Op&Maint R10 040410 01-22

India Railways
Operation and Maintenance
Converter
India 180 kVA
U760AC/415AC3-110DC/P180-2/F50
Version 1.0 Apr 10, 2004
Transtechnik GmbH & Co KG
All rights reserved.

No part of this manual may be reproduced
or copied in any form without the written approval
of transtechnik GmbH.
Transtechnik GmbH & Co KG . Ohmstrae 13 . D-83607 Holzkirchen . Germany . Tel +49 80 24 9 90-0 . Fax +49 80 24 9 90-300
Internet: http://www.transtechnik.com . eMail: info@transtechnik.com
India 180 kVA Operation & Maintenance
TOC and List of Figures
Table of Contents
1
1.1
1.2
1.3
2
2.1
2.2
2.3
3
3.1
3.2
General .........................................................................................................................................................4
List of Abbreviations ......................................................................................................................................4
Document History..........................................................................................................................................4
Warning Page................................................................................................................................................5
Transportation, Shipping, Storage ............................................................................................................6
Transportation ...............................................................................................................................................6
Shipping.........................................................................................................................................................6
Storage ..........................................................................................................................................................6
Setting to operation ....................................................................................................................................7
Mounting........................................................................................................................................................7
Electrical connection .....................................................................................................................................8
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
Terminal Cover 1: Connecting AC Input Cables ................................................................................................9

Terminal Cover 1: Connecting DC Output Cables and Earth Cable.................................................................10
Terminal cover 2: Connecting 3-phase output cables and earth connection....................................................11
Terminal cover 2: Connecting single phase AC output cables .........................................................................11
Singal connector X700.....................................................................................................................................12
Starting the Converter......................................................................................................................................13
4 Control System and Diagnostics .............................................................................................................14

4.1 External controlling equipment ....................................................................................................................14
4.1.1
4.1.2
4.1.3
4.1.4
Converter Control Unit A710 ............................................................................................................................16

Digital controller unit A702 for IVPS.................................................................................................................17
Inverter Control Unit A703................................................................................................................................18
LVPS control unit A704....................................................................................................................................20
5 Computer Aided Diagnostics ...................................................................................................................22

5.1 What is the purpose of the WinDiag software? ...........................................................................................22
5.2 Requirements to the computer system .......................................................................................................23
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
WinDiag needs to run: .....................................................................................................................................23

What ports can be used? .................................................................................................................................23
Connection between the converter control system and the computer..............................................................23
Null-modem cable and interfaces.....................................................................................................................25
Transmission protocol......................................................................................................................................25
5.3 How does WinDiag work? ...........................................................................................................................26

5.3.1
Operating modes of the converter control unit .................................................................................................26
5.4 Screen Views ..............................................................................................................................................27

5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
Diag view: overview of all converter signals.....................................................................................................27

Osci view: charts of important measured values..............................................................................................34
List view: list of saved error events ..................................................................................................................34
Conf view: changing settings ...........................................................................................................................35
PTE mode (portable test equipment) ...............................................................................................................35
Saving, printing, and deleting error logs...........................................................................................................36
6 Maintenance...............................................................................................................................................37
6.1 General instructions ....................................................................................................................................37
6.1.1
6.1.2
6.1.3
6.1.4
Special tools and equipment ............................................................................................................................37

Maximum torques ............................................................................................................................................37
Removal of modules ........................................................................................................................................38
Installation of modules .....................................................................................................................................39
6.2 Maintenance Task List ................................................................................................................................40

6.3 Maintenance Tasks .....................................................................................................................................41
6.3.1
6.3.2
6.3.3
Replacing Buffer Battery of Converter Control Unit..........................................................................................41

Changing electrolytic capacitors according to maintenance plan.....................................................................42
Board TT1703 ..................................................................................................................................................42
6.4 Recommended Spare Parts ........................................................................................................................45
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TOC and List of Figures
List of Figures
Figure 1: Position of mounting holes ....................................................................................................................7
Figure 2: Converter connection diagram ..............................................................................................................8
Figure 3: Schematic view of converter .................................................................................................................8
Figure 4: Access to AC input and DC output terminals (1) ..................................................................................9
Figure 5: Access to AC input and DC output terminals (2) ................................................................................10
Figure 6: AC output terminals.............................................................................................................................11
Figure 7: Single phase AC output terminals .......................................................................................................11
Figure 8: Signal connector X700 ........................................................................................................................12
Figure 9: Detailed view of external controlling equipment..................................................................................14
Figure 10: Detailed view of converter error display A740 ..................................................................................15
Figure 11: Converter control unit A710 ..............................................................................................................16
Figure 12: LED array of the digital controller unit A702 for IVPS .......................................................................17
Figure 13: LED array of the inverter control unit A703 .......................................................................................18
Figure 14: LED array of LVPS control unit A704................................................................................................20
Figure 15: Diagnostic system .............................................................................................................................22
Figure 16: Connecting the computer to the interface of the converter control unit A710...................................23
Figure 17: Pin assignment of the null modem cable ..........................................................................................25
Figure 18: 9-pole Sub-D connectors ..................................................................................................................25
Figure 19: Menu bar ...........................................................................................................................................26
Figure 20: Diagnostic view (data mode) in WinDiag ..........................................................................................27
Figure 21: Info box 1...........................................................................................................................................28
Figure 22: Info box 2...........................................................................................................................................28
Figure 23: Info box 3...........................................................................................................................................29
Figure 24: Info box 4...........................................................................................................................................31
Figure 25: Info box 5...........................................................................................................................................32
Figure 26: Info box 6...........................................................................................................................................33
Figure 27: Osci view ...........................................................................................................................................34
Figure 28: List view.............................................................................................................................................34
Figure 29: Conf view...........................................................................................................................................35
Figure 30: Print Log Entry window......................................................................................................................36
Figure 31: Battery replacement at control board TT 1932 ................................................................................41
Figure 32: Driver board TT1703, locations of the electrolytic capacitors ...........................................................42
Figure 33: LVPS control board TT1967, locations of the electrolytic capacitors................................................43
Figure 34: IVPS control board TT1933, locations of the electrolytic capacitors.................................................44
Figure 34: Overview to all replacable components ............................................................................................47
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General
General
1.1
List of Abbreviations
AC
Alternating current
CAN
Controller area network
DC
Direct current
EN
Europanorm = European standard
IEC
International Electrotechnical Commission
IGBT
Insulated gate bipolar transistor
IP
International protection (level)
IVPS
Intermediate circuit voltage power supply
LVPS
Low voltage power supply
NC
normally closed (contact)
NO
normally open (contact)
PG
Panzergewinde, a german type of pass-through fittings for cables and wires
PWM
Pulse width modulation
RMS
Root mean square
RS
Recommended standard
THD
Total harmonic distortion
VDE
Verein deutscher Elektrotechniker = Association of German Electrical engineers
1.2
Document History
File name:
Content:
20999_Op&Maint_R10_040410.doc
Operation and Maintenance of India 180 kVA converter.
Revision Remarks
1.0
Initial release
20999_Op&Maint_R10_040410.doc
No. Pages
Author
Date
47
R. Niejodek
April 10, 2004
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1.3
General
Warning Page
The five safety rules

1.De-energize
2.Secure against switching on again
3.Make sure the equipment is dead
4.Ground and short
5.Cover over or barrier off adjacent parts that are live
DISCHARGE TIME
LONGER THAN
5 MINUTES
You will find the above shown sticker on the converter enclosure. After cut-off of the
converter from the line the filter capacitors in the converter need time to discharge by
means of the discharge resistor switched in parallel to the capacitors. During the
discharge time the voltage across the capacitor contacts is decreasing.
Under proper technical conditions you can expect that this voltage has dropped down to
undangerous values within at least 5 minutes.
Always measure this voltage before you start to work!
This sticker is attached inside the converter close

to points of dangerous voltages under normal
operating conditions (for example input and output
terminals).
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2
2.1
Transportation, Shipping, Storage
Transportation, Shipping, Storage

Transportation
The converter must be transported carefully to avoid damage.

Generally hard impacts must be avoided for all devices with electronic components.
Environmental conditions must be clean for transportation. Openings in the enclosure must be closed with
some suitable material.
2.2
Shipping
On pallet: Required is a pallet with a suitable size:

The converter outer dimensions are 1740 mm (L) x 610 mm (W) x 1700 mm (H). To fix the converter use
safety straps. To protect it against pollution and humidity use plastic films.
In container with cover e.g. of wood (weight of converter about 1500 kg). The converter must be fixed
against moving.
2.3
Storage
Do not stack the converters on top of each other.
The storage location must be clean and dry.
The openings in the enclosure must be closed with some suitable material if the converter is stored for a
longer period of time.
Storage temperature: 0 to + 55 C
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3
3.1
Setting to operation
Mounting
The figure below shows the positions of the mounting holes.

The converter will be mounted upright inside of the railcar.
Figure 1: Position of mounting holes
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3.2
Electrical connection
Converter Enclosure
A710
Converter
Control
Board
X3
RS232
X700
1
Relay K5
X7
2
3
Earth cable
cross section:
10 mm
Size of terminal/
cable lug: M10
Torque: 45 Nm
AC Input
760/830 V, 50Hz
(590...1.110 V)
Enable X5
Size of terminal/
cable lug: M10
Torque: 45 Nm
Earth cable
cross section:
10 mm
1L1
3L1
Wire cross section:

Recommended
2 x 70 mm
or 1 x 120 mm
DC output
110 V, 2 kW
3L2
1L2
Size of bolt terminals/

cable lugs: M16
Torque: 65 Nm

cable lugs: M16
Torque: 65 Nm
LB+
Wire cross section:

Recommended 4 mm
Minimum 1,5 mm
3 phase output
415 V AC, 180 kVA, 50 Hz
LB -

cable lugs: M8
Torque: 6...12 Nm

cable lugs: M6
Torque: 3...6 Nm
3L3
Wire cross section:

Recommended: 70 mm
2L1
1 phase output
110 V AC, 500 VA, 50 Hz
Wire cross section:
Recommended 1,5 mm
Minimum 0,75 mm
2L2
Figure 2: Converter connection diagram

The numbers 1 and 2 refer to numbers 1 and 2 of the next picture:
Display
Side
Terminal
Cover 2
Fan
Cover
Terminal
Cover 1
Figure 3: Schematic view of converter
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Figure 3 shows the schematic view of the converter with both places (terminal covers 1 and 2, see Figure 3)
where the train wiring has to be connected to the converter terminals.
The table above shows all required designations and values around cable fixing.
Terminal Connection
cover
Terminals
65 Nm
M8
4 mm
6...12 Nm
M10
10 mm
45 Nm
160 A max.
M16
70 mm
65 Nm
M6
1,5 mm
36 Nm
M10
10 mm
45 Nm
1L1
1L2
350 A max.
M16
DC output
LB+
LB
20 A
3AC output
3L1
3L2
3L3
1AC output
2L1
2L2
Earth
Signal
connector
X700
Max. Torque
to fix cable lugs
at terminals
2 x 70 mm
or
1 x 120 mm
AC input
Earth
Max. current Bolt terminal/ Recomm.

Cable lug size wire size
(recomm.
(train)
value)
5A
1-2 (relay K5)

3-4 (Enable)
2A
Table 1: Cables and terminals - designations and values
3.2.1
Terminal Cover 1: Connecting AC Input Cables
Figure 4 shows
the AC input terminals
the DC output terminals and
one of the earth connection terminals
Access to these terminals is given after removal of the fan cover 1 and the terminal cover 2 and/or the small
terminal cover around the corner (see next Figure 5).
2
DC Out
Earth
1L1 1L2
1. Remove fan cover 1:

Unscrew 8 x M6 x 1,5
hex socket screws.
Use hex key 3 mm.
2. Remove terminal
cover 2:
hex socket screws.
Use hex key 3 mm.
3. Attach cable lugs to
M16-terminals 1L1 and
1L2 and fix them
according to Table 1.
Figure 4: Access to AC input and DC output terminals (1)
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3.2.2
Terminal Cover 1: Connecting DC Output Cables and Earth Cable
Access to the terminals is given after removal of the fan cover 1 and the terminal cover 2 and/or the small
terminal cover around the corner (see Figure 5).
DC Output Connection
1. Remove cover 1:
Unscrew 8 x M6 x 1,5 hex
socket screws.
Use hex key 3 mm.
2. Attach cable lugs to M8terminals LB and LB+ and
fix them according to Table 1.
Earth Connection
1. Attach cable lug to M10terminal and fix it according to
Table 1.
LB
LB+
Earth
AC Input
Figure 5: Access to AC input and DC output terminals (2)
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3.2.3
Terminal cover 2: Connecting 3-phase output cables and earth connection
Access to the 3-phase output terminals and the earth terminal is given after removal of the terminal cover 2
(see Figure 3).
3-Phase Terminals:
1. Remove cover 2:
hex socket screws.
Use hex key 3 mm.
2. Attach cable lugs to
M16-terminals 3L1,
3L2 and 3L3 and fix
them according to
Table 1.
3L3
3L2
3L1
Earth
Single
phase
output
Earth Connection
1. Attach cable lug to
M10-terminal and fix it
according to Table 1.
Figure 6: AC output terminals
3.2.4
Terminal cover 2: Connecting single phase AC output cables

Single Phase Terminals
1. Remove cover 2:
Unscrew 12 x M6 x 1,5 hex
socket screws.
Use hex key 3 mm.
2. Attach cable lugs to M6terminals 1L1 and 1L2 and fix
them according to Table 1.
1L1
2L1
Figure 7: Single phase AC output terminals
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3.2.5
Singal connector X700
Access to signal connector X700 is given after removal of terminal cover 2. The connector is located above
the AC output terminals (see Figure 8). Only pins 1 to 4 are used.
X700
Figure 8: Signal connector X700
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3.2.6
Starting the Converter
Apply battery voltage.

Ensure that battery voltage of at least 50 V is available at DC output.
Check error display and status LEDs at control panel.

Yellow LED DISPLAY OK is on.
Error display shows NO FAULT
LED General Fault is ON as long as no AC input voltage has been
applied.
Apply AC input voltage.

Ensure that AC voltage of at least 590 V RMS and not exceeding
1.110 V RMS is available.
Converter is running.
Green LED AC Input OK is ON.
In case of failure:
1
Switch off high voltage.
Ensure that no disable signal is applied to signal connector

X700, pins 3 and 4.
Switch between these two pins must be OPEN for ENABLE.
Check error display and status LEDs at control panel.

Start fault finding according to fault messages and trouble shooting
instructions.
Check LEDs at control boards.

Start fault finding according to LED messages and trouble shooting
instructions.
Connect test equipment to converter.

Connect notebook to RS232 interface at X3 of converter control
board A710 (see page 23)
Start diagnostic software WinDiag.
Go on with fault finding according to infoboxes and trouble shooting
instructions.
Switch on high voltage.
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4
4.1
Control System and Diagnostics

External controlling equipment
The external controlling equipment is located on the left lateral service cover. The detailed view is shown in
Figure 9.
N O FA U LT
4
V
2
A
175.0 V
1
2
3
4
5
6
7
AC output voltage meter P901

AC input voltage meter P903
Converter fault display A740
Type plate of converter
AC output ammeter P902
Phase selection switch S902
Phase selection switch S901
Figure 9: Detailed view of external controlling equipment
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Figure 10: Detailed view of converter error display A740
ERROR DISPLAY
NO
FAULT
AC INPUT OK
DISPLAY OK
GENERAL FAULT
INTERNAL FAULT
INVERTER FAULT
IVPS/SCR FAULT
TT1823
Descr. in Figure 10
AC INPUT OK
LED
Signal name
Colour
green
LED is on, if
AC input voltage
AC input voltage is in specified range
GENERAL FAULT
red
Fault of inverter section
Fault has occured within the inverter section
INTERNAL FAULT
red
Fault of LVPS section
Fault has occured within the LVPS section
INVERTER FAULT
red
Phase/ground fault of
AC output
Earth fault has occured at the AC output or at the

AC input
IVPS/SCR FAULT
red
Fault of IVPS section
Fault has occured within the IVPS section

(thyristor bridge A201)
Heartbeat
Converter fault display A740 is in operation

(no fault)
DISPLAY OK
yellow
Detailed alphanumeric fault messages of fault display A740

Alphanumeric character
N O
F A U L T
H - B R I D G E
I N V E R T E R
L V P S
T E M
H - B R
T E M
I N V
T E M
L V P S
T E M
T 3 0 2
F 0 1
Q 9 0 1
Q 9 0 2
Q 3 0 1
E A R T H
F A
20999_Op&Maint_R10_040410.doc
Description
No fault
Fault of IVPS section
Fault of inverter section
Fault of LVPS section
Overtemperature in IVPS section
Overtemperature in inverter section
Overtemperature in LVPS section
Overtemperature of autotransformer T302
Fault of fuse F01
Fault of motor-circuit switch Q901
Fault of motor-circuit switch Q902
Fault of circuit breaker Q301
Ground fault
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4.1.1
4.1.1.1
Converter Control Unit A710

PURPOSE
Saving of error state data signalled by the control units
Relay contacts interface to external control system
RS232 port for computer aided diagnostics. This port is galvanically isolated from the input and output
voltages.
4.1.1.2
DESCRIPTION
The converter control unit A710 holds the battery-buffered status memory and maintains constant
communication with the other control units. If any defect is signalled, relevant data plus the time of the event
are saved in the status memory. Additionally, the status and duration of certain operating states are constantly
stored. Relay K5 provides a failure indication signal which is available at the drivers desk.
Figure 11: Converter control unit A710
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4.1.2
Digital controller unit A702 for IVPS
4.1.2.1
PURPOSE
The control unit controls and monitors the functions and processes of the semicontrolled thyristor bridge
A201 (IVPS).
The control unit continuously receives the current values from the elements of the IVPS. These measured
values are compared with the reference values. The resultant control ensures that the IVPS functions
properly under changing operating conditions.
If an error occurs, the control unit responds in real-time and triggers emergency functions, such as
powering down the thyristor bridge to prevent consequential damage.
The control unit passes on messages about errors or other special events to the converter control unit
A710.
4.1.2.2
LED ARRAY
The control unit incorporates a LED array providing detailed information on operating state and any error state
in the modules controlled during operation. The LED array is accessible via the service cover of the converter
and is consequently separated from high voltage.
TT 1933-1/05 A
Overall indications
LED
Colour
Meaning
Betrieb
= Run
Power down
green
IVPS in operation (no fault)
Bereit
= Ready
yellow
IVPS ready for operation, but input no

voltage UI < min (stand by)
Stoer
= Error
red
Serious fault. For details see

adjacent LEDs.
yes
15V
green
Electronics supply voltage present

and in tolerance
(13,5 V to 16,5 V). (If LED is not
on: Fault!)
no
no
Figure 12: LED array of the digital controller unit A702 for IVPS
Detailed indications
LED
Colour
Meaning
UAL
yellow
DC output (= intermediate circuit) voltage has fallen below minimum

permitted value.
no
ILIM
yellow
Maximum output current has been reached

SCR bridge in current limitation
no
UNSY
yellow
Not assigned
UAH
red
DC output (= intermediate circuit) voltage has exceeded maximum

permitted value four times per minute.
yes
TEXT
red
Not assigned (external temperature monitoring)
IDYN
red
Dynamic current limitation has responded four times within one minute.
yes
M1
yellow
Not assigned
M2
yellow
Not assigned
UEL
yellow
The AC input voltage has fallen below minimum permitted value.
no
UEH
yellow
The AC input voltage has exceeded maximum permitted value.
yes
ZW1
red
Fault thyristor V01.1
yes
ZW2
red
Fault thyristor V01.2
yes
ZW3
red
Not assigned
no
T-MAX
red
Heat sink of thyristor bridge has exceeded 85 C
yes
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Power down
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4.1.3
Inverter Control Unit A703
4.1.3.1
PURPOSE
The inverter control unit A703 controls and monitors the functions of the inverter section A300.
The control unit continuously receives the current values from the voltage and current transducers of the
inverter modules A301.1, A301.2 and A301.3. These measured values are compared with the reference
values. The resultant control ensures that the inverter output voltage is maintained within the specified
limits under varying operating conditions.
powering down the inverter to prevent consequential damage.
A710.
4.1.3.2
LED ARRAY
in the inverter modules controlled during operation. The LED array is accessible via the service cover of the
converter and is consequently separated from the high voltage.
TT1619-2/27
Overall indications
BETRIEB
UZ MAX.
UZ MIN.
LED
Colour
Meaning
BEREIT
BETRIEB
= Run
Green
Inverter is operating (no error)
STOER
BEREIT
= Ready
Yellow
TREIB-R
Inverter is ready to operate

but input voltage is below
minimum (stand by)
15V OK
UA MAX.
STOER
= Error
Red
Serious error. For details see

adjacent LEDs.
15V OK
Green
Supply voltage for electronics

is present and is within
tolerances
(13,5 V to 16,5 V).
If LED is off: Fault!
Control circuit is operating
(internal processor operates)
CLK
Green
TREIB-S
TREIB-T
I-BEGR.
AUSG.
CLK
PHASE
T80 *
LEDTEST
T100*
1619-2
TMAX-EXT
green
yellow
red
Figure 13: LED array of the inverter control unit A703

Power
Down
LED
Colour
Meaning
UA MAX
Red
Output voltage is too high.
Yes
I-BEGR.
Red
Output current is at its upper limit

(inverter runs under current limitation condition)
No
T80 *
Yellow
Temperature prewarning (85 C) of inverter module A301.1, A301.2

and/or A301.3
No
T100*
Red
Overtemperature (95 C) of inverter module A301.1, A301.2 and/or

A301.3
Yes
TMAX-EXT
Red
Autotransformer T302: Coil overtemperature
Yes
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UZ MAX.
Red
Inverter input voltage (= intermediate circuit voltage) is too high.
Yes
UZ MIN.
Yellow
Inverter input voltage (= intermediate circuit voltage) is too low.
No
TREIB-R
Red
IGBT-error (e.g. saturation voltage UCE is too high)

of inverter module A301.1
Yes
TREIB-S
Red

Yes
TREIB-T
Red

Yes
AUSG.
Red
IGBT UCE monitoring has triggered more than 4 times within a

specified time
Yes
PHASE
Red
Unbalanced / asymmetric loads at the output phases.
Yes
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4.1.4
LVPS control unit A704
4.1.4.1
PURPOSE
The control unit controls and monitors the functions and processes of the DC/DC module A401 (LVPS
section).
The control unit continuously receives the current values from the elements of the DC/DC module A401.
These measured values are compared with the reference values. The resultant control ensures that the
DC/DC module A401 functions properly under changing operating conditions.
powering down the DC/DC module A401 to prevent consequential damage.
A710.
4.1.4.2
LED ARRAY
in the modules controlled during operation. The LED array is accessible via the service cover of the converter
and is consequently separated from the high voltage.
Betrieb
P AB
UEL
M1
UBL
Tmax1
Bereit
P CD
UEH
M2
UBH
Tmax2
Strung
AB
Ipr
M3
S LIM
I>X
15 V ok
CD
AUX
M4
Batt-LIM
ext.EN
green
yellow
red
orange
Figure 14: LED array of LVPS control unit A704
TT 1967-2/24 A
LED
Colour Meaning
Power down
Overall indications
Betrieb
green
DC/DC module A401 in operation (no fault)
no
Bereit
yellow
DC/DC module A401 ready for operation, but input voltage

(= intermediate circuit voltage) UIC < min (stand by)
no
Strung
red
Serious fault. For details see adjacent LEDs.
yes
State of module voltage supply

green
Electronics supply voltage present and in tolerance

(13,5 V to 16,5 V). (If LED is not on: Fault!)
no
P AB
green
IGBT-module V01.1 of DC/DC module A401 is receiving clock pulses.

Light density depends on pulse width.
no
P CD
green
IGBT-module V01.2 of DC/DC module A401 is receiving clock pulses.

Light density depends on pulse width.
no
AB
red
Fault in IGBT-module V01.1 of DC/DC module A401

(e.g. saturation voltage UCE too high)
yes
CD
red
Fault in IGBT-module V01.2 of DC/DC module A401

(e.g. saturation voltage UCE too high)
yes
UEL
yellow
Input voltage (= intermediate circuit voltage) UIC is too low
no
UEH
red
Input voltage (= intermediate circuit voltage) UIC is too high
yes
15V ok
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Ipr
red
Primary current IPRIM at transformer T01 is too high
yes
M1
red
Serious fault in DC/DC module A401
yes
M2
red
Not assigned
M3
red
Not assigned
M4
red
Not assigned
UBL
yellow
DC output voltage UDC is too low
no
UBH
red
DC output voltage UDC is too high
yes
SLIM
orange
Total current limitation is active
no
Batt-LIM
orange
Not assigned
Tmax1
red
Heat sink temperature of DC/DC module A401 exceeds 100 C
Tmax2
red
Not assigned
I>X
yellow
Load control: Load current exceeds certain value
ext.EN
red
Not assigned
20999_Op&Maint_R10_040410.doc
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5
5.1
Computer Aided Diagnostics
Computer Aided Diagnostics

What is the purpose of the WinDiag software?
The WinDiag program and the chip software of the control unit A710 make up the converters diagnostic
system. All control systems of the converter are interconnected over the internal CAN bus. The control unit
A710 is equipped with a status memory which constantly records relevant operational data. If malfunctions or
defects are detected in one of the converter modules during operation, data on the time and the
characteristics of the occurrence are saved to the status memory. WinDiag is shipped with the converter as a
standard accessory. It allows for instant or delayed evaluation and printout of these data over a notebook or a
PC connected to the converter via the serial interface of the converter control card. Troubleshooting is thus
greatly facilitated.
Relay contact
for status indication
Converter control unit A710
RS232-C
with data memory and diagnostics interface
CAN-Bus
Notebook
Digital controller
unit A702
for IVPS
Inverter control
unit A703
LVPS chopper
control
unit A704
Printer
IVPS section
A200
Inverter section
A300
LVPS section
A400
Figure 15: Diagnostic system

The values are recorded over the CAN bus and transmitted to the computer via the serial interface.
The following analogue values and temperature limits are monitored:
UI
Input voltage of converter
UIC
Intermediate circuit voltage (= input voltage of inverter and LVPS)
IIC
Intermediate circuit current (= input current of inverter and LVPS)
UCE
Module monitoring of IVPS and LVPS
IPRIM
Primary current tot the transformers of IVPS and LVPS
UAC
AC output voltage
IAC
Output current
Driver R/S/T
Module monitoring of inverter
T75C, T85C
Temperature of SCR bridge
T85C, T95C
Temperature of inverter
T 100C
Temperature of LVPS
UDC
Output voltage of LVPS
IDC
Output current of LVPS
20999_Op&Maint_R10_040410.doc
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Operation and Maintenance

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India 180 kVA Operation & Maintenance

TOC and List of Figures

Terminal Cover 1: Connecting AC Input Cables ................................................................................................9

4 Control System and Diagnostics .............................................................................................................14

Converter Control Unit A710 ............................................................................................................................16

5 Computer Aided Diagnostics ...................................................................................................................22

WinDiag needs to run: .....................................................................................................................................23

5.3 How does WinDiag work? ...........................................................................................................................26

Operating modes of the converter control unit .................................................................................................26

5.4 Screen Views ..............................................................................................................................................27

Diag view: overview of all converter signals.....................................................................................................27

Special tools and equipment ............................................................................................................................37

6.2 Maintenance Task List ................................................................................................................................40

Replacing Buffer Battery of Converter Control Unit..........................................................................................41

6.4 Recommended Spare Parts ........................................................................................................................45

India 180 kVA Operation & Maintenance

TOC and List of Figures

India 180 kVA Operation & Maintenance

Controller area network

Europanorm = European standard

International Electrotechnical Commission

Insulated gate bipolar transistor

International protection (level)

Intermediate circuit voltage power supply

Low voltage power supply

normally closed (contact)

normally open (contact)

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

Pulse width modulation

Root mean square

Total harmonic distortion

Verein deutscher Elektrotechniker = Association of German Electrical engineers

April 10, 2004

India 180 kVA Operation & Maintenance

The five safety rules

This sticker is attached inside the converter close

India 180 kVA Operation & Maintenance

Transportation, Shipping, Storage

Transportation, Shipping, Storage

The converter must be transported carefully to avoid damage.

On pallet: Required is a pallet with a suitable size:

Do not stack the converters on top of each other.

The storage location must be clean and dry.

India 180 kVA Operation & Maintenance

The figure below shows the positions of the mounting holes.

Figure 1: Position of mounting holes

India 180 kVA Operation & Maintenance

Wire cross section:

Size of bolt terminals/

Size of bolt terminals/

Wire cross section:

Size of bolt terminals/

Size of bolt terminals/

Wire cross section:

Figure 2: Converter connection diagram

Figure 3: Schematic view of converter

India 180 kVA Operation & Maintenance

Max. current Bolt terminal/ Recomm.

1-2 (relay K5)