Maintenance Manual AC DC EMU (Siemens) PDF

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 2 AUXILIARY CONVERTER UNIT (ACU) 2.0 INTRODUCTION The Auxiliary Converter Unit (ACU) contains all component...

CAMTECH/E/13-14/MM AC-DC EMU/1.0 1 CHAPTER 2 AUXILIARY CONVERTER UNIT (ACU) 2.0 INTRODUCTION The Auxiliary Converter Unit (ACU) contains all components needed to supply the power system load including battery charger. The ACU is installed in the middle car (motor coach) of a basic train unit and is designed for an input voltage of DC 1500V. It receives this from the traction link. 2.1 INSTALLATION POSITION Every three-part basic train unit contains an Auxiliary Converter Unit. This is installed in the HT compartment in the middle car (Motor Coach). TC Trailer Car HT High Tension Compartment TPC Transformer Power Car NDMC Non Driving Motor Car Figure 1 - Block diagram of one train basic unit 2.2 SUPPLY SYSTEM The input of the Auxiliary Converter Unit is connected to the traction link.  During AC operation of the driving train, the ACU is fed from the four quadrant regulators of the drive power converter.  During DC operation, the ACU is supplied via the input filter of the traction system from the contact line. The rotary current output (3 phase AC 415V) of the Auxiliary Converter Unit feeds the rotary current drives, e.g. for the primary air compressor or the components fan/blower. The AC output (AC 110V) supplies the passenger compartment fan and the primary lighting. The DC output (DC 110V) serves to charge the battery and feed the DC equipment, such as electronic control devices, protective equipment and emergency lighting. Maintenance Manual for AC-DC EMU (Siemens) Chapter 2 2 CAMTECH/E/13-14/MM AC-DC EMU/1.0 In normal operation, an Auxiliary Converter Unit supplies one three-part basic train unit. If an ACU fails, the AC 110V and DC 110V equipment of the affected unit are supplied by a neighboring unit. Figure 2 - Block diagram of one train basic unit 2.3 COMPONENT LAYOUT IN THE CABINET The following diagrams show the position of the major components in the Auxiliary Converter Unit. T1 Pulse-width-modulated inverter T2 Pulse-width-modulated Inverter T3 Battery charger Figure - Position of the power modules in the cabinet Figure 3 - Position of mounting plates and components in the cabinet A1 Mounting plate A1 A2 Mounting plate A2 A3 Mounting plate A3 A4 Mounting plate A4 A5 Diode module A5 A6 Capacitor assembly A6 Chapter 2 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 3 A8 Pivoting frame A8 R9 Sine filter resistor R13 OVP resistor R14 OVP resistor V6 Capacitor assembly Q7 Decoupling diode Figure 4 - Back side of the cabinet M1 Fan M2 Internal fan M3 Internal fan R4 Line choke R15 BC line choke R20 Air intake temperature sensor T4 Main transformer FUNCTIONS OF MAJOR COMPONENTS IN AUXILIARY CONVERTER UNIT Sr. Component Designation Brief description and application in the No. Converter 1 PWMI T1,T2 These Pulse width modulated Inverter modules are Module used for the basic inverter operation in the Auxiliary converter. They are fed with DC supply and the PWM outputs of these modules are then fed to the transformer which connects them in series for high DC link voltage operation. 2 Battery T3 The Battery charger is used to charge the battery in Charger the train. It is fed with DC voltage which is derived Module form the main Transformer (3 Phase AC) through the Battery charger rectifier and filter. 3 Master K1 The M1300 SIBCOS Main controller is used to Controller control the overall operation of the Auxiliary Converter and to take the feedback signals for fault detection and preventive actions. 4 CAN Bus K2 The M9000 CAN bus Communication card is used Controller for the communication between Auxiliary converter and external devices. 5 Line Filter R4 The DC Line choke is used to filter out the ripple in Choke the DC link voltage fed to the PWMI modules. Maintenance Manual for AC-DC EMU (Siemens) Chapter 2 4 CAMTECH/E/13-14/MM AC-DC EMU/1.0 Sr. Component Designation Brief description and application in the No. Converter 6 Main T4 The PWM inverter Outputs are connected to Transformer the main transformer, which has two 3 phase primary winding and three secondary windings for 3 phase 415 volts output, 1 phase 110 Volts output and 3 phase 500 Volts output. 7 BC Line Filter R15 The Battery Charger filter choke is used to Choke filter out the DC voltage fed to the Battery charger module after rectification from 3 phase supply from the transformer secondary. 8 Main Blower M1 The Main blower is used for cooling of the modules and transformer and line choke. It takes Air from the duct and forces it on the module heatsinks, this air is then forced on the main transformer and line choke and goes out from bottom of the converter. 9 Aux. Blower M2, M3 The auxiliary Blowers are used for internal cooling of 2.4 COOLING The Auxiliary Converter Unit is forced-air cooled. The cabinet contains one main fan and two internal fans. 2.4.1 External air flow The Auxiliary Converter Unit receives its cooling air from the auxiliary operator console. The cooling air is drawn in via an intake air grate on the top of the cabinet. Within the cabinet, the cooling air runs through the main fan to the heat sinks of the power modules and to the main transformer. The air leaves the cabinet via a ventilation grate on the bottom of the cabinet. The air leaves downward into the bogie. 1 Air inlet 2 Main fan 3 Power modules heat sinks (4x parallel) Figure 5- External air flow 4 Main transformer 5 Air outlet The main fan is switched ON as soon as the Auxiliary Converter Unit produces output voltage. Chapter 2 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 5 2.4.2 Internal air flow The internal air circulation is produced by two internal fans M2 and M3. They run continuously, i. e. they are switched ON together with DC 110V supply of the unit. 1 Internal fan M2 2 Internal fan M3 Figure 6- Internal air flow 2.5 CIRCUIT DESCRIPTION Figure 7- Auxiliary converter ckt. The Auxiliary Converter Unit is fed via the traction converter link. The nominal link voltage is DC 1500V. The prerequisites for operation of the Auxiliary Converter Unit are:  The ACU receives the activation signal from the vehicle control.  The input voltage lies within the valid range.  No errors occur in the ACU. Maintenance Manual for AC-DC EMU (Siemens) Chapter 2 6 CAMTECH/E/13-14/MM AC-DC EMU/1.0 If the activation conditions are met, the DC input voltage is fed to the PWMI modules via the input fuses A2-F1 / A2-F2, the line choke R4 and the input diode A5-Q1. The two PWMI modules connected in series are switched ON and started up. If the voltage at the PWMI output is in the specified range, the output fuses A1-Q2 / A1-Q3 are closed. The ACU control sends a message to the vehicle control that the 3phase AC output is ready for operation. Then the battery charger is switched ON and a message is sent to the vehicle control. The AC 110V and 3 phase AC 415V output is fed via the main transformer T4, sinus filter, EMV filter and output fuses behind the PWMI modules. The battery charger operated via the main transformer and the battery charger input rectifier A5-Q10 generates a DC 110V voltage at the output and supplies the DC 110V rail of the train unit and charges the train battery with this. Battery charging characteristic The batteries used in the train are Lead acid batteries with a nominal voltage of DC 110V. The load program corresponds to a IU-characteristic. Maximum device current: 82A Maximum battery charging current: I5=30A Charging voltage: U1= 115V The battery is charged with the maximum battery charging current of I5=18A until U1=110V is achieved. Then the charge continues with a constant charging voltage U1 (with decreasing charging current). 2.6 OPERATING THE AUXILIARY CONVERTER UNIT 2.6.1 Switching-ON in Normal Operating Special operation of the Auxiliary Converter Unit is not necessary. The ACU automatically switches ON when  High voltage is present at the traction link,  The activation signal from the train signal is sent and  No error exists on the ACU. 2.6.2 Switching-off in Normal Operating The Auxiliary Converter Unit automatically switches OFF itself when the activation signal is withdrawn by the vehicle control. Chapter 2 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 7 2.7 ELECTRICAL DATA 2.7.1 Input DC 1500V Requirements Values Comments Nominal input voltage 1500 V DC mode 1800 V AC mode Voltage range, stationary 1000 - 1800 V DC mode 1700 - 1800 V AC mode Short time minimum 800 V DC mode Occasional maximum 2000 V DC mode 2100 V AC mode Ripple 4% DC mode +/- 135 V AC mode 2.7.2 Three Phase AC 415V 50Hz Output One secondary of auxiliary converter having 3 Ø AC, 415V, 50 Hz (121A/ 87 kVA) supply is used for Main compressor & other auxiliaries. Output frequency 50 Hz ± 1 % Output voltage 415 V AC, 3-phase Static tolerance of output voltage ±5% Dynamic tolerance of output voltage ± 15 % Max. voltage rise of output voltage < 10 V/s Total harmonic distortion < 10 % Output filter EMC filter/ sinusoidal filter, isolation transformer Output nominal power: 87 kVA at Cos  = 0.85 Unsymmetrical load: ≤ 10 % of nominal power 2.7.3 Single Phase 110V AC 50 Hz Output One secondary of auxiliary converter having 1Ø AC, 110V (20 kVA) supply is used for light & fans in the passenger compartment. One tapping is taken out for redundancy lines of supply for adjacent units. Output frequency 50 Hz ± 1 % Output voltage: 110 VAC, 1-phase Static tolerance of output voltage: ± 10 % Dynamic tolerance of output voltage: ± 15 % Max. voltage rise of the output voltage: < 10 V/s Total harmonic distortion: < 10 % Output filter: EMC filter / sinusoidal filter, isolation transformer Output nominal power: 20 kVA at cos  = 0.89 Maintenance Manual for AC-DC EMU (Siemens) Chapter 2 8 CAMTECH/E/13-14/MM AC-DC EMU/1.0 2.7.4 DC 110 V Output One secondary of auxiliary converter having 3 Ø AC supply for battery charging equipment is used. Battery having 110 V DC supply is connected across this battery charging equipment to charge continuously. This 110 V DC supply is used for control supply as well as for emergency light supply when normal light & fan supply of 110 V AC is failed due to any reason. Output Voltage 110 V DC ( Pay attention to battery charging characteristic) Static tolerance of output voltage: +20%, -30 % Output nominal power 9 kW At nominal output voltage Max. output current (continuous) 82 A Control precision of battery ± 1.5 % At voltage detection point. voltage: (Detection point = battery charger output) Control precision of the current ±5% limiter: Ripple on output voltage: ≤1 % RMS At Nominal output voltage Output filter: EMC filter 2.8 SAFETY REGULATIONS FOR WORK ON THE ACU Whenever working on the cabinet the following five operations must be completed. i. De-energize the ACU  De-energize the Auxiliary Converter Unit according to the instructions of the person responsible for the train.  Then switch OFF the battery power. You can only disconnect the connection between the battery charger and car battery by pulling the battery plug or by removing the car battery fuse.  Switch off the master control SIBCOS-M1300 by interrupting the DC 110V supply. To do this, pull the plug "X040" from the control. ii. Ensure ACU cannot be switched ON again  Ensure power cannot be switched ON again and pantographs cannot be raised.  Mark points that have been switched to voltage free with a warning sign. Chapter 2 Maintenance Manual for AC DC EMU (Siemens) CAMTECH/E/13-14/MM AC-DC EMU/1.0 9 iii. Check that the installation is dead on both parts of ACU  Measure the absence of voltage at the following points. The measured voltage should not be more than 60V. DC 1500V Component Measuring points Spherical grounding electrode -E1 -E2 -E3 DC 650V (Input to battery charger) Component Measuring points Battery charger T3 T3: -X4 (+650V) T3: -X5 (0V) DC 110V (Output to battery charger) Component Measuring points Battery charger T3 T3: -X3:1 (0V) T3: -X3:2 / -X3:3 (+110V) iv. Ground and short-circuit the ACU Short-circuit the spherical grounding electrodes E1, E2 and E3 (refer to Figure 1) using a suitable ground short-circuiting kit in order to ground and short-circuit the DC link of the ACU. NOTE  Use a three-terminal grounding and short circuit device (with short-circuit ropes and earthing cable) for ball fixed-points Ø20mm.  Note the correct order. First connect E3 to the grounding / short circuit device, then E1 and E2. Figure 8 – Position of the spherical grounding electrodes in the cabinet v. Cover or isolate parts After opening the hatches, cover or isolate parts nearby that are live. Maintenance Manual for AC-DC EMU (Siemens) Chapter 2