H OOOO STATIC CONVERTER OFOOFFOF …rdso.indianrailways.gov.in/works/uploads/File/Handbook on Static...and BHEL in 1997. Presently CLW is manufacturing only static converter fitted

CAMTECH/E/10-11/SIV-Loco/1.0

Handbook on Static Converter of AC Electric Locomotives October 2010

1

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

egkjktiqj, Xokfy;j & 474 005 Maharajpur, GWALIOR - 474 005

dSeVsd@bZ@10&11@,lvkdSeVsd@bZ@10&11@,lvkdSeVsd@bZ@10&11@,lvkdSeVsd@bZ@10&11@,lvkbbbbZZZZooooh&yksdks@1h&yksdks@1h&yksdks@1h&yksdks@1----0000 CAMTECH/ E/ 10-11/ SIV-LOCO/ 1.0

vDVwcj 2010vDVwcj 2010vDVwcj 2010vDVwcj 2010 October 2010

dsoy dk;Zky;hu mi;ksx gsrq (For Official Use Only)

,lh,lh,lh,lh fo|qr yksdkseksfVo ds LVsfVd dU fo|qr yksdkseksfVo ds LVsfVd dU fo|qr yksdkseksfVo ds LVsfVd dU fo|qr yksdkseksfVo ds LVsfVd dUoVZj ij gLriqfLrdkoVZj ij gLriqfLrdkoVZj ij gLriqfLrdkoVZj ij gLriqfLrdk

HHHHANDBOOK ANDBOOK ANDBOOK ANDBOOK OOOON N N N STATICSTATICSTATICSTATIC CONVERTERCONVERTERCONVERTERCONVERTER OFOFOFOF

ACACACAC EEEELECTRIC LECTRIC LECTRIC LECTRIC LLLLOCOMOTIVES OCOMOTIVES OCOMOTIVES OCOMOTIVES

y{; lewg% fo|qr yksdks ifjpkyu ,oa vuqj{k.k deZpkjhy{; lewg% fo|qr yksdks ifjpkyu ,oa vuqj{k.k deZpkjhy{; lewg% fo|qr yksdks ifjpkyu ,oa vuqj{k.k deZpkjhy{; lewg% fo|qr yksdks ifjpkyu ,oa vuqj{k.k deZpkjh TARGET GROUP: Electric Loco O perating & Maintenance Staff


October 2010 Handbook on Static Converter of AC Electric Locomotives

2

,lh fo|qr yksdkseksfVo ds LVsfVd daoVZj ij ,lh fo|qr yksdkseksfVo ds LVsfVd daoVZj ij ,lh fo|qr yksdkseksfVo ds LVsfVd daoVZj ij ,lh fo|qr yksdkseksfVo ds LVsfVd daoVZj ij

gLriqfLrdkgLriqfLrdkgLriqfLrdkgLriqfLrdk

HHHHANDBOOK ANDBOOK ANDBOOK ANDBOOK OOOON N N N STATICSTATICSTATICSTATIC CONVERTERCONVERTERCONVERTERCONVERTER OFOFOFOF

ACACACAC EEEELECTRIC LECTRIC LECTRIC LECTRIC LLLLOCOMOTIVES OCOMOTIVES OCOMOTIVES OCOMOTIVES

xq.koRrk uhfrxq.koRrk uhfrxq.koRrk uhfrxq.koRrk uhfr

jsyksa esa ;k=h vkSj eky ;krk;kr dh c<+rh ek¡x dks iwjk djus ds fy, xq.koRrk Áca/k Á.kkyh esa vuqla/kku]

fMtkbuksa vkSj ekudksa esa mRd`"Vrk rFkk lr~r lq/kkjksa ds ek/;e ls lkafof/kd vkSj fu;ked vis{kkvksa dks iwjk djrs gq, lqjf{kr] vk/kqfud vkSj fdQk;rh jsy ÁkS|ksfxdh dk

fodkl djuk AAAA

QUALITY POLICY

“To develop safe, modern and cost

effective Railway Technology complying

with Statutory and Regulatory

requirements, through excellence in

Research, Designs and Standards and

Continual improvements in Quality

Management System to cater to growing

demand of passenger and freight traffic on

the railways”.



3

ÁkDdFkuÁkDdFkuÁkDdFkuÁkDdFku

vkuksZ dUoVZj dh fuEu n{krk ,ao rhu Qst lIykbZ esa oksYVst vlarqyu dh leL;kvksa dks nwj djus ds fy, Hkkjrh; jsy }kjk 180 dsoh, LVsfVd dUoVZj dks fo|qr batuksa esa yxk;k x;k gSA

;s dUoVZj vR;k/kqfud rduhd dk Á;ksx djrs gq, nks"k Áca/ku Á.kkyh vkSj mlds

okLrfod le; ds lkFk HkaMkj.k djus esa l{ke gSaA p¡wfd ;g rduhd rqyukRed :Ik ls u;h gS vr% bldh ÁkFkfed tkudkjh dks fo|qr yksdks ifjpkyu ,oa vuqj{k.k deZpkfj;ksa rd igqpkus ds fy, ,d gLriqfLrdk dh vko’;drk eglwl gks jgh FkhA

dSeVsd us bl gLriqfLrdk dks cuk;k gS ftlesa dUoVZj dh egRoiw.kZ fo’ks"krkvksa]

fofHkUu lc vlsEcyh] rduhdh fo’ks"krkvksa] nks"k çn’kZd ¼fMLIys½] egRoiw.kZ ekWMhfQds’ku vkfn dks crk;k x;k gSA

eq>s fo’okl gS fd ;g nLrkost gekjs yksdks ik;yV] fo|qr yksdks

'ksM@dk;Z’kkykvksa ds deZpkfj;ksa ds fy, mi;ksxh fl) gksxhA dSeVsd]Xokfy;j ,l-lh fla?ky fnukad % 09 uoEcj 2010 dk;Zdkjh funs’kd



4

FOREWORD

To overcome the problem of voltage imbalance of 3 phase supply and lower efficiency of ARNO converters, 180 kVA static converters have been introduced on Indian Railways.

These converters are designed using state of the art technology with in-built fault

management system and its storage in real time. Since this technology is comparatively new, need has been felt for a handbook to disseminate basic knowledge about the system among the electric loco driving crew and maintenance personnel.

CAMTECH has prepared this handbook which describes important features of the converter, various sub-assemblies, technical specifications, fault indications/ displays, important modifications etc.

I am sure this document will be very useful for our electric loco pilots, maintenance staff

in electric loco sheds and workshops.

CAMTECH, GWALIOR S.C. SINGHAL DATE : 09th November 2010 EXECUTIVE DIRECTOR



5

Hkwfedk

1997 esa vkjMh,lvks ,oa ch,pbZ,y }kjk la;qDr :Ik ls fodflr ÁFke LVsfVd dUoVZj dks WCAM-3 yksdkseksfVo esa Á;ksx fd;k x;k FkkA orZeku esa fprjatu yksdkseksfVo odZ’kkWIk dsoy LVsfVd dUoVZj yxs gq, fo|qr batuksa dk fuekZ.k dj jgk gSA orZeku esa LVsfVd dUoVZj yxs gq, fo|qr batuksa dh la[;k yxHkx ckjg lkS gSA

LVsfVd dUoVZj lHkh vkWDthyjh eksVjksa ,oa cSVjh pktZj dks 415 oksYV ± 5%] 50

gVZt] 3Qst] fLFkj ,lh lIykbZ Ánku djrk gSA ;g xSj eksVj yksM ¼LVsfVd midj.kksa½ dks Hkh 415 oksYV flaxy Qst ,lh lIykbZ Ánku djrk gSA orZeku esas lhesUl] vkWVksehVj] es/kk] fgUn jsDVhQk;j] cEckfMZ;j ,oa ,chch }kjk LVsfVd dUoVZj cuk;s ,oa vkiwrhZ fd;s tk jgs gSaA

dSeVsd }kjk LVsfVd dUoVZj ij ;g gLriqfLrdk dUoVZj ,oa mlls lEcaf/kr

ifjiFkksa ds lkFk muds ekWMhfQds’kuks dh csfld tkudkjh nsus ds mn~ns’; ls cukbZ xbZ gSA ;g Li"V fd;k tkrk gS fd ;g gLriqfLrdk vkjMh,lvks ;k jsyos cksMZ@{ks=h;

[email protected] fuekZrk }kjk fofuZfn"V fdlh Hkh fo/kku dks foLFkkfir ugha djrh A ;g gLriqfLrdk dsoy ekxZn’kZu gsrq gS ,oa ;g ,d oS/kkfud nLrkost+ ugha gSA

eSa] dk;Z{ks= ds mu lHkh deZpkfj;ksa dk vkHkkjh gwWa ftUgksus bl gLriqfLrdk dks

cukus esa gekjh lgk;rk dh A rduhdh mUu;urk vkSj lh[kuk ,d lrr~ izfdz;k gSA vr% bl gLriqfLrdk esa

tksM+us @ lq/kkjus ds fy;s gesa fy[kus esa Lora= eglwl djsa A bl fn’kk esa ge vkids ;ksxnku dh ljkguk djsaxsA

dSeVsd] Xokfy;j dSeVsd] Xokfy;j dSeVsd] Xokfy;j dSeVsd] Xokfy;j ih;w"k xqIrk ih;w"k xqIrk ih;w"k xqIrk ih;w"k xqIrk fnfnfnfnukad ukad ukad ukad % % % % 08 uoEcj 08 uoEcj 08 uoEcj 08 uoEcj 2010201020102010 lalalala---- funs’kd ¼fo|qr½ funs’kd ¼fo|qr½ funs’kd ¼fo|qr½ funs’kd ¼fo|qr½



6

PREFACE

The first static converter was used in WCAM – 3 locomotives jointly developed by RDSO and BHEL in 1997. Presently CLW is manufacturing only static converter fitted electric locomotives. At present the population of electric locomotives equipped with static converters is approximate 1200.

Static converter gives constant 415 Volts ±5%, 50 Hz, three phase, AC supply to all

auxiliary motors and to battery charger. It also gives 415 volts single phase AC to non-motor loads (static devices). At present static converters are being manufactured and supplied by SIEMENS, AAL, MEDHA, HIRECT, Bombardier and ABB.

This handbook on Static Converter has been prepared by CAMTECH with the objective to

disseminate basic knowledge of the converter and its associated circuits with modifications.

It is clarified that this handbook does not supersede any existing provisions laid down by RDSO or Railway Board/ Zonal Railways/ OEMs. The handbook is for guidance only and it is not a statutory document.

I am sincerely thankful to all field personnel who helped us in preparing this handbook.

Technological upgradation and learning is a continuous process. Hence feel free to write us for any addition/ modification in this handbook. We shall highly appreciate your contribution in this direction.

CAMTECH, GWALIOR PEEYOOSH GUPTA DATE: 08th November 2010 Jt. DIRECTOR ELECTRICAL

[email protected]



7

fo"k; lwphfo"k; lwphfo"k; lwphfo"k; lwph

ØeØeØeØe lalalala---- fooj.kfooj.kfooj.kfooj.k i`"B lai`"B lai`"B lai`"B la----

çkDdFku iii Hkwfedk v fo"k; lwph vii la’kks/ku ifpZ;ksa dk izdk’ku xi

1.0 izLrkoukizLrkoukizLrkoukizLrkouk 01010101 2.0 LVsfVd dUoZVj ds Qk;nsLVsfVd dUoZVj ds Qk;nsLVsfVd dUoZVj ds Qk;nsLVsfVd dUoZVj ds Qk;ns 02020202

3.0 gVk, x, midj.kgVk, x, midj.kgVk, x, midj.kgVk, x, midj.k 02020202

4444----0000 yxk, x, u;s midj.kyxk, x, u;s midj.kyxk, x, u;s midj.kyxk, x, u;s midj.k 02020202

5555----0000 ,lvkboh iSuy ij fMLIys ,lvkboh iSuy ij fMLIys ,lvkboh iSuy ij fMLIys ,lvkboh iSuy ij fMLIys ,oa,oa,oa,oa ladsrdladsrdladsrdladsrd 03030303 5-1 ,ybZMh ladsrd 03 5.2 dk;kZRed iSjkehVj dk Án’kZu 03

5.3 QkWYV dksM dk çn’kZu 04

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7.0 flLVe vlsEcyhflLVe vlsEcyhflLVe vlsEcyhflLVe vlsEcyh 06060606

8.0 flLVe CykWd Mk;xzkeflLVe CykWd Mk;xzkeflLVe CykWd Mk;xzkeflLVe CykWd Mk;xzke 08

9.0 rduhdh fo’ks"krk,sarduhdh fo’ks"krk,sarduhdh fo’ks"krk,sarduhdh fo’ks"krk,sa 09 9.1 buiqV 09

9.2 vkÅViqV 09 9.3 lkekU; 10

10.0 dk;Z fl)kardk;Z fl)kardk;Z fl)kardk;Z fl)kar 10

11.0 lqj{kklqj{kklqj{kklqj{kk 12

11.1 vkWDthyjh okbfUMax dk [kqyk ifjiFk 12

11.2 dUoVZj esa ¶;wt QSY;ksj 13

11.3 FkeZy vksojyksfMax 13

11.4 Mhlh fyad esa mPp@fuEu oksYVst 13

11.5 dUVªksy bySDVªksfuDl dh ikoj lIykbZ dk QSY;ksj 13

11.6 {kf.kd ,oa ltZ lqj{kk 13

11.7 vf/kd@ de buiqV oksYVst 13

11.8 vf/kd buiqV djUV 13

11.9 vf/kd@ de vkmViqV oksYVst 13

11.10 vf/kd vkmViqV djUV 13

11.11 vkmViqV ij 'kkWVZ lfdZV 14 11.12 vFkZ yhdst 14

11.13 flaxy Qsft+ax 14



8

CONTENTS

Item No. Description Page No.

Foreword iv Preface vi Contents viii

Correction Slip xii

1.0 INTRODUCTION 01

2.0 ADVANTAGES OF STATIC CONVERTER 02

3.0 EQUIPMENT REMOVED 02

4.0 NEW EQUIPMENT PROVIDED 02

5.0 DISPLAYS AND INDICATIONS ON SIV PANEL 03 5.1 Led Indications 03 5.2 Display of Functional Parameters 03 5.3 Display of Fault Codes 04

6.0 LOADS ON STATIC CONVERTER 05

7.0 SYSTEM ASSEMBLIES 06

8.0 SYSTEM BLOCK DIAGRAM 08

9.0 TECHNICAL SPECIFICATIONS 09 9.1 Input 09 9.2 Output 09 9.3 General 10

10.0 WORKING PRINCIPLE 10

11.0 PROTECTIONS 12 11.1 Open Circuit in Auxiliary Winding 12 11.2 Fuse Failure in Converter 13 11.3 Thermal Overloading 13 11.4 High/Low Voltage in DC Link 13 11.5 Failure of Power Supply to Control Electronics 13 11.6 Transient & Surge Protection 13 11.7 Input Over/Under Voltage 13 11.8 Input Over Current 13 11.9 Output Over/Under Voltage 13 11.10 Output Over Current 13 11.11 Short Circuit at Output 14 11.12 Earth Leakage 14 11.13 Single Phasing 14



9

ØeØeØeØe lalalala---- fooj.kfooj.kfooj.kfooj.k i`"B lai`"B lai`"B lai`"B la---- 12.0 lqj{kk lsfVaxlqj{kk lsfVaxlqj{kk lsfVaxlqj{kk lsfVax 14

12.1 ,,,y çksVsD’ku lsfVaXl 14

12.2 lhesUl çksVsD’ku lsfVaXl 15

13.0 lsalj ¼, , ,y½lsalj ¼, , ,y½lsalj ¼, , ,y½lsalj ¼, , ,y½ 16161616

13.1 buiqV djUV Vªk¡lQkWeZj 16

13.2 buiqV iksVsaf’k;y Vªk¡lQkWeZj 16

13.3 Mhlh fyad djUV Vªk¡lM~;wlj 16 13.4 Mhlh fyad oksYVst Vªk¡lM~;wlj 16

13.5 pkSij djUV Vªk¡lQkWeZj 16

13.6 vkÅViqV djUV Vªk¡lQkWeZj 16

13.7 vkÅViqV iksVsaf’k;y Vªk¡lQkWeZj 17 13.8 ’kwU; djUV Vªk¡lQkWeZj 17

14.0 fu;a=.k ifjiFk esa egRoiw.kZ la’kks/kufu;a=.k ifjiFk esa egRoiw.kZ la’kks/kufu;a=.k ifjiFk esa egRoiw.kZ la’kks/kufu;a=.k ifjiFk esa egRoiw.kZ la’kks/ku 17171717 14.1 D;w lh vks ,u fjys 17

14.2 D;w ,l vkbZ Vh fjys 17

14.3 D;w,loh,e fjys 18

14.4 D;wVhMh 101 vkSj D;w 119 fjys 18

14.5 flXufyax ySEi ifjiFk 21

14.6 LVsfVd dUoVZj dk fu;a=.k ifjiFk 21

14.7 ,pvkj,ohVh fLop 21

15.0 ifjpkyu funsZ’kifjpkyu funsZ’kifjpkyu funsZ’kifjpkyu funsZ’k 22222222

15.1 bujtkbZt+ djus dh fof/k 22

15.2 Cyksvjksa dks cUn djuk 22

15.3 dk;kZRed fjyksa dk ijh{k.k 22

16.0 vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½ 23

17.0 =qfV fuokj.k=qfV fuokj.k=qfV fuokj.k=qfV fuokj.k 25252525

17.1 ,ybMh fMLIys ds vuqlkj =qfV fuokj.k 25

17.2 LVsfVd bUoVZj ds fVªfiax QSY;ksj 26

18.0 egRoiw.kZ funsZ’kegRoiw.kZ funsZ’kegRoiw.kZ funsZ’kegRoiw.kZ funsZ’k 28

19.0 vko’;d vkSt+kj rFkk midj.kvko’;d vkSt+kj rFkk midj.kvko’;d vkSt+kj rFkk midj.kvko’;d vkSt+kj rFkk midj.k 29292929

20.0 D;k djsa vkSj D;k u djsa ¼vuqj{k.k ds nkSjku½ D;k djsa vkSj D;k u djsa ¼vuqj{k.k ds nkSjku½ D;k djsa vkSj D;k u djsa ¼vuqj{k.k ds nkSjku½ D;k djsa vkSj D;k u djsa ¼vuqj{k.k ds nkSjku½ 30303030

20.1 D;k djsa 30

20.2 D;k u djsa 31

21.0 lkekU; fn’kkfunsZ’klkekU; fn’kkfunsZ’klkekU; fn’kkfunsZ’klkekU; fn’kkfunsZ’k 31313131 lUnHkZlUnHkZlUnHkZlUnHkZ 32323232



10

Item No. Description Page No.

12.0 PROTECTION SETTINGS 14 12.1 AAL Protection Settings 14 12.2 Siemens Protection Settings 15

13.0 SENSORS 16 13.1 Input Current Transformer (ACCT) 16 13.2 Input Potential Transformer (ACPT 1) 16 13.3 DC Link Current Transducer (DCCT) 16 13.4 DC Link Voltage Transducer (DCPT) 16 13.5 Chopper Current Transducer (CHCT) 16 13.6 Output Current Transformer (ACCT1/ACCT2/ACCT3) 16 13.7 Output Potential Transformer (ACPT2) 17 13.8 Zero Current Transformers (ZCT 1 & 2) 17

14.0 IMPORTANT MODIFICATIONS IN CONTROL CIRCUIT 17 14.1 QCON Relay 17 14.2 QSIT Relay 17 14.3 QSVM Relay 18 14.4 QTD 101 and Q 119 Relay 18 14.5 Signaling Lamp Circuit 21 14.6 Static Converter Control Circuit 21 14.7 HRAVT Switch 21

15.0 OPERATING INSTRUCTIONS 22 15.1 Procedure for Energisation 22 15.2 Stopping of Blowers 22 15.3 Testing of Functional Relays 22

16.0 MAINTENANCE SCHEDULES (Siemens SCD) 23

17.0 TROUBLE SHOOTING 25 17.1 Trouble Shooting as per Display LEDs 25 17.2 Tripping Failures of Static Converter 26

18.0 IMPORTANT INSTRUCTIONS 28

19.0 TOOLS & INSTRUMENTS REQUIRED 29

20.0 DO’S AND DON’TS (DURING MAINTENANCE) 30 20.1 Do’s 30 20.2 Don’ts 31

21.0 GENERAL GUIDELINES 31

REFERENCES 33



11

la’kks/ku ifpZ;ksa dk izdk’kula’kks/ku ifpZ;ksa dk izdk’kula’kks/ku ifpZ;ksa dk izdk’kula’kks/ku ifpZ;ksa dk izdk’ku

bl gLriqfLrdk ds fy;s Hkfo"; esa izdkf’kr gksus okyh la’kks/ku ifpZ;ksa dks fuEukuqlkj la[;kafdr fd;k tk;sxkA

dSeVsd@bZ@dSeVsd@bZ@dSeVsd@bZ@dSeVsd@bZ@10101010&11&11&11&11@@@@,lvkboh&yksdks,lvkboh&yksdks,lvkboh&yksdks,lvkboh&yksdks@1@1@1@1----0000 lh,l lh,l lh,l lh,l # XX fnukadfnukadfnukadfnukad---------------

tgkWa “XX” lEcfU/kr la’kks/ku iphZ dh dze la[;k gS ¼ 01 ls izkjEHk gksdj vkxs dh vksj½ izdkf’kr la’kks/ku ifpizdkf’kr la’kks/ku ifpizdkf’kr la’kks/ku ifpizdkf’kr la’kks/ku ifpZ;k¡ Z;k¡ Z;k¡ Z;k¡ dzdzdzdz----lalalala---- izdk’ku dh izdk’ku dh izdk’ku dh izdk’ku dh

rkjh[krkjh[krkjh[krkjh[k la’kksf/kr Ik`"B la[;k rFkk en la[;kla’kksf/kr Ik`"B la[;k rFkk en la[;kla’kksf/kr Ik`"B la[;k rFkk en la[;kla’kksf/kr Ik`"B la[;k rFkk en la[;k fVIi.khfVIi.khfVIi.khfVIi.kh



12

ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows : CAMTECH/E/10-11/SIV-LOCO/C.S. # XX date--------- Where “XX” is the serial number of the concerned correction slip (starting from 01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. Date of issue Page no. and Item no. modified

Remarks



1

1.0 ÁLrkouk@ÁLrkouk@ÁLrkouk@ÁLrkouk@INTRODUCTION

Indian Railway introduced 180 kVA static converters to replace ARNO converter to over come the problem of voltage unbalance of 3 phase supply of ARNO converter and lower efficiency of ARNO system.

The first static converter was used in WCAM – 3 locomotives jointly developed by

RDSO and BHEL in 1997. This converter was supplied by ACEC. In late nineties SIEMENS provided 8 nos 180 KVA static converters in conventional locomotives at ELS / NCR / CNB. Presently CLW is manufacturing only static converter fitted electric locomotives. At present the population of electric locomotives equipped with static converters is approximate 1200.

Static converter gives constant 415 Volts ±5%, 50 Hz, 3Ø AC supply to all auxiliary

motors and to battery charger. It also gives 415 volts 1Ø AC to non-motor loads (static devices). At present static converters are being manufactured and supplied by SIEMENS, AAL, MEDHA, HIRECT, Bombardier and ABB.

This unit is being designed & manufactured in accordance with RDSO specification

no. ELRS/ SPEC/ SI/ 0018 (REV.1) March, 2006 & amendment – 1 dtd. 05.02.2009 for electric locomotives. Further RDSO issued report no. RDSO/ 2007/ EL/ IR/ 0126 Rev. ‘0’ dated January 2008 on “Standardization of 180 kVA Static Inverter of Electric Locomotive”.

AAL SIV SIEMENS SIV



2

2.0 LVsfVd dULVsfVd dULVsfVd dULVsfVd dUoZVj ds Qk;ns@oZVj ds Qk;ns@oZVj ds Qk;ns@oZVj ds Qk;ns@ADVANTAGES OF STATIC CONVERTER

• State-of-art technology with high efficiency (>90%).

• Stable output voltage (415 ± 5%) & frequency (50Hz ± 3%) irrespective of OHE Variations.

• All the three phase output voltages are balanced resulting in balanced supply to the loads.

• Output voltage & current THD < 5%. No overheating / counter torque problems.

� Standard motors can be used, leading to higher efficiency & power factor.

• Soft starting of loads possible resulting in reduced system over loading.

• In-built fault management system with storage of faults monitoring, with real time clock and traces.

• Various problems of auxiliary machines are reduced due to regulated and balanced supply voltage.

• Inbuilt protections (viz. overload, single phasing, short circuit) for safety of loads.

• Minimum Maintenance.

• Life of 3Ø E.M. contactors increases since operated on ‘OFF’ load.

• Higher system reliability due to elimination of time delay relays, C118, R118 etc.

• Noise less smooth operation.

• No switching surges due to soft starting feature.

• Power losses minimized during startup due to soft starting feature. 3.0 gVk, x, midj.k@gVk, x, midj.k@gVk, x, midj.k@gVk, x, midj.k@EQUIPMENT REMOVED

a) ARNO, C118, R118, QCVAR, HQCVAR, QOA, HQOA, QLA, Q100, HCHBA, CHBA, TFVT(220V/ 110V), QTD 105 & QTD 106, Fuse CCVT 6A .

4444----0000 yxk, x, u;s midj.k@yxk, x, u;s midj.k@yxk, x, u;s midj.k@yxk, x, u;s midj.k@NEW EQUIPMENT PROVIDED

b) Static converter (Rectifier, Inverter, BA charger and Sine Filter are the parts of SIV)

c) a0, a8 bushings of TFWA are used to get 830 V, 1phase AC supply.

d) QTD 101 time delay relay of 5 sec (cab-2 back panel) for delayed starting of compressors.

e) Contactor C-108 (in contactor panel) for 3 Ø AC supply to MVRF.

f) QCON (in relay panel) for checking the functioning of static converter.

g) QSIT (in relay panel) for tripping of DJ whenever static converter trips.

h) CCINV fuse 6 amps (in switch panel) for converter electronics.

i) LSSIT (on loco Pilots desk) indication lamp for static converter tripping.

j) QSVM (2 seconds time delay) relay for soft starting of blowers.

k) HRAVT switch (in switch panel) related to cab heaters, cab fans, NR and walkie- talkie charger.

l) HSIV switch (in switch panel) for bypassing of earth fault during permanent earth fault.



3

m) RSIV 1500 Ohms, 500 Watts n) TFVT 415V/110V o) Fuse CCVT 3A p) Two Capacitors across a0-a8 each of 1mfd, 2000V in series with midpoint earthed.

5.0 ,lvkboh iSuy ij fM,lvkboh iSuy ij fM,lvkboh iSuy ij fM,lvkboh iSuy ij fMLLLLIysIysIysIys ,oa,oa,oa,oa ladsrdladsrdladsrdladsrd@@@@DISPLAYS & INDICATIONS ON SIV PANEL 5.1 ,ybZMh ladsrd@,ybZMh ladsrd@,ybZMh ladsrd@,ybZMh ladsrd@Led Indications Following set of status indication LEDs are provided for the driving crew information:

S.No. Description LED Colour

Remarks

1. SI unit OK Green The indication is ‘ON’, when there is no fault in the SIV.

2. Input voltage in range

Red The indication is ‘OFF’, when the input voltage is within the operating range.

3. Internal fault Red The indication in ‘ON’, when fault occurs inside the SIV.

4. External fault Red The indication is ‘ON’, when fault occurs on the input/ load side including faults such as Earth fault, Output single phasing, Over load, etc.

5. CHBA OK Green The indication is ‘ON’ (and LSCHBA lamp is ‘OFF’) when the battery charger unit is working.

6. Earth fault by pass lamp

Red The indication is ‘ON’, when earth fault is in bypassed mode.

5.2 dk;kZRed iSjkehVj dk Ándk;kZRed iSjkehVj dk Ándk;kZRed iSjkehVj dk Ándk;kZRed iSjkehVj dk Án’k’k’k’kZZZZu@u@u@u@ Display of Functional Parameters

Following parameters are displayed with the instantaneous value one after another on LCD/ VFD panel:

S.No. Parameter Displayed as Remarks

1. Input/ DC link voltage XXX

2. Input / DC link current XXX

3. Output voltage XXX Line to line voltage

4. Output current XXX Line current

5. CHBA voltage XXX CHBA voltage shown by separate meter is also acceptable.

6. CHBA current XXX CHBA current shown by separate meter is also acceptable.

• The text describing the parameter is followed by the numerical value of the parameter. • In event of a fault in the system, the parameter displayed is replaced by the fault

display on the panel.



4

5.3 QkWYV dksM dk çn’kZu@QkWYV dksM dk çn’kZu@QkWYV dksM dk çn’kZu@QkWYV dksM dk çn’kZu@ Display of Fault Codes

In event of a fault occurring in the SIV due to any reason (internal or external) the same will be displayed on the display panel.

• The faults will remain displayed till the operator/ driver acknowledges them by pressing the acknowledgement key.

• Once reset button is pressed or 110V DC battery power supply to converter is switched OFF & ON, the fault display will be reset and functional parameters will be displayed.

The following fault code will be displayed according to the fault.

S.N Fault displayed as Fault description

1. Input Fuse failure In case the input fuse is blown due to high current drawn.

2. Input voltage high Input voltage exceeding upper limit.

3. Input voltage low Input voltage drops below limit.

4. DC link/ Input current high

Excess current flowing in the DC Bus or input high current conditions persisting.

5. DC link voltage high DC link voltage exceeds upper limit.

6. DC Link low voltage DC Link voltage drops below lower limit.

7. Output current high In case of output high current conditions persisting.

8. Output voltage high Output voltage exceeding upper limit.

9. Output voltage low Output voltage drops below lower limit.

10. Earth fault In event of earth fault at input/ output of SIV.

11. Single phase fault Unbalance/ single phasing at the output.

12. Blower fault Failure of blower for cooling.

13. CHBA fault Battery Charger fault.

14. Rectifier fault In event of fault in Rectifier section.

15. Inverter fault In event of fault in inverter section.

16. Chopper fault In event of fault in chopper section (If design includes chopper).

17. Over temperature Any temperature sensing device operated in the Rectifier and inverter sections.

18. Power supply fault In event of failure of any of the electronic/ control power supply.

19. Chopper current high Chopper section current exceeds upper limit (If design includes chopper).

20. CHBA current high Battery charger current limit exceeded.

21. CHBA voltage high Battery Charger voltage exceeding upper limit.

22. CHBA voltage low Battery Charger voltage drops below lower limit.

23. CHBA temp high Battery Charger temperature exceeds upper limit.

24. No synchronization/ Communication Error

Communication fault in software.



5

6.0 LVsfVd dUoVZj ij Hkkj@LVsfVd dUoVZj ij Hkkj@LVsfVd dUoVZj ij Hkkj@LVsfVd dUoVZj ij Hkkj@LOADS ON STATIC CONVERTER

Converter is designed to feed following loads as given in the following table.

S.No. Code Name of Auxiliary Machine

Rating (kW)

Rated Current at 415V (A)

Starting Current at 415V (A)

1. MVSI 1 & 2 Motor for silicon rectifier cooling blowers 1 & 2

2 × 2.2 2 × 4.7 2 × 32.4

2. MVSL 1 & 2 Motor for smoothing rectifier cooling blowers 1 & 2

2 × 2.2 2 × 4.7 2 × 32.4

3. MPH Motor for transformer oil pump

3.2 7.0 36.5

4. MCP 1 & 2 or

MCP 1, 2 & 3

Motor for main compressors (2000 lpm) Motor for main compressors (1000 lpm)

2 × 20.5

3 × 10.5

2 × 43.13

3 × 23.1

2 × 328.7

3 × 154.85

5. MVRH Motor for main transformer cooling blower

22.0 41.33 278.5

6. MVMT 1 & 2 Motor for traction motor cooling blowers 1 & 2

2 × 26 2 × 47.43 2 × 309

7. CHBA Battery charger and other load

2.5 7.0 7.0

8. MVRF DBR blower 33.0 63.0 380.0



6

7.0 flLVe vlsEcyh@flLVe vlsEcyh@flLVe vlsEcyh@flLVe vlsEcyh@SYSTEM ASSEMBLIES (Siemens SCD)

Text Display Reset Switch Indication Lamps

Voltmeter and Ammeter

Text Display (Rear) Text Display power supply O/P Voltage sensors I/P ELR Input Fuse Input Isolator 1 Ph. Input

Input ZCT

MCB for Cooling Fan Volt and Ampere Meter SIBCOS M 1300 I/P Volt sensors O/P ELR Battery Charger Output 3 Ph. Output

Output ZCT



7

Sine Filter Capacitor Commutation choke DC Link Choke Output Sine Filter Choke

Transformer Output Sine Filter Choke

DC Link Current Sensor Rectifier Module Crowbar Circuit Battery Charger Output Current Sensor Inverter Module PWR 2 Inverter Module PWR 1 Internal churning fan Cooling Fan

Internal churning fan



8

8.0 flLVe flLVe flLVe flLVe CykWd Mk;xzkeCykWd Mk;xzkeCykWd Mk;xzkeCykWd Mk;xzke@@@@SYSTEM BLOCK DIAGRAM

RECTIFIER INVERTER

+

-

∼ AC DC

=

DC

= ∼ AC

1Φ

AC

3Φ

AC

Siemens Single Cubicle design

RECTIFIER INVERTER

SINE FILTER

BLOWER

INPUT760/830/860V, 50Hz

NOMINAL

3AC 415V, 50Hz

180kVA

OUTPUT 1

BATTERY

CHARGER

2.2 kW110V DCOUTPUT 2

SIBCOS CONTROLLER



9

9.0 rduhdh fo’ks"krk,sarduhdh fo’ks"krk,sarduhdh fo’ks"krk,sarduhdh fo’ks"krk,sa@@@@TECHNICAL SPECIFICATIONS 9.1 buiqV@buiqV@buiqV@buiqV@ Input

Nominal voltage : AC single phase, 760V / 830V (corresponding to catenary voltage of 22.5KV)

Min. voltage continuous : 642 V AC

Max. Voltage continuous : 1014 V AC

Min. voltage at which converter trips on under voltage

: < 591V AC

Max. Voltage beyond which converter trips on over voltage

: 1150V AC

Input voltage range for which guaranteed converter performance is available

: 642 V to 1014 V AC

Input voltage range for which guaranteed converter performance is not available but converter will not trip on either under voltage or over voltage

: 591V to 642V on lower side 1014V to 1150V on higher side

Power factor : ≥ 0.8 (At rated conditions)

Input frequency : 50 ± 3 Hz

9.2 vkÅvkÅvkÅvkÅViqV@ViqV@ViqV@ViqV@Output

Output power : 180 kVA, 0.8 pf (lag) at nominal operation

Overload (short time) : 200% for 5 sec. (360 kVA & current limit of 600A)

Voltage 1 (AC output) : AC 415V ± 5%, 3 phase system (fundamental at nominal continuous rated input voltage between 642 - 1014V)

Frequency : 50Hz ± 3%

Waveform : Sine wave

THD in voltage : ≤ 10% (up to 20th harmonic)

Efficiency : ≥ 92% (At nominal input voltage & rated load)

Voltage 2 (DC output) : DC 110 V ± 5%, 20 A for battery charger

[less than ± 5% current ripple (rms) at full load and at nominal continuous rated input voltage of 642 - 1014V]



10

9.3 lkekU;@lkekU;@lkekU;@lkekU;@General

Ambient temperature : 0º C to 70º C (max. 55ºC inside loco)

Humidity : Upto 100% during rainy season (90% at 55ºC)

Altitude : Upto 1200 m above mean sea level

Dust : 1.6 mg/ cub m, max. Ph 8.5

Audible noise : 80 dB (A) at 1meter distance from cubicle as per IEC1287-1.

Display & communication : Vacuum fluorescent display and RS-232 port for data logging.

Control voltage : DC 110 V

10.0 dk;Z fl)kar@dk;Z fl)kar@dk;Z fl)kar@dk;Z fl)kar@WORKING PRINCIPLE

The converter generates 415V, 3 phase, 50Hz output from 760V / 830V, 1 phase, 50Hz input which is available from the main locomotive transformer. General schematic of the converter is shown below.

The static converter is made using a half controlled single phase bridge rectifier at

the input, a DC link filter and a three phase IGBT based PWM inverter. All functions of the converter are controlled through 32 bits Digital signal processor (DSP) together with an EPLD & host of digital gates and analog amplifiers.



11

The converter consists of following sub-modules:

A. Input Section B. Rectifier Section C. DC Link Filter & Over Voltage Chopper D. Inverter Section E. Output Section

A. Input Section

The input section consists of input fuse (MF), Metal oxide varistors and input

bus bar. Input fuse is used to protect the converter and for ensuring safe operation of the converter under worst input conditions. Metal oxide varistors (MOV) are used to protect the converter from surges.

B. Rectifier Section

The rectifier section is made

using a half controlled single phase bridge rectifier. This consists of a half controlled bridge rectifier, made up of 2 thyristors and 2 diodes. When the input AC voltage is positive, one of the thyristors is fired with a predetermined delay. It starts conducting and the voltage of the DC link rises. The current continues to flow due to the DC link reactor, until the input voltage changes polarity and the other thyristor is fired. Now, the other thyristor with the corresponding diode takes over the current. The rectifier circuit converts single-phase AC input voltage into DC voltage of desired level (760 volts).

The main controller

maintains the DC link voltage at a preset value by controlling the firing angle of the thyristors. A PI controller is used to determine the firing angle. If the DC link voltage is lower than desired voltage, the firing angle will be small and if the DC link voltage is higher than the desired voltage, the firing angle will be increased. RC snubber circuit is provided across each thyristors and diode’s to protect against high dv / dt experience by devices.

DM1K

ASC1

SR

1 2P

DM2K

A

SR

2 2P

SC2

TM1

K

A

SR

3 2P

SC3

TM2

A

K

SC4

SR

4 2P

C

L



12

C. DC Link Filter & Over Voltage Chopper

The DC link filter consist of DC link choke (FL) and DC link capacitors (FC). DC link choke and capacitors provided at the output of the rectifier to reduce the ripples in the DC link voltage that is fed to the inverter.

The over voltage chopper is made-up of an IGBT switch with a resistor and

an anti-parallel diode. The IGBT switches the resistor on and off in the DC circuit if the DC voltage exceeds a preset value. The chopper dissipates the extra energy and protects the system from over voltage, especially during transients at start-up.

D. Inverter Circuit

The Inverter consists of six IGBT modules. IGBT modules are configured as

a 3-phase bridge circuits. The bridge is made up of three identical phase branches and each branch consists of two IGBTs.

The DC link voltage is converted into PWM sinusoidal waves by switching

IGBTs at a high frequency. The width of the individual pulses in the PWM wave determines the amplitude of the output voltage and the width of the pulse block determines the output frequency.

As the system is a constant voltage, constant frequency system, the output

frequency is maintained at 50Hz and the PI controller receives an output voltage feedback in order to keep the voltage constant too. The final stage is responsible for generation of switching signals utilizing Space Vector Pulse Width Modulation (SVPWM) technology.

State-of-the-art space vector PWM technique has been adopted in the design

of inverter software as this technology is more flexible & adapts to wider variations in the input DC link voltages. For better regulation of the output voltage, proportional integrated control has been used.

E. Output LC Filter

The Inverter output voltage is PWM, which is converter into sine wave by

using output filter. It consists of 3 phases AC Choke (ACL) and 3 phases Capacitor (ACC).

11.0 lqj{kk@lqj{kk@lqj{kk@lqj{kk@PROTECTIONS

The Static converter is equipped with circuits to protect itself and its load from all disturbances. Its operation is stopped by all fault conditions.

11.1 vkWDthyjh okbfUMax dk [kqyk ifjiFk@vkWDthyjh okbfUMax dk [kqyk ifjiFk@vkWDthyjh okbfUMax dk [kqyk ifjiFk@vkWDthyjh okbfUMax dk [kqyk ifjiFk@Open Circuit in Auxiliary Winding

This circuit detects that input voltage is too low or completely absent. It is practically the protection from input under voltage.



13

11.2 dUoVZj esa ¶;wt QSdUoVZj esa ¶;wt QSdUoVZj esa ¶;wt QSdUoVZj esa ¶;wt QSY;Y;Y;Y;ksksksksj@j@j@j@Fuse Failure in Converter

This circuit monitors the signals from the fuse contacts and if a fuse blows the converter is tripped.

11.3 FkeZy vksojyksfMax@FkeZy vksojyksfMax@FkeZy vksojyksfMax@FkeZy vksojyksfMax@Thermal Overloading

Temperature sensors are mounted on the heat sinks of the rectifier unit and the inverter unit. If the temperature of the heat sink exceeds a predetermined level, a fault signal is sent to the main controller. The operation of inverter is stopped. The circuit resumes operation automatically when the temperature returns to normal.

11.4 Mhlh fyad esa mPMhlh fyad esa mPMhlh fyad esa mPMhlh fyad esa mPp@fuEu oksYVst@p@fuEu oksYVst@p@fuEu oksYVst@p@fuEu oksYVst@High/Low Voltage in DC Link

A voltage sensor monitors the DC link voltage. If DC link voltage is too high or too low, the main controller shuts down the converter.

11.5 dUVªksy bdUVªksy bdUVªksy bdUVªksy bySDVªksfuDl dh ikoj lIykbZ dk QSySDVªksfuDl dh ikoj lIykbZ dk QSySDVªksfuDl dh ikoj lIykbZ dk QSySDVªksfuDl dh ikoj lIykbZ dk QSY;Y;Y;Y;ksksksksj@j@j@j@Failure of Power Supply to

Control Electronics

The main controller monitors the power supply. If a failure is detected, the main controller blocks the gate signals of IGBTs and thyristors.

11.6 {kf.kd ,oa ltZ lqj{kk{kf.kd ,oa ltZ lqj{kk{kf.kd ,oa ltZ lqj{kk{kf.kd ,oa ltZ lqj{kk@@@@Transient & Surge Protection

Voltage surge suppressor is provided at the input. 11.7 vf/kd@ devf/kd@ devf/kd@ devf/kd@ de buiqV oksYVst@ buiqV oksYVst@ buiqV oksYVst@ buiqV oksYVst@Input Over/Under Voltage

The main controller monitors input voltage continuously. The sensor is located at the input of the rectifier circuit. In case the input voltage exceeds the predetermined value of under voltage or over voltage, an alarm signal is given to the main controller, which initiates adequate protective operation. When the input voltage returns to normal, the inverter resumes normal operation.

11.8 vf/kd vf/kd vf/kd vf/kd buiqV djUV@ buiqV djUV@ buiqV djUV@ buiqV djUV@ Input Over Current

The current sensors are also installed at the input of the rectifier circuit. Whenever the input current exceeds the predetermined value, a fault signal is sent to the main controller to initiate required protection.

11.9 vf/kd@ devf/kd@ devf/kd@ devf/kd@ de vkmViqV oksYVst@ vkmViqV oksYVst@ vkmViqV oksYVst@ vkmViqV oksYVst@Output Over/Under Voltage

The voltage of the filter capacitors is monitored continuously by the main controller. In case the output voltage exceeds the predetermined value of over voltage or under voltage, a fault signal is sent to the main controller to initiate the protective operation. The main controller immediately switches off the inverter.

11.10 vf/kd vf/kd vf/kd vf/kd vkmViqV djUV@vkmViqV djUV@vkmViqV djUV@vkmViqV djUV@Output over Current

The output of the inverter is protected against overload. Whenever the output current exceeds the predetermined value, a fault signal is sent to the main controller to initiate required protection.



14

11.11 vkmViqV ij 'kkWVZ lvkmViqV ij 'kkWVZ lvkmViqV ij 'kkWVZ lvkmViqV ij 'kkWVZ lffffdZV@ dZV@ dZV@ dZV@ Short Circuit at Output

The output of the inverter is protected against short circuit. Whenever the output current exceeds the predetermined value, the main controller initiates required protection. Under short circuit conditions, a fast current limit protects the power semi-conductors in the 3-phase Inverter Bridge.

11.12 vFkZ yhdst@vFkZ yhdst@vFkZ yhdst@vFkZ yhdst@ Earth Leakage

In case the earth leakage detector has detected an earth leakage current, an earth fault is initiated and the inverter trips.

11.13 flaxy Qsft+ax@flaxy Qsft+ax@flaxy Qsft+ax@flaxy Qsft+ax@Single Phasing

The single phasing protection is automatically available in the inverter through the over current protection. If the output current of the inverter exceeds the predetermined limit due to single phasing, then the inverter will trip.

12.0 lqj{kk lsfVax@lqj{kk lsfVax@lqj{kk lsfVax@lqj{kk lsfVax@PROTECTION SETTINGS 12.1 ,,,y çksVsD’ku lsfVaXl@,,,y çksVsD’ku lsfVaXl@,,,y çksVsD’ku lsfVaXl@,,,y çksVsD’ku lsfVaXl@ AAL Protection Settings

Sr. No Parameter Setting Limit

1 Input Over Voltage 1150 +/- 20 V

2 Input Under Voltage 550 +/- 20 V

3 DC Link Over Voltage 950 V

4 DC Link Under Voltage 450 V

5 Output Over Voltage 540 V

6 Output Under Voltage 350 V

7 Input Over Current (Instantaneous) 1300 + / - 25 A

8 Input Over Load 500 A

9 Output Over Current (Instantaneous) 1300 + / - 25 A

10 Output Over Load 450 A for 10 sec

11 DC Link Over Current 1120 A

12 Chopper Over Current 150 A

13 Earth Leakage Detection Fault 300 +/- 50 mA

14 Output Single Phasing Fault 60 + / - 3 A

15 Over Temperature 105 0 C

16 Battery Charger Boost Voltage 114 V

17 Battery Charger Float Voltage 107 V

18 Battery Charger Boost Current 8A

19 Battery Charger Float Current 2 - 4 A



15

12.2 lhesUl çksVsD’ku lsfVaXl@lhesUl çksVsD’ku lsfVaXl@lhesUl çksVsD’ku lsfVaXl@lhesUl çksVsD’ku lsfVaXl@ Siemens Protection Settings

Sr. No.

Name of protection When protection will be activated Indication lamp glows

1. Input under voltage input voltage < 591 V AC H1

2. Input over voltage input voltage > 1150 V AC H1

3. Input Isolator open input isolator is not closed properly H2

4. Input fuse failure input fuse is blown H2

5. Input earth fault Earth fault is within the converter & fault current exceeds 300mA

H2

6. Rectifier over load/ over current

Rectifier current exceeds 310A / 1 min or 600A/ 5s or 950A/ 1.25 ms

H3

7. Rectifier over temperature

Rectifier heat sink temperature exceeds 85 deg C

H2

8. DC Link under voltage DC link voltage < 300V/500µs or 450V/ 3s H2

9. DC Link Over voltage DC link voltage > 850V/ 3s H2

10. Crowbar active DC link voltage > 1020V/500µs H2

11. Inverter Heat sink over temperature

Inverter heat sink temperature exceeds 85 deg C

H2

12. SIBCOS M2000 over temperature

SIBCOS M2000 temperature exceeds 78 deg C

H2

13. CAN Error No CAN communication with Master Controller

H2

14. IGBT Short circuit (Uce)

Short circuit or over current with very steep rate of rise

H2

15. Inverter overload/ over current

Any of the Inverter line current >310A/ 5s or 700A/ 500µs

H3

16. Inverter fault Any of the fault in Inverter is activated H2

17. Output overload/ over current

Output current > 600A/ 5s H3

18. Output single phasing Single phasing in inverter output H3

19. Output earth fault Earth fault is outside the converter (on the load side) & fault current exceeds 300mA

H3

20. Battery Charger output short circuit

Output of the battery charger is short circuited

-

21. Battery charger current limit

Battery charging current limited to 8A & total current limited to 20A

-

22. Battery charger heat sink over temp.

Battery charger heat sink temperature exceeds 85 deg C

-

23. Cooling fan failure Fan/ Isolation transformer MCB trips due to problem in the fan

H2

24. Reverse polarity for control electronics

Control supply with reverse polarity is connected to the interface WAGO terminals

-



16

13.0 lsalj ¼, , ,y½@lsalj ¼, , ,y½@lsalj ¼, , ,y½@lsalj ¼, , ,y½@SENSORS (AAL) 13.1 buiqV djUVbuiqV djUVbuiqV djUVbuiqV djUV Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Input Current Transformer (ACCT)

The Input Current Transformer (ACCT) is use to measure the input current. It is located near to input section / Fuse. Its ratio is 800 / 1 Amp. A burden resistor of 6 Ώ is always connected across its terminals.

13.2 buiqV iksVsaf’k;ybuiqV iksVsaf’k;ybuiqV iksVsaf’k;ybuiqV iksVsaf’k;y Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Input Potential Transformer (ACPT 1)

The Input Potential Transformer (ACPT 1) is use to measure the input voltage. It is located at RFU section area. Its ratio is 1300/ 7.22 volts.

13.3 Mhlh fyad djUV Vªk¡lM~;wlj@Mhlh fyad djUV Vªk¡lM~;wlj@Mhlh fyad djUV Vªk¡lM~;wlj@Mhlh fyad djUV Vªk¡lM~;wlj@DC Link Current Transducer (DCCT)

The DC Link Current Transducer (DCCT) is use to measure the DC link current.

13.4 Mhlh fyad oksYVst Vªk¡lM~;wlj@Mhlh fyad oksYVst Vªk¡lM~;wlj@Mhlh fyad oksYVst Vªk¡lM~;wlj@Mhlh fyad oksYVst Vªk¡lM~;wlj@DC Link Voltage Transducer (DCPT)

The DC Link Voltage Transducer (DCPT) is use to measure the DC link voltage. It is located at RFU section area.

13.5 pkSij djUV Vªk¡lQkWeZj@pkSij djUV Vªk¡lQkWeZj@pkSij djUV Vªk¡lQkWeZj@pkSij djUV Vªk¡lQkWeZj@Chopper Current Transducer (CHCT)

The Chopper Current Transducer (CHCT) is use to measure the Chopper current.

13.6 vkÅViqV dvkÅViqV dvkÅViqV dvkÅViqV djUV Vªk¡lQkWeZj@jUV Vªk¡lQkWeZj@jUV Vªk¡lQkWeZj@jUV Vªk¡lQkWeZj@Output Current Transformers

(ACCT1 / ACCT2 / ACCT3)

The Output Current Transformers (ACCT1 / ACCT2 / ACCT3 ) are use to measure the output current. These are located near to output section. Its ratio is 800 / 1 Amp. A burden resistor of 6 Ώ is always connected across its terminals.



17

13.7 vkÅViqV iksVsaf’k;yvkÅViqV iksVsaf’k;yvkÅViqV iksVsaf’k;yvkÅViqV iksVsaf’k;y Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Vªk¡lQkWeZj@Output Potential Transformer (ACPT 2)

The Output Potential Transformer (ACPT 2) is use to measure the output voltage. It is located at RFU section area. Its ratio is 600/ 7.22 volts.

13.8 ’kwU; djUV Vªk¡lQkWeZj’kwU; djUV Vªk¡lQkWeZj’kwU; djUV Vªk¡lQkWeZj’kwU; djUV Vªk¡lQkWeZj@@@@Zero Current Transformers (ZCT 1 & 2)

The Zero Current Transformer are use to measure the Input leakage current (ZCT 1) and Output leakage current (ZCT 2). They are located near Input section and Output section respectively.

14.0 fu;a=.k ifjiFk esa egRoiw.kZ la’kks/ku@fu;a=.k ifjiFk esa egRoiw.kZ la’kks/ku@fu;a=.k ifjiFk esa egRoiw.kZ la’kks/ku@fu;a=.k ifjiFk esa egRoiw.kZ la’kks/ku@ IMPORTANT MODIFICATIONS IN CONTROL CIRCUIT

14.1 D;D;D;D;w w w w lhlhlhlh vksvksvksvks ,u fjys@,u fjys@,u fjys@,u fjys@ QCON Relay

This relay is used to give the indication that converter output voltage is fully developed i.e. 3 phase AC, 415V. The battery negative is directly connected to the relay and positive (wire no.700) is routed through potential free contact of converter. When the converter is in “OFF” condition, the potential free contact is also open means QCON relay not in energized condition. But when converter is in “ON” condition and develops full voltage, the potential free contact closes and positive path to QCON relay completed and relay energized. Two NO contact of QCON is used in control logic of compressor circuit, which ensure that compressor will start only after converter fully developed voltage.

14.2 D;wD;wD;wD;w ,l,l,l,l vkbZvkbZvkbZvkbZ Vh fjys@Vh fjys@Vh fjys@Vh fjys@QSIT Relay

This relay is used to give the indication that there are some fault (internal/ external) due to which converter is tripped. This relay also opens the DJ. The battery negative is directly connected to the relay and positive (wire no.700) is routed through potential free contact of converter. When the converter is in “OFF” condition, the potential free contact is also open means QSIT relay not in energized condition. But if the converter trips three consecutive times due to any reason internal/ external (except fuse fault) then on fourth time this potential free contact will close and complete the positive path and QSIT relay energizes. Two NC contacts of QSIT are used in control logic of DJ circuit branch, which opens the DJ, and make impossible to close DJ till we reset the converter. Resetting can be done by pressing the reset switch provided in MCU card or Reset switch provided near SIV “ON” switch. But the easy way to resetting is just switch “OFF /ON” the HBA.

QV

60

QV

60

QCON

INVERTER

6" C

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18

14.3 D;w,loh,e fjys@D;w,loh,e fjys@D;w,loh,e fjys@D;w,loh,e fjys@ QSVM Relay

This relay is used for automatic operation of converter, even when driver switch “ON” BLVMT after converter fully “ON”. This is a time delay relay (2 sec ON delay timer) and provided in MVMT branch. The battery negative is directly connected to the relay and positive (wire no. 700) is routed through BLVMT switch. One normally open (NO) interlock is given in contactors C105, C106 and C107 control circuit.

One normally open (NO) interlock of timer relay QSVM is added in parallel to it’s normally close (NC) instantaneous interlock in positive 110 volts circuit routed to converter. After implementation of the modification, if driver operates the BLVMT switch after converter “ON” then static converter will “OFF” first then MVMT 1, 2 and MVRH contactor (C105, C106 and C107) will close and converter re-start after 2 sec.

14.4 D;wVhMh 101 vkSj D;w 119 fjys@D;wVhMh 101 vkSj D;w 119 fjys@D;wVhMh 101 vkSj D;w 119 fjys@D;wVhMh 101 vkSj D;w 119 fjys@

QTD 101 and Q119 Relay

These relays are time delay relays (5 sec delay timer) and provided in control logic of compressor circuit. The battery negative is directly connected to the relay and positive (wire no. 700) is routed through BLCP / BLCPD switch & QCON relay normally close (NO) interlocks for QTD101 and through NC contacts of C101, C102 and C103 for Q119.

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21

14.5 flXufyax ySEi ifjiFk@flXufyax ySEi ifjiFk@flXufyax ySEi ifjiFk@flXufyax ySEi ifjiFk@ Signaling Lamp Circuit

1. LSSIT indication lamp is provided through QSIT N/O inter lock and BL N/O inter lock.

2. When SIV trips, QSIT energizes and LSSIT lamp glows on driver’s desk.

3. QCON interlock is also provided in MU signaling. After the energizing of QCON, LSCHBA extinguishes.

14.6 LVsfVd dUoVZj dk fu;a=.k ifjiFk@LVsfVd dUoVZj dk fu;a=.k ifjiFk@LVsfVd dUoVZj dk fu;a=.k ifjiFk@LVsfVd dUoVZj dk fu;a=.k ifjiFk@ Static Converter Control Circuit

1) After closing DJ, BLVMT “ON”, Inverter electronics gets battery supply through a) CCINV 6A fuse. b) N/C I/L of QSVM c) QV60 N/C I/L.

2) After closing BLVMT, relay QSVM energises in

blowers control circuit. 3) QSVM N/C I/L opens, converter electronics

battery supply is disconnected hence converter stops working.

4) QSVM N/O time delay I/L closes after 2 seconds. 5) Again converter starts after 2 seconds.

This arrangement is done for “OFF load”

operation of blower contactors C105, C106, C107. 14.7 ,pvkj,ohVh fLop@,pvkj,ohVh fLop@,pvkj,ohVh fLop@,pvkj,ohVh fLop@HRAVT switch

HRAVT switch is provided to isolate cab heaters, cab fans, notch repeater and walkie-talkie charger in case of fault. Various positions are given as under:

Switch position Cab heaters Cab fans Notch

repeater Walkie-talkie

charger 0 Isolate Isolate Isolate Isolate 1 Working Working Working Working

2 Isolate Working Working Working 3 Isolate Isolate Working Isolate

INVERTER

QV 60 QV 60

QSVMQVSM2 SEC

CCINV 6A

LSSIT LSCHBALS GROUP QVLSOL

QSIT

QV 60

QV 63

QV 64

QV 61

QCON

QCON

BL1 BL2

CCLS 6A



22

15.0 ifjpkyu funsZ’k@ifjpkyu funsZ’k@ifjpkyu funsZ’k@ifjpkyu funsZ’k@ OPERATING INSTRUCTIONS 15.1 bujtkbZt+ djus dh fof/k@bujtkbZt+ djus dh fof/k@bujtkbZt+ djus dh fof/k@bujtkbZt+ djus dh fof/k@ Procedure for Energisation

1. Before closing DJ, ensure the following: • Keep MP on “0”. • Open all top row BL switches. • Ensure GR is on zero (LSGR is glowing). • Ensure all safety relays are normal. • Ensure C107, C105 & C106 contactors are opened fully. • Keep HBA on position “1” and check battery voltage is above 90 volts.

2. Start MCPA to build up RS pressure to 8 kg/cm2. Unlock BL key. Keep ZPT in 1 or 2 positions to raise pantograph.

3. Close BLVMT switch.

4. Close BLDJ, press BLRDJ. After closing DJ, LSDJ extinguishes. OHE voltage indicates in UA meter. Release BLRDJ after UA meter deviation (don’t wait for extinguishing of LSCHBA and auxiliaries sound).

5. 110V DC supply is given to static converter.

6. Static converter starts functioning approximately 6 to 10 sec after closing of DJ.

7. Converter “ON” sensor will close on QCON branch after static converter starts functioning. When QCON energized, LSCHBA lamp extinguishes.

8. Static converter takes 760/830 V 1 phase AC supply from TFWA to convert into 415 V 3 phase AC supply feed to all auxiliary motors.

9. Close BLCP to build up air pressure. 15.2 Cyksvjksa dks cUn djuk@Cyksvjksa dks cUn djuk@Cyksvjksa dks cUn djuk@Cyksvjksa dks cUn djuk@ Stopping of Blowers

For stopping of blowers, after stopping train at station, open BLVMT, converter stops working and all blower contactors open in “OFF” load condition. Relay QSVM (2 seconds time delay) de-energises and after 2 seconds converter restarts again.

15.3 dk;kZRed fjyksa dk idk;kZRed fjyksa dk idk;kZRed fjyksa dk idk;kZRed fjyksa dk ijjjjhhhh{k.k@{k.k@{k.k@{k.k@ Testing of Functional Relays

The loco pilots and maintenance staff shall observe Function of the relays QCON, QSIT, QTD101, 119, QSVM and closing sequence of C107 and C108 contactor while testing.

a) QCON - This relay will ensure the compressors to work only after SIV picks up full voltage ie. compressors contactors should not close before extinction of LSCHBA lamp. If CPs start along with SIV, it will result in over load and DJ will trip.

b) QSIT - This relay’s function is same as relays QOA & QLA in ARNO fitted locos. For any fault in Auxiliaries & SIV system this will energise. To reset this relay press reset button or OFF & ON HBA switch.

c) QTD101 - This relay ensures a time delay of 5 sec even after extinction of LSCHBA to close compressor contactors.

d) Q119 - This relay ensures a time delay of 5 sec between closing of two compressor contactors.



23

e) QSVM - It will ensure soft starting of blowers. When BLVMT switch is closed in loco energized condition, SIV shall be ‘OFF’ for a while and start working again.

f) While using rheostatic braking, C107 contactor shall be opened before closing C108 contactor (in case of AC MVRF).

16.0 vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½@vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½@vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½@vuqj{k.k 'ksM~;wy ¼lhesUl ,llhMh½@

MAINTENANCE SCHEDULES (Siemens SCD)

Schedules S.No Work to be done

IA IB IC AOH IOH

1. Visual Inspection

Check for any foreign objects/ traces of water. √ √ √ √ √

Check for burn marks/ sparking. √ √ √ √ √

Check for mechanical damage to any part. √ √ √ √ √

Check for any cut/ break in control wires. √ √ √ √ √

Check for any visible loose connections. √ √ √ √ √

2. Fault memory download √ √ √ √ √

3. Dust cleaning

Clean the cubicle(s) √ √ √

Clean the fan blades √ √ √

4. Check Tightness of equipment mountings √ √ √

5. Protections/sensor check

Check input voltage sensor functioning √ √ √

Check DC Link voltage sensor √ √ √

Check Fuse failure if any √ √ √

Check Auxiliary Contactor functioning √ √ √

Check Main Contactor functioning √ √ √

Check Input isolator opening √ √ √

Check Rectifier assembly temperature sensor √ √ √

Check Inverter DUO/PWR-1 temperature sensor

√ √ √

Check Inverter KOMBI/PWR-2 temperature sensor

√ √ √

Earth fault & earth fault by pass check √ √ √ √ √

6. Check Tightness for electrical wiring/ connections

√ √ √

7. Verification of Loco control logic interface with inverter

√ √



24

Schedules S.No Work to be done

IA IB IC AOH IOH

8. Cooling fan (3 phase & churning) function test

√ √ √ √ √

9. Functionality test

No Load test √ √ √ √ √

Load test √ √ √ √ √

Check of functioning of text display √ √ √ √ √

10. Fan replacement

Replacement of 3 phase, 415V cooling fans √

Replacement of 110V d.c. cooling fans √

Note: Refer RDSO/ OEMs instructions for maintenance of various make static converters.



25

17.0 =qfV fuokj.k@=qfV fuokj.k@=qfV fuokj.k@=qfV fuokj.k@TROUBLE SHOOTING

17.1 ,ybMh fMLIys ds vuqlkj =qfV fuokj.k@,ybMh fMLIys ds vuqlkj =qfV fuokj.k@,ybMh fMLIys ds vuqlkj =qfV fuokj.k@,ybMh fMLIys ds vuqlkj =qfV fuokj.k@ Trouble Shooting as per Display LEDs

Following instructions should be followed by the driving crew in respect of the display LEDs:

S.No. Indication Action to be taken

1. Green LED indication of “SI unit OK” goes OFF

This is definite indication of a fault in the SIV. The action to be taken as per the other indication and fault code displayed.

2. Red LED indication of “Input voltage in range” comes ON

• On<17.5 KV VCB will trip through No volt relay Q-30.

• On > 30 KV VCB will not trip, SIV will trip and LSCHBA glows without VCB tripping (without glowing LSDJ) voltage indication will remain on UA meter.

• The driver can easily monitor the OHE voltage with this differentiation.

• Watch the level of OHE voltage and wait for some time till OHE voltage becomes normal. Energize the locomotive and work the train.

3. Red LED indication of “Internal fault” comes ON

This indicates that fault is inside the SIV. Normally such faults cannot be tackled on line, unless the fault is transient. Driver should turn OFF the battery, turn it ON again and energize the locomotive and if successful, work the train.

Action should be taken in the following sequence:

1. Isolate the cab heater and cab fans by putting HRAVT on position 3. Restart the SIV. If successful, work the train.

2. If not successful, switch OFF BLCP and BLVMT. Restart the SIV. If SIV trips through earth fault isolate the faulty motor from MVSIs, MVSLs and MPH. follow existing troubleshooting directory and work the train.

3. If not successful, switch ON BLVMT. Restart the SIV. If SIV trips through earth fault, isolate the faulty MVMT or MVRH. Follow existing troubleshooting directory and work the train.

4. If not successful, switch ON BLCP. Restart the SIV. If SIV trips through earth fault, isolate the faulty MCP. Follow existing troubleshooting directory and work the train.

5. If not successful in identifying the fault, isolate all loads connected at the output of SIV. If SIV trips through earth fault, the fault is inside the SIV.

4. Red LED indication of “External Fault” comes ON

6. Advise TLC accordingly and work the train or ask for assistance.



26

S.No. Indication Action to be taken

5. Green LED indication of “CHBA OK” goes OFF

LSCHBA lamp on the driver desk will also glow. Trip DJ and momentarily switch OFF and ON HBA and try, if not succeeded, isolate the battery charger, if loco is tripping through SIV. Advise the Traction Loco Controller and Work the train till next relief point.

17.2 LVsfVLVsfVLVsfVLVsfVd bUoVZj ds fVªfiax QSd bUoVZj ds fVªfiax QSd bUoVZj ds fVªfiax QSd bUoVZj ds fVªfiax QSY;Y;Y;Y;ksksksksj@j@j@j@Tripping Failures of Static Converter

ICDJ (While re-closing DJ, LSDJ remains glowing)

1. If Q118, Q45, Q44 are not energized, trouble shooting is same like conventional loco.

2. If MTDJ(VCB)/ EFDJ is not energizing…..

a) Check QSIT and glowing of LSSIT.

b) If QSIT is energized, trouble shoot for SIV tripping and other troubleshooting for EFDJ not energized is same as conventional loco.

c) If unsuccessful, place HOBA in OFF and try,

d) Switch OFF battery, wait for three minutes and try.

I.

e) If unsuccessful contact TLC for advice,

NO TENSION (While closing DJ, LSDJ extinguishes, UA meter does not deviate, input voltage out of range LED glows and DJ trips on releasing BLRDJ).

II.

Trouble shoot for “NO TENSION” like conventional loco

DJ closed and converter does not start. i.e. LSCHBA remains glowing and DJ trips

1. Check CCINV fuse. If it is melted, replace with a new one

2. Keep BLVMT in open position and check that SIV working or not. If not working, close BLVMT and check for SIV working.

3. Ensure QSVM energises after closing BLVMT.

4. If QSVM is not energized, Check CCA fuse. If CCA is melted replace the same.

5. Change the cab and try.

6. If unsuccessful keep HOBA in OFF and try.

7. If CCINV and QSVM found normal, Switch OFF battery and wait for three minutes and try.

8. If QSVM is not energized after closing BLVMT, wedge QSVM in energise position and work.

III.

Precautions after wedging QSVM: - BLVMT should be switched ON before closing DJ and BLCP should be switched on after 5 Sec of SIV developed full voltage. (SIV ON LED glows or LSCHBA extinguishes )



27

If SIV is working & LSCHBA glowing on run:

1. SIV will continue to function even if battery charger trips due to any fault.

2. Trip DJ and press RESET button on SIV panel and momentarily switch OFF & switch ON HBA and try.

3. Check Battery Voltage between 90 to 135Volts.

4. If BA voltage above 90 and CHBA not working, inform TLC and work onwards

IV.

5. Minimize the BA load by switching OFFcompartment lights and unnecessary loads by watching BA voltage frequently.

V. After closing DJ, LSDJ extinguishes, UA meter deviates, LSCHBA extinguishes & DJ trips with in 15 seconds after extinguishing of LSCHBA

1. Put HPH on 0, HVSL1 & 2, HVMT 1 & 2 and HVRH on 3 and close DJ.

2. If DJ does not trip ensure the working of auxiliaries if any one of the auxiliaries is not working isolate the same and work accordingly.

3. If MVSL 1 & 2, MVMT 1 & 2, MVRH are working, switch off DJ and put HPH on 1 and try. If DJ does not trip trouble shoot for any defect in air flow relays after clearing section.

4. If DJ trips with in 15 seconds after extinguishing of LSCHBA, trouble with MPH.

5. After taking safety measures put HPH on ‘0’ and normalize other switches, close DJ and clear the section with 750 /500 amps and contact TLC.

DJ trips on taking 1ST notch with LSCHBA glowing & no sound from auxiliary motors

VI.

Check CCINV/ CCA, if fuse melts trouble shoot for SIV not starting. Remaining trouble shooting is same as conventional loco.

DJ trips after taking 6th notch within 15 seconds

1. If BLVMT in OFF, Check CCA if it melts trouble shoot just like conventional loco

2. If C107 alone is not closing, ensure CTFs are in traction side. Put HVRH on 3 and try.

3. If C105, 106 and 107 are not closing clean the interlocks of QCON and try

VII.

4. If unsuccessful, put concerned switch on 3 and try.

If CP contactors alone are not closing:

1. Close BLCPD and try.

2. If unsuccessful, tap QTD101 and try.

3. If unsuccessful clean the interlocks of QCON and wedge QTD101 & try.

VIII.

4. If unsuccessful try from rear cab.

5. Precautions after wedging QTD 101: BLCP/BLCPD should be switched ON after 5 Sec of SIV ramping up of full voltage. (SIV ON LED glows or LSCHBA extinguishes)



28

18.0 egRoiw.kZ funsZ’k@ egRoiw.kZ funsZ’k@ egRoiw.kZ funsZ’k@ egRoiw.kZ funsZ’k@ IMPORTANT INSTRUCTIONS

1) On run whenever DJ trips, along with safety relays, check LSSIT lamp also.

2) Do not wedge any electro magnetic contactor.

3) Don’t operate any program switch while static Inverter is functioning. If necessary operate the switch only after opening of DJ.

4) Whenever SIV unit trips, Static Inverter will try restart within 20 sec. for 2 times before going to permanent shutdown mode (for 3 tripping).

5) Whenever LSDJ glows first, before LSCHBA, trouble may be with loco. Trouble shoot accordingly.

6) Whenever LSCHBA glows before LSDJ, it indicates static inverter has initiated the tripping.

7) Do not take notches without closing BLVMT, other wise DJ will trip after taking 6th notch.

8) During on run examination of the loco, assistant loco pilot / co-loco pilot should check for SIV panel lamps and also CHBA voltmeter and ammeter readings.



29

19.0 vko’;d vkSt+kj rFkk midj.k@a vko’;d vkSt+kj rFkk midj.k@a vko’;d vkSt+kj rFkk midj.k@a vko’;d vkSt+kj rFkk midj.k@a TOOLS & INSTRUMENTS REQUIRED

S.No. Description

1 Laptop

2 Multimeter (true RMS)

3 Tong tester

4 Wire Stripper

5 Rachet Big (1/2")

6 Extention Rod Big (1/2")

7 Extention Rod (1/2")

8 Rachet Bitt Big 10 To 19 (1/2")

9 Universal joint (1/2")

10 Open Spanner 6-7, 8-9, 10-11, 12-13, 14-15, 16-17, 18-19, 20-22

11 Ring Spanner 6-7, 8-9 , 10-11, 12-13, 14-15, 16-17, 18-19, 20-22

12 Screw Driver

13 Philips Head Screw Driver

14 Side cutting pliers

15 Rachet Small (1/4")

16 Rachet Bitt Small (1/4") 7, 8, 9, 10, 11, 12, 13

17 Extension rod of length 150 mm (1/4")

18 Extension rod of length 100 mm (1/4")

19 Universal joint (1/4")

20 Adjustable Spanner

21 Torque Wrench (0-20nm)

22 Torque Wrench (20nm- 100nm)

23 Analog voltmeter with crocodile clip (AC 1500 volt)

24 110 V DC Blower

25 Helmet

26 Head torch

27 Safety shoes

28 ESD band

29 WAGO

30 Dust Mask

Note: 1. The above tool list is taken from Siemens manual. 2. Refer OEMs instructions for tool list for maintenance of various make static

converters.



30

20.0 D;k djsa vkSj D;k u djsa ¼vuqD;k djsa vkSj D;k u djsa ¼vuqD;k djsa vkSj D;k u djsa ¼vuqD;k djsa vkSj D;k u djsa ¼vuqj{k.k ds nkSjku½@ j{k.k ds nkSjku½@ j{k.k ds nkSjku½@ j{k.k ds nkSjku½@ DO’S AND DON’TS (DURING MAINTENANCE)

20.1 D;k djsa@ D;k djsa@ D;k djsa@ D;k djsa@ Do’s

1. Wear safety shoes.

2. Clean the dust from fan blades with a light brush.

3. Remove the dust from the panel before doing maintenance.

4. Handle the PCBs only from the sides, without touching the components.

5. Use only the correct hardware (screw driver, tools, spanner etc.).

6. Take care not to damage the bolt/ screw heads.

7. Take care not to drop the washers inside the assemblies while removing the parts.

8. Ensure that all hardware is safely stored after removal.

9. Shut all doors/ openings properly otherwise dust/ water entry may cause problems.

10. While meggering load side cables, disconnect the power cables (415V, 110V, input side) from the converter.

11. Use new cable-ties in place of ones which are cut.

12. Keep the doors closed (Rat problem).

13. Always refer circuit diagram while troubleshooting/ removal of parts/ re-fitment of parts.

14. Always ensure that the Isolator is in properly closed condition.

15. Ensure that all connections are restored & appropriately tightened.

16. Be careful while cutting cable-ties, not to damage the cables/ wires.

17. Check that all fuses in loco circuit are of proper rating & properly fixed.

18. Do check that all loco circuitry is functioning properly (QSVM, QV60, QSIT, QCON, Compressor time delay, blower air vane relays etc.).

19. Replace fans/ bearings at mentioned intervals by OEMs to prevent online failures.

20. Check all connections at input/ output connectors & ensure they are not interchanged. This will lead to system malfunction and may lead to accident.

21. Simulation test is mandatory after every change of cables/components, new program loading etc. to avoid any malfunction incident on line.

22. Only trained/ confident staff shall attend these locos as the trial and error methods are not at all acceptable and may lead to major fire or such fatal things.

23. Ensure dust proof covering for all the system components as it will avoid malfunction and extend useful life of the equipment.

24. Always ensure vibration free fitment of the equipment.

25. Download the fault data and analyze carefully to take corrective action.

26. Record all activities carried on a particular system.



31

20.2 D;k u djsa@ D;k u djsa@ D;k u djsa@ D;k u djsa@ Don’ts

1. Do not use Nylon brush on electronic cards/ assemblies. This will result in ESD failure.

2. Do not touch Driver Card components/ IGBT Gate circuit.

3. Do not let any parts be fixed with less quantity of bolts/ screws.

4. Do not do pull test on wires/cables.

5. Do not do Di-electric test/ Meggering of parts inside the converter.

6. Do not lift assemblies by holding the bus-bar or sensitive components (capacitor bank etc.).

7. Do not place the removed PCBs, parts in dirty /wet areas.

8. Do not place the removed PCBs, parts in plastic bags. This will result in ESD failure.

9. Never open the Isolator.

11. Do not bypass any protection.

12. Do not do welding on the converter panel. If welding is to be done on converter/ locomotive, isolate all input, output & control connections between the loco & the converter.

13. Do not remove assemblies from the converter , during regular maintenance activities.

14. Do not drop the fan or place it on the impeller.

15. Do not interchange the battery & lead wire connections inside the converter. This will cause the battery charging current limit protection to malfunction.

16. Never try to bypass any input/ output cards by using external cables without properly studying the repercussions after such bypassing.

17. Never try to modify the main configuration settings of the system without proper knowledge of the software/ hardware.

18. Never switch ‘OFF’ the battery supply while the system displaying “Busy with USB communication”.

19. Never do any Hammering, Welding, Gas cutting in the vicinity of the CPU as it may lead to malfunctioning or permanently damage the system.

21.0 lkekU; fn’kkfunslkekU; fn’kkfunslkekU; fn’kkfunslkekU; fn’kkfunsZ’k@Z’k@Z’k@Z’k@GENERAL GUIDELINES

1. Encourage all concerned staff to always follow systematic approach while working on

the sophisticated equipment.

2. Make available all related information like trouble shooting and maintenance manuals.

3. Use proper tools & handling equipment.

4. Maintain good understanding with firm’s service personnel to give and take the information as and when required.



32

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33

REFERENCES

1. RDSO specification no. ELRS/ SPEC/ SI/ 0018 (REV.1) March, 2006 &

amendment – 1 dtd. 05.02.2009 for single phase to three phase Static Converter with soft start feature for electric locomotives.

2. RDSO report no. RDSO/ 2007/ EL/ IR/ 0126 Rev. ‘0’ dated January 2008 on

“Standardization of 180 kVA Static Inverter of Electric Locomotive” and RDSO letter no. EL/ 1.2.9.1 dated 23.07.2009 on the subject.

3. Training Module on 180 kVA Static Converter of Autometers Alliance Limited.

4. Training Module on 180 kVA Static Converter of AC Loco of Siemens India Limited.

5. Training Module on 180 kVA Static Converter prepared by Electric Traction Training Centre, Vijaybada, South Central Railway.

6. Training Module on 180 kVA Static Converter of AC Loco of Hind Rectifier Limited.

7. Presentations given by participants from various Electric Loco Sheds during seminar conducted on 20TH October 2010 at IRCAMTECH/ Gwalior.

*****



34

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bZ&esy : [email protected]

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35

To upgrade maintenance technologies and methodologies and achieve improvement in productivity, performance of all Railway assets and manpower which inter-alia would cover reliability, availability, utilisation and efficiency.

OUR OBJECTIVE

If you have any suggestions and any specific Comments please write to us. Contact person : Director (Elect.) Postal Address : Indian railways

Centre for Advanced Maintenance technology, Maharajpur, Gwalior. Pin code – 474 005

Phone : 0751 – 2470740

0751 – 2470803 E-mail : [email protected] Fax : 0751 - 2470841

Documents

H OOOO STATIC CONVERTER OFOOFFOF …rdso.indianrailways.gov.in/works/uploads/File/Handbook on Static...and BHEL in 1997. Presently CLW is manufacturing only static converter fitted