Apcjab Fmi C10adhoc A en 220301

Relocation of capacitor C10
APCJAB-01
Auxiliary power converter
Relocation of capacitor C10 Version A APCJAB-01_FMI_C10adhoc_B_EN_220301

APCJAB-01 Dinghan SMART Railway Technology GmbH
Revision
Document number Document name
D000114084 APCJAB-01_FMI_C10adhoc_B_EN_220301
Version Section Modification Date Author
A 4 First edition based on final modification 01.03.2022 A. Krug
Name Date Signature
Checked by H. Diehl 09.02.2022
Approved by S. Angersbach 17.02.2022
Relocation of capacitor C10 Version A Page 2 / 27

Table of contents
1 Notes on this document ............................................................................................................................ 4
1.1 Validity ............................................................................................................................................... 4
1.2 Target group ...................................................................................................................................... 4
1.3 Storage .............................................................................................................................................. 4
1.4 Additional information ........................................................................................................................ 4
1.5 Symbols ............................................................................................................................................. 5
1.5.1 Warning labels ........................................................................................................................... 5
1.5.2 Special symbols ......................................................................................................................... 5
1.6 Abbreviations ..................................................................................................................................... 6
1.7 Reference documents ........................................................................................................................ 6
1.8 Copyright............................................................................................................................................ 6
2 Safety ........................................................................................................................................................ 7
2.1 Appropriate usage ............................................................................................................................. 7
2.2 Safety instructions ............................................................................................................................. 8
3 Preparation.............................................................................................................................................. 10
3.1 Measuring points ............................................................................................................................. 10
3.2 Tools ................................................................................................................................................ 15
4 Modification/relocation of capacitor C10 ................................................................................................. 17
5 Contact .................................................................................................................................................... 23
6 Inspection protocol .................................................................................................................................. 24

1 Notes on this document
Notes on this This document provides all the information required for the relocation of capacitor
document
C10 for auxiliary power converter APCJAB-01. Danger notices and warnings
against property damage are located in the section just before the instructions
containing potential risks to personnel or property.
1.1 Validity
Validity This document only describes the auxiliary power converter APCJAB-01 from
Dinghan SMART Railway Technology GmbH.
1.2 Target group
Target group The document is intended for certified, qualified personnel who has been trained
and authorized for carrying out each of the instructions listed in the document.
Only qualified electricians may perform work on the device. Make sure to always
follow the safety precautions, since otherwise you can expose yourself and others
to serious danger!
1.3 Storage
Storage Store the document in a place that is easily accessible to the qualified personnel at
all times.
1.4 Additional information
Additional In the case of problems or questions about the system, please contact our customer
information
service
• by phone: +49 (0)561 50634-6600

• or by e-mail: Service@Dinghan-Germany.com
Always request by mail or by phone an RMA number when a problem with the
product occurs. Please note this number on the delivery note and on the product
when you send it back.

1.5 Symbols
1.5.1 Warning labels
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in

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

death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury.
NOTICE
NOTICE indicates a situation which, if not avoided, can result in property

damage.
INFORMATION
Information provides tips that are valuable for the optimal installation and
operation of your product.
1.5.2 Special symbols
Table 1.1 Symbols Symbol Description
High voltage
Information
Instruction for maintenance operation, assembly, disassembly

1.6 Abbreviations
APC Auxiliary power converter
EMC Electromagnetic compatibility
ESD Electrostatic discharge
PPE Personnel protective equipment
1.7 Reference documents
Table 1.2 Reference

No. Document title Document number Issuer
documents
[1] APCJAB-01_MM_B_EN_200422 Maintenance Manual Dinghan
1.8 Copyright
Dinghan SMART Railway Technology GmbH owns the copyright to this document.
The operator may duplicate and process this document for his own purposes,
whereas changing this document is only allowed with the explicit permission of
Dinghan SMART Railway Technology GmbH. All rights reserved.

2 Safety
2.1 Appropriate usage
Appropriate usage The auxiliary power converter complies with all binding legal provisions and safety
regulations for railway rolling stock. The auxiliary power converter is used for
supplying Metro Jabodetabek. If used improperly, the system may endanger people
and property. The safety precautions described in this document are intended to
prevent dangers to people or property. In addition to the safety precautions
described in this document, the local safety and accident prevention regulations as
well as the operator's safety regulations apply.
5 safety rules For every work within the system, the 5 safety rules are valid according to DIN EN
50110:2014-02 or BS EN 50110-1:2013-04-30:
• Disconnect the auxiliary power converter completely.

• Secure against reconnection.
• Verify that the auxiliary power converter is voltage-free.
• Ground and short-circuit the auxiliary power converter.
• Protect against adjacent live components using guards and barriers and
place suitable warning signs.

2.2 Safety instructions
DANGER
Risk of lethal electric shock and burn injury due to dangerous voltages present.
• Disconnect the device from all voltage sources.

• Secure against re-connection.
• Verify that the device is free of voltage.
• Ground and short circuit the device.
• Cover and safeguard any adjacent live components.
The product operates with voltages up to 1,000 V DC. Dangerous voltages are
present at the terminals and voltage may therefore also be present outside the
product. Dangerously high voltages may be present even if measured values
indicate that the product is free of voltages.
WARNING
Risk of lethal electric shock until at least 5 minutes after disconnection due to
high voltage capacitors.
• Wait at least 5 minutes after disconnection.

• Verify that the product is free of voltage at the measuring points outlined
(see maintenance manual of the product, Section Disconnection).
The product contains high voltage capacitors. Their discharging time is up to

5 minutes. Dangerously high voltages are present in the product up to at least
5 minutes after the train line has been switched off. Voltage may therefore also
be present at the product terminals and outside the product. Under fault
conditions, the discharging time may exceed the time specified.

WARNING
Lethal risk due to unspecialized and unequipped personnel.
• Have expert personnel work on the device.

• While performing works such as mounting, commissioning, and
maintaining, respect the applicable technological rules and regulations.
• Wear personal protective equipment (PPE).
Inappropriate behavior regarding the APCJAB-01 cause lethal injury to personnel

and others and damage of the device.
NOTICE
Damage of electronic parts due to electrostatically charged parts and bodies.
• Ensure ESD safe working, packaging, and transport conditions for all
parts containing electronic components.
• Keep away from electro-statically charged parts and bodies (minimum
3 m).
• Discard electronic boards exposed to electro-statically charged bodies
or parts.
Electrostatically charged parts and bodies can cause high voltage discharge in
electronic boards. As a consequence, the boards are damaged.

3 Preparation
3.1 Measuring points
DANGER
Risk of lethal electric shock due to dangerous voltages present.
• Observe the instructions below
The product operates with voltages up to 1,000 V DC. Dangerous voltages are
present at the terminals and voltage may therefore also be present outside the
product. Dangerously high voltages may be present even if measured values
indicate that the product is free of voltages.
WARNING
Risk of lethal electric shock until at least 5 minutes after disconnection due to
high voltage capacitors.
• Observe the instructions below
WARNING
Risk of electric shock due to residual voltage on workshop supply connection
• Risk of electric shock due to residual voltage on workshop supply con-

nection.
After disconnection of the workshop supply from the vehicle, dangerous voltage
can be present on the workshop supply connection inside the product and on
accessible pins of the workshop supply connector on train side for up to
15 seconds. After 15 seconds the voltage is below 50 V
To check before any work on the system:
1. Provide suitable personal protective equipment (see Section3.2, Page 15).

2. Provide suitable tools and equipment (see Section 3.2, Page 15).
3. Switch off the high voltage source connected to terminals X1 and X2.
4. Switch off the workshop supply feed to the workshop supply input at
terminals X12.1 to X12.5.
5. Switch off the car battery connected to terminals X21 (DC1+), X23 (BAT+)
and X24 (DC-).
6. Switch off the 110 V DC electronics power supply.
7. Secure against reconnection.
8. Wait at least 5 minutes for the capacitors to discharge.

9. Verify that the product is free of voltage at the respective measuring points
(see Table and Illustrations below) with a suitable high voltage tester (see
Section 3.2, Page 15).
10. If the voltage on the capacitors outlined below is more than 60 V after
5 min, discharge the capacitors with suitable resistors.
11. Earth and short-circuit the product.
12. Protect against adjacent live components using guards and barriers and
place suitable warning signs.
13. Contact the Dinghan Germany Service Line in the case of a failure (see
Section 4, Page 17).
Table 3.1 Measuring Measuring point Maximum

Measuring point Description
points high voltage location voltage
Input terminals
DC input voltage, input
X1 against PE SC3INCO and blank 1000 V
capacitor C1
metal surface
Input terminals
X2 against PE SC3INCO and blank 1000 V
capacitor C2
metal surface
Input terminals
X5 against X6 SC3INCO (EMC 1000 V
capacitor C10
choke)
SRC DC link upper Measurement

X141 against X142 1200 V
positive capacitors terminals SC3INCO
SRC DC link upper Measurement

negative capacitors terminals SC3INCO
SRC DC link lower Measurement

positive capacitors terminals SC3INCO
SRC DC link lower Measurement

negative capacitors terminals SC3INCO
Measurement
Serial resonant inverter terminals SC3INCO
capacitor C201 and output terminal
SC3INCO
Measurement
capacitor C301/1-3 and output terminal
SC3INCO

Table 3.1 Measuring Measuring point Maximum

Measuring point Description
points high voltage location voltage
Measurement
capacitor C202 and output terminal
SC3INCO
Measurement
capacitor C302/1-3 and output terminal
SC3INCO
Power terminal
WSS contactor, EMC
X12:1 against PE WSS contactor and 240 V
capacitor WSS Z12
blank metal surface
Power terminal
WSS contactor, EMC
capacitor WSS Z12
blank metal surface
Power terminal
WSS contactor, EMC
capacitor WSS Z12
blank metal surface
Output terminal
X331 against PE AC output voltage SC3OUTCO and 240 V
blank metal surface
Output terminal
blank metal surface
Output terminal
blank metal surface
DC link voltage three DC link capacitor

phase inverter board
DC link voltage three DC link capacitor

phase inverter board
Potential difference of
DC output terminals
X21 against X24 DC output capacitors 140 V
SC3OUTCO
A21
Potential difference of DC output terminals

X21 against PE DC output EMC filter SC3OUTCO against 140 V
Z20 blank metal surface



Figure 3-1 Measuring

points INCO
1 X1 10 X144
2 X2 11 X145
3 X12:5 12 X146
4 X12:3 13 X112
5 X12:1 14 X114
6 X5 15 X141
7 X6 16 X142
8 X118 17 X143
9 X116

Figure 3-2 Measuring

points OUTCO
1 X333 6 X21
2 X332 7 X343
3 X331 8 X342
4 X24 9 X341
5 X23

3.2 Tools
To prepare:
1. Ensure a safe and clean working environment and personal protective

equipment (see Table 3.2, page 15).
WARNING
Lethal risk due to unspecialized and unequipped personnel.
• Have expert personnel work on the device.

• While performing works such as mounting, commissioning, and
maintaining, respect the applicable technological rules and regulations.
• Wear personal protective equipment (PPE).
Inappropriate behavior regarding the APCJAB-01 cause lethal injury to personnel

and others and damage of the device.
Table 3.2 PPE Equipment Application range
Safety boots including ESD protection Protection against heavy parts falling on the
and steel toe according to EN 0682-331 ground
Safety gloves according to Protection against injuries of the skin due to

EN 60903:2003 sharp edges
Protective clothing according to

Protection of the human body
EN 50286: 1999
2. Provide tools and consumables that comply with international safety

standards (see Table 3.3 and Table 3.4, page 16 and Manual [1]).

NOTICE
Damage of electronic parts due to electrostatically charged parts and bodies.
• Ensure ESD safe working, packaging, and transport conditions for all
parts containing electronic components.
• Keep away from electro-statically charged parts and bodies (minimum
3 m).
• Discard electronic boards exposed to electro-statically charged bodies
or parts.
Electrostatically charged parts and bodies can cause high voltage discharge in
electronic boards. As a consequence, the boards are damaged.
Table 3.3 Tools Tools Application range
Voltage range up to 5 kV AC / 7 kV DC
High voltage tester
For example Tietzsch MultiSafe DSP HS5
Opening and closing doors

Hex key
Loosening and fastening screws
Loosening screws
Open-end wrench
Several screw types M4-M12
Fastening screws
Click type torque wrench
Several screw types M4-M12
Diagonal pliers Cutting cable ties
Permanent marker Marking hardware version on type plate sticker
Table 3.4 Consumables Consumables Application range
Cable ties Fixing cables

4 Modification/relocation of capacitor C10
Reused components
Pos. Quantity Designation
1 1 Capacitor C10 (available in the INCO module, to be reused)
2 3 Nut M8, A2
3 2 Hexagon screw M8x16, A2
4 5 Washer M8, A4, Form M
5 2 Hexagon screw M5x8, A2
6 1 Serrated locking washer NSK-S5-A4
7 1 Distance bolt M5x20, A1 (stainless steel)
8 1 Distance bolt M5x20, PA (plastic)
9 1 RTDIS2M2-00 discharge board
Provided components in adhoc modification kit

Dinghan Mat. Nr.
Pos. Quantity Designation
11 2 - Connection wire M8 / M8
12 1 - Discharge resistor with M6 lugs
13 1 1003628-A Plastic spacer bolt M8 60x30mm (included in adhoc kit)
14 2 1003612-A Washer M8, A4, Form M
15 2 101448-00.01 Screw M8x12, A2
16 2 Cable ties 350mm

To relocate capacitor C10:

1. Access the capacitor C10 located in the upper left corner of the INCO module.
Figure 4-1: Front view of the INCO module, capacitor C10

2. Unscrew the capacitor by removing the two M8 screws. Keep the screws and washers in a safe place
for later reuse. Start with the rear screw and then continue with the screw in the front.
NOTE: To unscrew the rear screw, it is recommended to use an Allen key because the angle is very
steep. If the screw is difficult to loosen, a longer lever must be attached to the end of the Allen key.
1.
2.
Figure 4-2: Top view of the INCO module on the capacitor, correct sequence for loosening screws
3. Attach the plastic spacer bolt where the capacitor was located with the two reused M8 screws and
washers to stabilize the rail. Tighten the screws with the correct tightening torque: 15.2 Nm.
Figure 4-3: Top view of the INCO module, plastic spacer bolt mounted
4. Check that the isolator is properly fastened.

5. Remove the M8 nuts and washers from terminal X101 andX102. Keep the nuts and washers in a safe
place for later reuse. Disconnect the two wires from X101 and X102.
Figure 4-4: Front view of the INCO module, terminals X101 and X102
6. Assemble the capacitor C10 with the provided connection cables (Pos. 11) and discharge resistor (Pos.
12) with the provided M8x12 screws and locking washers (Pos 14 + 15).
Figure 4-5: set of cable for the capacitor

7. Tightening torque: 7 Nm. NOTE: Tightening torque exceeding 7 Nm will damage the capacitor!
Figure 4-5 Preassembly of connection wires and capacitor
8. Attach the capacitor with the wires to X101 and X102.

Fasten the capacitor to the cable rails with two cable ties. Cut of excess from cable ties.
Reconnect the wires from the input choke to X101 and X102.
Reuse the M8 nuts and locking washers. Ensure that the cable lugs are positioned in and angle of 80-
90degree to each other on each terminal as shown in picture below.
Tightening torque: 15.2 Nm.

Figure 4-6 Front view of INCO module with capacitor on X101/ X102.
9. Close the left door of the container (see Maintenance manual [1]).
10. Power up the APCJAB-01 and check the proper operation of the converter via the SMARTview
webpage (see Maintenance manual [1]).
11. Note the modification and test result in the attached list (see Section 6).

5 Contact
Dinghan Germany Service line:

Tel.: (+49) 561 50634 – 6600
Fax: (+49) 561 50634 – 6849
E-mail: Service@Dinghan-Germany.com
Postal address:
Dinghan SMART Railway Technology GmbH
Miramstraße 87
34123 Kassel (Germany)
Dinghan Germany login area for our clients:

www.dinghan-germany.com

6 Inspection protocol Ad hoc modification C10
After the modification, please fill in the respective column in this following table
and forward the complete table to Dinghan.
APCJAB-01 serial Functional test

Capacitor relocated? Checked by
number passed?
10
11
12
13
14
15
16
17
18
19


number passed?
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41


number passed?
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63


number passed?
64
65
66
67
68
69

Apcjab Fmi C10adhoc A en 220301

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Relocation of capacitor C10

Relocation of capacitor C10 Version A APCJAB-01_FMI_C10adhoc_B_EN_220301

Version Section Modification Date Author

A 4 First edition based on final modification 01.03.2022 A. Krug

Name Date Signature

Checked by H. Diehl 09.02.2022

Approved by S. Angersbach 17.02.2022

Relocation of capacitor C10 Version A Page 2 / 27

Relocation of capacitor C10 Version A Page 3 / 27

1 Notes on this document

1.2 Target group

1.4 Additional information

• by phone: +49 (0)561 50634-6600

Relocation of capacitor C10 Version A Page 4 / 27

1.5.1 Warning labels

DANGER indicates a hazardous situation which, if not avoided, will result in

WARNING indicates a hazardous situation which, if not avoided, could result in

NOTICE indicates a situation which, if not avoided, can result in property

1.5.2 Special symbols

Table 1.1 Symbols Symbol Description

Instruction for maintenance operation, assembly, disassembly

Relocation of capacitor C10 Version A Page 5 / 27

EMC Electromagnetic compatibility

ESD Electrostatic discharge

PPE Personnel protective equipment

1.7 Reference documents

Table 1.2 Reference

[1] APCJAB-01_MM_B_EN_200422 Maintenance Manual Dinghan

Relocation of capacitor C10 Version A Page 6 / 27

2.1 Appropriate usage

• Disconnect the auxiliary power converter completely.

Relocation of capacitor C10 Version A Page 7 / 27

2.2 Safety instructions

• Disconnect the device from all voltage sources.

• Wait at least 5 minutes after disconnection.

The product contains high voltage capacitors. Their discharging time is up to

Relocation of capacitor C10 Version A Page 8 / 27

Lethal risk due to unspecialized and unequipped personnel.

• Have expert personnel work on the device.

Inappropriate behavior regarding the APCJAB-01 cause lethal injury to personnel

Damage of electronic parts due to electrostatically charged parts and bodies.

Relocation of capacitor C10 Version A Page 9 / 27

3.1 Measuring points

Risk of lethal electric shock due to dangerous voltages present.

• Observe the instructions below

Risk of electric shock due to residual voltage on workshop supply connection

• Risk of electric shock due to residual voltage on workshop supply con-

To check before any work on the system:

1. Provide suitable personal protective equipment (see Section3.2, Page 15).

Relocation of capacitor C10 Version A Page 10 / 27

Table 3.1 Measuring Measuring point Maximum

SRC DC link upper Measurement

SRC DC link upper Measurement

SRC DC link lower Measurement

SRC DC link lower Measurement

Relocation of capacitor C10 Version A Page 11 / 27

Table 3.1 Measuring Measuring point Maximum

DC link voltage three DC link capacitor

DC link voltage three DC link capacitor

Potential difference of DC output terminals

Potential difference of DC output terminals

Potential difference of DC output terminals

Relocation of capacitor C10 Version A Page 12 / 27