtained using a standard PC/laptop connected to a standard interface on the display door. For on-line monitoring the current operating data can also be displayed using the BORDLINE diagnostic tool.

11.9 Bordline-View : Transient Recorder data interpretation

Transient recorder files contain the type of fault, time of fault and all associated parameters, inputs & outputs signals(voltage/current) which can be plotted to give real time status of the converter during trip. Fig 28: Sample waveforms plotted from a TR file.

-1500

-1000

-500

0

500

1000

1500

1 83 165 247 329 411 493 575 657 739 821 903 985


Chapter 12 -Protections

12.1 Protection concept

Protection functions in Bordline M180 AC static converter are classified into three levels based on the importance & the response time with which a certain protective function is enabled. See Section 23.4 for details regarding each trip.

1. Hardware protection through gate drivers (Response time is in us range) In case of Inadequate supply voltage for driving the IGBT, loss of communication, overcurrent and Vce saturation, the driving pulses are blocked immediately and trip signal is sent to the controller.

2. PLD protection (Response time is in us range) Some protections like DC link overvoltage, DC link voltage rate and battery over voltage are implemented in the PLD.

3. Software protection (Response time is in ms range) These are protections whose limits can be changed based on application requirements. Example Over current with time limit.

12.2 Protection zones

The easy troubleshooting converter is divided into 10 protection zones to easily identify the location of fault. They also help to decide whether the entire converter or parts of the converter needs to be switched off. The different zones are given below (see also Figure 34)

Zone 1 - Input circuit Zone 2 U21 (4QS) Zone 3 DC link Zone 4 U22 (VLU) Zone 5 U23/U22 Inverter (WR) Zone 6 U23/U22 Inverter Gate Driver (WR) Zone 7 U24 Full bridge DC/DC converter (BL) Zone 8 - Battery output circuit Zone 9 - Main Control Zone 10 Temperature sensor alarm


12.3 Trips

Depending on the severity of trip either the entire converter is switched off or only the section where the fault has occurred. Eg. An inverter fault will switch off the inverter but the battery charger will be still functioning. Also some of the less relevant trips are counted trips. Eg. VLU resistor energy high, the converter trips if the fault occurs frequently within a time period. The following trips are defined:

Trip1: Switch off all power parts of the converter Trip3_BL: Switch off the battery charger (BL) full bridge converter Trip3_WR: Switch off the Inverter (WR)

The end letters with each trip have the following meaning:

nr: Not resettable trip cr: Counted trip (20s / 3 times) r: Resettable trip

12.4 Fault Classification

The following faults have been grouped as external taking into consideration RDSO REPORT No. RDSO/2007/EL/IR/0126 Rev0

Zone External Fault 1 Ip voltage high rms, pk1 Ip voltage high pk 1 Input voltage low 1 Ip frequency range 3 Earth fault 5 WR OC trip 5 WR OC limitation 5 Open phase ph1 5 Open phase ph2 5 Open phase ph3 5 WR unbalance trip 8 Battery OC trip 8 Battery UV trip 8 Battery OV trip


12.5 Protection Zones

Fig : Protection zones


12.6 Faultwords & limits

Name Value Description Uref 650V 1100V DC link voltage reference IHBN_max 185 A Maximum VLU current IXN 251 A Maximum inverter current Iin_max 503 A Maximum input current UTN 380V/415V/430V Auxiliary secondary winding nominal voltage IbBL 30A Maximum DC output current Ibattery_max 8A Maximum battery current Ubattnom 110V Nominal DC output voltage

12.6.1 Zone 1 Input circuit

Bit Protection function Identification Level Trip name 1 Ip voltage high rms Simulink > 1.378 UTN / 60ms Trip1_r 2 Ip voltage high pk Simulink > 2.33 UTN Trip1_r 3 Input voltage low Simulink < 0.733 UTN / 0.5s Trip1_r 4 Ip frequency range Simulink + / - 10% Trip1_nr 5 Main switch fault Simulink Trip1_nr 6 Charging failed Simulink Trip1_nr 7 Charging sw fault Simulink Trip1_r 8 4QS ph current dev Simulink 30A / 20ms Trip1_cr 9 Ip choke overtemp Simulink 85C / 90C Trip1_nr 10 Ambient overtemp Simulink 70C / 75C Trip1_nr 11 Input fuse failure Simulink Trip1_nr

12.6.2 Zone 2 U21 (4QS)

Bit Protection function Identification Level Trip name 1 4QS OC trip Simulink 1.2*Iin_max / 10s Trip1_nr 2 4QS OC limitation PLD 1900Apeak / 60ms Trip1_nr 3 PLL not synch Simulink Trip1_nr 4 4QS cooler overtemp Simulink 85C / 90C Trip1_nr 5 VCEsat fault U51 Gate drive Trip1_nr 6 VCEsat fault U52 Gate drive Trip1_nr 7 Power fault U51 Gate drive Trip1_nr 8 Power fault U52 Gate drive Trip1_nr 9 Gate short ckt U51 Gate drive Trip1_nr 10 Gate short ckt U52 Gate drive Trip1_nr 11 PowerLink err U51 Gate drive Trip1_nr 12 PowerLink err U52 Gate drive Trip1_nr 13 U51 OC trip Gate drive - Trip1_nr 14 U52 OC trip Gate drive - Trip1_nr 15 Off curr meas>ph1 Simulink Trip1_nr 16 Off curr meas>ph2 Simulink Trip1_nr


12.6.3 Zone 3 DC link

Bit Protection function Identification Level Trip name 1 DC link voltage high Simulink 0.92 * Uref / 15s Trip1_cr 2 DC link voltage low Simulink 1150 Vavg / 0.2s Trip1_nr 3 DClink implausible Simulink >1 Trip1_nr 4 DC link OV PLD-4QS PLD 1300 Vpk Trip1_nr 5 DC link OV PLD-WR PLD 1300 Vpk Trip1_nr 6 DC link OV PLD-VLU PLD 1300 Vpk Trip1_nr 7 DC link OV PLD-BL PLD 1300 Vpk Trip1_nr 8 Earth fault Simulink 0.4 < Uef < 0.6 Trip1_nr 9 DC link dU/dt> PLD 250V/125us Trip1_nr

12.6.4 Zone 4 U22 (VLU)

Bit Protection function Identification Level Trip name

1 VLU OC trip Simulink 1.2 * IHBN_max Trip1_nr 2 VLU short ckt Simulink m 6.5A Trip1_nr 3 VLU open ckt Simulink m > 0.08 & IHBN = 52V Trip1_nr 4 VLU resistor energy Simulink 150kWs Trip1_cr 5 VCEsat fault U53 Gate drive Trip1_nr 6 Power fault U53 Gate drive Trip1_nr 7 Gate short ckt U53 Gate drive Trip1_nr 8 PowerLink err U53 Gate drive Trip1_nr 9 U53 OC trip Gate drive - Trip1_nr

12.6.5 Zone 5 U23/U22 Inverter (WR)

Bit Protection function Identification Level Trip name 1 WR OC trip Simulink 1.12*IXN / 10s Trip3_WR_nr 2 WR OC limitation Simulink 1000Apk / 5s Trip3_WR_nr 3 Open phase ph1 Simulink Trip3_WR_nr 4 Open phase ph2 Simulink Trip3_WR_nr 5 Open phase ph3 Simulink Trip3_WR_nr 6 Off curr meas>ph1 Simulink Trip3_WR_nr 7 Off curr meas>ph2 Simulink Trip3_WR_nr 8 Off curr meas>ph3 Simulink Trip3_WR_nr 9 WR unbalance trip Simulink 30A /5s Trip3_WR_nr 10 U22 cooler overtemp Simulink 80C / 85C Trip3_WR_nr 11 U23 cooler overtemp Simulink 80C / 85C Trip3_WR_nr 12 Sine choke overtemp Simulink 85C / 90C Trip3_WR_nr 13 Ventilator overload Simulink Trip1_nr


12.6.6 Zone 6 U23/U22 Inverter Gate Driver (WR)

Bit Protection function Identification Level Trip name 1 VCEsat fault U54 Gate drive Trip3_WR_nr 2 VCEsat fault U55 Gate drive Trip3_WR_nr 3 VCEsat fault U56 Gate drive Trip3_WR_nr 4 Power fault U54 Gate drive Trip3_WR_nr 5 Power fault U55 Gate drive Trip3_WR_nr 6 Power fault U56 Gate drive Trip3_WR_nr 7 Gate short ckt U54 Gate drive Trip3_WR_nr 8 Gate short ckt U55 Gate drive Trip3_WR_nr 9 Gate short ckt U56 Gate drive Trip3_WR_nr 10 PowerLink err U54 Gate drive Trip3_WR_nr 11 PowerLink err U55 Gate drive Trip3_WR_nr 12 PowerLink err U56 Gate drive Trip3_WR_nr 13 U54 OC trip Gate drive - Trip3_WR_nr 14 U55 OC trip Gate drive - Trip3_WR_nr 15 U56 OC trip Gate drive - Trip3_WR_nr

12.6.7 Zone 7 U24 Full bridge DC/DC converter (BL)

Bit Protection function Identification Level Trip name 1 BL IGBT overtemp Simulink 80C / 85C Trip3_BL_nr 2 BL diode overtemp Simulink 80C / 85C Trip3_BL_nr 3 BL choke overtemp Simulink 80C / 85C Trip3_BL_nr 4 BL Trafo overtemp Simulink 80C / 85C Trip3_BL_nr 5 VCEsat fault U57 Gate drive Trip3_BL_nr 6 VCEsat fault U58 Gate drive Trip3_BL_nr 7 Power fault U57 Gate drive Trip3_BL_nr 8 Power fault U58 Gate drive Trip3_BL_nr 9 Gate short ckt U57 Gate drive Trip3_BL_nr 10 Gate short ckt U58 Gate drive Trip3_BL_nr 11 PowerLink err U57 Gate drive Trip3_BL_nr 12 PowerLink err U58 Gate drive Trip3_BL_nr 13 U57 OC trip Gate drive - Trip3_BL_nr 14 Fullbridge OC trip Simulink 1.2* IbBL / 10s Trip3_BL_nr

12.6.8 Zone 8 Battery output circuit

Bit Protection function Identification Level Trip name 1 Battery OC trip Simulink 1.2*Ibattery_max / 10s Trip3_BL_cr 2 Battery UV trip Simulink 77V / 2s Trip3_BL_nr 3 Battery OV trip Simulink 1.3*Ubattnom / 0.1s Trip3_BL_nr 4 Battery OV PLD PLD 1.4*Ubattnom / 100us Trip3_BL_nr 5 BL discharging trip Simulink (IBL


12.6.9 Zone 9 Main Control

Bit Protection function Identification Level Trip name 1 PEC overtemp Simulink 95C / 100C Trip1_nr 2 Board overtemp Simulink 80C / 85C Trip1_nr 3 PEC Power fail PLD Trip1_nr 4 PEC CPU Watchdog PLD Trip1_nr 5 PEC ADC Watchdog PLD Trip1_nr 6 PowerLink err U51 PLD Trip1_nr 7 PECPowerLink err U52 PLD Trip1_nr 8 PECPowerLink err U53 PLD Trip1_nr 9 PECPowerLink err U54 PLD Trip1_nr 10 PECPowerLink err U55 PLD Trip1_nr 11 PECPowerLink err U56 PLD Trip1_nr 12 PECPowerLink err U57 PLD Trip1_nr 13 PECPowerLink err U58 PLD Trip1_nr

12.6.10 Zone 10 Temperature sensor alarm

Bit Protection function Identification Level Trip name 1 Ip choke sensor br Simulink Alarm 2 Ambient sensor br Simulink Alarm 3 U21 sensor br Simulink Alarm 4 U22 sensor br Simulink Alarm 5 U23 sensor br Simulink Alarm 6 Sinefilter sensor br Simulink Alarm 7 BL IGBT sensor br Simulink Alarm 8 BL diode sensor br Simulink Alarm 9 BL choke sensor br Simulink Alarm 10 BL Trafo sensor br Simulink Alarm


Chapter 13 - Electrical & Mechanical Installation

13.1 Installing the Converter inside Locomotive

When installing the converter to the vehicle the cover should remain closed. When using a lifting device make sure that the distribution of pressure covers as wide an area as possible. When lifting or moving the converter the cover should remain closed. When using a lifting device use the hike bolts and lift with suitable hooks. Do not use metal chain ropes and lift the converter from bottom as they will damage the converter.

Provision is made to mount the panel on a C channel provided by Indian Railways with M-18 bolt as per the mounting dimensions in RDSO Specification [1] without the need to open the end covers. Foundation drawing of converter is given below.

Fig. Foundation Drawing

Mounting holes


13.2 Electrical Connections

13.2.1 Cable Entry

Cable entry holes are provided at the bottom of converter and for easy termination it is recommended to remove the channel below the terminal assembly by removing the M8 screws provided on either end as shown below. Fix the channel back in position after cable terminations are completed.

Table: Pin Designations, Cable Cross-sections and Tightening Torques

Terminal Designation Type of connection Recommended cable cross-section

Tightening torque

AC Input X1 to X4 cable lug M16 120 Sq.mm Nm

DC Output X5 to X8 cable lug M6 6 to 16 Sq.mm Nm

AC Output X9 to X11 cable lug M16 120 Sq.mm Nm

Power Earth X12 cable lug M16 120 Sq.mm Nm

Signalisation: analog signals , X15 1 to 16

Pin type lung 1.5 to 2.5 Sq.mm NA

Cable protection

The outputs from the converter are protected against short-circuits. Protection of the vehicle battery directly at its terminals is essential in order to protect the battery and to prevent fires breaking out in the cables in the event of a short circuit.

Mounting holes

Cable Entry


Chapter 14 - Commissioning

14.1 Preparation for Commissioning

Before operating the auxiliary converter for the first time, make sure converter is completely de-energized and the notes on safety detailed contained in Chapter 1 - is complied with.

14.1 .1 Visual Checks

The operating staff responsible must check that the converter has been correctly assembled and wired up, and that all electrical connectors have been screwed tight. After the converter has been stored for a long period of time or if it is suspected that damage has occurred during transport then check the housing cover along the edges of the seal for signs of deformation, and check the seal itself for signs of damage. Check whether installation has been carried out in-accordance with instructions given in Chapter 13 -

14.1.2 Wiring

Check all the converter connections have been properly done with correct cables used and in accordance with 13.2 Electrical Connections).

14.2 Commissioning

The static converter is tested and subjected to an endurance test at our works. All the appropriate settings are made in the factory. The converter can therefore be switched on after the checks referred to above have been made and without the need for any further measurements or adjustments. Sequence of commissioning is given below.

Complete power & control wiring as described in sec. Complete preparatory checks as described in sec. Disconnect or Isolate loads connected to converter AC & DC output. Connect measuring devices ( oscilloscopes / meters to converter input & output) Switch on control electronics power supply and conduct checks described in sec. Establish communication between service PC & converter as described in sec. Verify converter operating condition with BORDLINE-View. In particular check for any faults

or warning messages in the 'message window. If a fault is displayed, proceed as described in sec 16.4. Switch ON input voltage if there are no fault or warning messages. Enable START command and check operation as described in Chapter 8 -. Check cooling fan rotational direction and air flow rate as described in Chapter 5 - Verify proper converter operation by using the measuring instruments Start connecting loads in steps as per loco testing logic Run the converter on full load and observe converter parameters with BORDLINE-View


Chapter 15 - Maintenance Instructions

15.2 General Maintenance Work

The static converters are generally maintenance-free. The following table gives the approximate intervals for checking and/or replacing parts which have a limited lifetime.

IMPORTANT!

All maintenance operations can be done with the converter installed on the train.

Table 1: Periodic Component Replacements and Maintenance Tasks

Pos. Component Pieces

. Position

Maintenance Period (years)

Required Time (h)

Electrical Components

1 External Ventilator 2 E951 & 952 7 1

2 Internal Ventilator 1 E953 & 954 10 1

3 Capacitors on PM4 1 C625 20 2

4 Capacitors on PM5 8 C601-608 20 2

5 Capacitors on DC output 1 C642 20 2.5

Seals

6 Seal on the housing cover and on the heat sinks

4 NA 10* 2

Maintenance Tasks

7 Cleaning of heat sinks on power modules, ventilators and air ducts 0.5 1

*Note: only exchange seals when they are defective.


Chapter 16 - Repair Instructions

16.1 Service Concept

Converter is designed based on a service concept which allows replacement or repair of most parts with the converter in its installed position inside the locomotive. Access provisions have be provided for visual inspection and replacement of most components in converters installed in all types of tap changer type locomotives.

A precise fault analysis with the converter in its installed position on the vehicle is mandatory for easy troubleshooting. The repair work described below is to be carried out either by the manufacturer or the operator in a suitably equipped workshop.

16.2 Requirements for Carrying out Repairs on the Vehicle

To allow on-vehicle repairs to be carried out, access to the covers, service compartments and the heat sinks on the auxiliary converter must be ensured. A clean and dry surface must be available on which to put the replacement parts and the parts to be removed.

16.2.1 Looking for Faults with the Converter Installed

The search for the cause of the fault is made with the help of the following diagnostic aids:

Digital outputs LCD Display BORDLINE View Maintenance Tool

16.2.2 Replacement of the Defective Components

NOTE!

The power modules weigh 60 kg (PM1) & 20 kg (PM4)

Removal of the power modules weighting more than 25 kg from the vehicle should only be carried out at least 2 people.

The notes on safety contained in Chapter 1 -of this handbook as well as the safety regulations of the operator and the vehicle manufacturer must be complied with.


16.3 Requirements for Repairs Carried out Outside the Vehicle

16.3.1 Replacement of the Defective Components

After the defective component has been located, the converter can be removed from the vehicle. The defective component should be stored in a dry place protected against the weather.

16.3.2 Looking for Faults in Converter which is not Installed

If e.g. for reasons of time it is not possible to carry out a diagnosis and to identify the defective component on the vehicle, a suitable test bed will have to be constructed. The minimum requirements for this are:

Single Phase AC voltage source rated for 415 Vac, 500 A which can be switched on and off. A 110 VDC power supply (ca. 300 W) for control voltage supply. Possibility of loading both the outputs of the auxiliary converter. A test arrangement which satisfies the relevant regulations. Trained personnel. Dry working area, protected against the weather. If the fault search is carried out outside the vehicle, it is important to make sure that as much information as possible about the fault which has occurred is kept available. Other useful information includes e.g. the weather conditions at the time of the breakdown, overhead conductor voltage, any changes to the vehicle, etc.

All the tools referred to in 16.2.1 Looking for Faults with the Converter Installed are available for diagnosis carried out on the test bed.

16.4 Procedure on the Occurence of a Fault in the Converter

In general a fault in the converter will be roughly indicated by a suitable message being given out in the driver's cab on the vehicle (using the digital outputs) & the LCD display.

Should the source of a fault be more precisely located, then other diag

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