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India 180 kVA

Circuit Diagrams

Figure 6: Circuit Diagram Sheet 6 of 12

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India 180 kVA

Circuit Diagrams

Figure 7: Circuit Diagram Sheet 7 of 12

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India 180 kVA

Circuit Diagrams

Figure 8: Circuit Diagram Sheet 8 of 12

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India 180 kVA

Circuit Diagrams

Figure 9: Circuit Diagram Sheet 9 of 12

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India 180 kVA

Circuit Diagrams

Figure 10: Circuit Diagram Sheet 10 of 12

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India 180 kVA

Circuit Diagrams

Figure 11: Circuit Diagram Sheet 11 of 12

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India 180 kVA

Circuit Diagrams

Figure 12: Circuit Diagram Sheet 12 of 12

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India 180 kVA

Mechanical Overview

3.4

Mechanical drawings

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Functional Description

4
4.1

Functional Description
Technical Profile

The converter described in this manual is characterized by the type no. U760AC/415AC3-110DC/P180-2/F50. It supplies the AC and DC consumers of the train with electric energy taken from the power line. The converter consists of five main sections: Input section The input section consists of input fuse F01 input EMI choke A101 voltage divider A102 and voltage transducer U101 for measurement of actual input voltage The IVPS (Intermediate circuit Voltage Power Supply) section consists of semicontrolled thyristor bridge A201 choke L201 short circuit module voltage divider A501 and voltage transducer U501 for measurement of actual intermediate circuit voltage voltage divider A502 and voltage transducer U502 for voltage measurement which is indicating earth faults The inverter section consists of inverter A301.1 3 each with an IGBT driver board A01 current transducers T901 903 for measurement of actual output currents with analogue ammeter P902 digital voltmeter P901 for measurement of actual output voltages output filter section: 3 phase chokes L301 303 and capacitors C302.1 6 autotransformer T302 AC-EMI filter module A302 The LVPS (Low voltage power supply) consists of DC/DC module A401 with the chopper unit A01, the IGBT driver A02, the transformer T01, the rectifier A03 and the current sensor U01 DC-EMI filter module A402 The control section consists of converter control unit A710 digital control unit A702 for IVPS LVPS chopper control unit A704 inverter control unit A703 power supply A720

IVPS section

Inverter and output filter section

LVPS section

Control section

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X700 1 Protection Circuit X7 K4 Relays K5 Monitoring RS485 X4 GND fault Internal CAN bus CAN UBatt 15 V Temp AC feedb. T302 Q301 Fan General Fault Disable X3 RS232 X5 X7 Battery A722 A740 2 3 4

A710

Converter Control Board (tt1932-1/33 F)

20999_TechDesc_R20_040519.doc
Display Board (tt1823-2/03 A) P903 Q901 15 V DC A703 Inverter Control Board (tt1619-1/68 C) T U301 Volt. A730 Signal sensor Condit. A304 Volt. divider A303 Q302 UCE IL1 IL2 IL3 UAC Q902 M902 3~ S901 S902 Drv. Drv. Drv. L301 R301 L302 L303 Rectif. Bridge T302 A302 L01.1-.3 Fan 2 SCR Control Board (tt1933-1/05 D) T Volt. A770 divider IIC UIC A704 LVPS Control Board (tt1967-2/24 E) UIC UCE T ICharge UBatt M901 3~ Fan 1

F101 blown

Temp. Pre-warning

AC input voltage

A702

UInp

A750

One Phase Filter

F101 A201 Driv. L201


U01

A101 Driv.

U101 Volt. sensor A102 Volt. divider U501 Volt. sensor A501 Volt. divider Volt. U502 sensor Volt. A502 divider

P901 444.4V P902

AC output phase voltages

AC output phase currents

1L1

L01.1-.3

Figure 13: Functional sections and modules of the converter


A202 C301
A01 V01

450 A

L101

3L1 3L2 3L3

AC Input 760/830 V 50Hz (590 -1110 V)

3 phase output 415 V AC 180 kVA 50 Hz A301.3 AC Filter Autotransf. T301

1L2 Semi Controlled SCR Bridge Short Circuit Thyristor A301.1

L102

EMI Module

A301.2 PWM inverter

2L1 2L2
Q301 Single Phase Transformer A720 F701 10 A V701 A402 AC EMI-Filter

1 phase output 110 V AC 500 VA 50 Hz

A401 A02 Driver L01 A01 L02 T01 A03 L03


U01

15 V DC Power Supply

C701

F401 25 A

L01

LB+
DC output 110 V DC 2 kW

LBDC EMI-Filter Low Voltage Power Supply

Functional Description

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Mechanical Design

4.2
4.2.1

Mechanical Design
Enclosure

The enclosure of the converter is manufactured of stainless steel and its sealing satisfies the international protection class IP55. Access All maintenance and service work can be carried out without removing the power converter. The enclosure can be easily opened even while the unit is in place. Two service covers sideways of the converter allow quick access to all modules of the converter. Access to the inductances is possible via a revision cover at the converters front side. The input and output connections are via stud terminals and are brought out through cut outs for cable entry. An isolated plug-in connector is provided for the connection of the control cable.

Connections

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Module Descriptions

5
5.1

Module Descriptions
Input section and IVPS section

A702 Digital controller unit for IVPS UI UCE UCE Temperature prewarning Overtemperature IIC UIC

S01 75C
A750 1-phase filter

S02 85C

A01.2 Driver

A01.1 Driver

U501 Voltage sensor A502 Voltage divider U201

to converter control unit A710

U101 Voltage sensor A102 Voltage divider V01.1 A101 L101 R01.1 V02.1 C01.1 R02 C01.2 R01.2

L201 +UIC

Current sensor

UI

1L1 1L2

F01

Figure 14: Input section and IVPS section Input EMI choke A101 Input chokes L101 and L102 Thyristor bridge It suspends guided electromagnetic disturbances and thus improves the electromagnetic compatibility of the converter. Input filter chokes The thyristor bridge mainly consists of the two thyristors V01.1 and V01.2 and the two diodes V02.1 and V02.2. It converts the AC input voltage into a DC voltage (= intermediate circuit voltage) L201 smoothes the rectified input voltage Current sensor U201 detects the intermediate circuit current. The output signal of U201 is wired to the SCR control board A702. Short circuit thyristor unit A202 with thyristor V01 works as emergency protection if the DC output (=intermediate circuit) voltage exceeds a specified value. Firing the thyristor shorts the section and thus blows the input fuse outside of the converter (crowbar function). Trigger circuit is A01. L201 limits the current rise. The digital controller unit for IVPS A702 controls and monitors the operation of the thyristor bridge and communicates with the converter control unit A710.

Smoothing choke L201 Current detection

Short Circuit Thyristor Unit A202

Digital controller unit A702 for IVPS

20999_TechDesc_R20_040519.doc

{
L102

to inverter section A300, LVPS section A400


V02.2 R01.4

R01.3 V01.2

R01
C01.4

C01.3

V01

C01

Crow A01 bar assy -UIC

A201 Semicontrolled Thyristor Bridge B2HZ

A202 Short circuit thyristor module

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Module Descriptions

5.2

Inverter section

The inverter modules A301.1, A301.2 and A301.3 transform the filtered input voltage into a system of three AC voltages each with 120 degrees phase shift against the other voltages. Inverter modules A301.1, A301.2, A301.3 Each module is a three single-phase IGBT half bridge with a six-fold driver A01. Each module consists of two individual IGBT's V01 and V02. The connected inverter modules convert the intermediate circuit voltage into a three-phase AC voltage (3 x 415 V/50 Hz). The downstream AC filter consists of chokes L301-L303 and capacitors C302.1-6. The EMI filter is located downstream of the AC filter and consists of the EMI choke L01 and the capacitors C01-10. The output terminals 2L1 and 2L2 provide a phase-to-phase voltage UAC of 110 V / 50 Hz with a power of 500 VA. The output terminals 3L1, 3L2 and 3L3 provide a phase-to-phase voltage UAC of 3 x 415 V / 50 Hz with a power of 180 kVA. The inverter control unit A703 controls and monitors the operations of each inverter module and communicates with the converter control unit A710. It also supplies the IGBTs with the necessary switching signals via the six-fold drivers A01.

AC filter EMI filter

Output terminals 2L1 and 2L2 Output terminals 3L1, 3L2 and 3L3 Inverter control unit A703

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Module Descriptions

UCE

Temperature Overprewarning temperature IL1

A703 Inverter control unit


UCE IL2 UCE IL3

S01 80C

S02 90C

S01 80C

S02 90C

S01 80C

S02 90C

A01 IGBT driver +U IC


R301.1-4 C301.1-3

A01 IGBT driver

A01 IGBT driver

V01
C01.1-3

V01
C01.1-3

V01
C01.1-3

T01 T01 T01

V02

V02

V02

-U IC

A301.1 Inverter

A301.2 Inverter

A301.3 Inverter

A502 Voltage divider

A710 Converter control unit

A302 AC-EMI filter 2L1

L301 L302 L303

Sine wave filter Q901 Q902 P901 M901 3~

{
T301 Q301
C302.1-6

2L2

T302

T901 T902 T903 L01 C01-10

3L1 3L2 3L3

P902

3~ M902

Figure 15: Inverter section

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Module Descriptions

Inverter

The IGBT inverter modules divide the input voltage UIC into separate pulses of constant amplitude, but varying durations (pulse frequency: 3,6 kHz). The variable switching ratio controls the amplitude of the output voltage (sine pulse width modulation, see Figure 16.
Filter output voltage V(t) +VZ Inverter output voltage

-VZ

Figure 16: Generation of sinusoidal alternating voltage by means of sine pulse width modulation. The figure shows the input voltage UDC switched through as square-wave pulses and the inverter output voltage after smoothing by the AC filter (sine curve). Wide voltage pulses +UIC, narrow voltage pulses UIC: amplitude of output voltage close to +UIC Narrow voltage pulses +UIC, wide voltage pulses UIC: amplitude of output voltage close to UIC Voltage pulses of same width for +UIC and UIC: amplitude of output voltage = 0. The combination of three inverter branches like this, which will be triggered with a phase shift of 120, creates a three-phase AC system.

AC filter

Due to the pulse width modulation at a constant pulse frequency, the only oscillation that occurs is harmonic oscillation with the pulse frequency (3,6 kHz) or higher. Even a relatively small-sized filter is sufficient to eliminate this. The filter creates an almost sinusoidal voltage curve from the square-wave voltage pulses of varying length (harmonic distortion factor < 10 % RMS). The alternating voltage UAC at 3 x 415 V / 50 Hz is available to the consumer loads at terminals 3L1, 3L2 and 3L3.

AC output

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Module Descriptions

5.3

Low Voltage Power Supply section

The LVPS converts the intermediate circuit voltage UIC to an DC output voltage of 110 V / 2 kW. It also stabilizes the DC output voltage constant within a specified range irrespective of fluctuations in the intermediate circuit voltage and monitors the total current, in particular limits it to the permissible maximum value. DC/DC module A401 Chopper unit A01 The DC/DC module A401 (LVPS) consists of the IGBT chopper unit A01, the transformer T01 and the rectifier module A03. The chopper unit forms an IGBT full bridge including the two dual IGBT modules V01.1 and V01.2 and the quadruple driver A02. The IGBT driver provides the control signals for the IGBTs. The switching frequency is 20 kHz. The chopper unit A01 switches the filtered intermediate circuit voltage through to the primary winding of the transformer T01 in the form of voltage blocks. The transformer T01 has one primary and two secondary windings (center-tap connection). It transforms the block-shaped AC voltage down to the required output voltage. The rectifier module A03 rectifies the block-shaped AC voltage supplied by the secondary windings of the transformer T01. The ripple-filter choke L03 and the capacitor C02 smooth and dampen the rectified voltage. Furthermore the LVPS has measurement devices for DC output voltage, DC output current and a downstream EMI filter, consisting of the filter choke L01 and the capacitors C01-04. The LVPS chopper control unit A704 controls and monitors the operations of the DC/DC module A401 and communicates with the converter control unit A710. It also supplies the IGBTs with the necessary switching signals via the IGBT driver A01.

Transformer T01

Rectifier modules A03 and A04 Output filter EMI filter

LVPS chopper control unit A704

A704 LVPS chopper control unit UCE IPRIM Overtemperature ITOT

UB

to converter control unit A710

S01 100C

A730 Signal conditioning

A02 IGBT driver

A01 IGBT chopper unit +UIC


L01

V01.1

V01.2 T01 A03


T1 L03 L02 V02

+/- 15 V to A702 IVPS digital controller A703 Inverter control unit A704 LVPS control unit A710 converter control unit A740 converter display board A760 1-phase filter A901 Ground fault detection

A720 Power supply

A402 DC-EMI filter


C01 L01 C03

{
U01

LB+

V03

C02

-UIC A401 DC/DC module

C02

C04

LB-

Figure 17: Low voltage power supply A401

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Module Descriptions

5.3.1

Generation of the Low Voltage Power Supply

Figure 18 shows how the DC/DC module A401 generates the stabilized DC output voltage (= 110 V DC) from the intermediate circuit voltage UIC. 1 The input is the intermediate circuit voltage after smoothing by the line coil L01 (1). This voltage is not constant. The diagram shows two different cases: Input voltage at the upper end of the tolerance range (left column) Input voltage at the lower end of the tolerance range (right column) 2 The chopper unit A01 switches the DC voltage through to the primary winding of the transformer T01 in the form of square-wave voltage blocks of alternating polarity. The switching times of the IGBTs are controlled in such a way that the area of these voltage blocks is always constant (pulse-width modulation): Higher input voltage IGBTs conduct for a shorter time [(2), left] Lower input voltage IGBTs conduct for a longer time [(2), right] The transformer T01 converts the block-shaped AC voltage to a different voltage. The form of the voltage curve is retained (3). After rectification by A03, all the square-wave voltage pulses have the same polarity (4). The height and length of the voltage pulses is still dependent on the level of the original input voltage: Higher input voltage higher but shorter voltage pulses (left) Lower input voltage lower but longer voltage pulses (right) The product of the height and length of the voltage pulses (the area of the voltage blocks) is constant, irrespective of the input voltage. The downstream filter then smoothes the voltage by filling in the gaps between the voltage pulses. The maximum value of the voltage drops during this process more for high, short voltage pulses (because there are large gaps to be filled), and less for low, long voltage pulses where the gaps to be filled are only narrow. Observed over a cycle time , the product of the length () and the height of the voltage on the other hand remains constant. The result is a constant output voltage, which is largely independent of the fluctuating input voltage [(5), left and right].

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Module Descriptions

Uin

Uin t t

UCh

UCh t t

USec t

USec t

URect

URect t t

Uout t

Uout t

Figure 18: Generation of constant DC voltage in the Low Voltage Power Supply

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Module Descriptions

5.4

Earth fault detection

The earth fault detection consists of a centre tapped resistor network R1 and R2, which is connected across the negative and positive bus of the intermediate circuit. The centre point of this resistor network is connected to the housing via the resistor R3. The voltage over the resistor R 3 is measured. During regular operation, there is no additional galvanic connection between the housing and the intermediate circuit / output circuit. Thus there is no current through R3. If there is an earth fault (in our example in L3), then the Resistor R3 will be switched parallel to R1 resp. R2 via the earth fault resistance Re, depending on the switching conditions of the IGBT's V5 and V6. The IGBTs V5 and V6 will be switched on and off in the switching frequency of the inverter. There will be an ac current through R3. The earth fault detection recognizes the voltage over R3 and shows an earth fault. There will be detected earth faults at the input circuit, the intermediate circuit as well as at the phases.

AC R1 R2 DC Input filter Thyristor Bridge R3

V1

V3

V5

V2

V4

V6

Inverter UR3 Control

RE Output Filter

Figure 19: Earth fault detection

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External Controlling Equipment

The external controlling equipment is located on the left lateral service cover (see No. 1 in Figure 20). The detailed view is shown in Figure 21.

N O FAU LT

4
V

2
A

175.0 V

1 2 3 4 5 6 7

AC output voltage meter P901 AC input voltage meter P903 Converter fault display A740 Type plate of converter AC output ammeter P902 Phase selection switch S902 Phase selection switch S901

Figure 20: Left lateral service cover with controlling equipment

Figure 21: Detailed view of external controlling equipment

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ERROR DISPLAY
NO FAULT
DISPLAY OK

Figure 22: Detailed view of converter fault display A740

AC INPUT OK GENERAL FAULT INTERNAL FAULT INVERTER FAULT IVPS/SCR FAULT

TT1823

Descr. in Figure 22 AC INPUT OK GENERAL FAULT INTERNAL FAULT INVERTER FAULT IVPS/SCR FAULT DISPLAY OK

LED Signal name Colour green red red red red yellow AC input voltage Fault of inverter section Fault of LVPS section Phase/ground fault of AC output Fault of IVPS section Heartbeat

LED is on, if AC input voltage is in specified range a fault occurs in the inverter section a fault occurs in the LVPS section an earth fault occurs at the AC output or at the AC input a fault occurs in the IVPS section (thyristor bridge A201) converter fault display A740 is in operation (no fault)

Detailed alphanumeric fault messages of fault display A740 Alphanumeric character N O F A U L T H - B R I D G E I N V E R T E R L V P S T E M H - B R T E M I N V T E M L V P S T E M T 3 0 2 F 0 1 Q 9 0 1 Q 9 0 2 Q 3 0 1 E A R T H F A Description No fault Fault of IVPS section Fault of inverter section Fault of LVPS section Overtemperature in IVPS section Overtemperature in inverter section Overtemperature in LVPS section Overtemperature of autotransformer T302 Fault of fuse F01 Fault of motor-circuit switch Q901 Fault of motor-circuit switch Q902 Fault of circuit breaker Q301 Ground fault

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