TCC - Copy.pptx TCC - Copy.pptx TCC - Copy.pptx

TCC - Copy.pptx

1. T raction C onverter C abinet ( TCC ) Chief Instructor(DSL) MAS 696

2. Traction Converter Cabinet

3. DC Link Block Diagram DC Link Capacitor Grid Resistors Brake Chopper Crowbar DC Link Contactors Main DC Link

4. Traction Inverter and Motor

5. Contents 1. Function of TCC 2. Traction Computer 3. Description about cards 4. Operation of Inverter 5. ABB Inverter and Booster Assembly 6. Brake Chopper 7. Crowbar

6. Traction Converter Cabinet

7. DC Link Contactors

8. DC Link Contactors Total six DC link contactors are provided – each for one traction inverter Any one of the contactors can be operated independently Each contactor has positive and negative terminals at input and output ends.

9. DC Link Contactors These contactors are used to isolate particular Traction Inverter from main DC link Through the display the contactors can be opened to isolate inverters from main DC link System opens the contactors only if the voltage of DCL is less than 50V These can also be manually opened through circuit breakers DCL 1 to 6 provided in CB panel in ECC#1 Isolation switch in the Engine Control Panel in ECC #1 should be put in to ISOLATE position to manually switch off DCL 1 to 6

10. DC Link Capacitors

11. DC Link Capacitors Total six DC link capacitors are provided – each for one traction inverter These capacitors are provided to reduce the DC link voltage ripple Temperature of each DC link capacitor is monitored by respective Traction Computer (TC) through temperature sensors (PT100) If the temperature raises above 68° C, TC will reduce the torque of the particular traction motor If the temperature still raises beyond 75° C, TC will cut off the Traction Inverter and motor. DC Link Capacitor

12. IGBT phase modules

13. IGBT phase modules Traction Inverter 1 Traction Inverter 5 Traction Inverter 3 Brake chopper

14. IGBT phase modules Each Traction Inverter is comprised of 3 IGBT phase modules Each phase module contains 2 IGBTs Traction computer sends the firing signals through OFC to individual IGBT gate drive cards to control the Traction Inverter output Each IGBT gate drive card has an independent power supply The health of the power supplies and gate drive cards are continuously monitored by TC

15. IGBT phase modules Each module has two temperature sensors to monitor the temperatures of two IGBTs individually The temperatures are monitored by TC for necessary actions When the temperature raises above 80° C – torque of respective Traction Motor will be derated. When the temperature further raises above 85° C – respective Traction Inverter will be cutoff.

16. TCC Cooling System

17. Block Diagram: Booster – ABB inverter CA output (40-240V AC) Bridge Rectifier Blower Inverter Booster Traction Inverter Blower motor 30/40/50 Hz Block Diagram: 330 V DC constant Speed selection Signals from TC

18. TI Blower Motor Each Traction Inverter (three IGBT phase modules) is provided with one blower motor The blower motor is controlled by respective TC through booster and ABB inverter assembly The speed of the blower motor is controlled in three different levels depending on the temperature of the phase module Low Speed Medium Speed High Speed

19. Booster Inverter Assembly Supply to the TI blower motors are provided through Booster inverter assembly Booster gets the input from Companion Alternator Booster provides the necessary DC link input to the ABB inverter ABB inverter is controlled by TC to regulate the output of the inverter to control the speed of the blower motor

20. Traction Computer TC1 TC3 Common Cards (DIO/ Comm.) TC5

21. Traction Computer Traction Control Cabinet has Six Traction Computers put into two cabinets in either side TC135 TC246 Three traction computers, one DIO card and one communication card comprises one Traction Computer Cabinet Each traction computer cabinet controls three traction inverters and three traction motors

22. Modules in Traction Computer Each traction computer comprises of five different modules MTCPS – Power Supply MTMOFC – OFC IGBT control MTCC – Computer Card TC MAIP 10#1 – Analog Input Card 1 TC MAIP 10#2 – Analog Input Card 2

23. Traction Computer modules interface MTCC MTMOFC TC MAIP10#2 TC MAIP10#1 MTCPS 74 V +15 V -15 V +9 V -9 V IGBT Phase Module IGBT Phase Module IGBT Phase Module MTC OFC Common for three TCs (1, 3, 5 / 2, 4, 6) Main Redundant MTC DIO Common for three TCs (1, 3, 5 / 2, 4, 6) TI thermal switch, Booster inverter, Harting connector Optical Fiber Communication Rx & Tx From MLCC MACC Main Redundant

24. Traction Computer Control Card It is the heart of Traction Converter controlling Traction Inverter and traction motor This module contains one Digital Signal Processor (DSP) and one microcontroller DSP is the main Traction Motor Computer (TMC) and the microcontroller is Auxiliary Traction Computer (ATC)

25. Traction Motor Computer (TMC) This module continuously receives torque command from MLCC and controls Traction Inverter and Motor to meet the torque requirement It does all the computations required to control the torque of the Traction Motor and issues the firing pulses to the Traction Inverter accordingly Measures 3-Ph output currents, Traction Motor RPM to control the Traction Motor torque Provides overload and short circuit protection to Traction Inverter and traction motor

26. Auxiliary Traction Computer (ATC) It establishes communication with MLCC (Locomotive Control Computer) via Main OFC communication channel Monitors various parameters like IGBT Heat Sink temperatures, DC link capacitor temperatures, output voltages, Traction Motor stator temperature, health of speed signal of the Traction Motor and output currents through two TC MAIP10#1 /2 analog input cards Controls the Traction Inverter blower motor speed based on the temperatures of the Traction Inverter IGBT Heat Sink modules Monitors the health status of the power supplies It monitors health of all the gate drive cards of all IGBTs

27. MTCC – Traction Control Card 1. Vcce External Positive ON: Healthy 2. System Health: ON: FAILED OFF: Healthy 3. VccI Internal Positive ON: Healthy 4.VeeI Internal Negative ON: Healthy 5. Vc Communication health FLICKERS: when there is a proper communication between LCC and MTCC 6.DSP status (spare LED) 7.Vccx: MTCC Positive ON: under healthy condition OFF: Power Supply Failed

28. Traction Computer Power Supply (MTCPS) MTCPS (Medha Traction Computer Power Supply) Module is a Power supply module provided individually for each traction computer It converts 74 V into low voltage sources required for operation of all the modules in Traction Computer These are switch mode power supplies which can accept wide variation of input voltage. These modules work satisfactorily even at very low battery voltage of 20V during cranking Input supply is filtered to avoid propagation of switching noise back into the locomotive control supply It provides isolation between input and output voltages

29. Traction Computer Analog Input Card1 (TC MAIP10#1) It processes various signals like Three phase output currents Two ‘line to line’ voltages of the traction inverter Traction Motor stator temperature Traction Inverter blower motor current Traction Inverter input current Provides the isolation from the signals received from various sensors to the MTCC card This module is connected to MTCC card through mother board of the traction computer cabinet

30. TC MAIP10#1 LED indications Internal Power Supply Positive and Negative ON if healthy OFF if failed External Power Supply Positive and Negative ON if healthy OFF if failed

31. Traction Computer Analog Input Card2 (TC MAIP10#2) This module processes the temperature signals related to particular Traction Inverter and converts the signal to levels readable to MTCC card This card processes Six IGBT Heat Sink module temperatures DC link capacitor temperature It also provides isolation between the signals from sensors and the MTCC card This module is connected to MTCC card through mother board of the traction computer cabinet

32. TC MAIP10#2 LED indications External Power Supply Positive and Negative ON if healthy OFF if failed Internal Power Supply Positive and Negative ON if healthy OFF if failed

33. Traction Motor Optical Fiber Card (MTMOFC) The function of this module is to convert the analog signals received from the MTCC card to light signals and vice versa The light signals are transferred to IGBT gate drive cards to fire the respective IGBTs Similarly this card also receives the feedback signals from the IGBTs gate drive card acknowledging firing of the IGBTs. Hence, feedback of each IGBT firing pulse is monitored MTCC and MTMOFC card are interconnected through mother board of the traction computer cabinet

34. Traction Computer Digital input and Output Card (MTCDIO) This card is common to three TCs either TC1,3,5 or TC2,4,6 This module receives digital inputs required for proper operation of the TMC (Traction Motor computer) like status of the Harting connector (Traction Motor cable connection) thermal switches (each module heat sink has one thermal switch in addition to temperature sensor) and TI blower inverter If the Harting connector is slack or thermal switches are open, then TMC shuts down the respective inverter for safety If any card is missing or not inserted properly, MTCDIO card senses the same and displays a message on driver display

35. Traction Computer Digital input and Output Card (MTCDIO) Heat Sink Thermal Switch ON under Healthy Condition OFF when Thermal Switch opens Harting Connector Spare ABB inverter Feedback

36. Harting Connector Total six Harting connectors are used one for each traction motor The Traction Motor speed signals and stator temperature signals are fed to the TC WAGO connector via Harting connector Health status of the Harting connector is monitored by MTCC card in conjunction with MTCDIO When Harting connector is open or not properly connected, respective TC will shutdown for safety (with message on driver display)

37. Harting Connector XA1 – TM1 speed signal and stator temperature XB1 – TM2 speed signal and stator temperature XA2 – TM4 speed signal and stator temperature XC1 – TM3 speed signal and stator temperature XB2 – TM5 speed signal and stator temperature XC2 – TM6 speed signal and stator temperature

38. Brake Chopper Assembly The main function of the Brake chopper is to control the DC link voltage. It acts as primary protection for TCC against DC link over voltage Brake chopper assembly consists of an IGBT phase module in series with resistor The Brake chopper IGBT phase module assembly is kept beside the traction inverter3 in TCC cabinet When the DC link voltage crosses 2800 V, MLCC issues a firing signal to the IGBT in brake chopper to pull down the DC link voltage to below 2650 V.

39. Brake Chopper Resistor Brake chopper resistor is approximately 10  It is located in clean air room (between Traction Alternator and TCC).

40. Crowbar Assembly This acts as secondary protection against DC link over voltage The main function of the Crowbar assembly is to protect the TCC during high DC link voltage conditions Crowbar assembly consists of a resistor in series with a Thyristor and a free wheeling diode. Crowbar can be fired in two ways Soft Crowbar Hard Crowbar

41. Crowbar Assembly In soft crowbar MLCC issues the firing signals to thyristor to protect the TCC when the DC link voltage crosses 3400 V. To protect TCC in case of soft crowbar failure, and if the voltage crosses 3400 V and reaches 3600 V the hard ware circuit of the crowbar assembly fires the thyristor. At any time if the crowbar thyristor fires it will be in latching and needs shut down of the engine to release the crowbar from latching.

42. Crowbar Resistor Crowbar resistor assembly consists of two resistors of 2.94  in parallel, with effective resistance of 1.47  It is located in clean air room (between Traction Alternator and TCC)

43. Current Sensors All current sensors used are hall effect type (non contact) Provides isolation from the power circuit to control circuit Total 31 sensors are provided in TCC Traction inverter input current sensors 6 Nos Traction inverter 3 Ph output current sensors 18 Nos TCC BLOWER current sensors 6 Nos Brake chopper current sensor 1 No

44. Traction inverter input current sensors Total 6 numbers of these sensors are provided to measure the input current to each traction inverter Can measure up to ±512 A These are kept in between DC link contactor and DC link capacitor for each traction inverter Physically placed next to the DC link contactors in TCC Input current sensor

45. Output Phase Current Sensors Total 3 numbers of these sensors are provided to measure the output current of each traction inverter Total 18 sensors are provided Can measure up to ±700 A peak current These are kept in between Traction Inverter phase modules and Traction Inverter output terminals in TCC Physically placed in between Traction Inverter and Output terminals in TCC On the backside of Output terminals

46. Brake chopper current sensor This sensor is provided to measure the output current of the brake chopper Only one sensor is provided Can measure up to 400 A This is kept in between brake chopper resistor and brake chopper IGBT module Physically placed at the bottom in TCC on traction inverters 1, 3, 5 side

47. Voltage Sensors All voltage sensors used are hall effect type Provides isolation from the power circuit to control circuit Measures up to 4096 V Total 13 sensors are provided in TCC Traction inverter line to line output voltage sensors 12 No Each Traction Inverter has two voltage sensors (U &V, V&W) One number main DC link voltage sensor (DCLV2)

48. Voltage Sensors - Location Six voltage sensors are provided in the upper part of TCC cabinet beside Traction Inverter 1 Six voltage sensors are provided in the upper part of TCC cabinet beside Traction Inverter 2 Main DC link voltage sensor (DCLV2) at the bottom in TCC on traction inverters 2,4,6 side One more voltage sensor – DCLV 1 is provided in ECC#1 to measure the same voltage Two sensors are provided for redundant operation

49. Temperature Sensors Various temperature sensors are provided to measure the heat sink temperature of all IGBT modules (total 37 numbers) and DC link capacitor temperatures (6 numbers) All are PT 100 type measures in the range from -36°C to 133.6°C Apart from these Traction Motor temperatures are monitored through Traction Motor in built temperature sensors Measuring range of Traction Motor stator temperature is from -30°C to 270°C

50. Service Entry

51. DC Link Motor Terminal Connections TM1 input terminals from TCC TM2 input terminals from TCC TM3 input terminals from TCC TM4 input terminals from TCC TM6 input terminals from TCC TM5 input terminals from TCC DC Link input terminals

52. Service / Maintenance Though there is a service entry provided in TCC, no need to open any door of the cabinet for maintenance For general maintenance, blow air into the air inlet of the filter

53. MAS 696 Questions Please...???

54. Thank You