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Circuit Diagrams
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Circuit Diagrams
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Circuit Diagrams
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Circuit Diagrams
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Circuit Diagrams
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Circuit Diagrams
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Mechanical Overview
3.4
Mechanical drawings
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Functional Description
4
4.1
Functional Description
Technical Profile
The converter described in this manual is characterized by the type no. U760AC/415AC3-110DC/P180-2/F50. It supplies the AC and DC consumers of the train with electric energy taken from the power line. The converter consists of five main sections: Input section The input section consists of input fuse F01 input EMI choke A101 voltage divider A102 and voltage transducer U101 for measurement of actual input voltage The IVPS (Intermediate circuit Voltage Power Supply) section consists of semicontrolled thyristor bridge A201 choke L201 short circuit module voltage divider A501 and voltage transducer U501 for measurement of actual intermediate circuit voltage voltage divider A502 and voltage transducer U502 for voltage measurement which is indicating earth faults The inverter section consists of inverter A301.1 3 each with an IGBT driver board A01 current transducers T901 903 for measurement of actual output currents with analogue ammeter P902 digital voltmeter P901 for measurement of actual output voltages output filter section: 3 phase chokes L301 303 and capacitors C302.1 6 autotransformer T302 AC-EMI filter module A302 The LVPS (Low voltage power supply) consists of DC/DC module A401 with the chopper unit A01, the IGBT driver A02, the transformer T01, the rectifier A03 and the current sensor U01 DC-EMI filter module A402 The control section consists of converter control unit A710 digital control unit A702 for IVPS LVPS chopper control unit A704 inverter control unit A703 power supply A720
IVPS section
LVPS section
Control section
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X700 1 Protection Circuit X7 K4 Relays K5 Monitoring RS485 X4 GND fault Internal CAN bus CAN UBatt 15 V Temp AC feedb. T302 Q301 Fan General Fault Disable X3 RS232 X5 X7 Battery A722 A740 2 3 4
A710
20999_TechDesc_R20_040519.doc
Display Board (tt1823-2/03 A) P903 Q901 15 V DC A703 Inverter Control Board (tt1619-1/68 C) T U301 Volt. A730 Signal sensor Condit. A304 Volt. divider A303 Q302 UCE IL1 IL2 IL3 UAC Q902 M902 3~ S901 S902 Drv. Drv. Drv. L301 R301 L302 L303 Rectif. Bridge T302 A302 L01.1-.3 Fan 2 SCR Control Board (tt1933-1/05 D) T Volt. A770 divider IIC UIC A704 LVPS Control Board (tt1967-2/24 E) UIC UCE T ICharge UBatt M901 3~ Fan 1
F101 blown
Temp. Pre-warning
AC input voltage
A702
UInp
A750
A101 Driv.
U101 Volt. sensor A102 Volt. divider U501 Volt. sensor A501 Volt. divider Volt. U502 sensor Volt. A502 divider
1L1
L01.1-.3
450 A
L101
L102
EMI Module
2L1 2L2
Q301 Single Phase Transformer A720 F701 10 A V701 A402 AC EMI-Filter
15 V DC Power Supply
C701
F401 25 A
L01
LB+
DC output 110 V DC 2 kW
Functional Description
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Mechanical Design
4.2
4.2.1
Mechanical Design
Enclosure
The enclosure of the converter is manufactured of stainless steel and its sealing satisfies the international protection class IP55. Access All maintenance and service work can be carried out without removing the power converter. The enclosure can be easily opened even while the unit is in place. Two service covers sideways of the converter allow quick access to all modules of the converter. Access to the inductances is possible via a revision cover at the converters front side. The input and output connections are via stud terminals and are brought out through cut outs for cable entry. An isolated plug-in connector is provided for the connection of the control cable.
Connections
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Module Descriptions
5
5.1
Module Descriptions
Input section and IVPS section
A702 Digital controller unit for IVPS UI UCE UCE Temperature prewarning Overtemperature IIC UIC
S01 75C
A750 1-phase filter
S02 85C
A01.2 Driver
A01.1 Driver
U101 Voltage sensor A102 Voltage divider V01.1 A101 L101 R01.1 V02.1 C01.1 R02 C01.2 R01.2
L201 +UIC
Current sensor
UI
1L1 1L2
F01
Figure 14: Input section and IVPS section Input EMI choke A101 Input chokes L101 and L102 Thyristor bridge It suspends guided electromagnetic disturbances and thus improves the electromagnetic compatibility of the converter. Input filter chokes The thyristor bridge mainly consists of the two thyristors V01.1 and V01.2 and the two diodes V02.1 and V02.2. It converts the AC input voltage into a DC voltage (= intermediate circuit voltage) L201 smoothes the rectified input voltage Current sensor U201 detects the intermediate circuit current. The output signal of U201 is wired to the SCR control board A702. Short circuit thyristor unit A202 with thyristor V01 works as emergency protection if the DC output (=intermediate circuit) voltage exceeds a specified value. Firing the thyristor shorts the section and thus blows the input fuse outside of the converter (crowbar function). Trigger circuit is A01. L201 limits the current rise. The digital controller unit for IVPS A702 controls and monitors the operation of the thyristor bridge and communicates with the converter control unit A710.
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{
L102
R01.3 V01.2
R01
C01.4
C01.3
V01
C01
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Module Descriptions
5.2
Inverter section
The inverter modules A301.1, A301.2 and A301.3 transform the filtered input voltage into a system of three AC voltages each with 120 degrees phase shift against the other voltages. Inverter modules A301.1, A301.2, A301.3 Each module is a three single-phase IGBT half bridge with a six-fold driver A01. Each module consists of two individual IGBT's V01 and V02. The connected inverter modules convert the intermediate circuit voltage into a three-phase AC voltage (3 x 415 V/50 Hz). The downstream AC filter consists of chokes L301-L303 and capacitors C302.1-6. The EMI filter is located downstream of the AC filter and consists of the EMI choke L01 and the capacitors C01-10. The output terminals 2L1 and 2L2 provide a phase-to-phase voltage UAC of 110 V / 50 Hz with a power of 500 VA. The output terminals 3L1, 3L2 and 3L3 provide a phase-to-phase voltage UAC of 3 x 415 V / 50 Hz with a power of 180 kVA. The inverter control unit A703 controls and monitors the operations of each inverter module and communicates with the converter control unit A710. It also supplies the IGBTs with the necessary switching signals via the six-fold drivers A01.
Output terminals 2L1 and 2L2 Output terminals 3L1, 3L2 and 3L3 Inverter control unit A703
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Module Descriptions
UCE
S01 80C
S02 90C
S01 80C
S02 90C
S01 80C
S02 90C
V01
C01.1-3
V01
C01.1-3
V01
C01.1-3
V02
V02
V02
-U IC
A301.1 Inverter
A301.2 Inverter
A301.3 Inverter
{
T301 Q301
C302.1-6
2L2
T302
P902
3~ M902
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Module Descriptions
Inverter
The IGBT inverter modules divide the input voltage UIC into separate pulses of constant amplitude, but varying durations (pulse frequency: 3,6 kHz). The variable switching ratio controls the amplitude of the output voltage (sine pulse width modulation, see Figure 16.
Filter output voltage V(t) +VZ Inverter output voltage
-VZ
Figure 16: Generation of sinusoidal alternating voltage by means of sine pulse width modulation. The figure shows the input voltage UDC switched through as square-wave pulses and the inverter output voltage after smoothing by the AC filter (sine curve). Wide voltage pulses +UIC, narrow voltage pulses UIC: amplitude of output voltage close to +UIC Narrow voltage pulses +UIC, wide voltage pulses UIC: amplitude of output voltage close to UIC Voltage pulses of same width for +UIC and UIC: amplitude of output voltage = 0. The combination of three inverter branches like this, which will be triggered with a phase shift of 120, creates a three-phase AC system.
AC filter
Due to the pulse width modulation at a constant pulse frequency, the only oscillation that occurs is harmonic oscillation with the pulse frequency (3,6 kHz) or higher. Even a relatively small-sized filter is sufficient to eliminate this. The filter creates an almost sinusoidal voltage curve from the square-wave voltage pulses of varying length (harmonic distortion factor < 10 % RMS). The alternating voltage UAC at 3 x 415 V / 50 Hz is available to the consumer loads at terminals 3L1, 3L2 and 3L3.
AC output
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Module Descriptions
5.3
The LVPS converts the intermediate circuit voltage UIC to an DC output voltage of 110 V / 2 kW. It also stabilizes the DC output voltage constant within a specified range irrespective of fluctuations in the intermediate circuit voltage and monitors the total current, in particular limits it to the permissible maximum value. DC/DC module A401 Chopper unit A01 The DC/DC module A401 (LVPS) consists of the IGBT chopper unit A01, the transformer T01 and the rectifier module A03. The chopper unit forms an IGBT full bridge including the two dual IGBT modules V01.1 and V01.2 and the quadruple driver A02. The IGBT driver provides the control signals for the IGBTs. The switching frequency is 20 kHz. The chopper unit A01 switches the filtered intermediate circuit voltage through to the primary winding of the transformer T01 in the form of voltage blocks. The transformer T01 has one primary and two secondary windings (center-tap connection). It transforms the block-shaped AC voltage down to the required output voltage. The rectifier module A03 rectifies the block-shaped AC voltage supplied by the secondary windings of the transformer T01. The ripple-filter choke L03 and the capacitor C02 smooth and dampen the rectified voltage. Furthermore the LVPS has measurement devices for DC output voltage, DC output current and a downstream EMI filter, consisting of the filter choke L01 and the capacitors C01-04. The LVPS chopper control unit A704 controls and monitors the operations of the DC/DC module A401 and communicates with the converter control unit A710. It also supplies the IGBTs with the necessary switching signals via the IGBT driver A01.
Transformer T01
UB
S01 100C
V01.1
+/- 15 V to A702 IVPS digital controller A703 Inverter control unit A704 LVPS control unit A710 converter control unit A740 converter display board A760 1-phase filter A901 Ground fault detection
{
U01
LB+
V03
C02
C02
C04
LB-
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Module Descriptions
5.3.1
Figure 18 shows how the DC/DC module A401 generates the stabilized DC output voltage (= 110 V DC) from the intermediate circuit voltage UIC. 1 The input is the intermediate circuit voltage after smoothing by the line coil L01 (1). This voltage is not constant. The diagram shows two different cases: Input voltage at the upper end of the tolerance range (left column) Input voltage at the lower end of the tolerance range (right column) 2 The chopper unit A01 switches the DC voltage through to the primary winding of the transformer T01 in the form of square-wave voltage blocks of alternating polarity. The switching times of the IGBTs are controlled in such a way that the area of these voltage blocks is always constant (pulse-width modulation): Higher input voltage IGBTs conduct for a shorter time [(2), left] Lower input voltage IGBTs conduct for a longer time [(2), right] The transformer T01 converts the block-shaped AC voltage to a different voltage. The form of the voltage curve is retained (3). After rectification by A03, all the square-wave voltage pulses have the same polarity (4). The height and length of the voltage pulses is still dependent on the level of the original input voltage: Higher input voltage higher but shorter voltage pulses (left) Lower input voltage lower but longer voltage pulses (right) The product of the height and length of the voltage pulses (the area of the voltage blocks) is constant, irrespective of the input voltage. The downstream filter then smoothes the voltage by filling in the gaps between the voltage pulses. The maximum value of the voltage drops during this process more for high, short voltage pulses (because there are large gaps to be filled), and less for low, long voltage pulses where the gaps to be filled are only narrow. Observed over a cycle time , the product of the length () and the height of the voltage on the other hand remains constant. The result is a constant output voltage, which is largely independent of the fluctuating input voltage [(5), left and right].
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Module Descriptions
Uin
Uin t t
UCh
UCh t t
USec t
USec t
URect
URect t t
Uout t
Uout t
Figure 18: Generation of constant DC voltage in the Low Voltage Power Supply
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Module Descriptions
5.4
The earth fault detection consists of a centre tapped resistor network R1 and R2, which is connected across the negative and positive bus of the intermediate circuit. The centre point of this resistor network is connected to the housing via the resistor R3. The voltage over the resistor R 3 is measured. During regular operation, there is no additional galvanic connection between the housing and the intermediate circuit / output circuit. Thus there is no current through R3. If there is an earth fault (in our example in L3), then the Resistor R3 will be switched parallel to R1 resp. R2 via the earth fault resistance Re, depending on the switching conditions of the IGBT's V5 and V6. The IGBTs V5 and V6 will be switched on and off in the switching frequency of the inverter. There will be an ac current through R3. The earth fault detection recognizes the voltage over R3 and shows an earth fault. There will be detected earth faults at the input circuit, the intermediate circuit as well as at the phases.
V1
V3
V5
V2
V4
V6
RE Output Filter
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The external controlling equipment is located on the left lateral service cover (see No. 1 in Figure 20). The detailed view is shown in Figure 21.
N O FAU LT
4
V
2
A
175.0 V
1 2 3 4 5 6 7
AC output voltage meter P901 AC input voltage meter P903 Converter fault display A740 Type plate of converter AC output ammeter P902 Phase selection switch S902 Phase selection switch S901
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ERROR DISPLAY
NO FAULT
DISPLAY OK
TT1823
Descr. in Figure 22 AC INPUT OK GENERAL FAULT INTERNAL FAULT INVERTER FAULT IVPS/SCR FAULT DISPLAY OK
LED Signal name Colour green red red red red yellow AC input voltage Fault of inverter section Fault of LVPS section Phase/ground fault of AC output Fault of IVPS section Heartbeat
LED is on, if AC input voltage is in specified range a fault occurs in the inverter section a fault occurs in the LVPS section an earth fault occurs at the AC output or at the AC input a fault occurs in the IVPS section (thyristor bridge A201) converter fault display A740 is in operation (no fault)
Detailed alphanumeric fault messages of fault display A740 Alphanumeric character N O F A U L T H - B R I D G E I N V E R T E R L V P S T E M H - B R T E M I N V T E M L V P S T E M T 3 0 2 F 0 1 Q 9 0 1 Q 9 0 2 Q 3 0 1 E A R T H F A Description No fault Fault of IVPS section Fault of inverter section Fault of LVPS section Overtemperature in IVPS section Overtemperature in inverter section Overtemperature in LVPS section Overtemperature of autotransformer T302 Fault of fuse F01 Fault of motor-circuit switch Q901 Fault of motor-circuit switch Q902 Fault of circuit breaker Q301 Ground fault
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