oTROn INSTALLATION & MAINTENANCE MANUAL FOR A.C. FUEL PUMP MOTOR WITH BUILT IN INVERTER MODEL-FP-3-72 AS PER RDSO SPEC. NO. MP-0.24.00.20 OF JUNE, 2000 (REV.00) Issue No : 01 Rev. No. : 04 Issue Date : 28.07.2000 Rev. Date : 10.09.2006 Issued by: SIGNOTRON (INDIA) PVT. LTD Plot J1-6, Block-EP, Sector-V Salt Lake Electronics Complex Kolkata-700 091 Phone: (033) 23573484 Fax No.: (033) 23577877 E-mail: signomail@vsni.net / sigp!@cal3.vsnl.net.in Website: www.signotron.com DOC.No.INVIFP/2K/04 (Rev.04) —— ee een |TABLE OF CONTENTS 1. Introduction Technical Specification Salient Features Description of the Systems Bill of Materials Installation Maintenance en Oo oP Y KN Trouble Shooting DOC.No.INVIFP/2KI04 (Rev.04) = t=SenoTRan 1) 2) INTRODUCTION The A.C. Fuel Pump Motor with Built in Inverter — Model: FP-3-72 accepts DC nominal 72V. Its 3-phase inverter inverts this DC Voltage to 3-phase, 40V AC voltage, which runs the A.C. Fuel Pump Motor, This equipment is specially designed for Diesel Electric Locomotives as per RDSO Specification No. MP.O.24.00.20 of June, 2000, Rev.00. The equipment works on SPWM Technology with very high efficiency. The unit is to be coupled with Fuel Booster Pump and Governor Pump. The unit is easily interchangeable with existing DC motor. TECHNICAL SPECIFICATION (2.1) Inverter - Input Voltage (Rated) @ Input Voltage Range @ Output Waveform Type of Control Output Range oe Output Frequency ¢ Output Power Protection ° Cooling Power Circuit Configuration : Control Circuit ° Type of Protection of Cabinet.: : 72VDC + 50 to 90V DC with 15% ripple. The inverter will operate even at 20V DC input voltage, ‘so that the unit does not trip at time of cranking. : Multi Pulse Sinewave PWM. : Constant torque operation by V/f control. 3-Phase, 40V + 5% at input voltage range 65 to 90V DC. : 60 Hz. + 2 Hz. in input voltage range 65 to 90V DC. ‘+ 1.5 .P. (continuous). : a) Input under voltage protection (auto reset), b) Input Over Voltage (auto reset) ¢) Output Over Load (power ON reset). d) Output Short Circuit (power ON reset). e) Reverse Polarity (auto reset). : Natural self-cooled. 3-Phase full bridge with Ultra-fast IGBT. : Micro-controller based waveform generator. IP-65, = DOC.No.INVIFPI2KI04 (Rev.04)(2.2) Motor - @ Rating : 1.5 H.P. (continuous). Operation Parameters : 40V, 3-Phase, 60 Hz. Synchronous Speed + 1800 rpm. # Actual Speed : 1728 rpm. Cooling arrangement : Self-cooled. @ insulation : Class “H”. Type of Winding : 3-Phase, DELTA. No. of Poles 24 Frame Size : Non-standard. Type of Protection : IP-54, © Type & Make of Bearing. : SKF make deep grooved ball. bearing. (6305 2RS C3) Overall efficiency of Motor : > 81% Inverter Set. Weight of Motor Inverter Set. : 39 kgs. 3) SALIENT FEATURES Single PCB based design for high reliability; Fully Micro-controller based design; Inter-connection between PCBs eliminated to achieve zero failure rate; Improved enclosure design for total water and oil-ingress protection; Motor and inverter can be easily separated for sepatate testing and easy changing of bearing during maintenance; Motor input terminal is accessible from outside, so inverter output can be easily checked during maintenance and testing without opening the unit; Single PCB based design so trouble-shooting is very easy; coo eoe 4) DESCRIPTION OF THE SYSTEM The A.C. Fuel Pump Motor with built-in Inverter operates with Sinewave PWM technology. The input DC voltage is inverted by a 3-phasé power module i.e. 3-phase inverter bridge to 3-phase, 40V, 60 Hz. AC voltage. At the rated input DC voltage 65V — 90V DC the output voltage is 40V, DOC.No.INVIFPI2KI04 (Rev.04) ag-60 Hz. If the voltage drops below 65V DC, the output voltage and frequency drops keeping the voltage and frequency ratio constant. This way using v/f control technology output torque remains almost constant. At the time of cranking when the voltage dips as below as 20V, the system will operate at lower rpm. A micro-controller controls all the operation and generates the drive signals for driving the power module. A trip and protection circuit senses DC current and input voltage and trips the unit for any abnormal condition such as input over voltage, input under voltage, output short circuit, output over load. A internal SMPS generates the necessary + 12V and + 5V from the input DC voltage. This 3-phase AC voltage generated by the inverter is directly given to the 3-phase AC motor. 5) BILL OF MATERIALS Item Specification Make Qty. 1. Reverse Protection Diode | S-282 B SIGNOTRON 1 2. Capacitor 150V, 2,200 MFD, PG-6DI ALCON 2 3. Main Card $-6012C Signotron if | 1 4. Power Module 3-Phase, IGBT Bridge with ‘Signotron 1 Snubber (SIG-242B/A) 5. Input Snubber Module | S-4048 Signotron 1 6. Air Core Inductor ALI Signotron 7. Motor. 1.5 H.P., 40V, 3-Phase, 60 Hz. Shamal 1 Harand of India Pvt. Ltd. POWER MODULE (SIG 242B/A) IGBT (Half Bridge) EUPEC, SEMIKRON 3 150A/600V Zener Diode — 18V/1W CDIL/EQV 6 10KQ, % W CFR PHILIPS/IEQV 6 Capacitor (Poly) 1:F/250V cTR 3 Axial MPEAR ate DOC.No.INVIFP/2K/04 (Rev.04)6) INSTALLATION (6.1) (6.2) Pre-Installation, check and storage — On receipt of the equipments at customer's premises or installation sites, visually check the same for any physical damage during transportation or handling. In case of any damage, the same should be rectified before use. In case the equipments are not installed immediately and need to be stored in a dry clean place, preferably inside a shed, duly covered to ensure that the equipments do not get wet or accumulate any dirt, moisture etc. Periodically clean the equipments to remove any dirt etc. and also rotate the motor shaft by hand for some time to prevent corrosion of bearings and hardening of grease. Before proceeding to install, check the following : i) The equipments complete in all respects, all components are O.K. No physical damage, all fasteners are properly tightened, especially the electrical terminals in the terminal block. Rotate Motor Shaft manually and ensure the same moves freely. iii) If the unit is stored for few months run the motor at no load for 2 to 3 hours to improve the insulation resistance of stator winding (in case it is less). iv) Check the direction of rotation of motor. Installation & Commissioning — The unit is retrofittable in place of the present DC Fuel Pump Motor, i.e. it will be fitted in the present base- plate of the DC Fuel Pump Motor in the same direction. The fuel booster pump and governor pump will be fitted in the motor exactly in the same way and same side as of DC fuel pump motor. After fittings in the base-plate and fitting of the pump, input DC voltage will have to be connected in the input terminal box (marked as DC INPUT) of the inverter. Terminal box cover will have to be opened and wires to be inserted through the cable gland, terminals are marked with + and — sign. Input DC should be connected properly otherwise motor will not start. In the terminal box there are three other terminals marked as R,Y,B for motor connection. Three output wires for inverter comes to the terminal box and connected with the motor input. The output of the inverter and input to the motors are marked as R,Y,B. These connections are done at factory and should not be changed If changed motor will rotate in the reverse direction, if the input DC is connected in this terminal by mistake, the inverter will be damaged. This R,Y,B terminals are covered by a plate marked as motor terminal. This plate is given to isolate the motor terminals from input DC terminal. Before starting, the shaft should be rotated by hand for checking whether it is free. Then input breaker at the cab should be made ON, then the DOC.No.INVIFPI2KI04 (Rev.04) +55unit will start, There is a soft-start feature for reducing starting current. The motor will gain full speed within 10 Sec. of starting. | 7) MAINTENANCE (7.1) Maintenance Schedule of AC Small Motors with built in Inverter a) Monthly Schedule — 30 Days b) M4/M8/M16/M20/M28/M32/M40/M44 Schedule — Every 4 Months c) M12/M24/M36 Schedule — Every 12 Months d) M48 Schedule — Every 48 Months This schedule should be continued for 16 Years / Throughout the life span of the AC Motors. This schedule is made as per the Instruction of RDSO. a) Monthly Schedule: (i) To be Done in the Loco (ji) Outside body & heatsink cleaning with dry cloth (iii) Check for abnormal sound of the bearing in loco dead condition b) M4/M8/M16/M20/M28/M32/M40/M44 Schedule — Every 4 Months (i) To be Done in the Loco (ii) Outside cleaning with Dry Cloth (iii) Check for any loose electrical connection at the DC Input terminal box (iv) Check for abnormal sound of the bearing in loco dead condition (v) Check the motor RPM c) M12/M24/M36 Schedule - Every 12 Months To be removed from the locomotive and carryout the following. (i) Outside cleaning with dry cloth (ii) Check for any loose electrical connection at the DC input terminal box (ii) Change the bearings (iv) Check all the inverter & motor screws are properly tightened (v) Run the motor with full load for 4 hours. Check the RPM. Measure the temperature rise of the heatsink & motor. d) M48 Schedule — Every 48 Months (i) To be done removing from the loco (ii) Change the bearings (iii) Check all the inverter & motor screws are properly tightened (iv) Check all the sealing, gasketing joints, screw ends for proper oil ingress protection. If needed apply anabond (v) Run the unit with full load for 4 hours. Check the RPM, measure the temperature rise of the heatsink & motor <6 DOC.No.INVIFPI2KI04 (Rev.04)TRON DETAILS OF SPARE AC FUEL PUMP MOTOR ‘Component Description Manufacturer 01. AC FUEL PUMP MOTOR (40V, 3 PHASE, 60Hz. | SAMAL HARAND OF 1.5HP.) () PVT. LTD. (7.2) OVERHAUL These squirrel cage induction motors are simple in construction but even so every care should be exercised when dismantling or reassembling the machine. Damage can be caused to the Winding, Bearing, Shaft, Rotor if handled indifferently. a) Dismantling of Motor (Ref. Fig. 1) (i) Remove End Bracket fixing Bolts/or Bracket fixing Studs. 4 of the end bracket fixing studs fixed the inverter with the motor. Then open the terminal box and open the motor terminal covering plate. Disconnect the motor input wires (R,Y,B) from the R, Y, B terminal. Then the cable gland through which motor input wire come to the DC input terminal box will have to be disconnected from the terminal box by opening the gland nut. Now, motor and inverter can be separated. (ii) After placing a block of wood against the shaft extension and followed by gentle hammering slowly, slide out the Rotor assembly through any one side. (ili) Remove the other side Bracket (iv) Hold the Rotor assembly with bearing and the remaining Bracket, with the remaining bracket hanging free and vertically downwards. With two hammers held each in one hand-gently tap the remaining bracket at two position always 180 deg. Apart till the bracket comes out free from the Rotor. (v) Remove bearings using drawing ee a ——— gear applying pressure in the inner race only. The devices used for with drawing 0 e bearings should where ever cole possible exert pressure on the j inner race and the pressure on the inner race should be uniformly j distributed, parallel with the shaft and at right angles to the bearings. aoe = i= DOG.No.INVIFPI2KI04 (Rev.04)Use jackscrew passing through a hole in the center of the plate, applied against the end of the shaft. Place packing (a) between the jackscrew and shaft to prevent damage to tapped holes or counter sunk centering holes in the shaft end. b) Reassemble of Bearings Reassemble is the reverse of dismantling procedure. c) Bearing Fitting Put the bearing (b) on the shaft, place a tube (c) over the shaft against the inner race, gently drive on by means of a hammer or. mallet until the inner face is hard against the shaft shoulder (d) care should be taken to see that the shoulder is clean and free from burrs. When the Bearing is fitted, check the alignment by means of a ‘clock indicator. (7.3) REASSEMBLE OF MOTOR (Ref. Fig.1) Please note carefully the sequence of assembly/fitting of the different items/components while dismantling and as shown in Fig. 1 especially the wave washer. The reverse sequence should be followed while reassemble. a) All fixing screws are to be tightened evenly, making certain that no distortion of end shields occur. i b) Rotate the shaft, if locked or stiff, loosen the end shields screws | and re-tighten while spinning the shaft to ensure freedom. A few sharp taps with a mallet axially on the shaft extension both side may also be required to free the bearings of stress and ensure freedom. DOG.No.INVIFP/2KI04 (Rev.04) -9-NoMa 8) TROUBLE SHOOTING - (8.1) Trouble Shooting for Motor — Observation Possible Reasons Action called for 1, Mechanical / Metallic Noise from the Motor. a) b) ) Presence of foreign Matter in the air gap between stator and rotor Damaged Bearing. la) Remove rotor from Stator, clean the surfaces and re-assemble. b) tfnoise still persists. check the noise of bearing with a screw driver. if abnormal sound is noticed take out the bearings concerned and replace with new bearing 2. Steady Electrical HUM Running single phase fa) Open the terminal box and check whether the output of the inverter is properly connected to the motor input terminal. Check for loose connection. b) If connection is proper then check the voltage of the inverter 3-Phase output. lc) If all are O.K. restart and 3. No Rotation a) b) °) ‘Some abnormal input or output condition occurs such as over voltage, under voltage, over load or output short} circuit ocours and the inverter trips. Failure of the inverter. Motor is faulty. let it run. la) Check the input voltage whether it is between 50 90V DC and ripple is within 15% b) Check whether rotor is jammed. ic) If problem is still there, disconnect the inverter output connection from terminal. Give 72V DC in the input terminal and check whether output of inverter is 40V AC, 60 Hz. |d) If inverter is O.K. then replace the motor with another fuel pump motor. =10- DOC.No.INVIFP/2KI04 (Rev.04)NOTE : Use a analog meter to measure inverter output voltage. Digital meter may give wrong reading due to harmonics present in the output. (8.2) Trouble Shooting for Inverter — Observation Possible Reasons Action called for 1. There is no output from the inverter. '@) There is some abnormal input voltage condition or output is over loaded or short-circuited. b) Inverter is faulty. ‘@) Check whether the input Voltage is within range (50-90V DC) with maxi- mum + 15% ripple and output is loaded with rated load. b) If problem is still there, open the _ inverter enclosure. 2. No output from the inverter though input is normal Please note — a) Any connection opened from SIG-6012C b) The inverter still not working. a) Check the connection of SIG-6012C. If found O.K. change the card. b) Change the power module (SIG-242B/A). 1) Inthe test bench, the unit should be tested with a variable power supply with 3- phase input so that the output ripple of the power supply is less. Otherwise, it can be tested with a battery in the test bench. If itis tested with a power supply with single-phase input, then output voltage ripple should be less than +/- 15%. 2) As the inverter has IP-65 type of protection, if it is opened for repair it should be properly fitted with proper gasketing and pasting by Anabond (666 Silicon seal-ant for gasketing) of Anabond Ltd. to prevent ingress of oil or water inside it. Otherwise, it may fail while in operation. 3) Only qualified technical personnel should trouble shoot this eqipment. 9) INSTRUMENT FOR MOTOR INSPECTION Following is a suggested list of instruments which would enable maintenance ‘engineer & his team to perform necessary electrical tests & check alignment/ vibration during on board maintenance. i) Portable A.C. Voltmeter (0-600V) ii) Clip on Ammeter iii) 500 Volt Meggar iv) Tachometer v) Thermometer (0-200 Deg.C) vi) Vibration Meter vii) Dial indicator and magnetic mount. viii) Multimeter DOC.No.INVIFP/2K/04 (Rev.04) +1tesENoTRON ASSEMBLY DETAILS OF FUEL PUMP MOTOR, | i | gid{ | gs 34 ; y | (idan z | | 5 3 382 3 3 8 ba Ey dail) st gi gai go Ses gags <425 DOC.No.INVIFP/2K/04 (Rev.04)oem Torman/as/aov “oNowO ust-a1ONT300n ay| aw | 1 ons | | tSt OPS) poarwmoa tt erat SS | anew | jaomvuenos | VEDVIC ONT JO TVIEG mun | Rf] ovo | CEVONIVA DZ109-8 “ALYIAd (1 NOMLONOIS NOMLONDSS Lr az. | TAG Geom | | Gan “IVNINUAL YOLOW OL (oar | CUE ———— _ [ee | 0: LaD1 o 6 | [46] 73a oO 1 1 1 NOES 2 z 7O7T | mate woLDvavo sng 870s aAw anret oA a6 ce cava ane oo watts € € : ee 9 9 90 f] 99 00 #7 roe O | me ‘avo ga01g auats bbe $6 $6 soa DOC.No.INVIFP/2KI04 (Rev.04)Fh 6E RVDC — ‘mous, Santo -ft, S- 6012 C set I " Sots x7 us as as os na reso J wine yoow wor an Toa \eBT iBT ier Taam A war = seNorrOn ee Shp | meammcmarmrne| SaEeaee en [mere were. | Jer | wove ne. (onan AcrR/PeTa/ win. -14- DOG.No.INVIFPI2K/04 (Rev.04)