India Railways

Terchnical Description

Converter
India 180 kVA
U760AC/415AC3-110DC/P180-2/F50
Version 2.0 May 19, 2004
Transtechnik GmbH & Co KG

All rights reserved.

No part of this manual may be reproduced
or copied in any form without the written approval
of transtechnik GmbH.

Transtechnik GmbH & Co KG . Ohmstrae 13 . D-83607 Holzkirchen . Germany . Tel +49 80 24 9 90-0 . Fax +49 80 24 9 90-300
Internet: http://www.transtechnik.com . eMail: info@transtechnik.com

India 180 kVA

TOC and List of Figures

Table of Contents
1 General ...........................................................................................................................................................4
1.1 List of Abbreviations ...................................................................................................................................4
1.2 Document History.......................................................................................................................................4
2 Technical Data ...............................................................................................................................................5
3 Diagrams ........................................................................................................................................................7
3.1 Block Diagram ............................................................................................................................................8
3.2 Circuit diagrams .........................................................................................................................................9
3.3 Mechanical drawings................................................................................................................................21
4 Functional Description................................................................................................................................22
4.1 Technical Profile .......................................................................................................................................22
4.2 Mechanical Design ...................................................................................................................................24
4.2.1

Enclosure .................................................................................................................................................................................... 24

5 Module Descriptions ...................................................................................................................................25

5.1 Input section and IVPS section ................................................................................................................25
5.2 Inverter section .........................................................................................................................................26
5.3 Low Voltage Power Supply section ..........................................................................................................29
5.3.1

Generation of the Low Voltage Power Supply.............................................................................................................................. 30

5.4

Earth fault detection .................................................................................................................................32

6 External Controlling Equipment ................................................................................................................33

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India 180 kVA

TOC and List of Figures

List of Figures
Figure 1: Circuit Diagram Sheet 1 of 12 ...............................................................................................................9
Figure 2: Circuit Diagram Sheet 2 of 12 .............................................................................................................10
Figure 3: Circuit Diagram Sheet 3 of 12 .............................................................................................................11
Figure 4: Circuit Diagram Sheet 4 of 12 .............................................................................................................12
Figure 5: Circuit Diagram Sheet 5 of 12 .............................................................................................................13
Figure 6: Circuit Diagram Sheet 6 of 12 .............................................................................................................14
Figure 7: Circuit Diagram Sheet 7 of 12 .............................................................................................................15
Figure 8: Circuit Diagram Sheet 8 of 12 .............................................................................................................16
Figure 9: Circuit Diagram Sheet 9 of 12 .............................................................................................................17
Figure 10: Circuit Diagram Sheet 10 of 12 .........................................................................................................18
Figure 11: Circuit Diagram Sheet 11 of 12 .........................................................................................................19
Figure 12: Circuit Diagram Sheet 12 of 12 .........................................................................................................20
Figure 13: Functional sections and modules of the converter............................................................................23
Figure 14: Input section and IVPS section .........................................................................................................25
Figure 15: Inverter section..................................................................................................................................27
Figure 16: Generation of sinusoidal alternating voltage .....................................................................................28
Figure 17: Low voltage power supply A401 .......................................................................................................29
Figure 18: Generation of constant DC voltage in the Low Voltage Power Supply.............................................31
Figure 19: Earth fault detection ..........................................................................................................................32
Figure 20: Left lateral service cover with controlling equipment ........................................................................33
Figure 21: Detailed view of external controlling equipment................................................................................33
Figure 22: Detailed view of converter fault display A740 ...................................................................................34

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India 180 kVA

General

General

1.1

List of Abbreviations

AC

Alternating current

CAN

Controller area network

DC

Direct current

EN

Europanorm = European standard

IEC

International Electrotechnical Commission

IGBT

Insulated gate bipolar transistor

IP

International protection (level)

IVPS

Intermediate circuit voltage power supply

LVPS

Low voltage power supply

NC

normally closed (contact)

NO

normally open (contact)

PG

Panzergewinde, a german type of pass-through fittings for cables and wires

PWM

Pulse width modulation

RMS

Root mean square

RS

Recommended standard

THD

Total harmonic distortion

VDE

Verein deutscher Elektrotechniker = Association of German Electrical engineers

1.2

Document History

File name:
Content:

20999_TechDesc_R20_040519.doc
Technical Description India 180 kVA converter

Revision Remarks

No. Pages

Author

Date

1.0

Initial release (Word 2000) preliminary version

68

J. Khn

2002-11-15

1.1

Update

68

J. Khn

2002-12-10

1.2

Update

69

J. Khn

2003-01-16

1.3

Update

68

J. Khn

2003-02-05

1.4

Updated acc. to progress of development

68

R. Niejodek

Jan 30, 2004

2.0

Updtaed acc. to final release

34

R. Niejodek

May 19, 2004

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India 180 kVA

Technical Data

Technical Data

Input characteristics
UI
UI

=
=

760 / 830 V AC
640 V
...

1110 V

UI

590 V

640 V

UI
UI
f
U
U

=
=
=
=
=

V AC
V AC
Hz ( 6 %)
V DC
V
...

950 V

Nominal intermediate circuit voltage:

Intermediate circuit voltage range:

UIC
UIC

=
=

544 V DC
500 V
...

670 V

Minimum intermediate circuit voltage:

Maximum intermediate circuit voltage:
Nominal intermediate circuit current:
Intermediate circuit current range:

UIC
UIC
IIC
IIC

=
=
=
=

450
700
276
0

290 A

Discharge time for capacitors:

300 s

Nominal input voltage:

Input voltage range:
(with nominal output power/output voltage)
Input voltage range
(with reduced output power/ output voltage)
Minimal cut-off limit:
Maximal cut-off limit:
Input frequency:
Trigger voltage for crowbar:
Crowbar trigger voltage range:

590
1110
50
950
850

Intermediate circuit characteristics

V AC
V AC
A ( 5 %)
A
...
at UI 50 V

Output characteristics
AC OUTPUT 1 (INVERTER)
Nominal input voltage (PWM inverter):
Input voltage range (PWM inverter):
Minimal cut-off limit (PWM inverter):
Maximal cut-off limit (PWM inverter):
Output voltage (phase to phase):
Output voltage range:
Frequency, nominal:
Max. output power (permanent):
Power factor:
Short-time power (for start up):
Power factor:
Maximal duration of start up:
Surge current (IPK= PAN /3/U*2):
PWM clock frequency:
Form of output voltage:
Max. total harmonic voltage distortion:

UIC =
UIC =
UIC =
UIC =
UAC =
UAC =
f =
PN =
cos
PN =
cos

t
=
IPK
=
fCLK
=

544
500
450
700
3 x 415
394
50
180
0,8
430

V DC
V ... 670
V AC
V AC
V AC ( 5 %)
V ... 436
Hz ( 1 %)
kVA

kVA

THD

<

0,5
5
846
3600
PWM sine
10

UIC
UIC
UAC
UAC
f
PN

=
=
=
=
=
=

415
394
110
99
50
0,5

s
A
Hz
%

AC OUTPUT 2 (500 VA TRANSFORMER)

Nominal input voltage of transformer:
Input voltage range:
Output voltage (phase to phase):
Output voltage range:
Frequency, nominal:
Max. output power (permanent):

20999_TechDesc_R20_040519.doc

V AC
V
...
436 V
V AC ( 10 %)
V
...
121 V
Hz ( 1%)
kVA

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India 180 kVA

Technical Data

Low Voltage Power Supply

Nominal input voltage (LVPS module):
Input voltage range (LVPS module):
Minimal cut-off limit (LVPS module):
Maximal cut-off limit (LVPS module):
Nominal output voltage (LVPS module):
Setting by factory:
Range:
Output undervoltage:
Output overvoltage:
Max. charging current (design)

UIC
UIC
UIC
UIC
UDC
UDC

=
=
=
=
=
=

UDC
UDC
ICH

=
=
=

Charging current settable with potentiometer

Charging current (set at factory)
Tolerance:
I > X (charging control):
Output power:
Charging characteristics:
Ripple:
Clock frequency of chopper:

ICH
ICH

544
500
450
700
110
110
109
115
130
22

=
=

I>X
=
P
=
I / U - curve

fCLK
=

10
15
5
2,2
2,5

V DC
V
...
V AC
V AC
V DC
V DC ( 1 %)
V
...
V
V
A

670 V

111 V

A
A
%
A
kW

22 A

2,2 mVRMS
20 000 Hz

Test voltages
INPUT, AC3 OUTPUT (TOWARDS AC1 OUTPUT, DC OUTPUT AND HOUSING)
Initial test:
Second test (80 % of initial test):

UP1
UP2

=
=

3300 V (50 Hz / 1 min)

2800 V (50 Hz / 1 min)

AC1 OUTPUT (TOWARDS INPUT, AC3 OUTPUT, DC OUTPUT AND HOUSING)

Initial test:
Second test (80 % of initial test):

UP1
UP2

=
=

2000 V (50 Hz / 1 min)

1700 V (50 Hz / 1 min)

DC OUTPUT (TOWARDS INPUT, AC OUTPUTS AND HOUSING)

Initial test:
Second test (80 % of initial test):

UP1
UP2

=
=

1500 V (50 Hz / 1 min)

1300 V (50 Hz / 1 min)

Diverse
Total efficiency at UI and full load:

92 %

Environmental conditions
Valid operating range of temperature:
Valid range of humidity:

0 C
0 %

...
...

55 C
100 %

Mechanical construction
Dimensions:

Weight:
Cooling:
Mounting:

20999_TechDesc_R20_040519.doc

Length
1740 mm
Width
700 mm
Height
1650 mm
approx.
1500 kg
IP
55 for converter
The inverter is forced cooled
Upright inside of railcar

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India 180 kVA

3
3.1

List of Diagrams

Diagrams
List of Diagrams

Diagram

Sheet no.

Block diagram (sheet 1 of 1)

uf-1127-040101

Sheet 1 of 12

Revision

Rev. date

page

May 14, 2004

uf-1127-010101

Mar 02, 2004

Sheet 2 of 12

uf-1127-010102

Mar 04, 2004

10

Sheet 3 of 12

uf-1127-010103

Mar 02, 2004

11

Sheet 4 of 12

uf-1127-010104

Mar 02, 2004

12

Sheet 5 of 12

uf-1127-010105

Mar 02, 2004

13

Sheet 6 of 12

uf-1127-010106

Mar 02, 2004

14

Sheet 7 of 12

uf-1127-010107

Mar 02, 2004

15

Sheet 8 of 12

uf-1127-010108

Mar 02, 2004

16

Sheet 9 of 12

uf-1127-010119

Apr 01, 2004

17

Sheet 10 of 12

uf-1127-010110

Mar 02, 2004

18

Sheet 11 of 12

uf-1127-010111

Mar 02, 2004

19

Sheet 12 of 12

uf-1127-010112

Mar 02, 2004

20

uf-1127-060101

Sep 10, 2003

21

Circuit Diagrams

Mechanical Drawings
Sheet 1 of 1

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20999_TechDesc_R20_040519.doc

AC Input
760/830 V
50Hz
(590 -1110 V)

1L2

1L1

450 A

F101

F101 blown

EMI
Module

L01.1-.3

A101

U101 Volt.
sensor
A102 Volt.
divider

L102

X5

Driv.

X7

A722

Short Circuit
Thyristor

V01

L201

U501 Volt.
sensor
A501 Volt.
divider

UIC

15 V DC

Internal CAN bus

Disable

A01

A202

U01

IIC

SCR Control Board

(tt1933-1/05 D)

Driv.

Protection Circuit

General
Fault

Semi Controlled
SCR Bridge

A201

K4 Relays K5

X7

Temp.
Pre-warning

One Phase
Filter

L101

A750

UInp

A702

Converter Control Board (tt1932-1/33 F)

A710

X700

UIC

L01

Drv.

UCE

L02 T01

A03

nderung
Modification

Erstausgabe / 1st Revision

Datum
Date

Dec 14, 03
Jan 11, 00

revised
I
A
Zustand
Revision

Mar 30, 04 nio

Mar 03, 04 AWi

Add A710 K4
Add Q302, change A202

Name
Name

nio
rp

Ext. disable, inverter, T302... May 14, 04 nio

L
K
J

Tel. (201) 8 28 98 04
Fax (201) 8 28 98 13

transtechnik Corp. USA

U01

27 McKee Drive, Mahwah, NJ 07430, USA

L03

Rectif.
Bridge

A303

AC Filter

L303

L302

L301

A304 Volt.
divider

Ohmstr. 1-3, 83607 Holzkirchen/Germany

Tel. (0 80 24) 990 - 0

Fax (0 80 24) 990 - 330

UBatt 15 V

X3
RS232

A720

Q302

Q301

25 A

F401

S902

S901

M902
3~

M901
3~

P902

LB-

LB+

2L2

2L1

3L3

3L2

3L1

Schlickenr. P

May 14, 04

Ident-Nr.:
Ident no.:

Ersatz fr:
Replacement for:

Zeichnungsnr.:
Drawing no.:

Ersetzt durch:
Replaced by:

UF-1127/04-01

P901
444.4V

Fan 2

Fan 1

P903

Display Board
(tt1823-2/03 A)

A402

DC EMI-Filter

L01

AC EMI-Filter

A302
L01.1-.3

X4

A740

Blockschaltbild
Block Diagram

India 180 kVA

R. Niejodek

Name
Name

C701

V701

Single Phase
Transformer

T301

Q902

Q901

RS485

U760AC/415AC3-110DC/P180-2/F50

10 A

F701

Autotransf.

T302

May 14, 04

Datum
Date

Visio 2000

Bearbeitet:
Design:
Geprft:
Checked:
Norm:
Approved:

Bezeichnung:
Designation:

Projekt:
Project:

Typ:
Type:

Monitoring

Temp
AC feedb. T302 Q301 Fan

15 V
DC
Power Supply

U301 Volt. A730 Signal

sensor
Condit.

UAC

transtechnik GmbH

A301.3

Drv.

IL1 IL2 IL3

Inverter Control Board

(tt1619-1/68 C)

A301.2
PWM inverter

A703

Low Voltage Power Supply

A01

Drv.

A301.1

UCE T ICharge UBatt

A02 Driver

A401

R301

Volt. U502
sensor
Volt. A502
divider

C301

CAN

A704
LVPS Control Board
(tt1967-2/24 E)

Volt. A770
divider

GND fault

Battery

1
1

Blatt
Sheet
von
of

20999

DC output
110 V DC
2 kW

1 phase output
110 V AC
500 VA
50 Hz

3 phase output
415 V AC
180 kVA
50 Hz

AC output
phase currents

AC output
phase voltages

AC input voltage

10

3.2

The copying, distribution and utilization of this document as well as the communication of its contents,
to others without expressed authorization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, utility model or ornamental design.

Weitergabe sowie Vervielfltigung dieses Dokuments, Verwertung und Mitteilung seines Inhalts sind
verboten, soweit nicht ausdrcklich gestattet. Zuwiderhandlungen verpflichten zu Schadenersatz. Alle
Rechte fr den Fall der Patent-, Gebrauchsmuster-oder Geschmacksmustereintragung vorbehalten.

India 180 kVA

Block Diagram

Block Diagram

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India 180 kVA

3.3

Circuit Diagrams

Circuit diagrams

Figure 1: Circuit Diagram Sheet 1 of 12

20999_TechDesc_R20_040519.doc

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India 180 kVA

Circuit Diagrams

Figure 2: Circuit Diagram Sheet 2 of 12

20999_TechDesc_R20_040519.doc

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India 180 kVA

Circuit Diagrams

Figure 3: Circuit Diagram Sheet 3 of 12

20999_TechDesc_R20_040519.doc

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India 180 kVA

Circuit Diagrams

Figure 4: Circuit Diagram Sheet 4 of 12

20999_TechDesc_R20_040519.doc

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India 180 kVA

Circuit Diagrams

Figure 5: Circuit Diagram Sheet 5 of 12

20999_TechDesc_R20_040519.doc

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