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28/07/14

25 KVA Inverter Preventive


Maintenance Training


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2
Agenda
Overview of 25 KVA Inverter
Functional Description of the Sub Assemblies of Inverter
Details of LED Indications of the Inverter
Interfacing Details of Inverter & OBDP
Questions & Answers


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3


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4
ALT 1
25KW
ALT 2
25KW
A
A
BATTERY+
BATTERY --
R
E
G

1

R
E
G

2

T
R
A
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S
F
O
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R

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117
P
B

RSW 1
RSW 2
400A
400A
400A
63 A
CONTROLFUSE
COIL
PB IN P/PANEL
OLR
250 A 250 A
S1 NO
S2 NO
--VE JUNCTION
17
T
O

I
N
V

1

-
-
V
E

T
O

I
N
V

2

-
-
V
E

L

/

F


-
-
V
E

10
18
TO INV1 + VE
TO INV 2 + VE
26
FROM EXT
3 PH .415 V
TO L / F&WRA +VE
250 A
+
+
+
+
-
440V AC
A
RSW1
1 ALT1
2 ALT2
3 ALT 1&2
97V AC
110V DC


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5


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6


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7
25kVA Under slung Inverter
These inverters are mounted under frame in Self-Generating type Air Conditioned
passenger coaches provided with 110V battery bank in parallel with belt driven
Alternator Cum Rectifier to supply input DC voltage to the inverter. The IGBT based
25kVA Inverter then converts 90 to 140VDC into regulated 3Ph, 415VAC5%,
50Hz3% to feed roof mounted A/C package unit.

Transfer of Technology agreement with transtechnik, Germany
Followed by design approval & type testing; Bombardier is now qualified as Part II source
56Nos. of inverters supplied till date and 40 inverters are in the field service till date


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8
Technical Specifications of 25 KVA Inverter
Input Characteristics Sym Value
Nominal input voltage V
IN
110 Vdc
Min. operation voltage V
Imin
90 Vdc
Max. operation voltage V
Imax
140 Vdc
Output Characteristics Value
Overall efficiency at full load > 92 %

3-Phase output voltage 3 x 415 V
RMS
5 %
Frequency F 50 Hz 1 %
Output power (continuous) P 25 kVA, cos 0,8
Output power for motor inrush P 45 kVA for 5 s, cos 0,45
Output wave shape sinusoidal (PWM)
THD < 10 %
Diagnostics and external interfaces Value
Status and event indication Recording of last 60 faults
Storage of operation parameters with date and time
Display via RS232 on diagnostic notebook

Diagnostics down to module level
Interfaces RS 232 (event diagnostics via notebook)
Floating relay contacts (for resistive loads only)


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9
Overview of Subsystem
The 3phase under slung converter consists of the following subsystems:

Input Section _ MCCB
input fuses
input current measurement
Step-Up Chopper
step-up chopper modules A100.1 and A100.2
chokes L01 and L02
Intermediate Circuit eight capacitors C01.1 to C01.8 with total capacity of 9.4 mF
AC section PWM inverter module A300
AC filter
- Output contactor K31
15VDC Electronics Supply With Electronic power supply A06
Control system Control Board A08 for Chopper- and Inverter Control
Converter Control Board A09


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10
System overview
Input Section:
Well coordinated MCCB & fuses with fuse blown indication
Highly accurate input current measurement


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11
Chopper Assembly
Gate Drive
Unit
Diode
s
IGBTs


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12
System Overview
A100.1
Step Up
Chopper 1
IGBT
driver
boards
V11.2
V11.1
A11.1 A11.2
A08
U
CE
T
max
Control board
L01.1
L01.2
U01
A03
U
Z
L02.1
L02.2
PWM Inverter
IGBT
driver
boards
V11.2 A11.1 A11.2
100 C
(92 C)
S12
100 C
(92 C)
S12
U02
T
max
U
CE
A100.2
Step Up
Chopper 2
Intermediate
Circuit
to A08
I
input
IGBT
D
IGBT
D
IGBT
D
IGBT
D
Volt. Transd.
Volt. Divider
U
input = 110 V nom. U
Z

Step-Up Choppers & Intermediate Circuit

Step-up chopper modules
Booster chokes
Optimized capacitor bank


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13
Operation of Step-up Chopper
Base Circuit
The ideal step-up chopper has the five basic components, namely a
power semiconductor switch (IGBT), a diode D, a choke L, a
capacitor C (with R) and a control board. The basic circuit of the
step-up chopper is shown in Figure 1.
The control board of the circuit in Figure 1 is turning the IGBT on
and off.
IGBT ON
When the IGBT is ON (= when the switch is closed), the current through the
choke increases and the energy stored in the choke builds up.
The diode does not conduct and the capacitor sustains the output voltage.
The circuit can be split into two parts, as shown in Figure 2.
As long as the RC time constant is very much larger than the on-period of the
IGBT, the output voltage would remain more or less constant
IGBT OFF
When the IGBT is OFF (= when the switch is open) as shown in Figure 3, current
through the choke continues to flow via the diode D, the RC network and back to
the input. The choke is discharging its energy and the polarity of choke voltage is
such that its terminal connected to the diode is positive with respect to its other
terminal connected to the input.
The choke acts like a pump, receiving energy when the switch is closed
(IGBT ON) and transferring it to the RC network when the switch is open
(IGBT OFF).


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14
Inverter Assembly
Gate Drive Unit
IGBTs


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15
System Overview
V31 V33 V35
IGBT driver board
A300 Inverter IGBT Module
Control board
A31
A08
T301
L31
T302
T303
L1
L2
L3
AC filter
IL1 IL2 IL3
UCE
S32
100C
(92 C)
Tmax
V32 V34 V36
A301
EMI filter
A03
U
Z
U02
U
Z
Volt. Transd.
Volt. Divider
Intermediate
Circuit
from
Step-Up
Chopper

Inverter Section
PWM inverter module
AC sine filter


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PWM & Sine Output of the Inverter


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Load on Inverter ( Cooling Mode )
Sr.
No.
Type of load

Rating of each motor Nos. Total load
a) Compressor
motors
5.3 kW, 0.8 PF lag, 415 V , 50 Hz, 3
phase stating current 49 A for 0.3 sec.
to 3 sec. with DOL starting.
2 10.60 kW
b) Condenser fan
motor
1.3 kW, 0.8 PF lag, 415V, 50 Hz 3
phase, starting current 10 A for 0.3
sec to 3 sec. with DOL starting.
2 2.60 kW
c) Crank case
heaters of
compressors
50W, connected across 415 V line 2 0.10 kW
d) Evaporator fan
motor
1.5 kW, 0.8 PF, lag, 415 V, 50 Hz, 3
phase, starting current 15 A for 0.3
sec to 3 sec. with DOL starting.
1 1.50 kW
e) Control panel 200 W, 110 V AC 50 Hz, single phase
filtered sine wave
1 0.20 kW
f) WRA 746 W, 415 V, 3 phase 50 Hz. 1 0.746 kW
g) Coach fan 60W, 110V, 50Hz, single phase 14 0.840 kW
Total 16.586 kW


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Load on Inverter ( Heating Mode )
Sr.
No.
TYPE OF
LOAD

LOAD Nos. TOTAL
LOAD
a) Heating
elements
Star connected 3 kW, 3 phase, 415 V,
50 Hz.
2 6.00 kW
b) Evaporator fan
motor
1.5 KW, 0.8 PF lag, 415V, 50 Hz,
starting current 15 A for 0.3 sec to 3
sec.
1 1.50 kW
c) Control panel 200 W, 110 V AC, 50 Hz, single phase
filtered sine wave
1 0.20 kW
d) WRA 746 W, 415 V, 3 phase 50 Hz. 1 0.746 kW
e) Coach fan 60W, 110V, 50Hz, single phase 14 0.840 kW
Total 9.286 kW


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19
Current / Voltage Sensors for protection & control

Closed loop system - Magnetic flux created by the primary current is balanced through
Secondary coil using hall device and associated electronic circuit. The secondary
(compensating) current is an exact representation of the primary current.

Galvanic isolation between the high power circuit and electronic circuit

Features High Accuracy, Very good linearity, Low temperature drift, Optimized response
time, Wide frequency bandwidth, No insertion losses, High immunity to external interference,
Current overload capability

Well coordinated fuses (with blow off indication) & MCCB at the I/P side for O/L & S/C protection.

Over voltage & under voltage protection at Input side.

Output short circuit protection with IGBT trigger pulse block

Earth leakage, overload protection, single phase & unbalance protection

Reverse polarity protection at input side

Thermal overload protection of power semi-conductor devices
Protections


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20
Controller & Diagnostic Card of 25KVA Inverter
Controller
Card
TT1655
Diagnostic
Card
TT1444


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LED Indications of Controller Card


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LED Indications of Controller Card


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LED Colour Meaning Shutdown
General messages "Steller" (= Step-up chopper), left area of the LED array
Betrieb
(= run)
green Step-up chopper control board ready for operation no
Bereit
(= standby)
yellow Standby:
Step-up chopper ready for operation but input voltage Ui < Uimin
no
Str
(= fault)
red Serious step-up chopper fault. For details see adjacent LEDs yes
CLK green Clock pulses of the chopper are available
15 V ok green 15 V auxiliary voltage (electronics supply voltage) is OK
Step-up chopper messages
UEH red Input voltage has exceeded maximum allowed value red
UEL yellow Input voltage has dropped below minimum allowed value no
UE > UX green Input voltage exceeds adjustable value (= input voltage available) no
IEmax yellow Input current measured by U01 exceeds maximum allowed value yes
UZmax red Output voltage of step-up chopper (= intemediate circuit voltage)
exceeds maximum allowed value
yes
UZmin yellow Output voltage of step-up chopper (= intemediate circuit voltage)
drops below minimum allowed value
no

UCEMod1 red IGBT current overload or IGBT driver error in chopper module
A100.1 (UCE fault)
yes
UCEMod2 red IGBT current overload or IGBT driver error in chopper module
A100.2 (UCE fault)
yes
UCESW1 red IGBT current overload of V11.1 or driver error of A11.1
of the indicated chopper module
yes
UCESW2 red IGBT current overload of V11.2 or driver error of A11.2
of the indicated chopper module
yes
General messages "Wechselrichter" (= Inverter), right area of the LED array
Betrieb
(= run)
green Inverter control board ready for operation no
Bereit
(= standby)
yellow Standby: Inverter ready for operation no
Str
(= fault)
red Serious inverter fault. For details see adjacent LEDs yes
CLK green Clock pulses of the inverter are available
Inverter messages
UCE Tr. R red IGBT current overload or IGBT driver error in inverter module A300,
branch L1 / IGBTs V31 or/and V32 (UCE fault)
yes
UCE Tr. S red IGBT current overload or IGBT driver error in inverter module A300,
branch L2/ IGBTs V33 or/and V34(UCE fault)
yes
UCE Tr. T red IGBT current overload or IGBT driver error in inverter module A300,
branch L3 / IGBTs V35 or/and V36 (UCE fault)
yes
Ausgelst
(= triggered)
red UCE fault R, S or T has occured more than 4 times
within one minute
yes
Phase red Phase imbalance, load difference between phases exceeds allowed
threshold
yes
I-Begr.
(= current
limitation)
red AC output in current limitation mode no


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24
LED Indications of Controller Card


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25
LEDs And Relay Interfaces

LED Colour Relay Signal Meaning
H21 Green K1 Converter ON Converter is running
H22 Green K2 U
I
> 90 V Input voltage threshold 90 V exceeded
H23 Green K3 Step-up chopper fault U
CE
or temperature fault step-up
chopper
H24 Green K4 Inverter fault U
CE
or temperature fault inverter
H25 Green K5 Cumulative fault K3 or/and K4 or/and K6 or/and K7
H26 Green K6 Earth fault Earth fault detection triggered
H27 Green K7 U
I
> U
imax
Input voltage exceeds maximum
H28 Green K8 U
I
< 100 V Input voltage threshold 100 V not
exceeded
H29 Green K9 U
I
< 100 V Connected to alarm output at connector
X100

Led Indications of Diagnostic Card TT1444


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26
Interfacing details between Inverter & OBDP


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27


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28
Onboard Display Panel of 25 KVA Inverter


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29
Input & Output Connection
+
-
Input : 90-140
VDC
Output : 3 415 V 5%


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i
a
r
i
e
s
.

A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.

30


B
o
m
b
a
r
d
i
e
r

I
n
c
.

o
r

i
t
s

s
u
b
s
i
d
i
a
r
i
e
s
.

A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.

31


B
o
m
b
a
r
d
i
e
r

I
n
c
.

o
r

i
t
s

s
u
b
s
i
d
i
a
r
i
e
s
.

A
l
l

r
i
g
h
t
s

r
e
s
e
r
v
e
d
.

32