ABB Manual PDF

BORDLINE M180 AC Auxiliary Converter
Type: AL D715 C01
Operation & Maintenance Manual
Document Number
Release Version & Date
ABB Ltd
3BHS249852 E04
3BHS249852 E04
Rev.0, 30th Jan 2009
Page 1 of 65
Notice
The information in this document is subject to change without notice and should not be construed as
a commitment by ABB Ltd. This document has been prepared and checked with great care. If
however it still contains errors, then the user is asked to report these to ABB and ABB assumes no
responsibility for any errors that may appear in this document.
In no event shall ABB Automation Technology Products be liable for direct, indirect, special,
incidental or consequential damages of any nature or kind arising from the use of this document, nor
shall ABB Automation Technology Products be liable for incidental or consequential damages
arising from use of any software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without written permission from
ABB and the contents thereof must not be imparted to a third party nor used for any unauthorized
purpose.
Software & hardware described in this document were furnished under a license/contract and may be
used, copied or disclosed only in accordance with the terms of such license/contractual agreements.
Copyright 2009 ABB Ltd.
All rights reserved.
ABB Ltd
3BHS249852 E04
Page 2 of 65
Table of Contents
Chapter 1 - Safety Precautions.................................................................................................................. 6

1.1.
General ............................................................................................................................................ 6
1.2.
Introduction ..................................................................................................................................... 6
1.2.1
Responsibility .................................................................................................................................. 6
1.3.
Safety Instructions ........................................................................................................................... 6
1.4.
Safety & Protection Concept ........................................................................................................... 7
1.5.
General Notes on Safety .................................................................................................................. 7
Chapter 2 - Introduction............................................................................................................................ 9
2.1
Purpose of Document ...................................................................................................................... 9
2.2
Tareget Group & Required Qualifications ...................................................................................... 9
2.3
Manual Contents.............................................................................................................................. 9
2.4
Contact Details .............................................................................................................................. 10
Chapter 3 - Equipment Description........................................................................................................ 11
3.1
Brief Description ........................................................................................................................... 11
3.2
Block Diagram............................................................................................................................... 12
3.3
Electrical Schematics..................................................................................................................... 13
3.4
Mechanical Drawing ..................................................................................................................... 13
3.5
Arrangement of Components......................................................................................................... 14
3.6
Control Power Supply ................................................................................................................... 16
3.7
Control Electronics........................................................................................................................ 16
3.8
Control Board Description............................................................................................................. 17
3.9
Control Electronics Block Diagram .............................................................................................. 18
Chapter 4 - Mechanical Construction .................................................................................................... 19
4.1
Mechanical Arrangement .............................................................................................................. 19
Chapter 5 - Cooling System..................................................................................................................... 20
5.1
Cooling Concept ............................................................................................................................ 20
5.2
External Ventilation....................................................................................................................... 20
5.3
Internal Ventilation........................................................................................................................ 20
5.4
Power Supply for Cooling Fans..................................................................................................... 20
Chapter 6 - Electro Magnetic Compatibility ......................................................................................... 21
6.1
EMC Concept ................................................................................................................................ 21
Chapter 7 - Power & Control Interface ................................................................................................. 22
7.2
Power Wiring................................................................................................................................. 22
7.3
Control Wiring & Interface ........................................................................................................... 24
Chapter 8 - Converter Operation ........................................................................................................... 25
8.1
Self Test......................................................................................................................................... 25
8.2
Preparation for establishing communication with PC ................................................................... 26
8.3
IP Address Configuration .............................................................................................................. 27
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8.4
8.5
8.6
8.7
8.8
Verifying Communication State.................................................................................................... 28

Bordline View Configuration & Startup .................................................................................... 30
Converter Operating Sequence...................................................................................................... 32
Sequence Control (State Machine) ................................................................................................ 32
Description of Operating Sequence ............................................................................................... 33
Chapter 9 - Functional Description ........................................................................................................ 34

9.1
Input Passive Unit.......................................................................................................................... 34
9.2
IGBT based active front end rectifier ............................................................................................ 35
9.3
IGBT based output Voltage Source Inverter ................................................................................. 36
9.4
Voltage Limiting Unit ................................................................................................................... 36
9.5
Battery Charger ............................................................................................................................. 37
Chapter 10 - Battery Charging Characteristics ...................................................................................... 38
10.1
Charging Characteristics................................................................................................................ 38
Chapter 11 - Display & Diagnostics.......................................................................................................... 39
11.1
Introduction ................................................................................................................................... 39
11.2
Pilot Lamp Indication ................................................................................................................... 39
11.3
LCD ............................................................................................................................................... 40
11.3.1 Parameter Display ......................................................................................................................... 40
11.3.2 Fault Display ................................................................................................................................. 41
11.4
Earth Fault Bypass......................................................................................................................... 42
11.5
Service Access............................................................................................................................... 42
11.6
Bordline View Diagnostic Tool.................................................................................................. 42
11.7
Bordline View User Interface..................................................................................................... 43
11.8
Bordline-View : Transient Recorder .......................................................................................... 44
11.9
Bordline-View : Transient Recorder data interpretation ............................................................ 44
Chapter 12 - Protections ............................................................................................................................ 45
12.1
Protection concept ......................................................................................................................... 45
12.2
Protection zones............................................................................................................................. 45
12.3
Trips............................................................................................................................................... 46
12.4
Fault Classification........................................................................................................................ 46
12.5
Protection Zones............................................................................................................................ 47
12.6
Faultwords & limits ....................................................................................................................... 49
12.6.1 Zone 1 Input circuit .................................................................................................................... 49
12.6.2 Zone 2 U21 (4QS) ...................................................................................................................... 49
12.6.3 Zone 3 DC link ........................................................................................................................... 50
12.6.4 Zone 4 U22 (VLU) ..................................................................................................................... 50
12.6.5 Zone 5 U23/U22 Inverter (WR) ................................................................................................. 50
12.6.6 Zone 6 U23/U22 Inverter Gate Driver (WR) ............................................................................. 51
12.6.7 Zone 7 U24 Full bridge DC/DC converter (BL) ........................................................................ 51
12.6.8 Zone 8 Battery output circuit...................................................................................................... 51
12.6.9 Zone 9 Main Control .................................................................................................................. 52
12.6.10 Zone 10 Temperature sensor alarm ............................................................................................ 52
Chapter 13 - Electrical & Mechanical Installation ................................................................................. 53
13.1
Installing the Converter inside Locomotive .................................................................................. 53
13.2
Electrical Connections................................................................................................................... 54
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Chapter 14 - Commissioning ..................................................................................................................... 55

14.1
Preparation for Commissioning..................................................................................................... 55
14.1
.1 Visual Checks............................................................................................................................ 55
14.1.2 Wiring............................................................................................................................................ 55
14.2
Commissioning.............................................................................................................................. 55
Chapter 15 - Maintenance Instructions.................................................................................................... 56
15.2
General Maintenance Work........................................................................................................... 56
Chapter 16 - Repair Instructions .............................................................................................................. 57
16.1
Service Concept............................................................................................................................. 57
16.2
Requirements for Carrying out Repairs on the Vehicle................................................................. 57
16.2.1 Looking for Faults with the Converter Installed............................................................................ 57
16.2.2 Replacement of the Defective Components .................................................................................. 57
16.3
Requirements for Repairs Carried out Outside the Vehicle .......................................................... 58
16.3.1 Replacement of the Defective Components .................................................................................. 58
16.3.2 Looking for Faults in Converter which is not Installed................................................................. 58
16.4
Procedure on the Occurence of a Fault in the Converter............................................................... 58
16.4.1 Safety Precautions ......................................................................................................................... 58
16.4.2 Converter Reset ............................................................................................................................. 59
16.5
Request for Fault Diagnosis & Replacement of Parts ................................................................... 59
16.6
Packing and Shipment ................................................................................................................... 60
16.7
Name Plate..................................................................................................................................... 60
Chapter 17 - Packing, Transportation & Storage ................................................................................... 61
17.1
Packaging Information .................................................................................................................. 61
17.1
.1 Packaging Instructions for Returned Components .................................................................... 61
17.2
Transportation................................................................................................................................ 61
17.2.1 Lifting & Moving the converter .................................................................................................... 61
17.2.2 Power Modules.............................................................................................................................. 61
17.3
General Storage Conditions........................................................................................................... 61
Chapter 18 - Technical Data...................................................................................................................... 62
18.1
Input Data ...................................................................................................................................... 62
18.2
Output Data ................................................................................................................................... 62
18.2.1 AC output ...................................................................................................................................... 62
18.2.2 DC output ...................................................................................................................................... 62
18.3
Communication,Display & Signalisation ...................................................................................... 63
18.4
Mechanical Data ............................................................................................................................ 63
18.5
General Data .................................................................................................................................. 63
18.6
Environmental Specifications........................................................................................................ 64
18.7
Test Voltages ................................................................................................................................. 64
Chapter 19 - Additional Documentation .................................................................................................. 65
19.1
Annexures...................................................................................................................................... 65
ABB Ltd
3BHS249852 E04
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Chapter 1 -Safety Precautions

1.1.
General
Experience & familiarity with full implementation of safety regulations, safety instructions and
warnings stated in this manual are essential for safe installation, commissioning as well as for safety
during operation, maintenance and servicing of BORDLINE M180 AC auxiliary converter.
Only qualified personnel having specialist knowledge required to correctly interpret and implement
the safety requirements & instructions presented in this manual should be allowed to work on the
converter.
Fleet operator/owner must ensure that all the specified technical & environmental conditions are
fulfilled.
1.2.
Introduction
1.2.1 Responsibility
Customer or fleet operator of is responsible for ensuring that every person involved with the
installation, operation or maintenance of this equipment has read and understood the safety
regulations stated below and the safety notes given in the individual chapters. In particular the fleet
operator is responsible for the safety and training of personnel and prevention of material damage.
The fleet operator is also responsible for compliance with the applicable general regulations
concerning work safety, the safety regulations for working on low voltage electrical installations and
the specific safety regulations imposed by the application.
It is the customers or owners responsibility that all persons involved in the installation, operation
and maintenance have completed an appropriate course of training and have thoroughly read and
understood this manual.
When working with the static converter, all persons must comply with the appropriate regulations and
with the notes on safety contained in this operating manual.
Modifications and constructional changes to converter by fleet operator/owner are not allowed unless
authorized and approved by ABB. Maintenance staff of fleet operator/owner must ensure that the
converter is in fully serviceable state during its operating lifetime.
1.3.
Safety Instructions
Safety instructions always appear at the beginning of a section and/or in the context of instructions
which may involve potentially hazardous situations. The notes on safety have been divided into the
following five categories:
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3BHS249852 E04
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DANGER!
This symbol indicates an immediate and imminent hazard which can
lead to serious bodily injury or death.
WARNING!
This symbol indicates a potentially hazardous situation, which if not

avoided, could result in death or serious injury.
CAUTION!
This symbol indicates a potentially hazardous situation, which if not
avoided, may result in minor or moderate injury.
NOTE!
This symbol indicates a situation which could lead to damage, one in
which either the product or objects in its immediate vicinity could be
damaged & as attention to refer other information.
IMPORTANT!
This symbol is used to indicate notes on use and other useful
information. It may not be used to indicate dangerous or potentially
harmful situations.
1.4.
Safety & Protection Concept

NOTE! : Converter is designed with safety devices, required as per
design, which allow safe installation and risk free operation of
equipment if it is used correctly and in agreement with this manual.
However certain residual risks can still remain, and in particular where
notes on safety contained in this manual are ignored.
1.5.
General Notes on Safety
When working on the static converter it should be remembered that it is anelectrical equipment with
potential hazards to life and property if safety regulations are not followed correctly. Therefore user
must strictly comply with all the electro-technical safety regulations when handling it.
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DANGER! :
When input voltage is switched on, any contact with inside parts of the
converter can be fatal!
If you have to remove the cover of the converter to carry out maintenance or repair work, then make
sure that you follow the instructions given below:
DANGER!
The following safety regulations must be complied with before starting
any work on the static converter :
Disconnect or fully isolate input & output connections.
Make sure the converter cannot be switched ON again.
Wait for minimum 5 minutes to allow trapped energies in capacitors

are fully discharged, before proceeding for any work inside the
converter.
Check for presence of voltages with suitable test equipment before

touching or accessing any component.
Isolate/Insulate any parts which are live.
WARNING!
There is a risk of short-circuiting if any of the live terminals come into

contact with metallic objects such as wrist watches, rings, tools etc.
Make sure locomotive battery is disconnected!
CAUTION!
An earth strap must be connected between the users wrist and the
frame of a unit while accessing control electronic boards. Control
electronics could otherwise be destroyed by static electricity.
Watch out for sharp edges when the converter is open.
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Chapter 2 -Introduction
2.1
Purpose of Document
This operating manual pertains to BORDLINE M180 AC static converter type AL D715 C01 and is
intended to document the purpose, the type of use, operation and maintenance and the technical
details of the converter.
The following terms are interchangeably used at different places in this manual to signify
BORDLINE M180 AC static converter of type AL D715 C01:
static converter
auxiliary converter
converter
equipment
2.2
Tareget Group & Required Qualifications
The AL D715 C01 operating manual is aimed at the following target groups:
assembly and commissioning staff
operating staff
maintenance staff
The term "staff" refers to technical personnel (in accordance with EN 292) who have special
mechanical and electrical skills required to commission/operate/service similar equipment.
2.3
Manual Contents
This operating manual for the type AL D715 C01 converter contains detailed information on:
Description of converter
Installation & Commissioning
Operation & Maintenance
Diagnostics &Troubleshooting
Packing & Transport
Replacement of components
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3BHS249852 E04
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2.4
Contact Details
Please contact us at the following for any questions or comments on this manual and for technical
problems encountered during operation & maintenance of converter.
Contact Address:
ABB Ltd,
Dept: ATDP, Power Electronics Systems,
Traction Converters,
Plot no: 5&6, 2nd Phase, Peenya Indl.Area,
Bangalore 560058, Karnataka
Contact Information:
Telephone
: +91 2294 9409/9583
Facsimile
: +91 2294 9389
24 hrs Helpline
: +91 99014 90130
Email Id
: service.traction@in.abb.com
ABB Ltd
3BHS249852 E04
Page 10 of 65
Chapter 3 -Equipment Description

3.1
Brief Description
BORDLINE M series air cooled static converters are compact, rugged units for use as onboard
auxiliary power supplies in rail vehicles. Bordline M180 AC static converter is housed in a single
cubicle with H type construction suitable for onboard mounting in different types of conventional
single phase (tap-changer type) locomotives.
BORDLINE M180 AC static converter is equipped with Power Electronic Building Blocks (PEBB),
which is the new paradigm for designing high reliability static power conversion systems. These
PEBB modules together with their hardware managers provide an optimum solution for the highspeed control requirements of demanding power electronic systems.
The main controller, PEC 800, is realized with a digital system architecture based on microcontrollers
& FPGA, offering powerful computational resources as well as communication interfaces, enabling
ease of operation and interaction.
Control signals together with state variables measurements and various commands are transmitted
through and across hierarchies using common communications protocol, which enables PnP
capabilities to the system, exuding in modularity, re-configurability and reusability.
Input supply from the two auxiliary windings (a0-a1 & a7-a8) of traction transformer are separately
wired to the converter and connected in parallel inside the converter and connected to an IGBT based
single phase full bridge converter which converts the single phase AC input into a regulated DC
voltage, draws near sinusoidal input current and operates at unity power factor (Cos Phi) for its entire
operating range.
DC link is connected to an IGBT based three phase voltage source inverter, which generates three
phase sine weighted output of 415 V, 50 Hz output. This PWM output is delivered to auxiliary loads
through a sine filter, which filters out the switching current ripple and ensures output voltage
distortion is maintained below 10 %.
Operation of converter in presence of an earth fault is provided to enable the loco pilot clear the
section in case of earth fault in the middle of a section, in any of the auxiliary loads. Inverter will first
trip on earth fault in the event of an earth fault in any one of the phases of auxiliary load. However
earth fault trip can be bypassed for a period of 45 minutes by enabling the earth fault bypass switch
provided in the converter front panel.
DC link of 180 kVA static converter is also connected to a IGBT based switch mode type battery
charger which generates 110 Vdc required for charging vehicle battery & powering the DC loads in
the locomotive. 110 Vdc output is galvanically isolated from the input AC supply of static converter
& its AC output.
Bordline M180 converter has been designed to conform to IEC 61287 and other applicable
standards for rolling stock converters, as far as they are relevant to this type of equipment. An EMC
concept was specifically developed for this equipment, and also existing guidelines which were
formulated by EMC specialists from ABB have been complied with.
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3BHS249852 E04
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3.2
ABB Ltd
Block Diagram
3BHS249852 E04
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3.3
Electrical Schematics
Electrical schematic (3BHS249852 ZAB E03) of Bordline M180 AC static converter is provided
as annexure to this manual.
3.4
Mechanical Drawing
Dimensional drawing (3BHS248948_E05) of Bordline M180 AC static converter is provided as

annexure to this manual.
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3.5
Arrangement of Components
The following photographs show the arrangement of various components inside the converter. The figures show only the most important
components and elements.
Swing door display
Control Cabinet
Internal fan
Additional capacitor bank
Battery charger
Axial fan
Terminal chamber
Input choke
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Sine filter choke

3BHS249852 E04
Power modules
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Access for PM
inspection
Centrifugal fan
Fig : Rear Side View
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3BHS249852 E04
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3.6
Control Power Supply
Bordline M180 AC static converter requires 110 Vdc supply for its control electronics and is
derived from vehicle battery (Vbatt + & Vbatt-). This 110 Vdc supply from vehicle battery is fed to
the converter via connecter X15 and MCB S 971 , provided inside the converter and is fed to power
supplies G956 & G957 through a bridge rectifier, which provides reverse polarity protection for the
control electronics. The total power consumption of electronics is approximately 250 W.
Power supply G956 generates+ 15 V, 4A & + 5 V, 5.5 A outputs for powering the main control
electronics, current & voltage transducers, LCD & LED pilot lamps.
Power supply G957 generates 2 x 24 V, 2.2 A outputs for powering gate drive cards of all power
modules. (PM1 & PM4).
The power supply unit can bridge short interruptions of less than 10 ms to ride through short time
interruptions/sags during normal operation. Converter stops all the control signals if the break in
power supply is longer than 10 ms. Converter control stops all the control signals and protects the
converter safely, if the external 110 Vdc power supply from vehicle battery is disconnected for any
reason for more than 10 ms while converter is in operation.
Refer to electrical schematics 3BHS249852 ZAB E03 to check the connections and wiring of control
power supply.
3.7
Control Electronics
The Bordline Compact Converter Control PP D114 is a control platform for power converters in
traction applications. It is built modularly and can be made up with multiple boards in different
combinations based on application requirement. The core is the main controller AC 800 PEC, which
is a modular high speed programmable control device from ABB and is the optimum solution for
combining the high-speed control requirements of power electronics applications and low-speed
process control tasks.
The backplane consists of the CCC Base Board XV D824, which also hosts digital and analog IOs
required for basic converter applications. More application interfaces and IOs can be added with the
CCC Extension board XV D825, which can be plugged directly to the XV D824. A general purpose
digital interface is available on the XV D824 where a wide range of communication interfaces can be
adopted.
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Fast, time-critical control and I/O tasks are programmed by means of MATLAB/Simulink and
integrated into the control environment as a Simulink I/O unit. These fast control tasks and
configuration of the PEC 800 specific fast I/O's are programmed by means of MATLAB/
Simulink and Real Time Workshop (RTW). High Speed time-critical, hardware- specific
functions such as pulse-width modulators, pulse logic with associated protective functions, fast analog
and binary inputs and outputs, etc are implemented in FPGA and programmed in VHDL.
This board also has an Ethernet and RS232 port for system configuration, diagnostics and vehicle bus
communication. Additional potential free relay contacts are available for indications, alarms and for
remote signalling purposes. The driver electronics of the converters convert the information from the
control electronics into trigger signals and is also responsible for the protection of the power
semiconductors.
3.8
Control Board Description
The following boards are used in the BORDLINE M180 AC static converter (Refer section 3.9 for
block diagrams of major boards & electrical schematic for interconnection between boards):
Type (Designation)
Name
XV D824 (U31)
Compact
converter control
Functional description
-
Houses FPGA
Interfaces for V & I transducers.
Digital I/Os
NTC Temperature sensors
Service connection
CAN LCD display
Gate drivers
XF D151 (U33)
CAN
board
converter
Converts CAN optical pulses from XV

D824 to electrical signals for LCD
UF D827 (U32)
Optical extension
board
Interfaces between XV D824 and (GD

D830 & XF D151)
GD D830 (U51-U58)
Dual IGBT gate

driver
Current & DC link voltage

measurement
ECOMOT100(U41)
LCD dispaly
Vce saturation detection
Overcurrent
DC link overvoltage
Gate output short circuit /overload
Top/bottom switch interlock
DC link short circuit detection
Soft turn-ON & turn-OFF
LCD display
Table: Control boards description
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3.9
Control Electronics Block Diagram
Fig. : Control hardware block diagram
Fig. :: Compact converter control XV D824 (U31) with interfaces
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Chapter 4 - Mechanical Construction

4.1
Mechanical Arrangement
The converter is built with mild steel into a cabinet for onboard mounting inside locomotive and is
mechanically partitioned into two compartments of different ingress protection (IP) categories. One
compartment, with ingress protection level of IP 65, contains mainly the power modules of the entire
converter in four heatsinks, control electronics, auxiliary power supplies for control electronics,
switchgears and a cooling fan for internal air circulation. Higher ingress protection level of this
compartment protects the components from external environmental factors, thereby enhancing their
reliability.
The second compartment, with ingress protection level of IP 21, mainly contains the input inductor,
output sine filter, power & control terminals for interfacing the converter with the vehicle and an axial
fan for cooling. Apart from the above the converter is also provided with an LCD unit for parameter
& fault data display, pilot lamps to indicate the status of the converter and an ETHERNET interface
for service & diagnostics.
In order to have ease of replacement, the input converter and output inverter power modules are made
identical. The complete converter contains four power modules. One PEBB module contains the
active front end rectifier, two modules contain the inverter & voltage limiting unit and one power
module contains the battery charger.
Detailed dimensional drawing of Bordline M180 AC converter is given in drawing

3BHS248948_E05.
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Chapter 5 - Cooling System

5.1
Cooling Concept
The cooling of power modules and the converter is realized by means of forced air circulation with
four fans. Thermal monitoring devices are provided on different converter components to monitor
the temperatures and to protect them from thermal overloads.
5.2
External Ventilation
External air is sucked from the backside of the converter by a centrifugal fan (E951) and forced
through the heat sinks of converter & inverter power modules (PM1- U21 to 23) via an air duct at
the bottom. An axial fan (E952) is used for cooling input inductor (L701), sine filter inductor (
L705 707), battery charger power module (PM4 U24), power & control terminal interfaces (X1 to
X11) and input fuse (F981).
5.3
Internal Ventilation
Two centrifugal fans (E953 & E954) are used to cool the components inside the IP 65 chamber and
to maintain uniform temperature inside the power module and control electronics compartment by
circulating the air inside the IP 65 chamber.
5.4
Power Supply for Cooling Fans

All fans derive their supply (3 Phase, 415 V, 50 Hz) for their operation from inverter AC output and
are provided with a common manual motor starter for overload & short circuit protection. Refer to
Sec.3.3 Electrical Schematics for fan connections and Sec 14 Arrangement of Components for
location of different fans.
Fan
Operation
E951
Air inlet @ the back of converter behind the PM 1 modules.
Air outlet from the heat sink of U22. Velocity of air at heat sink outlet
should be minimum 10m/s
E952
Air inlet @ left side of the converter under display swing door.
Air outlet @ front of the converter above H cutout. Velocity of air at heat
sink outlet should be around 4 -5 m/s
E953
Blows air into the control cubicle
E954
Blows air into the PM1 module chamber
IMPORTANT! : Please verify & ensure correct rotational direction of fan
and check velocity of air at outlets are as below while commissioning the
converter for the first time or after repair work was done on the converter.
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Chapter 6 - Electro Magnetic Compatibility

6.1
EMC Concept
Bordline M180 converter has been designed to conform to the EMI/EMC requirements outlined in
IEC 61287 and other applicable standards for rolling stock converters, as far as they are relevant to
this type of equipment. An EMC concept was specifically developed for this equipment, and also
existing guidelines which were formulated by EMC specialists from ABB have been complied with.
The converter output is provided with midpoint grounded sine filter which eliminates the common
mode voltage at inverter output, to protect the motor insulation. With the sine filter the maximum
increase in the ripple voltage, which overlays the fundamental output voltage is also limited to <
10V/us.
Further, internal return of the HF interference currents to the source by means of Y capacitors
minimizes the emissions given off by the cables.
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Chapter 7 - Power & Control Interface

7.2
Power Wiring
Bordline M180 AC static converter is designed for operating with a nominal voltage of 380/415 V.
Therefore input supply from the auxiliary windings (a0-a1 & a7-a8) of traction transformer should be
separately wired to the converter. Bus bar terminals are provided inside the converter terminal
assembly for power cable terminations as given below.
Input Terminals
DC Output Terminals
AC O/p Terminals
Power Earth
: X1 to X4
: X5 to X8
: X9 to X11
: X12
DC Output Terminals
: Suitable for connecting 120 sq.mm cable with M-16 Bolt.

AC O/p Terminals
Power Earth
Input Terminals
Control Interface
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Following modifications needs to be carried out/ensured on the

locomotive, before connecting power cables to transformer
auxiliary windings or to the converter. Input power connections
should be as per fig. given below
Auxiliary windings (a0 a1) & (a7 a8) MUST NOT be connected
together. Link provided in the transformer to connect a1 & a7
terminals in series must be REMOVED.
Midpoint grounding of 1 uFD (0.47 uFD x 2) filter capacitors
provided across auxiliary windings MUST BE REMOVED and
capacitors should be connected as shown in fig. below
RC surge suppressor provided across transformer auxiliary
windings MUST be connected as below to avoid overheating of
resistors due to switching frequency ripple current.
Fig : Input power connections
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7.3
Control Wiring & Interface

The following inputs/outputs are delivered or received by the converter from vehicle control, as
control interfaces. Terminal blocks suitable for 12 nos x 1.5 to 4 sq.mm cables is provided inside the
converter terminal assembly for these interfaces.
Converter
Terminal
(X15)
Signal Description
1 & 21
110 Vdc battery voltage for control power supply
3&4
DI - START command from locomotive control system
7 & 83
9 & 10
DO - NO-NC, INVERTER ON feedback to locomotive control system

3
13 & 143
DO - NO-NC, CONVERTER TRIP feedback to locomotive control system

DO - NC-NO, CHBA TRIP feedback to locomotive control system
Reverse polarity protected (77 140 V DC),
NO contact from vehicle control
All contacts rated for 4A, 110V DC
DI Digital Input, DO Digital Output
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Chapter 8 - Converter Operation

8.1
Self Test
PP D114 compact converter control is equipped with four system status LEDs (V1900 to V1903) that
are placed on XV D824A CCC Base Board. These four LEDs indicate different device states and the
status of control electronics can be interpreted without additional hardwired connections by
monitoring their indicating status.
110 Vdc supply to control electronics should be switched ON and the LEDs status should be
monitored during the self test/booting process as given below. Converter is ready for operation and
application software can be downloaded only after successful completion of this test.
Green LEDs 2, 3 & 4 will glow permanently on successful completion of self test/boot up process.
Any other status indication point to potential problems with control electronics and appropriate action
shall be taken as per the status matrix given below.
LED No
LED_1: V1900
Color
Red
Marking
F(ault)
LED_2: V1901
Green
R(un)
LED_3: V1902
Green
P(ower)
LED_4: V1903
Green
S(upervisor)
Status and Meaning in Running State

LED is turned OFF.
LED may be turned ON to indicate a severe
system fault.
LED is SW controlled.
Fault, indicates error in PP D103A Software
LED is turned ON if FPGA is configured.
LED is turned OFF if the FPGA is cleared.
Run/Config Done, indicates that the FPGA
configuration in PP D103 is done successfully
LED is turned On.
LED is turned OFF if supply is out of range.
LED is HW controlled.
Power OK, indicates that the local power
supervision on the PP D103 has not detected
any errors
LED is turned ON.
LED is turned OFF if any operating condition is
out of range.
On successful completion of SELF TEST, SI unit OK LED on the converter front panel will glow.
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8.2
Preparation for establishing communication with PC

To establish communication with the converter and to view the converter status,
parameters, fault data etc with Bordline View Maintenance Tool the following
requirements/preparations are necessary.
1. A computer with Bordline View Software installed in it. Refer to the screen shot attached
below to check whether the required software is properly installed in the service PC.
2. Authorization for the users account to change IP Address of the PC used for service.
3. Crossover Ethernet Cat. 5 cable to connect the computer with the controller. Verify the cable
as per the pin out configuration given below.
From Connector 1
Pinout
1
2
3
4
5
6
7
8
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3BHS249852 E04
To Connector 2
Pinout
3
6
1
none
none
2
none
none
Page 26 of 65
4. Necessary project (.prj) & variable (.var) files are copied into the respective folders. Go to
Windows Explorer and verify presence of project specific .prj & .var files as shown in screen
shot below.
NOTE! : Refer to BORDLINE View maintenance tool users

manual, 3BHS221602 ZAB E01, Rev. A, attached as annexure to this
document, for further details.
Please contact ABB if the user does not have .var & .prj files.
8.3
IP Address Configuration
Before connecting the service PC to RJ 45 ETHERNET interface, following settings have to done as
per the procedure below.
Setup the Ethernet connection in the PC to a fixed IP-Address. Administrator rights on the PC
are required to do these changes.
To change TCP/IP-settings go to Windows Start-menu/Settings/Control Panel/Network

Connections/LAN (Click on LAN).
Click on Properties tab in the LAN Status window.
In the LAN Properties window select Internet Protocol (TCP/IP) and then click on the
Properties button.
Select Use the following IP address option and set the IP-address to 10.10.1.102 and
Subnet-mask as 255.255.0.0 as shown below,
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Fig.: PC IP Settings
8.4
Verifying Communication State

1. Interconnect service PC (TCP/IP port) and the converter (front panel RJ 45 harting
connector) with an Ethernet cross over cable.
2. Switch ON control electronics power supply and wait till control electronics self
check & booting processes have completed.
3. Go to Windows Start menu, Click on RUN.
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4. Type cmd and press OK to open MS DOS command prompt.
5. Type ipconfig and check the IP setting of service PC as shown in screen shot
below. IP Address & Subnet Mask values should be same as those set by the user as
per instructions in sec 27.
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Page 29 of 65
6. Type ping 10.10.1.101 and check whether the reply from PEC 800 controller is
received and there is no loss of data as shown is screen shot below.
7. Successful completion of stage 6 completes the tasks required to establish and verify
communication between service PC and the converter.
8.5
Bordline View Configuration & Startup

BORDLINE View maintenance tool is required to monitor converter parameters and
download fault data. This software tool runs under Windows 2000/XP on a standard
PC.
Configuration :
Interconnect service PC (TCP/IP port) and the converter (front panel RJ 45 harting
connector) with an Ethernet cross over cable.
Switch ON control electronics power supply and wait till control electronics self
check & booting processes have completed.
Establish communication between converter and service PC as per the instructions in

sec 27, 28 & 28.
Before starting Bordline View copy project specific variable list file
(IR_180kVA_H_Test.var) in the following directory: Program
Files\AbbMaintTool\VarLists and project file (IR_180kVA_H_Test.cfg) into the
following directory: Program Files\AbbMaintTool\Projects
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Startup :
Start Bordline View application and select the corresponding project
(IR_180kVA_H_Test) from the Project List and setup from the Setup List. Different
setups are available for different tests.
Fig.: Bordline View setup selection
Fig Bordline View user interface
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8.6
Converter Operating Sequence

All control and monitoring functions are dealt with by the control electronics, which is fitted with a
processor. As the control power supply is switched ON, the control electronics goes through selftests and initialization routines and then the control software application is started. When the input
voltage is within the operating limits, converter starts automatically if START signal from vehicle
control is present.
On receipt of START command, pre-charging contactor is closed to charge the DC link through a
current limiting resistor. Main contactor is closed, as soon as DC-Link is charged to a pre-set value
and charging contactor is opened.
After synchronization with the input supply, Battery charger modulation is started and grid control
for input 4QC is started. Shortly afterwards AC & DC output will be available at the inverter and
battery charger output terminals and DC link voltage limiting unit (VLU) will be initialized and kept
ready.
In case of a trip either the particular output sections are stopped or the entire converter except VLU
will be stopped based on the nature of trip and will remain in that state till the fault is cleared or the
reset button is pressed. For details of trips refer to section [12.3]
The operating status of the converter at any moment is displayed by an LCD provided on the front
panel along with LED pilot lamps. In-addition three potential free relay outputs have been provided
for on-vehicle signalization/interfacing with vehicle control.
8.7
Sequence Control (State Machine)

The sequence control (State Machine) through the central processor on the full unit instrument and
control takes place as shown in the following diagram.The state machine is based on the hierarchy of
states as shown in the diagram. TRIP1 states are highest in hierarchy, then are STOP states and then
ON states.
Initial
InitReset
ON
Normal
Trip1
OnInhibit
Test_Mode
Standby
ResetTrip
Fig : State Machine
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8.8
Description of Operating Sequence

The following notes describe the main operating sequence:
Initial State:
Initial condition after control power supply is switched ON.

Initialization of SW parameters is carried out and converter automatically changes from this
condition to the Init Reset condition.
Init Reset:
If input voltage is in operating range and if external START command is active, the state
machine moves to Normal condition.
Normal State:
In this state SW and HW are initialized.

The starting sequence begins pre-charging, start of the BL, 4QC & WR
Unit switches to Standby condition if start signal drops out or if input voltage is outside the
operating range
If a fault occurs, which requires the complete unit to be stopped or on failure of supply
voltage the State Machine automatically switches to Trip1 state.
Standby State:
Modulation of IGBTs are stopped and contactors opened.

If the external start signal is present and the input voltage is within the operating range the
auxiliary converter changes to the Normal condition.
If an error occurs the State Machine switches to condition Trip1 state
Trip1 State:
All power sections are stopped and contactors opened

The condition automatically changes from Trip1 to On Inhibit state.
On Inhibit State:
In this condition all the power sections and the charging IGBT are open
After a severe failure, one which does not allow the converter to be restarted, this condition is
no longer left
If a restart of the converter is allowed (resettable trip) then the auxiliary converter
automatically switches to the Reset Trip condition.
Reset Trip:
A general Trip Reset is carried out

From this condition the State Machine switches to Normal state.
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Chapter 9 - Functional Description

9.1
Input Passive Unit

The input passive unit consists of a pre-charging unit and a filter inductor. Pre-charging unit is used to
charge the DC link capacitors as soon as START command is received and the input filter inductor
limits the input current distortion, due to switching frequency ripple current generated by the input
converter.
Fig.2 : Input Passive Unit

The pre-charging unit consists of a charging contactor and a charging resistor. The charging contactor
is turned on as soon as the input voltage is sensed and is within operating range and the START signal
from vehicle control is active. The charging resistor ensures reduces the capacitor charging current to
an acceptable value for the power semiconductors.
After the DC link is charged to a preset value, the main contactor is closed and the charging contactor
is opened. The charging contactor is also opened if there is a command to stop the converter either
internal (due to trips, for example) or external (if Start is disabled).
The charging switch is then switched ON when the following conditions are fulfilled: Input voltage is
in the operating range, input voltage is more than a minimum threshold & External Start signal is
enabled.
Main contactor is switched ON, when the DC-Link is charged and the start command from vehicle
control is active. The main contactor is opened when there is as STOP command generated internally
from the converter (due to trips, for example) or external (if START is disabled).
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9.2
IGBT based active front end rectifier

The input four quadrant active front end rectifier is realized based on single phase full bridge
topology, utilizing IGBTs as the switching device. The input 4QC is actively pulse width modulated
and together with the DC link filter capacitors generate a regulated DC-link voltage for the output
voltage source inverter.
Fig.3: Input 4 Quadrant Converter

The input 4QC starts automatically if the input voltage lies within the working range, after precharging is completed and if the internal/external STOP signal is not active.
SPWM is used for modulating the input 4QC converter with unipolar switching. Use of SPWM
modulation with unipolar switching results in ripple frequency doubling effect (better THD for same
Fsw) at the input and reduces the voltage jumps from +Udc to Udc to 0 to +/ Udc, when compared
with bipolar switching.
Input rectification with active front end converter has many advantages over conventional rectifiers,
Viz., UPF operation at the Input, reduced harmonic distortion, constant DC link voltage irrespective
of supply voltage fluctuations c and the inherent capability to regenerate power back to the source.
The DC link capacitors are sized for absorbing the second harmonic ripple current and to ensure
sufficient ride through capacity.
The input 4QC converter converts the input AC voltage into a regulated DC link voltage. The
references and pulses for input 4QC are enabled by the state machine.
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9.3
IGBT based output Voltage Source Inverter

The output voltage source inverter (VSI) is realized with a three phase half bridge topology utilizing
IGBTs as the switching device. VSI is connected to the DC link and sine pulse width modulated to
generate a three phase sine weighted PWM output of 415V (Line to Line) & 50 Hz output at its
terminals. The topology of the output VSI is given below.
Fig.4 : Three Phase Voltage Source Inverter

The output of the voltage source inverter is connected to a sinusoidal LC-filter to filter the switching
frequency ripple current. The resultant waveform at the output of sine filter is nearly devoid of high
frequency components and can be directly connected to standard three-phase motors without shielded
supply leads. Voltage distortion at sine filter output is less than 10 % and the dV/dT of output voltage
is below 10 V/s, which results in lower stresses on the motor insulation.
Output voltage regulation is implemented as an open loop control, with compensation for variation in
DC link voltage & sine filter voltage drop. Inverter switching pulses are generated in the PLD, based
upon the modulation index and reference frequency. The three-phase output voltage (therefore the
modulation index) and reference frequency are fixed references.
Over current limitation is a function implemented in the PLD. The peak output current is limited to a
threshold of 350 A for 5 s and the inverter is switched OFF if the time threshold is exceeded.
9.4
Voltage Limiting Unit

An active switch (IGBT) based fast over voltage protection system, called voltage limiting unit
(VLU), is provided on the DC link to protect the power semiconductors and DC link capacitors
against DC link over voltage due to supply side transients or load regeneration. In-addition VLU is
also used to discharge the DC link fast if the converter is stopped due to external stop command. The
scheme of VLU is shown below,
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Fig.5: Voltage Limiting Unit

In case of DC link over voltage, VLU is operated for a specified band of DC link voltage range and
the duty cycle of the switch is varied linearly from 0 and 1 based on actual value of DC link voltage
within the band. If fast DC link discharge is required then the duty cycle is set to 1.
9.5
Battery Charger
The Battery charger converts the DC-Link voltage to a controlled DC output required by the vehicle
battery & DC loads with galvanic isolation. The scheme of the battery charger is given below.
Fig.6: Battery Charger

The input full bridge inverter generates a pulsating high frequency AC output and its duty cycle is
varied based on the battery charge state and the charging characteristic curve. The output of the this
inverter is connected to a step down transformer, which provides galvanic isolation between the input
and output as well as voltage level transformation and a full bridge diode rectifier is connected to the
transformer secondary to rectify the AC voltage.
An LC filter at the output of the diode rectifier smoothens the DC output voltage. Charging current of
the battery is measured and is limited to the maximum allowable battery charging current by reducing
the DC output voltage. The battery charger switches over to Boost/ Trickle charging mode based on
the current drawn by the battery and its charge state.
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Chapter 10 - Battery Charging Characteristics

10.1 Charging Characteristics
Battery charger provided in Bordline M180 AC static converter charges the battery based on three
stage IUoU charging characteristic with Boost & Trickle modes. This type of controlled charging
will ideally help in preventing overcharging, over heating & loss of electrolyte in the battery and
hence will have a positive impact on the usable life of batteries. Charging characteristics of the
battery charge is given below.
Fig.24: Battery Charging Characteristic

On completion of pre-charging, battery charger modulation is started. Battery charger controller
initially commands the charger to deliver a constant output voltage of 109.5 V (U) and monitors the
current drawn by the battery. If the current drawn by the battery is more than 4 A then the battery
charger switches over to Boost Charge Mode, as this indicates that the battery is not fully charged.
Under this condition the battery charger controller increases the charger output voltage reference
beyond 109.5 V, till the current limit of 8 A is reached. As the battery gets charged, boost charge
voltage is increased gradually, with maximum current limit of 8 A, till it reaches 114.5 V (Uo).
Once Boost Charge voltage is reached, a constant voltage of 114.5 Vdc is applied continuously till
the battery current falls below 3 A. Battery charger switches over to trickle charge mode from Boost
charge mode, when battery current falls below 3 A and will charge the battery at a constant voltage
of 109.5 V. Monitoring, adjustment of reference values & set points are based on battery charge state
and is done at a fast dynamic rate by the battery charger controller.
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Chapter 11 -Display & Diagnostics

11.1 Introduction
I/P not in range
Internal fault
External fault
Earth fault bypass
LCD
SI unit OK
CHBA OK
Service port
11.2 Pilot Lamp Indication

LED lamps are provided on the converter front panel swing door to indicate the status in of
the converter. Details of the lamps and remarks on their operation are given below.
Description
LED
Remarks
SI unit OK
Green
ON when unit has no fault
Input voltage in range
Red
OFF when input voltage is within operating range
Internal fault
Red
ON during internal fault
External fault
Red
ON during external fault (see section 23.5)
CHBA OK
Green
ON when battery charger unit is working
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11.3
LCD
The converter is fitted with a LCD display on the display door for displaying important
system parameters and faults.
Fig 29: LCD display unit
11.3.1
Parameter Display
The following information are displayed on the LCD (as per RDSO REPORT No.
RDSO/2007/EL/IR/0126 Rev0) and the same can be accessed by pressing function keys as
mentioned below.
Key
F1
Display on LCD (Remarks)
F3
Input voltage XXX V

Input current XXX A
Output voltage XXX V (Line line voltage, phase 1)
Output current XXX A (Phase 1 current)
CHBA voltage XXX V (Battery voltage)
CHBA current XX A (Battery charging current)
DC current XX A (Sum of DC load and charging current)
(Status of the converter)
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F4
F5
F6
F2
Page 40 of 65
11.3.2
Fault Display
In the event of a fault in the system, the parameter display will be replaced by the fault
display on the panel. The following messages (as per RDSO REPORT No.
RDSO/2007/EL/IR/0126 Rev0), will be displayed on the LCD in the case of respective
faults.
For faults which do not come under the list as per RDSO REPORT No.
RDSO/2007/EL/IR/0126 Rev0, the fault message will be as per text under column
protection function in section 23.4.
Fault message1
Input fuse failure
Input voltage high
Input voltage low
DC link current high
DC link voltage high
DC link voltage low
Output current high
Output voltage high
Output voltage low
Earth fault
Single phase fault
Blower fault
CHBA fault
Input current high
Rectifier fault
Inverter fault
Chopper fault
Over temperature
Power supply fault
Chopper current high
CHBA current high
CHBA voltage high
CHBA voltage low
CHBA temp high
Remarks
In case the input fuse blows
Input voltage exceeds upper limit
Input voltage drops below lower limit
-NADC link voltage exceeds upper limit
DC link drops below lower limit
High output AC current persisting
-NA-NAEarth fault at input/output of SIV
Unbalance/single phasing at the output
Failure of cooling blower
Battery charger fault
High input AC current persisting
Input rectifier fault
Inverter fault
Voltage limiter unit fault
Over temperature in rectifier/inverter
-NAVoltage limiter unit overcurrent fault
Battery charger current limit exceeded
Battery voltage exceeding upper limit
Battery voltage drops below lower limit
Battery charger over temperature
Alongwith the fault message, another message as per section 23.4 under column protection
function will also be displayed in the next line for further information on the location of the
fault. The messages persist until the esc button is pressed and the parameters are displayed.
For actual resetting of the fault, the Reset pushbutton has to be pressed.
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11.4
Earth Fault Bypass
Push button has been provided on the display door to manually bypass earth fault protection
to enable loco pilot clear the section in case of earth fault in the middle of a section, in any of the
auxiliary loads.
Inverter will first trip on earth fault in the event of an earth fault in any one of the phases of auxiliary
load. This earth fault trip can be bypassed for a period of 45 minutes by enabling the earth fault
bypass switch provided in the converter front panel. E/f bypassed message will be displayed on the
LCD status screen if this option is enabled.
CAUTION! : Careful analysis should be done, with record of
observations, by the loco pilot or vehicle operator before bypassing
earth fault protection.
It is NOT RECOMMENDED to RESET the converter and continue to
operate the converter after the first 45 minutes of operation in earth
fault bypass mode.
For further operation under an earth fault, the loco Pilot or vehicle
operator is advised to investigate & identify the location of fault and
operate the loco only after isolating the faulty motor as per RDSO
instructions.
11.5
Service Access
TCP/IP protocol is used for communication with PEC 800 controller and a RJ 45 Harting connector
has been provided on the converter front panel swing door for service access.
CAT 5 ETHERNET cross over cable should be used to communicate between service laptop & PEC
800 controller.
11.6
Bordline View Diagnostic Tool

BORDLINE View is used for diagnostics on the vehicle with a PC. Several faults, warnings and
actual process and status values like input voltage are displayed. In addition, resetting of trips &
downloading of fault data is performed with the diagnostic tool.
Service access can be obtained using a standard PC/laptop connected to a standard interface on the
display door. Current operating data is also displayed using the BORDLINE diagnostic tool for online monitoring.
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11.7
Bordline View User Interface

The maintenance tool BORDLINE -View displays detailed information on the operating condition
of the auxiliary converter. If a malfunction occurs the program BORDLINE -View, installed on
the standard PC, can be used to display additional data to help resolve the problem
1
2
Fig: Bordline-View user interface

1
2
3
Status indication of the converter

Message window for faults and warnings
Indication of actual values, e.g voltage, current, temperature
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11.8
Bordline-View : Transient Recorder

The BORDLINE M180 converter is provided with a transient recorder facility which
greatly eases troubleshooting and fault diagnosis. The functioning is as follows:
The occurrence of a fault (see section) triggers the transient recorder.
The transient recorder writes two TR (transient recorder) files into the FLASH
memory of the main controller (U31).
The recording of TR files in the FLASH memory is on FIFO (first in first out) basis.
The FIFO buffer size is for 50 faults i.e 100 TR files.
Each TR (transient recorder) file contains 1000 data samples (500 pre- & 500 post- events)
of predefined signals, parameters & internal status codes. The sampling time for data
logging is 300us.
The TR files can be directly converted into EXCEL filtes with BORDLINE diagnostic tool for
troubleshooting & post-fault analysis. Service access can be obtained using a standard PC/laptop
connected to a standard interface on the display door. For on-line monitoring the current operating
data can also be displayed using the BORDLINE diagnostic tool.
11.9
Bordline-View : Transient Recorder data interpretation

Transient recorder files contain the type of fault, time of fault and all associated parameters,
inputs & outputs signals(voltage/current) which can be plotted to give real time status of the
converter during trip.
1500
1000
500
0
1
83
165 247 329
411 493 575 657 739 821 903 985
-500
-1000
-1500
Fig 28: Sample waveforms plotted from a TR file.
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Chapter 12 -Protections
12.1 Protection concept
Protection functions in Bordline M180 AC static converter are classified into three levels
based on the importance & the response time with which a certain protective function is
enabled. See Section 23.4 for details regarding each trip.
1. Hardware protection through gate drivers (Response time is in us range) In case of
Inadequate supply voltage for driving the IGBT, loss of communication, overcurrent and
Vce saturation, the driving pulses are blocked immediately and trip signal is sent to the
controller.
2. PLD protection (Response time is in us range) Some protections like DC link
overvoltage, DC link voltage rate and battery over voltage are implemented in the PLD.
3. Software protection (Response time is in ms range) These are protections whose
limits can be changed based on application requirements. Example Over current with time
limit.
12.2
Protection zones
The easy troubleshooting converter is divided into 10 protection zones to easily identify the
location of fault. They also help to decide whether the entire converter or parts of the
converter needs to be switched off. The different zones are given below (see also Figure 34)
Zone 1 - Input circuit
Zone 2 U21 (4QS)
Zone 3 DC link
Zone 4 U22 (VLU)
Zone 5 U23/U22 Inverter (WR)
Zone 6 U23/U22 Inverter Gate Driver (WR)
Zone 7 U24 Full bridge DC/DC converter (BL)
Zone 8 - Battery output circuit
Zone 9 - Main Control
Zone 10 Temperature sensor alarm
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12.3 Trips
Depending on the severity of trip either the entire converter is switched off or only the
section where the fault has occurred. Eg. An inverter fault will switch off the inverter but
the battery charger will be still functioning. Also some of the less relevant trips are counted
trips. Eg. VLU resistor energy high, the converter trips if the fault occurs frequently within
a time period. The following trips are defined:
Trip1:
Switch off all power parts of the converter
Trip3_BL: Switch off the battery charger (BL) full bridge converter
Trip3_WR: Switch off the Inverter (WR)
The end letters with each trip have the following meaning:
nr: Not resettable trip
cr: Counted trip (20s / 3 times)
r: Resettable trip
12.4 Fault Classification

The following faults have been grouped as external taking into consideration RDSO REPORT
No. RDSO/2007/EL/IR/0126 Rev0

Zone
1
1
1
1
3
5
5
5
5
5
5
8
8
8
ABB Ltd
External Fault
Ip voltage high rms, pk
Ip voltage high pk
Input voltage low
Ip frequency range
Earth fault
WR OC trip
WR OC limitation
Open phase ph1
Open phase ph2
Open phase ph3
WR unbalance trip
Battery OC trip
Battery UV trip
Battery OV trip
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12.5 Protection Zones
Fig : Protection zones
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12.6
Faultwords & limits
Name
Uref
IHBN_max
IXN
Iin_max
UTN
IbBL
Ibattery_max
Ubattnom
Value
650V 1100V
185 A
251 A
503 A
380V/415V/430V
30A
8A
110V
Description
DC link voltage reference
Maximum VLU current
Maximum inverter current
Maximum input current
Auxiliary secondary winding nominal voltage
Maximum DC output current
Maximum battery current
Nominal DC output voltage
12.6.1 Zone 1 Input circuit

Bit
1
2
3
4
5
6
7
8
9
10
11
Protection function
Ip voltage high rms
Ip voltage high pk
Input voltage low
Ip frequency range
Main switch fault
Charging failed
Charging sw fault
4QS ph current dev
Ip choke overtemp
Ambient overtemp
Input fuse failure
Identification
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Level
> 1.378 UTN / 60ms
> 2.33 UTN
< 0.733 UTN / 0.5s
+ / - 10%
30A / 20ms
85C / 90C
70C / 75C
Trip name
Trip1_r
Trip1_r
Trip1_r
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_r
Trip1_cr
Trip1_nr
Trip1_nr
Trip1_nr
12.6.2 Zone 2 U21 (4QS)

Bit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
ABB Ltd
Protection function
4QS OC trip
4QS OC limitation
PLL not synch
4QS cooler overtemp
VCEsat fault U51
VCEsat fault U52
Power fault U51
Power fault U52
Gate short ckt U51
Gate short ckt U52
PowerLink err U51
PowerLink err U52
U51 OC trip
U52 OC trip
Off curr meas>ph1
Off curr meas>ph2
Identification
Simulink
PLD
Simulink
Simulink
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Simulink
Simulink
3BHS249852 E04
Level
1.2*Iin_max / 10s
1900Apeak / 60ms
85C / 90C
Page 49 of 65
Trip name
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
12.6.3 Zone 3 DC link

Bit
1
2
3
4
5
6
7
8
9
Protection function
DC link voltage high
DC link voltage low
DClink implausible
DC link OV PLD-4QS
DC link OV PLD-WR
DC link OV PLD-VLU
DC link OV PLD-BL
Earth fault
DC link dU/dt>
Identification
Simulink
Simulink
Simulink
PLD
PLD
PLD
PLD
Simulink
PLD
Level
0.92 * Uref / 15s
1150 Vavg / 0.2s
>1
1300 Vpk
1300 Vpk
1300 Vpk
1300 Vpk
0.4 < Uef < 0.6
250V/125us
Trip name
Trip1_cr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
12.6.4 Zone 4 U22 (VLU)

Bit
Protection function
Identification
Level
Trip name
1
2
3
4
5
6
7
8
9
VLU OC trip
VLU short ckt
VLU open ckt
VLU resistor energy
VCEsat fault U53
Power fault U53
Gate short ckt U53
PowerLink err U53
U53 OC trip
Simulink
Simulink
Simulink
Simulink
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
1.2 * IHBN_max
m <= 0 & IHBN > 6.5A
m > 0.08 & IHBN <= 5.2A & Udc >= 52V
150kWs
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_cr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
12.6.5 Zone 5 U23/U22 Inverter (WR)

Bit
1
2
3
4
5
6
7
8
9
10
11
12
13
ABB Ltd
Protection function
WR OC trip
WR OC limitation
Open phase ph1
Open phase ph2
Open phase ph3
Off curr meas>ph1
Off curr meas>ph2
Off curr meas>ph3
WR unbalance trip
U22 cooler overtemp
U23 cooler overtemp
Sine choke overtemp
Ventilator overload
Identification
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
3BHS249852 E04
Level
1.12*IXN / 10s
1000Apk / 5s
30A /5s
80C / 85C
80C / 85C
85C / 90C
Trip name
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip1_nr
Page 50 of 65
12.6.6 Zone 6 U23/U22 Inverter Gate Driver (WR)

Bit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Protection function
VCEsat fault U54
VCEsat fault U55
VCEsat fault U56
Power fault U54
Power fault U55
Power fault U56
Gate short ckt U54
Gate short ckt U55
Gate short ckt U56
PowerLink err U54
PowerLink err U55
PowerLink err U56
U54 OC trip
U55 OC trip
U56 OC trip
Identification
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Level
Trip name
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
Trip3_WR_nr
12.6.7 Zone 7 U24 Full bridge DC/DC converter (BL)

Bit
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Protection function
BL IGBT overtemp
BL diode overtemp
BL choke overtemp
BL Trafo overtemp
VCEsat fault U57
VCEsat fault U58
Power fault U57
Power fault U58
Gate short ckt U57
Gate short ckt U58
PowerLink err U57
PowerLink err U58
U57 OC trip
Fullbridge OC trip
Identification
Simulink
Simulink
Simulink
Simulink
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Gate drive
Simulink
Level
80C / 85C
80C / 85C
80C / 85C
80C / 85C
1.2* IbBL / 10s
Trip name
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
12.6.8 Zone 8 Battery output circuit

Bit
1
2
3
4
5
Protection function
Battery OC trip
Battery UV trip
Battery OV trip
Battery OV PLD
BL discharging trip
ABB Ltd
Identification
Simulink
Simulink
Simulink
PLD
Simulink
Level
1.2*Ibattery_max / 10s
77V / 2s
1.3*Ubattnom / 0.1s
1.4*Ubattnom / 100us
(IBL<5A&Ibatt<-5A) | (UB<99V&IBL<5A) / 2s
3BHS249852 E04
Page 51 of 65
Trip name
Trip3_BL_cr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_nr
Trip3_BL_cr
12.6.9 Zone 9 Main Control

Bit
1
2
3
4
5
6
7
8
9
10
11
12
13
Protection function
PEC overtemp
Board overtemp
PEC Power fail
PEC CPU Watchdog
PEC ADC Watchdog
PowerLink err U51
PECPowerLink err U52
12.6.10
Bit
1
2
3
4
5
6
7
8
9
10
ABB Ltd
Identification
Simulink
Simulink
PLD
PLD
PLD
PLD
PLD
PLD
PLD
PLD
PLD
PLD
PLD
Level
95C / 100C
80C / 85C
Trip name
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Trip1_nr
Zone 10 Temperature sensor alarm

Protection function
Ip choke sensor br
Ambient sensor br
U21 sensor br
U22 sensor br
U23 sensor br
Sinefilter sensor br
BL IGBT sensor br
BL diode sensor br
BL choke sensor br
BL Trafo sensor br
Identification
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
Simulink
3BHS249852 E04
Level
Trip name
Alarm
Alarm
Alarm
Alarm
Alarm
Alarm
Alarm
Alarm
Alarm
Alarm
Page 52 of 65
Chapter 13 - Electrical & Mechanical Installation

13.1 Installing the Converter inside Locomotive
When installing the converter to the vehicle the cover should remain closed. When using a lifting device
make sure that the distribution of pressure covers as wide an area as possible. When lifting or moving the
converter the cover should remain closed. When using a lifting device use the hike bolts and lift with
suitable hooks. Do not use metal chain ropes and lift the converter from bottom as they will damage the
converter.
Provision is made to mount the panel on a C channel provided by Indian Railways with M-18 bolt as per
the mounting dimensions in RDSO Specification [1] without the need to open the end covers. Foundation
drawing of converter is given below.
Fig. Foundation Drawing
Mounting holes
ABB Ltd
3BHS249852 E04
Page 53 of 65
13.2 Electrical Connections

13.2.1 Cable Entry
Cable entry holes are provided at the bottom of converter and for easy termination it is recommended to
remove the channel below the terminal assembly by removing the M8 screws provided on either end as
shown below. Fix the channel back in position after cable terminations are completed.
Mounting holes
Cable Entry
Table: Pin Designations, Cable Cross-sections and Tightening Torques

Terminal Designation
Type of connection
Recommended cable
cross-section
Tightening torque
AC Input X1 to X4
cable lug M16
120 Sq.mm
Nm
DC Output X5 to X8
cable lug M6
6 to 16 Sq.mm
Nm
AC Output X9 to X11
cable lug M16
120 Sq.mm
Nm
Power Earth X12
cable lug M16
120 Sq.mm
Nm
Signalisation: analog signals , X15

1 to 16
Pin type lung
1.5 to 2.5 Sq.mm
NA
Cable protection
The outputs from the converter are protected against short-circuits. Protection of the vehicle battery
directly at its terminals is essential in order to protect the battery and to prevent fires breaking out in the
cables in the event of a short circuit.
ABB Ltd
3BHS249852 E04
Page 54 of 65
Chapter 14 - Commissioning
14.1 Preparation for Commissioning
Before operating the auxiliary converter for the first time, make sure converter is completely de-energized
and the notes on safety detailed contained in Chapter 1 - is complied with.
14.1.1 Visual Checks

The operating staff responsible must check that the converter has been correctly assembled and wired up,
and that all electrical connectors have been screwed tight. After the converter has been stored for a long
period of time or if it is suspected that damage has occurred during transport then check the housing cover
along the edges of the seal for signs of deformation, and check the seal itself for signs of damage. Check
whether installation has been carried out in-accordance with instructions given in Chapter 13 -
14.1.2 Wiring
Check all the converter connections have been properly done with correct cables used and in accordance
with 13.2 Electrical Connections).
14.2 Commissioning
The static converter is tested and subjected to an endurance test at our works. All the appropriate settings are
made in the factory. The converter can therefore be switched on after the checks referred to above have been
made and without the need for any further measurements or adjustments. Sequence of commissioning is
given below.
Complete power & control wiring as described in sec.

Complete preparatory checks as described in sec.
Disconnect or Isolate loads connected to converter AC & DC output.
Connect measuring devices ( oscilloscopes / meters to converter input & output)
Switch on control electronics power supply and conduct checks described in sec.
Establish communication between service PC & converter as described in sec.
Verify converter operating condition with BORDLINE -View. In particular check for any faults
or warning messages in the 'message window.
If a fault is displayed, proceed as described in sec 16.4.
Switch ON input voltage if there are no fault or warning messages.
Enable START command and check operation as described in Chapter 8 -.
Check cooling fan rotational direction and air flow rate as described in Chapter 5 Verify proper converter operation by using the measuring instruments
Start connecting loads in steps as per loco testing logic
Run the converter on full load and observe converter parameters with BORDLINE -View
ABB Ltd
3BHS249852 E04
Page 55 of 65
Chapter 15 - Maintenance Instructions

15.2 General Maintenance Work
The static converters are generally maintenance-free. The following table gives the approximate intervals
for checking and/or replacing parts which have a limited lifetime.
IMPORTANT!
All maintenance operations can be done with the converter installed on the
train.
Table 1: Periodic Component Replacements and Maintenance Tasks

Position
Maintenance
Period
(years)
Required
Time (h)
Pieces
Pos.
Component
.
Electrical Components
External Ventilator
E951 & 952
Internal Ventilator
E953 & 954
10
Capacitors on PM4
C625
20
Capacitors on PM5
C601-608
20
Capacitors on DC output
C642
20
2.5
NA
10*
0.5
Seals
6
Seal on the housing cover

and on the heat sinks
Maintenance Tasks
Cleaning of heat sinks on power modules, ventilators and air ducts
*Note: only exchange seals when they are defective.
ABB Ltd
3BHS249852 E04
Page 56 of 65
Chapter 16 - Repair Instructions

16.1 Service Concept
Converter is designed based on a service concept which allows replacement or repair of most parts with the
converter in its installed position inside the locomotive. Access provisions have be provided for visual
inspection and replacement of most components in converters installed in all types of tap changer type
locomotives.
A precise fault analysis with the converter in its installed position on the vehicle is mandatory for easy
troubleshooting. The repair work described below is to be carried out either by the manufacturer or the
operator in a suitably equipped workshop.
16.2 Requirements for Carrying out Repairs on the Vehicle

To allow on-vehicle repairs to be carried out, access to the covers, service compartments and the heat sinks
on the auxiliary converter must be ensured. A clean and dry surface must be available on which to put the
replacement parts and the parts to be removed.
16.2.1 Looking for Faults with the Converter Installed
The search for the cause of the fault is made with the help of the following diagnostic aids:
16.2.2
Digital outputs
LCD Display
BORDLINE View Maintenance Tool

Replacement of the Defective Components
NOTE!
The power modules weigh 60 kg (PM1) & 20 kg (PM4)
Removal of the power modules weighting more than 25 kg from the vehicle
should only be carried out at least 2 people.
The notes on safety contained in Chapter 1 -of this handbook as well as the safety regulations of the
operator and the vehicle manufacturer must be complied with.
ABB Ltd
3BHS249852 E04
Page 57 of 65
16.3 Requirements for Repairs Carried out Outside the Vehicle

16.3.1
Replacement of the Defective Components
After the defective component has been located, the converter can be removed from the vehicle. The
defective component should be stored in a dry place protected against the weather.
16.3.2
Looking for Faults in Converter which is not Installed
If e.g. for reasons of time it is not possible to carry out a diagnosis and to identify the defective component
on the vehicle, a suitable test bed will have to be constructed. The minimum requirements for this are:
Single Phase AC voltage source rated for 415 Vac, 500 A which can be switched on and off.
A 110 VDC power supply (ca. 300 W) for control voltage supply.
Possibility of loading both the outputs of the auxiliary converter.
A test arrangement which satisfies the relevant regulations.
Trained personnel.
Dry working area, protected against the weather.
If the fault search is carried out outside the vehicle, it is important to make sure that as much information
as possible about the fault which has occurred is kept available. Other useful information includes e.g. the
weather conditions at the time of the breakdown, overhead conductor voltage, any changes to the vehicle,
etc.
All the tools referred to in 16.2.1 Looking for Faults with the Converter Installed are available for
diagnosis carried out on the test bed.
16.4 Procedure on the Occurence of a Fault in the Converter

In general a fault in the converter will be roughly indicated by a suitable message being given out in the
driver's cab on the vehicle (using the digital outputs) & the LCD display.
Should the source of a fault be more precisely located, then other diagnostics channels are available.
The LCD display on the converter can be used to identify the nature & loaction of the fault.
BORDLINE-View, a PC-based diagnostics tool, which can be used to read the information in the
converter via an Ethernet interface and to reset the auxiliary converter.
16.4.1 Safety Precautions
Make sure the input voltage is safely switched off before opening the cover on the converter prior to
carrying out the rest of the diagnosis. The notes on safety contained in Chapter 1 -must be read and
understood.
ABB Ltd
3BHS249852 E04
Page 58 of 65
16.4.2 Converter Reset

If a fault is present it is worth trying to start up the converter again by means of a new start following a
reset. The auxiliary converter can be reset using BORDLINE -View. To do this an ETHERNET
connection must be set up with the converter as explained in sec.
Transient recorder files pertaining to faults and the Transient Recorder messages must be downloaded and
analysed before starting any repair work.
Proceed then in accordance with sec. if a converter reset does not produce a successful result. Defective
components or converter can be sent to the following address for repair:
As a general rule, make al cross check off all the fault codes/messages shown, in order to identify more
precisely the damaged component.
The components which can be replaced are listed in sec. All the other components are not object of this
manual. Before carrying out any repair work on components inside the converter, switch off the power
supply for the electronics, to be sure that a reset of the software is done and all the parameters are correctly
reinitialized.
Contact Address for Repairs:

ABB Ltd,
Dept: ATDP, Power Electronics Systems,
Traction Converters,
Plot no: 5&6, 2nd Phase, Peenya Indl.Area,
Bangalore 560058, Karnataka.
16.5 Request for Fault Diagnosis & Replacement of Parts

Orders for replacement parts or converter should be sent either to us or to our appropriate
representatives. In order to execute your order quickly and correctly we need the following details:
Accurate description of fault will help reduce repair time.
Details of the converter: see rating plate in section

Name of converter
Type: AL D715 C01
Serial No of converter & faulty parts to be replaced
Details provided in part name plate
Description of fault including fault messages on display & TR files.
Position number of component in electrical schematic
A clear identification number of the part concerned is also helpful.
ABB Ltd
3BHS249852 E04
Page 59 of 65
16.6 Packing and Shipment

In case you have to send in replaced components and/or the converter for repair .Please follow the
instructions given in Sec. 17.1.
The converter or assemblies or the whole converter must be packed, labelled and dispatched and sent in for
repair as described in Sec. 17.1.
Please make sure you include a detailed description of the fault as described in Sec.16.5.
16.7 Name Plate

Example name plate is attached below
ABB Ltd
3BHS249852 E04
Page 60 of 65
Chapter 17 - Packing, Transportation & Storage

17.1 Packaging Information
The converter is transported from the manufacturer's factory in suitable wooden packaging material with
the converter fixed to the bottom pallet. To remove the converter from the packing, follow unpacking
instructions printed on the package to ensure that the converter is not damaged during unpacking
17.1 .1 Packaging Instructions for Returned Components

For the converter or the components to be returned to the factory please chose a kind of packaging which is
suitable for the mode of shipment selected. If possible, use the original (re-usable) packaging from the
manufacturer.Always protect the components and/or the converter against dirt and splashes of water. The
cable entries and the signal plugs must be sealed off.
17.2Transportation
All the openings on the static converter must be sealed properly before transportation. Converter must be
adequately protected against weather and mechanical damage. No condensation is allowed on the
converter (no large temperature changes).
17.2.1 Lifting & Moving the converter

When lifting or moving the converter the cover should remain closed. When using a lifting device use the
hike bolts and lifts with suitable hooks. Do not use metal chain ropes and lift the converter from bottom as
they will damage the converter. The converter must be moved, mounted and dismounted with a fork lift
and a euro-pallet.
17.2.2 Power Modules

The power modules are to be placed on the heat sink during storage and transport (use the ribs as bearing
surfaces). When packing the converter, special care must be taken to ensure that the sensitive parts (driver
electronics etc.) are well protected against the effects of weather and mechanical damage.
17.3 General Storage Conditions

The converter should where possible be stored in its original packaging, in a horizontal position, and in a
clean and dry area. Prevent condensation on the converter (no large temperature variations).All openings in
the housing must be closed and made watertight. The converter must not be stacked.
ABB Ltd
3BHS249852 E04
Page 61 of 65
Chapter 18 - Technical Data

18.1 Input Data
Nominal input voltage
UGN
: 415/380 VAC (22.5 kV)
Input voltage range
UG
: 572-304 VAC/523-278 VAC (16.5 kV to 31 kV)
Nom. Input current (at UGN, PON)
IG
: 388/424 A at 415/380 VAC
Input Power factor
Cos Phi : 0.99
Input Frequency
Hz
: 50Hz 6%
Output voltage
UON
: 3 x 415 Vrms 5%
Output frequency
fN
: 50 Hz 2%
Nominal output power (@cos phi = 0.8)
PON
: 180 kVA
Nom. output current
ION
: 250 Amps
18.2 Output Data

18.2.1
AC output
Overload capability
: 600 A for 5 Secs.
Output V THD % at nominal load
: Less than 10 % (upto 50th order)
dV/dT of output AC voltage
: < 10 V/s
Starting method
: Soft start with V/f control
18.2.2
DC output
Charger Type
: Switched mode charger with IGBT Converter
Charging Modes
: Boost & Trickle
Charging Characteristic
: IUoU
Output voltage
Udc
: 110V 3%
Total output current
Idc
: 20 A
Battery charging current
Ibatt
: 8 A (max) adjustable
Galvanic isolation between AC I/p & DC O/p
ABB Ltd
3BHS249852 E04
: Provided (with isolation transformer)
Page 62 of 65
18.3 Communication,Display & Signalisation

Communication Interface
: Ethernet with standard RJ 45 Connector
Display unit
: Backlit LCD with fault scrolling facility
Diagnostics Facility
: Bordline View Tool
Fault logging
: Max.50 Faults on FIFO basis
Internal/External Fault Segregation
: Provided
Potential Free Relay Outputs
: 3 nos, Suitable for 110 Vdc, 1A & as per Sec.7.3
Front Panel Signalization
: Provided (Refer Sec.11.2 for details)
Note : Galvanic separation from vehicle battery prevents circulation of ground currents in the vehicle
thereby reducing the possibility of electro-magnetic compatibility (EMC) problems due to internal cabling.
18.4 Mechanical Data

Cabinet Design
: Single Cubicle with H construction
Cabinet Dimensions incl. fixings (L x B x H )
: 1740(L) * 680 (B) * 1650(H)
Total Mass of Equipment
: 1300 Kgs (Approx)
Immunity to shock & vibrations
: As per IEC 61373, Cat:1,Cl:A, Body Mounted
Color
: Light Gray as per IS 5 Cl.631.
18.5 General Data

Type of input rectifier
: Active PWM Rectifier (UPF)
Type of output inverter
: Voltage source inverter
Switching devices used
: IGBT
Efficiency (with UGN and 100 & 80 % load)
: > 92 %
Type of cooling
: Forced Air Cooling
Noise level
: < 80dBA (at 1m distance from equipment)
MTBF
: > 30000 Hours
Earth Fault Bypass Option
: Provided (Refer Sec.11.4 for details)
ABB Ltd
3BHS249852 E04
Page 63 of 65
18.6 Environmental Specifications

Location of use
: Onboard locomotive machine room
Ambient temperature range
: -20C to +55C
Max. Start-up Temperature
: 70 C
Humidity
: Max 100%
Pollution degree (IEC 60721-3-3)
: PD3
Altitude
: upto 1200 m above sea level
General operating environment
: As per RDSO Spec
18.7 Test Voltages

Insulation Resistance Test
AC Circle
: 1500 Vdc
DC Circle
: 500 Vdc
Dielectric Test
AC Circle
: 3.3 kV AC rms
DC Circle
: 1.5 kV AC rms
To prevent pre-damages to insulation, the test voltage will be applied for only 10 s during routine tests.
Test voltage shall be applied progressively and decreased progressively to zero. For every repetition of this
test, test voltage will be reduced by a factor of 0.8 from the previous test voltage, till basic insulation level
is reached.
ABB Ltd
WARNING! : Performing IR & Dielectric tests require lot of careful

preparatory work on the converter. Therefore this test shall be
performed only in the presence of ABB service engineers. ABB will
not be responsible for any malfunction or failure of any components
due to performance of tests not authorized by ABB.
3BHS249852 E04
Page 64 of 65
Chapter 19 - Additional Documentation

19.1 Annexures
This annexure contains the following documents:
ABB Ltd
Dimensional Drawing
3BHS248948_E05
Electrical Schematic
3BHS249852 ZAB E03
Bordline View Manual
3BHS221602 ZAB E01, Rev. A
3BHS249852 E04
Page 65 of 65

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BORDLINE M180 AC Auxiliary Converter

Type: AL D715 C01

Operation & Maintenance Manual

Chapter 1 - Safety Precautions.................................................................................................................. 6

Verifying Communication State.................................................................................................... 28

Chapter 9 - Functional Description ........................................................................................................ 34

Chapter 14 - Commissioning ..................................................................................................................... 55

Chapter 1 -Safety Precautions

This symbol indicates a potentially hazardous situation, which if not

Safety & Protection Concept

General Notes on Safety

Disconnect or fully isolate input & output connections.

Make sure the converter cannot be switched ON again.

Wait for minimum 5 minutes to allow trapped energies in capacitors

Check for presence of voltages with suitable test equipment before

Isolate/Insulate any parts which are live.

There is a risk of short-circuiting if any of the live terminals come into

Tareget Group & Required Qualifications

assembly and commissioning staff

Installation & Commissioning

Operation & Maintenance

Packing & Transport

: +91 2294 9409/9583

: +91 2294 9389

: +91 99014 90130

Chapter 3 -Equipment Description

Dimensional drawing (3BHS248948_E05) of Bordline M180 AC static converter is provided as

Additional capacitor bank

Sine filter choke

Fig : Rear Side View

Control Power Supply

Control Board Description

Interfaces for V & I transducers.

NTC Temperature sensors

CAN LCD display

Converts CAN optical pulses from XV

Interfaces between XV D824 and (GD

Dual IGBT gate

Current & DC link voltage

Vce saturation detection

Gate output short circuit /overload

Top/bottom switch interlock

DC link short circuit detection

Soft turn-ON & turn-OFF

Table: Control boards description

Control Electronics Block Diagram

Fig. : Control hardware block diagram

Fig. :: Compact converter control XV D824 (U31) with interfaces

Chapter 4 - Mechanical Construction

Detailed dimensional drawing of Bordline M180 AC converter is given in drawing

Chapter 5 - Cooling System

Power Supply for Cooling Fans

Chapter 6 - Electro Magnetic Compatibility

Chapter 7 - Power & Control Interface

: Suitable for connecting 120 sq.mm cable with M-16 Bolt.

Following modifications needs to be carried out/ensured on the

Fig : Input power connections

Control Wiring & Interface

110 Vdc battery voltage for control power supply