Gate Unit (GU) :: Description

s Traction Drives / SE&A
Gate Unit (GU):

Device Names: A101-A3, A102-A3, A103-A3, A204-A3 [Inverter A Section]
A201-A3, A202-A3, A203-A2, A204-A3 [Inverter B Section]
Gate Unit modules: Generation 4 (silver)
Description:
The Gate Unit is used to control the gates of the GTOs inside the phase and chopper modules.
This is the interface between the control unit and the power part of the Inverter.
Each Gate Unit consists of:

♦ 1 two-channel controller (DST, left housing)
♦ 2 high-voltage units (HST, middle and right housing)
The two-channel controller provides the signals and the energy for the high-voltage unit. Each
high-voltage-unit can drive one GTO. They are locked against each other, so that only one GTO
can be switched 'on' at a time.
Application:
In the control cabinet there a total of 8 gate units. The ones used on the inverter A components
are labeled A101-A3, A102-A3, A103-A3, A104-A3. The ones used on the inverter B are labeled
A201-A3, A202-A3, A203-A3, and A204-A3.
The gate units mount on the front of the module and connect to terminals 9, 10, 11, and 12 with
small bus bars. The gate units supply voltage is 140VDC which is supplied by the DC-DC
converter called the Gate Unit power Supply.
The SiBAS interfaces with the gate units through the pulse amplifier cards. Signals are sent to
turn each GTO “ON” or “OFF”. In turn feedback is sent from the gate unit to the SiBAS when the
GTOs are “ON” or “OFF”.
The GTO is fired over terminals G and K of the high voltage parts (terminals 9,10,11,12 of the
module)
The connection to the GTO module is made by low-inductive bus bars.
UG-K ~ +2 V ⇒ GTO is 'on' (100% modulation)
UG-K ~ −15 V ⇒ GTO is 'off' (0% modulation)
Rev 2.1 Copyright © Siemens Energy and Automation, Inc. All Rights Reserved.
Device Manual – Parts 1 of 54

The LEDs located on the bottom mean:

Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.
Red LED: ON - positive pulse current available, G - K circuit functional
Front gate
terminals
9-10 11-12
Power LEM connector
From GUPS 140VDC
Input
E-prom plug
Grounding bolt (Prom
Stecker)
Signal LEM
connector
(Communication
signals) Gate Unit Components
WARNING
In operation mode of the TCU, the high-voltage units, even the covers of them, are under high
voltage! Working, measuring and servicing on this component is only permitted, when the TCC is
switched 'off' and grounded!
NOTE
For exchange of the GU, the supply-voltage has to be switched 'off'!
Technical Data:
Supply: Rated voltage: 140VDC (From Gate Unit Power Supply)
Terminal 1 +140 V
Terminal 2 Ground
Ripple: Maximum 5 %
Current consumption during operation (one GU):
at 140 V DC
Temp. Range > 0 °C ... 55 °C < 0 °C
Typically 5A 7A
Max. 8A 12 A
Ripple: Iripple : 0.5 A (aver. peak)

fripple : 50 kHz
Starting current: 35 A for 2 ms
Type: Short - circuit current (1 or 2 GTO defective) 15 A ... 25 A at 140VDC

CAUTION
The gate unit is not short-circuit proof! When short-circuit occurs, the supply must be switched off
within 10s!
Signals: The GU is connected to the TCU with a 10-pole AMP-plug at the two-channel controller
A3–A1, A2
NOTE
After removing and re-installing the plug-in connector, this connector must be locked with the
provided clamps on each side. It is locked only when the inserted plug ‘clicks’.
The GU is connected to the phase module by installing and tightening the screws.
Triggering: See Circuit Diagram GTO A/B – Inverter control Signals

Terminal 3 Y11 (70 mA ⇒ channel 1 'on')
Terminal 4 Y12 (70 mA ⇒ channel 1 'off')
Terminal 5 Y22 (70 mA ⇒ channel 2 'off')
Terminal 6 Y21 (70 mA ⇒ channel 2 'on')
Power Supply 24V:

Terminal 1
Grounding for Triggering:

Terminal 2
Feedback Signals TCU:

Terminal 7: channel 2 (Ri = 330 Ω)
(U = +12 V ⇒ storage time exceeded)
(U = 0 V ⇒ triggering o.k.)
Storage time channel 1 or 2 exceeded:
Output gets low-resistance
I8,max < 10 mA
U8-9 < 5 V at I8,max
Storage time not exceeded:
Output gets high-resistance
I8,max > 8 mA
U8-9 = +70 V
Output:
The GTO-thyristor is fired over terminals G and K of the high voltage part.
The connection to the cover of the evaporation bath module is made by low-inductive bus bars.
UG-K ~ +2 V ⇒ GTO is 'on'
UG-K ~ −15 V ⇒ GTO is 'off'
Simple check by LEDs:

Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.
Red LED: ON - positive pulse current available, G - K circuit functional

Gate Unit E-Prom (prom Stecker)
Gate Unit E-Prom
Description:
The Prom Stecker is a program chip installed in a LIMO style male connector. The program
installed on the chip controls whether the gate unit functions as a phase or chopper gating device.
Gen 2 prom Steckers will not physically fit in Gen 4 gate units. If a chopper prom Stecker is
plugged into a gate unit connected to a phase module the start up sequence will report a fault
during the GTO pulse test. Until the start up sequence completes without faulting the system held
in a protected state.

DC Grid Blower Constant Speed Panel
K191
K181
X900
U171
DC Grid Blower Constant Speed Panel
Application:
The DC Grid Blower constant speed panel is installed into the cabinet in the place of the IPM
panel. Without the IPM panel installed the choppers are designated as the primary way to
discharge the voltage in the event of a serious fault.
The constant speed panel holds the components used to control the application of the DC voltage
to the grid blower. Contactor K191 completes the power circuit that applies DC bus voltage
across the DC grid motor and motor control resistors, also called MCRs. This contactor K191
closes when 24V is applied across to its coil from K181. The contactor K181 decreases the
amount of current needed from the SiBAS digital output card (C019) to close contactor K191.
Also on the constant speed panel is a current transducer (U171) used for feedback to SiBAS.
Finally the panel contains a terminal block that allows for the installation of a diode (50V, 1A) and
resistor (50Ω, 5W) needed for the current transducer’s feedback to SiBAS.

Grid Blower DC Contactor

Device Name: K191
Arc chute
Insulating
Sheet
Grid Blower DC Contactor Grid Blower DC Contactor Parts
Application:
This is a high power DC contactor; it’s used as a control point to allow application of the DC Bus
voltage across the motor control resistors and grid blower motor. During installation it is extremely
important to install the included insulating sheet prior to mounting on the bracket.
Arc Chute:
The Arc chute is removable for inspection of the contactor tips or to make installation/removal of
the contactor easier. When re-installing the arc chute special care MUST be taken to ensure the
chute is completely seated on the contactor. If the arc chute is not properly seated the contactor
tips will not make complete contact and the contactor will be damaged during normal operation.
Install the arc chute by pressing the lower portion completely against the contactor then press the
top portion toward the contactor until the clip is holding the arc chute in place.
Technical Data:
2800V, 1250A
Diode V191: 600V, 3A

Grid Blower 24V Relay

Device Names: K181
Contactor K181
Application:
This relay is used to limit the amount of current needed to close the larger DC contactor K191.
The SiBAS digital output card C019 is current limited and without this relay it would not be
possible to close K191.
The relay should be mounted on Din rail. To remove it from the Din rail place a flat screwdriver
into the release tab on the side of the relay.
Technical Data:
Output Specifications:
Operating Voltage Range [Vdc] 3-60
Load Current Range [Adc] .02-7
Input Specifications:
Control Voltage Range 3.5-32 Vdc
Typical Input Current 2.2mA @ 5Vdc

Grid Blower Current Transducer

Device Names: U171
Current Transducer U171
Application:
This current transducer is used to monitor the grid blower constant speed circuit. It provides a
measured value to SiBAS card L095 for analysis. Based on the feedback from this transducer
SiBAS can determine if everything is working properly.
The transducer is direction sensitive; the arrow must be pointing in the direction of current flow.
On the grid blower constant speed panel the arrow should point toward the large DC contactor,
K191. Also for the proper feedback scale to SiBAS a diode (V71) and resistor (R71) must be
added at terminal block X900 on the constant speed panel, see schematics for proper wiring.
Pin 1: Supply voltage +12…15V

Pin 2: Measure
Pin 3: Supply voltage minus.
Pin 4: No Connection
Technical Data:
15V, 300A
Diode V71: 50V, 1A
Resistor R71: 50 Ohm, 5W

DC Link Capacitors
Device Names: C101, C102, C103
DC Link Capacitor
Application:
The DC-link capacitors stabilize the DC-link voltage, which improves the operation of the inverter
by providing a more stable DC-BUS Voltage. The system has three 2200uF capacitors they are
labeled C101, C102, and C103 and located in the upper portion of the far left compartment.
NOTE
Dc link capacitors may be charged to high voltage. Always be sure that they are discharged before
handling. Stored / disconnected capacitors have to be short-circuited by wires.

Temperature Probes, PT100 style

Device Names: F101, F102, F106, F107, F201, F202, F205, F206, F301, F302
PT100 Temperature Probe
Application:
The temperature probe contains a temperature-sensitive resistor (PT100, according to IEC 751).
This enables the TCU to detect either a fault in the cooling system or excessive temperature of
the device it is mounted near. These are used through out the system to monitor the grid box,
Snubber resistors. Inverter compartment.
Technical Data:
The probe has two non-deferrable terminals:
1: + supply (+ 2 mA)
+ M (measured voltage)
2: − supply (− 2 mA)
− M (measured voltage)
Resistance values: 108.5 Ω at 22 °C / 100 Ω at 0 °C.

Motor Module for DCL Contactor

Device Name: M6
Motor Module for DCL Contactor
Application:
The DCL motor module is labeled M6 and located on the rear left compartment. It is used to
move the DCL switch module (K104). On the top of the motor module are terminals for
connection of that motor as well as feedback contacts which indicate the motor’s current position.
The feedback contacts are used to indicate the position of the DCL switch since it is mechanically
coupled to the motor module.
The motor is fed with 24 V DC battery voltage from contactors K161 and K162. Depending on
which one is made the DCL switch (K104) opens (K161) or closes (162). Currently one NO and
one NC contactor are connected to SiBAS for feedback whether K104 is closed (connected to DC
link) or Open (DC-link grounded).
NOTE
If power is cutoff irregularly (not using the ignition switch) the motor remains in the state it was
at when power was lost. When power is restored the TCU will move the motor/switch to the
correct position.
Technical Data:
24VDC, 15A.
Dimensions: approx., 400 mm x 300 mm x 400 mm (L x W x H)
Weight: approx. 14 kg

Main Contactor DCL Switch

Device Name: K104, K204
Main Contactor (K104/204 configuration for Trolley) Main Contactor (K104)
Application:
The main contactor K104 connects the DC link voltage from the alternator, already rectified, to
the inverters and consequently the motors. This contactor is a double throw non-interrupting
switch it takes approximately 2 seconds to close but will NOT try to open or close when the
voltage is > 30VDC on the contacts.
The closing action is done by M6 mounted to the side a mechanically coupled. The TCU uses
K161 (opens) and K162 (closes) to operate K104. In the open position the system is grounded,
this can be seen either from the top of the contactor or by looking at the position indicator in front
of K104. If looking at it from the top the contacts inside K104 should be to the rear, which is the
grounded position. If looking at it from the front the position indicator should be pointing to “1”.
Inversely, if the contactor is closed the DC link is connected to the inverters. In the closed position
the contacts are to the front as seen from the top and the position indicator is pointing to position
“2”. There are two signals fed back to the TCU via two digital inputs (one for closed, one for open)
telling it whether K104 is closed or open.
On systems with 4 contacts, two DCL switches have been but together (K204/K104). In these
systems there is still only one motor (M6) used, the system reports the location of only one of the
switches, K104.
Technical Data:
1600A, 1500VDC
NOTE
If power is cut off irregularly (not using the ignition switch) the DCL switch remains in the state it
was at when power was lost. When power is restored the TCU will move to the correct position.

Snubber Capacitors
Device Names: C121-C126 (Inverter A section)
C221-C226 (Inverter B section)
Snubber capacitor assembly
Application:
The Snubber capacitors are used to prevent over-voltages at the phase and chopper modules
caused by switching. The inverter A section has a assembly of six capacitors labeled C121–C126
and mounted just behind the vertical bus bars in a cubby hole next to the chopper module. The
Inverter B section has a assembly of six capacitors labeled C221 – C226 and mounted just
behind the vertical bus bars in a cubby hole next to the chopper module
Technical Data (1 Capacitor):

42 µF, 700 V

Buffer Capacitor
Device Name: C107
Buffer Capacitor
Application:
The capacitor buffers and filters the SiBAS supply voltage (+ 24V). It is labeled C107 and located
in the far right top compartment.
Technical Data:
33 µF, 63 VDC
Rev 2.1 Copyright © Siemens Energy and Automation, Inc. All rights reserved.

SiBAS Input Power Filter

Device Name: Z102
SiBAS input Power Filter
Application:
The Input power filter helps to provide the SiBAS with a constant input voltage. The filter is
labeled Z102 and located in the front top right compartment. Z102 is mounted on the 24V
distribution panel just below the SiBAS computer. The filter has three channels that are used to
filter the P& N input power as well as the ON signal sent to the SIBAS card G163.
Technical Data:
36VDC, 15A

Input Power Filter

Device Name: Z101
Input Power Filter
Application:
The input power filter helps to smooth out the 24V power before it is sent to the rest of the
devices in the cabinet, except SiBAS. The filter is labeled Z101 and located in the upper right
front compartment. Z101 is mounted on the 24V distribution panel just below the SiBAS computer
and next to the SiBAS input filter, Z102.
Technical Data:
250V, 36A

Latching Diodes
Device Name: V111, V113
Latching Diodes
Application:
The latching diodes allow multiple sources to be used for the SiBAS ON signal. The diodes
labeled V111 and V113 are located on the 24V distribution panel below the SiBAS computer.

Blocking Diodes
Device Name: V110
Blocking Diodes
Application:
The blocking diode prevents the positive 24V input to the SIBAS Filter from energizing the wrong
portion of the circuit. The blocking diode is labeled V110 and located on the 24V distribution panel
just behind the buffer capacitor.

Complete 24V Distribution Panel

Latching diodes
Z102
Z101
X103 (GND)
X100 T.B. X102 (+24v)

Reactor Core Assembly

Device Names: L101 – L104 (Inverter A)
L201 – L204 (Inverter B)
Reactor Core, from back of cabinet
Application:
The reactor cores are necessary to limit di/dt of the GTOs during operation. The reactor cores
connected to inverter A are labeled L101 – L104 and located in the left rear compartment. The
reactor cores connected to inverter B are labeled L201 – L204 and located in the middle rear
compartment.
Technical Data:
64 torroid cores are mounted on each reactor core assembly

Snubber Resistor
Device Names: R113 (Inverter A)
R213 (Inverter B)
Snubber Resistor Snubber resistors located below Reactor Core
Application:
The Snubber resistor is used to dissipate the commutation losses of phase and chopper modules.
The resistor connected to inverter A is labeled R113 and located in the lower portion of the left
rear compartment. The resistor connected to inverter B is labeled R213 and located in the lower
right middle compartment. These resistors are located directly in the cooling airflow; their
temperature is measured by PT100s and sent to SiBAS
Technical Data:
0.18 Ohms, 30 kW.

Current Transducers
Device Names: U101 – Phase R current to motor A U201 – Phase R current to motor B
U102 – Phase S current to motor A U202 – Phase S current to motor B
U103 – Phase T current to motor A U203 – Phase T current to motor B
U104 – Chopper current Inverter A U204 – Chopper current Inverter B
U107 – DC Link current.
Current Transducers, monitoring chopper current Monitoring motor

current
Application:
The current transducers are used through out the drive to monitor the current and give constant
information to SiBAS for proper control.
The transducers for Inverter A output are labeled U101, U102, U103, these are located at the
bottom of the far right front compartment. The transducers for Inverter B output are labeled U201,
U202, U203, these are located at the top of the far right front compartment. The transducer
monitoring the current from chopper A is labeled U104 and located at the very bottom of the far
left front compartment. The transducer monitoring the current from chopper B is labeled U204
and located at the very bottom of the far left front compartment. The transducer monitoring the
DC-Link current is labeled U107 and located in the middle section of the far left front
compartment. Each transducer has a male LIMO type connector.

Gate Unit Power Supply

Device Name: A115
X1
Input power
X2 Input Power
X1
Yellow LED
X2
Green
LED
Gate Unit power supply View from top with

out wires
Application:
The Gate unit power supply is just that, the power supply for the gate units. It is labeled A115 and
located along the wall in the bottom far right front compartment. Connectors X1 and X2 contain
the outputs that go to the front of each gate unit. The Gate unit power supply is a DC-DC power
supply that supplies the large amount of current needed by the gate units to fire the GTOs. A
signal to enable this device is sent from SiBAS to X1 pin 2. The Unit gives its “ok “status by
closing a normally open contact between pins 10 and 11 of X1 after given the enable command.
Consequently pin 11 has been attached to 24 V so that the status read from pin 10 can be
inputted into a digital input card and used by the TCU to know if the Gate unit Power supply is
functioning, a very important fact to know.
For visual verification of its operation one can look at the two LED’s near X2. If the green one is
illuminated then everything is okay. If the yellow one is illuminated, then there is a short circuit
some where, either in the output or internally to the gate unit power supply. These LED’s should
be referenced only after giving the unit 20 seconds to finish start up.
Technical Data:
26VDC IN - 140 VDC Out

3TF41 Style Contactors (K161, K162, K105)

Device Name: K161, K162, K105
Contactor shown with aux contact on front
Application:
These contactors are used to power devices that the SiBAS can not power directly. The contactor
K161 is used to operate the motor M6 and in turn move K104. K161 is located in the rear right
compartment (above K104). The contactor K162 is used to operate the motor M6 and in turn
move K104. K161 is located in the rear right compartment (above K104). The contactor K161
opens K104 and contactor K162 closes K104. These contactors can be momentarily made by
pushing the black button on the front of the contactor.
Contactor K105 is used to turn the GTO heaters on and off. It can also be momentarily closed by
pushing the black button. Contactor K105 is located just below K161 and K162 in the rear right
compartment (above K104).
Note
Never close or open the contactor manually (using K161 or K162) when the DC-link has power
on it (i.e. engine running or Dc-link not discharged). The TCU moves K104 only after it is sure
there is no power coming from the Dc-link. This operation (by the TCU) protects the contactor
from arcing and subsequently burning up the contacts.
Technical Data:
24V, 15ADC

3TF47, 3TF48 Style Contactors (K101, K141, K142 and K143)

Device Name: K141, K142, K143, K101
Contactor with auxiliary contact on front
Application:
These contactors are used to properly apply power to a device based on outputs from the SiBAS.
The contactor labeled K141 controls the application of voltage to the Auxiliary rectifier from the
1.6 tap on the auxiliary transformer. K141 is located in the right rear compartment just above
K104. The contactor labeled K142 controls the application of voltage to the Auxiliary rectifier from
the 2.4 tap of the auxiliary transformer. K142 is located in the right rear compartment just above
K104. . The contactor labeled K143 allows for the connection of a precharge resistor (R143) so
the capacitors inside the Auxiliary inverter are not damaged by sudden voltage changes. K143 is
located in the right rear compartment just above K104. These contactor CAN NOT be operated
by pushing the black button on the front. The front black button can serve as a visual indication
that the contactor is closed/open but pressing it in WILL NOT to make the contactor.
The contactor K101 applies +24V power from the connector 1XF to the rest of the cabinet. K101
is located in the bottom front right compartment. When the system if first turned ON K101
receives it's coil voltage from the key switch input. After the SiBAS finishes the internal check of
the SiBAS cards a digital output keeps the contactor K101 ON even if the Key switch if turned off.
Only when the key is OFF and the truck in the proper state will the system shutdown and open
K101, removing +24V from the devices in the cabinet.

Technical Data:
480V, 100A
Complete rear contactor panel:
K143 K142 K141

K105
K161
K162

Circuit Breakers
Device Name: CB141, CB142, CB105, CB102
Circuit Breakers Panel
Application:
The circuit breakers labeled CB141 and CB142 are used as protection for K141 and K142 and
subsequently the auxiliary inverter. These Circuit Breakers are located in the far left front
compartment on a small swing panel. These are just like standard circuit breakers; they can be
switched on/off or reset using the switch on the front of each. The circuit breaker labeled CB105
protects the heating circuit.
Technical Data:
480V, 100Arms (CB141, CB142) used with 60Hz Main Blower

480V, 10Arms (CB105)

Pressurizing Blower
Device Name: B302
Outside view with Filter and cover Outside view Fan (Filter removed)
Filter
Application:
The pressurizing blower is installed to add filtered air to the control cabinet. With the doors
properly closed and the cable fittings tight the addition of the air keeps dust out. The blower is a
24V circular fan wired directly to the 24V supply inside the cabinet. The blower runs as long as
K101 is closed.
Note: The fan should never run unless the filter, pre-filter, and cover are installed.
Technical Data:
24V DC, 3A

Field Regulator
Device Name: A107
Output to alternator field
Input 24V from FU107
J1, 10 pin plug (Phoenix)
Field Regulator
Application:
The Field regulator is used to effectively control the current being put into the field of the
alternator thus controlling the amount of AC power generated by the alternator. The field regulator
is labeled A107 and located along the right wall of the far left front compartment.
The 24V style is the latest version of this device. It uses ONLY 24VDC and outputs current to the
alternator field based on the setting received from SiBAS.
Pin out:
Technical Data:
24VDC, Max output voltage = 80VDC

Field Regulator Fuse

Device Name: FU107
Fuse 107
Application:
The Fuse FU107 is wired at the input of the Field Regulator in order to protect it. It is located in
the lower portion of the left front compartment, next to the Circuit Breakers
Technical Data:
50A

Auxiliary Inverter
Device Name: A118
Power and
communication
connections
(behind door)
Com. Port
Covered Heat Sink
Application:
The auxiliary inverter takes input power from the Auxiliary transformer and uses it to control the
main blower motor (AC). It receives a set of points from the SiBAS then outputs the proper blower
motor frequency. The Auxiliary inverter is labeled A118 and located on the side on the inverter
cabinet or inside the far left compartment.
Interfacing with a Laptop computer:
The auxiliary inverter is a stand alone AC drive with internal parameters which must be set to
inform the electronics what type of motor is connected to the drive. In addition the aux inverter
has fault logging and electrical data monitoring capabilities. In order to program the parameters,
read fault codes, or monitor the electrical values a laptop computer must be connected via the
9pin serial com. port.

Hardware connection for communication cable (gender shown for cable connectors):
To Laptop COM1 To Auxiliary Inverter A1:X2

9 pin female 9 pin male
Software tool for communication: Hyper terminal.
Settings:
Bits per Second: 4800
Data Bits: 8
Parity: Odd
Stop Bits: 1
Flow Control: None
ASCII Setup: Send line ends with line feeds
Echo typed characters locally
NOTE: Pause slightly after each keystroke to ensure good communication.
Read the faults:

<CTRL-P> type ‘A’ <ENTER>
(For example: <CTRL-P> A <ENTER>)
Fault code Text

F010:LT__KS Short circuit in the Power circuit
F011:LT_KSA Over current fault
F020:ZK_UEU DC voltage overvoltage fault
F030:ZK_UNU DC voltage undervoltage fault
F040:KK_UET Temperature too low
F100:15_UNU 15V power supply failure
F120:KK_TMK Over temperature
F130:AD_CHK A/D conversion failure
F140:EP_CHK Checksum failure in EPROM
F150:EE_CHK EEPROM failure
F160:RA_CHK RAM-Test failure
F170:WD_UEL Watch-Dog failure
F180:WD_OSZ Oscillator failure
F220: Overload
F230: Over current
Clear all faults (if any):

<CTRL-P> type ‘X’ <ENTER>

Read the old parameters:

<CTRL-A> type ‘P’ <Parameter number> <ENTER>
(For example: <CTRL-A> P01 <ENTER>)
Change parameters (if necessary):

<CTRL-A> type ‘P’ <Parameter number> ‘;’<New Parameter Data> <ENTER>
(For example: <CTRL-A> P11; 01 <ENTER>)
Display the inverter output:

<CTRL-P> type ‘L’ <Parameter number> <ENTER>
Parameter no. Text

L01 OUTPUT FREQUENCY
L02 OUTPUT POWER
L03 OUTPUT VOLTAGE
L04 OUTPUT CURRENT
L05 DC VOLTAGE
L06 DC CURRENT
Technical Data:
Max power: 70 kVA

Max Frequency: 128 Hz

Auxiliary Rectifier
Device Name: A117
Auxiliary Rectifier
Application:
The Auxiliary rectifier changes the input voltage to the Aux inverter from AC to DC before it
reaches the DC capacitors inside the Auxiliary Inverter. The Aux Rectifier is labeled A117 and
located just inside the far left front compartment.
Technical Data:
1200V, 2 X 70A

AC Voltage Transducer
Device Name: U500
AC Voltage Transducer
Application:
The AC voltage transducer U500 monitors the voltage fed into the drive cabinet for the Auxiliary
inverter from the Auxiliary transformer. The value seen by the transducers is fed back to SiBAS
for proper control of the field regulator when the truck is in retard or idle mode. The transducer
U500 is wired to the input of the CB105 circuit breaker for connection to the 1:2.4 tap of the
auxiliary transformer. U500 is located in the far right front compartment.
Technical Data:
Primary Nominal Input: 3000V

Nominal Output: 50mA
Secondary: +/- 24V

Auxiliary Inverter Input Fuse

Device Name: FU500
FU500
Application:
The Fuse FU500 is wired at the input of the Auxiliary inverter after the auxiliary rectifier. It is
located in the lower portion of the left front compartment. The mounting location is behind the
circuit breaker swing panel.
Technical Data:
Voltage Rating: 750VDC

Current Rating: 150A

Voltage Transducers
Device Name: U105, U106
Voltage Transducer
Application:
The voltage transducers monitor the DC-link and ground voltage. The value seen by the
transducers is fed back to SiBAS for proper control of the inverters and fault reaction.
The transducer labeled U105 monitors the DC-Link voltage at the input to K104. U105 is located
on a panel above the contactor in the right rear compartment. The transducer labeled U106
monitors the ground voltage. U106 is also located on the panel above the contactors in the right
rear compartment. The values seen by these transducers are constantly sent to SiBAS. If the
ratio of the value seen at U106 to the value seen at U105 is not correct then a ground fault is
reported.
Technical Data:
4200VDC

Ground Voltage Monitoring Resistors

Device Name: R118 (30 kOhms)
R119 (90 kOhms)
Ground Voltage Monitoring Resistors
Application:
The ground voltage monitoring resistors are used to establish the proper ratio of the DC-link
voltage seen by U106 in reference to the frame. The resistor labeled R118 is mounted on the
panel above the contactors in the right rear compartment. The resistor labeled R119 is also
located on the panel above the contactors in the right rear compartment.
Technical Data:
R118: 30 KOhms, 300W
R119: 90 KOhms, 300W

Ground Tie Capacitor

Device Name: C131
Ground Tie Capacitor

Application:
The ground tie capacitor is used as a small filtering portion of the ground fault circuit. The
capacitor is labeled C131 and located on the panel above the contactors in the right rear
compartment.
Technical Data:
0.22uF, 2500V
Complete DC-link / Ground monitoring Panel
R118
R119
U106
U105
C131

Precharge Resistor
Device Name: R143
Precharge Resistor
Application:
This precharge resistor is used to protect the Auxiliary inverter capacitors. The resistor is Labeled
R143 and located in the bottom of the right rear compartment (below K104).
Technical Data:
5 Ohm, 300 W

Protocol Switch (Serial Interface Controller)

Device Name: A860
EPROM on top board
P1
U1, U2, U3, U4
On bottom board
P3
Application:
The protocol switch, also called serial interface controller is used to change the format of the data
coming from SiBAS card G063. The data transmitted from G063 is in RS232 format and the serial
interface controller is needed to convert this RS232 data to RS485 format.
The final device is a combination of various parts and a pre-programmed EPROM. These parts
are assembled during production and make up the final shipped product.
The production steps are included below for reference:
1). To enable the RS485 ports you must remove the LT1180 ICs from sockets U1 and U2 and
install the 75175 in U3 and 75174 in socket U4 (the nose of the ICs must look to the ports P3,
P4).
2). Pull out the blank EPROM (no label) from the socket U6 and put the EPROM with the Part
number A1 110 201 491 in this socket. The nose of the EPROM facing the nose of the socket
with 4 pins on the side of the nose unused.
3). Change the jumper J5 (Size of the EPROM) from 32k to 64k+
4). Check the jumper J6 (Pins in EPROM), must be on 28pin
Technical Data:
24VDC, 100mA

Main Blower (60hz)

3-BOLTED
LIFTING LUGS
LIFT
HERE
TYP
INLET
ACCESS DOOR FAN

L
C BOTH SIDES
FAN D
HANDLING
LUG
HQ1
HQ1
HQ1
445 L25
400 L25
L
C
Application:
The main blower mounts under the rear portion of the control cabinet. It cools the GTO modules
by drawing air from the front intakes across the heat sinks of all the modules. This air then passes
through the blower and is forced into the alternator/rectifier and wheel motors. The speed of the
AC blower motor is controlled by the Auxiliary inverter. The proper V/Hz is outputted based on a
set point from the SiBAS control computer.
Technical Data:
12000 cfm

Main Rectifier
Main Rectifier
Application:
The main rectifier converts the AC voltage coming out of the main alternator winding into DC
voltage. It is located in the enclosure on top of the alternator.
Technical Data:
Diode rating: 4400V

Alternator
Rectifier enclosure
AC Alternator
Alternator Alternator Connections
Application:
The alternator allows for the production of electricity from mechanical power. The alternator is an
AC generator using the interaction of magnetic fields to produce voltage when coupled to a
rotating engine. See the Alternator section in this manual for further information.
On the rotating shaft of the alternator there is a rectifier assembly consisting of 3 black diodes
and 3 red diodes, the color indicates which end is the cathode and anode.
Technical data:
Rotating diodes (Red & Black) = 1200V, 200A

Speed Sensors
Device Name: E101, E201, E301
Speed sensor coupling Speed Sensor Location
Application:
The speed sensor monitors speed and direction and sends this information back to SiBAS in the
form of pulses. The speed sensor labeled E101 monitors motor A and is located on motor A. The
speed sensor labeled E201 monitors motor A and is located on motor B. The speed sensor
labeled E301 monitors the alternator and is located end bell area of the alternator.
Each speed sensor has two channels which allows for the determination of direction. For the
sensors on the wheel motors both channels are used. For the speed sensor on the alternator only
one channel is used. The motors run in a closed loop control scheme so the speed sensor
feedback must be the correct direction and with in a defined limit otherwise the motors will not
rotate properly.
Technical Data:
Speed Sensor Type: Channel 1 Channel 2 15VDC GND Shield

KRAUSS-MATTEI = KMG-24 Blue White Orange Green Black
LEONARD BAUER = GEL247 Yellow White Red Blue
Proper gap between the sensor tip and wheel:

[KMG-24= 0.7mm +/- 0.2mm] [GEL 247= 0.4mm +/- 0.1mm]

Wheel Motor
Device Name: M1, M2
Wheel Motor
Application:
Each truck contains two Siemens wheel motors mounted at the rear of the truck. The motor
labeled Motor A is located on the grid box side of the truck. The motor labeled Motor B is located
on the driver side of the truck. Each motor drives a gear box which the tires mount to.
For control of the motors a speed sensor is mounted to each. The speed and direction is
constantly sent to SiBAS and monitored. See motor manual section for more information
including maintenance procedure/intervals.

Technical Data, 1250kW motor:

Four-pole, three-phase asynchronous motor for transverse mounting in the vehicle.
Mechanical motor data

Force ventilation: .......................................................................... 1.3 (1.5) m3/s
Diameter of the rotor: ....................................................................495 mm
Diameter of the stator bore: ...........................................................500 mm
Length of the core assembly: ........................................................450 mm
Air gap: .......................................................................................... 2.5 mm
Electrical motor data
Continuous point
Rated voltage: ............................................................................... 1800 V
Rated current: ................................................................................ 475 A
Rated power: ................................................................................. 1250 kW
Rated speed: ................................................................................. 1480 rpm
Displacement factor cos phi: .......................................................... 0.90
Rated frequency: ............................................................................ 50 Hz
Temperature class: ......................................................................... 200
Rated insulation voltage: ................................................................ 2300 V
Maximum voltage: ...........................................................................2183 V
Maximum current: ...........................................................................1000 A
Maximum speed: ............................................................................ 3465 rpm
Circuit: .............................................................................................Y
Supply cables: ................................................................ 1x 240 mm2 per phase
Standards: ............................................................................. VDE 0535 - 03 / 83
Motor weights
Motor complete: ............................................................................. 3400 kg
Rotor complete (balancing unit): .................................................... 1100 kg
Stator complete (core assembly with winding and frame): ............ 2012 kg
Bearing (D-end): Deep-groove ball bearing DIN 625 - 6236 M / C5H (insulated)
Bearing (N-end): Cylindrical roller bearing DIN 43283 - NU 232-ECM / C4H012 (insulated)
Rolling-contact bearing grease: Shell Retinax LX2 (corresponding to "H3.5" Appendix A1)
Initial/new grease quantity
Bearing (D-end): ............................................................................. 1300 g
Bearing (N-end): ............................................................................. 1150 g
Regreasing quantity:
Bearing (D-end): ............................................................................. 120 g
Bearing (N-end): ............................................................................. 120 g

Technical Data, 1500kW motor:

Four-pole, three-phase asynchronous motor for transverse mounting in the vehicle.
Mechanical motor data

Force ventilation: ............................................................................ 1.3 (1.5) m3/s
Diameter of the rotor: ..................................................................... 495 mm
Diameter of the stator bore: ........................................................... 500 mm
Length of the core assembly: ........................................................ 450 mm
Air gap: .......................................................................................... 2.5 mm
Electrical motor data
Continuous point
Rated voltage: ................................................................................ 1760 V
Rated current: ................................................................................. 575 A
Rated power: .................................................................................. 1500 kW
Rated speed: .................................................................................. 1480 rpm
Displacement factor cos phi: ........................................................... 0.91
Rated frequency: ............................................................................. 50 Hz
Temperature class: .......................................................................... 200
Rated insulation voltage: ................................................................. 2300 V
Maximum voltage: ........................................................................... 2183 V
Maximum current: ........................................................................... 1200 A
Maximum speed: ............................................................................. 3465 rpm
Circuit: ............................................................................................. Y
Supply cables: ..................................................................... 1x 240 mm2 per phase
Standards: .................................................................................. VDE 0535 - 03 / 83
Motor weights
Motor complete: ............................................................................... 3800 kg
Rotor complete (balancing unit): ...................................................... 1110 kg
Stator complete (core assembly with winding and frame): ............... 2175 kg
Bearing
Bearing (D-end): . Deep-groove ball bearing DIN 625 - 6236 M / C5H (insulated)
Bearing (N-end): Cylindrical roller bearing DIN 43283 - NU 232-ECM / C (insulated)
Rolling-contact bearing grease: Shell Retinax LX2 (corresponding to “H3.5” Appendix A1)
Initial/new grease quantity
Bearing (D-end): .............................................................................. 1300 g
Bearing (N-end): .............................................................................. 1050 g
Regreasing quantity:
Bearing (D-end): .............................................................................. 120 g
Bearing (N-end): .............................................................................. 120 g

Grid Box
The grid box is a separate structure located on the deck of the truck to the left of the drive system
cabinet. Its purpose is to dissipate the energy generated by the traction motors during electrical
braking (retarding). Various configurations exist; the configuration shown in the picture below is a
two way set up with 2 banks of 8 resistors plus a motor control resistor in each bank.
Chopper connections
+ DC Bus voltage connections
Motor Control Resistors
Grid Blower Capacitor

Grid Box

Grid Blower Motor

Device Name: M3
Grid Blower Motor
Application:
The DC Grid blower motor runs a circular fan, which provides the necessary cooling to the
braking resistors while the truck is in retard. The motor is turned on and off by the operation of
contactor K191 in the constant speed configuration. Based on the design of the fan wheel the
motor must be wired so that when looking from the deck of the truck the wheel turns
counterclockwise.
Refer to the Grid blower motor section of the instruction manual for brush inspection and
replacement procedures.
Technical Data:
100hp motor: 500VDC, 160A (max)
2-way configuration: 2600rpm (max)

Motor Control Resistor (MCR)

Device Names: RG1, RG3
Motor Control Resistor
Application:
The motor control resistors (MCRs) are used to provide the grid blower with the proper voltage
and current when the constant speed grid blower circuit is connected across the DC bus. Two
different resistors can be used depending on the grid box configuration and size of grid blower
motor. The 9 ohm version should be used when the grid blower motor is 50hp and the 5 ohm
version should be used when the grid blower motor is 100hp.
Technical Data:
9 ohm, 250kW
5 ohm, 300kW.

Grid Blower Capacitor

Device Name: CG2
Capacitor Capacitor Mounting
Application:
This grid blower capacitor is added when RG2 (A1110199203) is installed. Together these
components limit the voltage and current spikes into the grid blower motor when the grid circuit
contactor closes. A kit is available with CG2, RG2 and the hardware required to install them.
Technical Data:
Capacitance: 3 micro Farads
Rated voltage: 1500VDC

Grid Blower Resistor

Device Name: RG2
Grid Blower Resistor
Application:
It is used to provide the grid blower with the proper voltage and current when the constant speed
grid blower circuit is connected across the DC bus.
Technical Data:
Resistance: 6.0 ohms +/- 10% @ 400 C
Max Power: 45KW Continuous. W/FORCED AIR COOLING
Rated voltage: 2800VDC Continuous

Braking Resistor
Device Name: R101-R108
R201-R208
Braking Resistor
Application:
The braking resistor is a high power low resistance resistor used to dissipate the energy
generated by the traction motors during retarding. The total number of braking resistors installed
in the grid box depends on the size of the truck and traction motor as well as some environmental
parameters. Typically 14 – 18 are used.
Technical data:
0.26 - 0.32 OHM
Max power = 235 KW

Gate Unit (GU) :: Description

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Gate Unit (GU) :: Description

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s Traction Drives / SE&A

Gate Unit (GU):

Gate Unit modules: Generation 4 (silver)

Each Gate Unit consists of:

Device Manual – Parts 1 of 54

The LEDs located on the bottom mean:

Current consumption during operation (one GU):

Ripple: Iripple : 0.5 A (aver. peak)

Device Manual – Parts 2 of 54

Triggering: See Circuit Diagram GTO A/B – Inverter control Signals

Power Supply 24V:

Grounding for Triggering:

Feedback Signals TCU:

Simple check by LEDs:

Device Manual – Parts 3 of 54

Gate Unit E-Prom (prom Stecker)

Gate Unit E-Prom

Device Manual – Parts 4 of 54

DC Grid Blower Constant Speed Panel

Device Manual – Parts 5 of 54

Grid Blower DC Contactor

Grid Blower DC Contactor Grid Blower DC Contactor Parts

Device Manual – Parts 6 of 54

Grid Blower 24V Relay

Device Manual – Parts 7 of 54

Grid Blower Current Transducer

Current Transducer U171

Pin 1: Supply voltage +12…15V

Device Manual – Parts 8 of 54

Device Manual – Parts 9 of 54

Temperature Probes, PT100 style

PT100 Temperature Probe

Device Manual – Parts 10 of 54

Motor Module for DCL Contactor

Motor Module for DCL Contactor

Device Manual – Parts 11 of 54

Main Contactor DCL Switch

Main Contactor (K104/204 configuration for Trolley) Main Contactor (K104)

Device Manual – Parts 12 of 54

Snubber capacitor assembly

Technical Data (1 Capacitor):

Device Manual – Parts 13 of 54

Device Manual – Parts 14 of 54

SiBAS Input Power Filter

SiBAS input Power Filter

Device Manual – Parts 15 of 54

Input Power Filter

Input Power Filter

Device Manual – Parts 16 of 54

Device Manual – Parts 17 of 54

Device Manual – Parts 18 of 54

Complete 24V Distribution Panel

X100 T.B. X102 (+24v)

Device Manual – Parts 19 of 54

Reactor Core Assembly

Reactor Core, from back of cabinet

64 torroid cores are mounted on each reactor core assembly

Device Manual – Parts 20 of 54

Snubber Resistor Snubber resistors located below Reactor Core

0.18 Ohms, 30 kW.

Device Manual – Parts 21 of 54

Current Transducers, monitoring chopper current Monitoring motor

Device Manual – Parts 22 of 54