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BORDLINE® M180 AC Auxiliary Converter Type: AL D715 C01 Operation & Maintenance Manual Document Number Release Version & Date ABB Ltd 3BHS249852 E04 3BHS249852 E04 Rev.0, 30th Jan 2009 Page 1 of 65 Notice The information in this document is subject to change without notice and should not be construed as a commitment by ABB Ltd. This document has been prepared and checked with great care. If however it still contains errors, then the user is asked to report these to ABB and ABB assumes no
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  ABB Ltd 3BHS249852 E04 Page 1 of 65 BORDLINE ® M180 AC Auxiliary Converter Type: AL D715 C01 Operation & Maintenance Manual Document Number 3BHS249852 E04 Release Version & Date Rev.0, 30 th  Jan 2009   ABB Ltd 3BHS249852 E04 Page 2 of 65 Notice The information in this document is subject to change without notice and should not be construed as a commitment by ABB Ltd. This document has been prepared and checked with great care. If however it still contains errors, then the user is asked to report these to ABB and ABB assumes no responsibility for any errors that may appear in this document. In no event shall ABB Automation Technology Products be liable for direct, indirect, special, incidental or consequential damages of any nature or kind arising from the use of this document, nor shall ABB Automation Technology Products be liable for incidental or consequential damages arising from use of any software or hardware described in this document. This document and parts thereof must not be reproduced or copied without written permission from ABB and the contents thereof must not be imparted to a third party nor used for any unauthorized  purpose. Software & hardware described in this document were furnished under a license/contract and may be used, copied or disclosed only in accordance with the terms of such license/contractual agreements. Copyright © 2009 ABB Ltd. All rights reserved.  ABB Ltd 3BHS249852 E04 Page 3 of 65 Table of Contents Chapter 1 -   Safety Precautions..................................................................................................................6  1.1. General............................................................................................................................................6 1.2. Introduction.....................................................................................................................................6 1.2.1 Responsibility..................................................................................................................................6 1.3. Safety Instructions...........................................................................................................................6 1.4. Safety & Protection Concept...........................................................................................................7 1.5. General Notes on Safety..................................................................................................................7 Chapter 2 -   Introduction............................................................................................................................9  2.1 Purpose of Document......................................................................................................................9 2.2 Tareget Group & Required Qualifications......................................................................................9 2.3 Manual Contents..............................................................................................................................9 2.4 Contact Details..............................................................................................................................10 Chapter 3 -   Equipment Description........................................................................................................11  3.1 Brief Description...........................................................................................................................11 3.2 Block Diagram...............................................................................................................................12 3.3 Electrical Schematics.....................................................................................................................13 3.4 Mechanical Drawing.....................................................................................................................13 3.5 Arrangement of Components.........................................................................................................14 3.6 Control Power Supply...................................................................................................................16 3.7 Control Electronics........................................................................................................................16 3.8 Control Board Description.............................................................................................................17 3.9 Control Electronics Block Diagram..............................................................................................18 Chapter 4 -   Mechanical Construction....................................................................................................19  4.1 Mechanical Arrangement..............................................................................................................19 Chapter 5 -   Cooling System.....................................................................................................................20  5.1 Cooling Concept............................................................................................................................20 5.2 External Ventilation.......................................................................................................................20 5.3 Internal Ventilation........................................................................................................................20 5.4 Power Supply for Cooling Fans.....................................................................................................20 Chapter 6 -   Electro Magnetic Compatibility.........................................................................................21  6.1 EMC Concept................................................................................................................................21 Chapter 7 -   Power & Control Interface.................................................................................................22  7.2 Power Wiring.................................................................................................................................22 7.3 Control Wiring & Interface...........................................................................................................24  Chapter 8 -   Converter Operation...........................................................................................................25  8.1 Self Test.........................................................................................................................................25 8.2 Preparation for establishing communication with PC...................................................................26 8.3 IP Address Configuration..............................................................................................................27  ABB Ltd 3BHS249852 E04 Page 4 of 65 8.4 Verifying Communication State....................................................................................................28 8.5 Bordline® View Configuration & Startup....................................................................................30 8.6 Converter Operating Sequence......................................................................................................32 8.7 Sequence Control (State Machine)................................................................................................32 8.8 Description of Operating Sequence...............................................................................................33 Chapter 9 -   Functional Description........................................................................................................34  9.1 Input Passive Unit..........................................................................................................................34 9.2 IGBT based active front end rectifier............................................................................................35 9.3 IGBT based output Voltage Source Inverter.................................................................................36 9.4 Voltage Limiting Unit...................................................................................................................36 9.5 Battery Charger.............................................................................................................................37 Chapter 10 -   Battery Charging Characteristics......................................................................................38  10.1 Charging Characteristics................................................................................................................38 Chapter 11 -   Display & Diagnostics..........................................................................................................39  11.1 Introduction...................................................................................................................................39 11.2 Pilot Lamp Indication...................................................................................................................39 11.3 LCD...............................................................................................................................................40 11.3.1 Parameter Display.........................................................................................................................40 11.3.2 Fault Display.................................................................................................................................41 11.4 Earth Fault Bypass.........................................................................................................................42 11.5 Service Access...............................................................................................................................42 11.6 Bordline® View Diagnostic Tool..................................................................................................42 11.7 Bordline® View User Interface.....................................................................................................43 11.8 Bordline®-View : Transient Recorder..........................................................................................44 11.9 Bordline®-View : Transient Recorder data interpretation............................................................44 Chapter 12 -   Protections............................................................................................................................45  12.1 Protection concept.........................................................................................................................45 12.2 Protection zones.............................................................................................................................45 12.3 Trips...............................................................................................................................................46 12.4 Fault Classification........................................................................................................................46 12.5 Protection Zones............................................................................................................................47 12.6 Faultwords & limits.......................................................................................................................49 12.6.1 Zone 1 – Input circuit....................................................................................................................49 12.6.2 Zone 2 – U21 (4QS)......................................................................................................................49 12.6.3 Zone 3 – DC link...........................................................................................................................50 12.6.4 Zone 4 – U22 (VLU).....................................................................................................................50 12.6.5 Zone 5 – U23/U22 Inverter (WR).................................................................................................50 12.6.6 Zone 6 – U23/U22 Inverter Gate Driver (WR).............................................................................51 12.6.7 Zone 7 – U24 Full bridge DC/DC converter (BL)........................................................................51 12.6.8 Zone 8 – Battery output circuit......................................................................................................51 12.6.9 Zone 9 – Main Control..................................................................................................................52 12.6.10 Zone 10 – Temperature sensor alarm............................................................................................52 Chapter 13 -   Electrical & Mechanical Installation.................................................................................53  13.1 Installing the Converter inside Locomotive..................................................................................53 13.2 Electrical Connections...................................................................................................................54
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