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India 180 kVA Circuit Diagrams

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Figure 6: Circuit Diagram Sheet 6 of 12

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India 180 kVA Mechanical Overview

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3.4 Mechanical drawings

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India 180 kVA Functional Description

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4 Functional Description

4.1 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 formeasurement of actual input voltage

IVPS section 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

Inverterandoutput filter section

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 withanalogue 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 A302LVPS section The LVPS (Low voltage power supply) consists of

DC/DC module A401 with the chopper unit A01, the IGBT driver A02, thetransformer T01, the rectifier A03 and the current sensor U01

DC-EMI filter module A402

Control section 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

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SinglePhase

Transformer

T301

A202

ShortCircuit

ThyristorV

01

A01

L201

F101 4

50A

A101

EMI

Module

L01.1-.3

A201

AC

Input

760/830V

50Hz

(590-1110V)

3L1

3L2

3L3

3phaseoutput

415VAC

180kVA

50Hz

1phaseoutput

110VAC

500VA

50Hz

C301

A

P902

2L1

2L2

1L1

P901

1L2

L101

L102

Autotransf.

T302

LowVoltagePowerSupply

A401

DCoutput

110VDC

2kW

LB+

LB-

F701

V701

15VDC

A740

DisplayBoard

(tt1823-2/03A)

A710

ConverterControlBoard(tt1932-1/33F)

A102

A750

OnePhase

Filter

A702

SCRControlBoard

(tt1933-1/05D)

Driv.

Driv.

R

301

A

704L

VPSControlBoard

(tt1967-2/24E)

A720

PowerSupply

A402

A302

Volt.

divider

A77

0

InternalCANbus

X700

1

2

RS485

X4

X3

RS232

SemiControlled

SCRBridge

Volt.

sensor

U101

Volt.

divider

A501

Volt.

sensor

U501

Volt.

divider

A50

2

Volt.

sensor

U50

2

Volt.

divider

15V

DC

T

UCE

ICharge

UBatt

T

UInp

IIC

UIC

GNDfault

CAN

15V

Fan

K5

Relays

S901

S902

444.4

VV

P903

ACinputvoltage

ACoutput

phasevoltages

ACoutput

phasecurrents

U01

ACFilte

r

U301

InverterControlBoard

(tt1619-1/68C)

A703

IL1

IL2

IL3

UAC

T

UCE

U01

Signal

Condit.

A730

UBatt

Q901

T01

L301

L302

L303

L01.1-.

3

DCE

MI-Filter

L01

ACE

MI-Filter

L01

L02

L03

Driver

A

02

A01

A03

F101blown

Volt.

sensor

Volt.

divider

A304

M901

3~

Fan1

M902

3~

Fan2

X7

X5

3

4

Disable

ProtectionCircuit

A722

F401

25A

10A

Rectif.

Bridge

A303

Q902

ACfeedb.

K4

Temp.

P

re-warning

X7

PWMinverter

Drv.

Drv.

A301.2

A301.3

Drv.

A301.1

UIC

General

Fault

Battery

Temp

T302

Q302

C701

Q301

Q301

Monitoring

Figure 13: Functional sections and modules of the converter

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4.2 Mechanical Design

4.2.1 Enclosure

The enclosure of the converter is manufactured of stainless steel and its sealing satisfies the internationalprotection 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 theinductances is possible via a revision cover at the converters front side.

Connections The input and output connections are via stud terminals and are brought out through cutouts for cable entry. An isolated plug-in connector is provided for the connection of thecontrol cable.

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5 Module Descriptions

5.1 Input section and IVPS section

U201

A702Digital controller unit for IVPS

UI

UCE

Temperature

prewarning

Over-

temperature

S01

75C

S02

85C

Crow

bar

assy

UCE

A102

Voltage

divider{

A01.1Driver

A01.2Driver

V01.1

V01.2

R01.1

R01.3

C01.1

C01.3

R01.2

R01.4

C01.2

C01.4

V02.1

V02.2

V01R01

C01

L201

1L1

1L2

F01

A101L101

L102

to

inverter section A300,

LVPS section A400UI

+UIC

-UIC

to converter

control unit

A710

A201Semicontrolled Thyristor Bridge B2HZ

A750

1-phase

filter

R02

A202Short circuit thyristor module

A01

V

A502

Voltage

divider

U501

Voltage

sensor

UICIIC

Currentsensor

U101

Voltage

sensor

Figure 14: Input section and IVPS section

Input EMIchoke A101

It suspends guided electromagnetic disturbances and thus improves theelectromagnetic compatibility of the converter.

Input chokesL101 and L102

Input filter chokes

Thyristor bridge The thyristor bridge mainly consists of the two thyristors V01.1 and V01.2 and the twodiodes V02.1 and V02.2. It converts the AC input voltage into a DC voltage(= intermediate circuit voltage)

Smoothing chokeL201

L201 smoothes the rectified input voltage

Current detection Current sensor U201 detects the intermediate circuit current.The output signal of U201 is wired to the SCR control board A702.

Short CircuitThyristor Unit A202

Short circuit thyristor unit A202 with thyristor V01 works as emergency protection if theDC output (=intermediate circuit) voltage exceeds a specified value. Firing the thyristorshorts the section and thus blows the input fuse outside of the converter (crowbarfunction). Trigger circuit is A01. L201 limits the current rise.

Digital controllerunit A702 for IVPS The digital controller unit for IVPS A702 controls and monitors the operation of thethyristor bridge and communicates with the converter control unit A710.

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5.2 Inverter section

The inverter modules A301.1, A301.2 and A301.3 transform the filtered input voltage into a system of threeAC voltages each with 120 degrees phase shift against the other voltages.

Inverter modulesA301.1, A301.2,A301.3

Each module is a three single-phase IGBT half bridge with a six-fold driver A01. Eachmodule consists of two individual IGBT's V01 and V02. The connected invertermodules convert the intermediate circuit voltage into a three-phase AC voltage

(3 x 415 V/50 Hz).

AC filter The downstream AC filter consists of chokes L301-L303 and capacitors C302.1-6.

EMI filter The EMI filter is located downstream of the AC filter and consists of the EMI choke L01and the capacitors C01-10.

Output terminals2L1 and 2L2

The output terminals 2L1 and 2L2 provide a phase-to-phase voltage UACof 110 V / 50 Hz with a power of 500 VA.

Output terminals3L1, 3L2 and 3L3

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.

Inverter controlunit A703

The inverter control unit A703 controls and monitors the operations of each invertermodule and communicates with the converter control unit A710. It also supplies theIGBTs with the necessary switching signals via the six-fold drivers A01.

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A301.1 Inverter

V01

V02

A01 IGBT driver

A703 Inverter control unit

UCE IL2

L301

L302

L303

-UIC

S0290C

S0180C

Temperatureprewarning

Over-temperature

T01

+UIC

V01

V02

A01 IGBT driver

S0290C

S0180C

T01

V01

V02

A01 IGBT driver

S0290C

S0180C

T01

UCE UCE IL3IL1

VA

3~3~

A301.2 Inverter A301.3 Inverter

C302.1-6

Q901

M901

Q902

M902

T302

P901 P902

T901

T902

T903

L01

C01-10

A302AC-EMI filter

T301

{

A710Converter control unit

C01.1-3 C01.1-3 C01.1-3

C301.1-3R301.1-4

2L1

2L2

3L1

3L2

3L3

Q301

Sine wave filter

A502

Voltagedivider

Figure 15: Inverter section

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Inverter The IGBT inverter modules divide the input voltage UICinto separate pulses ofconstant amplitude, but varying durations (pulse frequency: 3,6 kHz). Thevariable switching ratio controls the amplitude of the output voltage (sine pulsewidth modulation, see Figure 16.

Inverter output voltage

+VZ

t

Filter output voltage

V(t)

-VZ

Figure 16: Generation of sinusoidal alternating voltage

by means of sine pulse width modulation.

The figure shows the input voltage UDCswitched through as square-wave pulsesand 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 +UICand UIC: amplitude of output voltage = 0.

The combination of three inverter branches like this, which will be triggered with a phase shift of 120, createsa three-phase AC system.

AC filter Due to the pulse width modulation at a constant pulse frequency, the onlyoscillation 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. Thefilter creates an almost sinusoidal voltage curve from the square-wave voltagepulses of varying length (harmonic distortion factor < 10 % RMS).

AC output The alternating voltage UACat 3 x 415 V / 50 Hz is available to the consumerloads at terminals 3L1, 3L2 and 3L3.

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5.3 Low Voltage Power Supply section

The LVPS converts the intermediate circuit voltage U ICto 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 theintermediate circuit voltage and monitors the total current, in particular limits it to the permissible maximumvalue.

DC/DC module

A401

The DC/DC module A401 (LVPS) consists of the IGBT chopper unit A01, the

transformer T01 and the rectifier module A03.

Chopper unit A01 The chopper unit forms an IGBT full bridge including the two dual IGBT modules V01.1and V01.2 and the quadruple driver A02. The IGBT driver provides the control signalsfor the IGBTs. The switching frequency is 20 kHz.The chopper unit A01 switches the filtered intermediate circuit voltage through to theprimary winding of the transformer T01 in the form of voltage blocks.

Transformer T01 The transformer T01 has one primary and two secondary windings (center-tapconnection). It transforms the block-shaped AC voltage down to the required outputvoltage.

Rectifier modules

A03 and A04

The rectifier module A03 rectifies the block-shaped AC voltage supplied by the

secondary windings of the transformer T01.

Output filter The ripple-filter choke L03 and the capacitor C02 smooth and dampen the rectifiedvoltage.

EMI filter Furthermore the LVPS has measurement devices for DC output voltage, DC outputcurrent and a downstream EMI filter, consisting of the filter choke L01 and thecapacitors C01-04.

LVPS choppercontrol unit A704

The LVPS chopper control unit A704controls and monitors the operations of theDC/DC module A401 and communicates with the converter control unit A710. It alsosupplies the IGBTs with the necessary switching signals via the IGBT driver A01.

A704 LVPS chopper control unit

A02 IGBT driver

V01.1

S01

100C

UCE

V01.2

U01

Over-

temperature

A03

L03

T01

T1L02

A401 DC/DC module

ITOT

A01 IGBT chopper unit

IPRIM

L01

C02

{

+UIC

-UIC

C03

C04

C01

C02

L01

A720Powersupply A402 DC-EMI filter

UB

A730

Signal

conditioning

to converter

control unit

A710

LB+

LB-

V02

V03

+/- 15 V toA702 IVPS digital controllerA703Inverter control unitA704LVPS control unitA710converter control unitA740converter display boardA7601-phase filterA901 Ground fault detection

Figure 17: Low voltage power supply A401

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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) fromthe 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 inthe form of square-wave voltage blocks of alternating polarity. The switching times of the IGBTs arecontrolled in such a way that the area of these voltage blocks is always constant (pulse-widthmodulation):

Higher input voltage IGBTs conduct for a shorter time [(2), left]

Lower input voltage IGBTs conduct for a longer time [(2), right]

3 The transformer T01 converts the block-shaped AC voltage to a different voltage. The form of thevoltage curve is retained (3).

4 After rectification by A03, all the square-wave voltage pulses have the same polarity (4). The height andlength 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.

5 The downstream filter then smoothes the voltage by filling in the gaps between the voltage pulses. Themaximum value of the voltage drops during this process more for high, short voltage pulses (becausethere 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 onthe other hand remains constant. The result is a constant output voltage, which is largely independent ofthe fluctuating input voltage [(5), left and right].

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Uin

t

1

2

3

4

5

t

t

t

t

t

t

URect

t

USec

t

Uout

t

UCh

Uin

URect

USec

Uout

UCh

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

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5.4 Earth fault detection

The earth fault detection consists of a centre tapped resistor network R1 and R2, which is connected acrossthe negative and positive bus of the intermediate circuit. The centre point of this resistor network is connectedto 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 IGBTsV5 and V6 will be switched on and off in the switching frequency of the inverter. There will be an ac currentthrough 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.

RE

Input filter

AC

DC

Output Filter Inverter

R1

R2

V1 V3 V5

V2 V4 V6

R3

Thyristor Bridge

}}}} ControlUR3

Figure 19: Earth fault detection

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6 External Controlling Equipment

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

1

2

34

57

NO FAULT

6

V

A

175.0 V

1 AC output voltage meter P901

2 AC input voltage meter P903

3 Converter fault display A740

4 Type plate of converter

5 AC output ammeter P902

6 Phase selection switch S902

7 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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India 180 kVA

TT1823

N O F A U L T

ERROR DISPLAY

AC INPUT OK

GENERAL FAULT

INTERNAL FAULT

INVERTER FAULT

IVPS/SCR FAULT

DISPLAY OK

Figure 22: Detailed view of converter fault display A740

Descr. in Figure 22 LEDColour

Signal name LED is on, if

AC INPUT OK green AC input voltage AC input voltage is in specified range

GENERAL FAULT red Fault of inverter section a fault occurs in the inverter section

INTERNAL FAULT red Fault of LVPS section a fault occurs in the LVPS section

INVERTER FAULT red Phase/ground fault ofAC output

an earth fault occurs at the AC output or at the ACinput

IVPS/SCR FAULT red Fault of IVPS section a fault occurs in the IVPS section(thyristor bridge A201)

DISPLAY OK yellow Heartbeat converter fault display A740 is in operation(no fault)

Detailed alphanumeric fault messages of fault display A740

Alphanumeric character Description

N O F A U L T No fault

H - B R I D G E Fault of IVPS section

I N V E R T E R

Fault of inverter sectionL V P S Fault of LVPS section

T E M H - B R Overtemperature in IVPS section

T E M I N V Overtemperature in inverter section

T E M L V P S Overtemperature in LVPS section

T E M T 3 0 2 Overtemperature of autotransformer T302

F 0 1 Fault of fuse F01

Q 9 0 1 Fault of motor-circuit switch Q901

Q 9 0 2 Fault of motor-circuit switch Q902

Q 3 0 1 Fault of circuit breaker Q301

E A R T H F A Ground fault

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