19. April 2023

25 KVA Inverter Preventive Maintenance Training

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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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ALT 1 25KW

ALT 2 25KW

A

ABATTERY+

BATTERY --

RE

G 1

RE

G 2

TRAN

SFO

RM

ER

RECT

IFIE

R

117

PB

RSW 1

RSW 2400A

400A

400A

63 A

CONTROLFUSECOIL

PB IN P/PANEL

OLR

250 A250 A S1 NO

S2 NO

--VE JUNCTION

17

TO

IN

V 1

--V

E

TO

IN

V 2

--V

E

L /

F

--V

E

10

18

TO INV1 + VE

TO INV 2 + VE

26

FROM EXT3 PH .415 V

TO L / F&WRA +VE

250 A

+

+

+

+

-

440V AC

A

RSW1

1 – ALT1

2 – ALT2

3 – ALT 1&2

97V AC110V DC

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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, 415VAC±5%, 50Hz±3% 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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Technical Specifications of 25 KVA Inverter

Input Characteristics Sym Value

Nominal input voltage VIN 110 Vdc

Min. operation voltage VImin 90 Vdc

Max. operation voltage VImax 140 Vdc

Output Characteristics Value

Overall efficiency at full load > 92 %

3-Phase output voltage 3 x 415 VRMS ± 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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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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System overview

Input Section:– Well coordinated MCCB & fuses with fuse blown indication

– Highly accurate input current measurement

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Chopper Assembly

Gate Drive Unit

Diodes

IGBTs

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System Overview

A100.1Step UpChopper 1

IGBTdriver

boards

V11.2

V11.1

A11.1 A11.2

A08

UCE Tmax

Control board

L01.1

L01.2

U01

A03

UZ

L02.1

L02.2

PWM Inverter

IGBTdriver

boards

V11.2A11.1 A11.2

100 °C(92 °C) S12

100 °C(92 °C) S12

U02

TmaxUCE

A100.2Step UpChopper 2

IntermediateCircuitto A08

Iinput

IGBT

D

IGBT

D

IGBT

D

IGBT

D

Volt. Transd.

Volt. Divider

Uinput = 110 V nom. UZ

Step-Up Choppers & Intermediate Circuit

• Step-up chopper modules • Booster chokes• Optimized capacitor bank

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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 ONWhen 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 OFFWhen 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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Inverter Assembly

Gate Drive Unit

IGBTs

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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 IL3UCE

S32100°C(92 °C)

Tmax

V32 V34 V36

A301

EMI filter

A03

UZ

U02

UZ

Volt. Transd.

Volt. Divider

IntermediateCircuit

fromStep-UpChopper

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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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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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

Stör (= 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

Stör (= 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

Ausgelöst (= 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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LED Indications of Controller Card

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LEDs And Relay Interfaces LED Colour Relay Signal Meaning H21 Green K1 Converter ON Converter is running H22 Green K2 UI > 90 V Input voltage threshold 90 V exceeded H23 Green K3 Step-up chopper fault UCE or temperature fault step-up

chopper H24 Green K4 Inverter fault UCE 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 UI > Uimax Input voltage exceeds maximum H28 Green K8 UI < 100 V Input voltage threshold 100 V not

exceeded H29 Green K9 UI < 100 V Connected to alarm output at connector

X100

Led Indications of Diagnostic Card TT1444

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Interfacing details between Inverter & OBDP

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Onboard Display Panel of 25 KVA Inverter

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Input & Output Connection

+ -

Input : 90-140 VDC

Output : 3 ø 415 V ± 5%

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