Training Module

on
3 x 130 kVA IGBT Based
Auxiliary Converter
 Rating of Equipment
Input Voltage 1000 V Output Frequency 50 Hz.
Input Frequency 50 Hz. Rated Output Current 180 A
Maximum input Phase 190 A Over Load Capacity 360 A for Sec.
Current
Input Power factor 0.8 Rate of change of Output ˂ 500 V/μs
voltage dV/dT
Nominal DC Link Voltage 750 V Switching Frequency 4000 HZ.

DC Link Capacitance 15 mF Battery Charger 3-phase 3x415 V

input Voltage
Rated Output Power 130 kVA Battery Charger Output DC 110 V
Voltage
Nominal Output Voltage 415 V Battery Charger Output DC 110 A
Current
 Sub Modules of Auxiliary Converter

• Input Section.
• Rectifier Section.
• DC Link Filter.
• Inverter Circuit.
• Output LC Filter.
 Input Section
• The input section consists of input fuse
and a metal oxide varistor (MOV) and
input bus bar.
• Input fuse protects the circuit in event of
failure of the power components in the
rectifier bridge and also for ensuring safe
operation of the converter under worst
input conditions like over current etc.
• The MOV protects the semiconductors of
the rectifier bridge over voltage spikes. It
also works as surge arrestor.
 Rectifier Section
• The rectifier section is made using two thyristors and two
diodes. Its designed as half controlled asymmetrical single
phase full wave bridge rectifier.
• The rectifier bridge is used to convert AC voltage into DC
voltage. A external triggering unit is required for control
purpose. By controlling the thyristor firing angle the output
DC link voltage in the range from 630 to 800 volt may be
produced. However the DC voltage may vary from 700 to
1200 volt depending upon the over head line voltage.
• The rectifier converts single-phase 1000 V AC input into the
desired DC link voltage (630 to 800 volt) by controlling firing
angle of the thyristors smoothing through DC link filter.
• The diodes are equipped with an RC- snubber to attenuate
any over voltage occurred during turning the diodes off as a
whole storage effect.
 DC link Filter
• The DC link smoothing choke, which is used in DC
link filter is actually housed in main transformer of
the locomotive.
• The DC link filter consists of DC link smoothing choke
and capacitors. The DC link capacitors are connected
in series parallel combination.
• DC link choke and capacitors are provided at the
output of the rectifier for converting the pulsating DC
output into a smooth DC for further feeding the
three phase IGBT inverter.It also filters the harmonics
in the line current & voltage that is fed to the
inverter.
 Inverter Circuit
• The inverter consists of six (or three) IGBT modules configured
as a three phase half bridge circuit. It is made up of three
identical phase branches and each branch consists of two IGBTs
modules. The DC link is directly connected to the three phase
modules.
• The DC link voltage is converted into PWM sinusoidal waves by
being appropriately switching on and off the IGBT modules 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.
• The three phase sine filter, consisting of 3 phases AC Choke and
3 phases Capacitor, are connected at the output of IGBT inverter
modules attendees the harmonics and provides a sinusoidal
three phase output voltage of 415 volt and 50 Hz frequency,
which being fed to different loads.
Three Phase IGBT Inverter
Auxiliary Power Circuit
 IGBT based 3x130 KVA Auxiliary Converter
• One set of Auxiliary Converter consists 03 nos. of converters
namely BUR-1,BUR-2 & BUR-3 , each having rating of 130
kVA, 50 Hz. BUR-1 is placed in cubicle called Box-1 whereas
BUR-2 & BUR-3 is placed in cubicle called Box-2.

• Each of the BURs takes single phase 1000 Volt,50 Hz from

the secondary winding of main transformer and feeds 3-
phase 415 volt,50/37 Hz to 12 nos. 3-phase auxiliary loads
and one battery charger.

• BUR-1 feds 3-phase 415 volt AC to oil cooling blower for

cooling the transformer oil and traction converter oil by
taking air from the roof.
• BUR-2 feds 3-phase 415 volt AC to traction motor blower for
cooling bogie, transformer oil pump for circulating oil from
transformer to cooling unit & traction oil pump for circulating
oil from traction converter to cooling unit.

• BUR-3 feds 3-phase 415 volt AC to main compressor unit for

creating MR pressure to 10 kg/cm² & scavenging blower for
cleaning dust from air filter of traction motor blower & oil
cooling blower respectively.

• BUR-3 also feds 3-phase 415 volt to battery charger kept

within the Box-2. which converts 415 volt AC in to 110 volt
DC for charging the vehicle batteries. These batteries
provides a direct power supply to loco dc loads
• If one of the on-board converters (BUR) fails the whole load is distributed
between the two remaining BURs. They can continue to supply the
auxiliary circuits, practically without losses and full traction is also
available.

• The machine room blower and the corresponding scavenge blowers are
fed directly from the auxiliary transformer. It operates independently of
the , as soon as the VCB is closed. Therefore the loco can be cooled even if
MCE is not in operation.

• The blowers on the traction motor and the oil cooling units are individually
supplied for each bogie by the auxiliary converter (BUR).

• However, if two BUR fail, there is no traction available and the power
supply to the auxiliary circuit fails,i.e. LOCO DEAD.
 Change of Frequency of BURs
• In case of failure of any one BUR the existing load is shared
in between the remaining other BURs and the frequency of
one of the BUR drops from 50 Hz. to 37 Hz.
• Whereas the frequency of other BUR remains at 50 Hz.

BUR-1 Frequency BUR-2 Frequency BUR-3 Frequency

Isolated Isolated Isolated

BUR-2 37 Hz. BUR-3 50 Hz. BUR-1 37 Hz.

BUR-3 50 Hz. Bur-1 37 Hz. BUR-2 50 Hz.

 Load Distribution of Auxiliary Converters

• Each of the IGBT based Auxiliary Converter BUR-1,BUR-2&

BUR-3 feds three phase 415 V,50 Hz AC supply to different
auxiliaries loads. The output power of each BUR is 130 kVA .

• All BUR working.

Load on BUR-1 MCB No.

Oil cooler blower-1 25 KW 59.1/1 in HB-1
Oil cooler blower-2 25 KW 59.1/1 in HB-1
Total Load 50 KW
Load on BUR-2 MCB No.
Traction Motor Blower -1 25 KW 53.1/1 in HB-1
Traction Motor Blower -2 25 KW 53.1/2 in HB-2
Transformer Oil Pump – 1 4.7 KW 62.1/1 in HB-1
Transformer Oil Pump – 2 4.7 KW 62.1/2 in HB-2
Oil pump converter – 1 11 KW 63.1/1 in HB-1
Oil pump converter – 2 11 KW 63.1/2 in HB-2
Total Load 81.4 KW

Load on BUR-3 MCB No.

Scavenge blower – 1 3 KW 55.1/1 in HB-2
Scavenge blower – 2 3 KW 55.1/2 in HB-2
Main Compressor – 1 15 KW 47.1/1 in HB-1
Main Compressor – 2 15 KW 47.1/2 in HB-2
Battery Charger housed 12 KVA 100 in HB-2 in old loco
in Box-2 & in door, left side wall
or top of Box-2
Total Load 48 KW
 BUR-1 Isolated
Load on BUR-2
Traction motor blower -1 25 KW
Traction motor blower -2 25 KW
Oil cooler blower – 1 25 KW
Oil cooler blower – 2 25 KW
Scavenge blower – 1 3 KW
Scavenge blower – 2 3 KW
Total Load 106 KW
Load on BUR-3
Oil pump transformer – 1 4.7 KW
Oil pump transformer – 2 4.7 KW
Oil pump converter – 1 11 KW
Oil pump converter – 2 11 KW
Compressor – 1 15 KW
Compressor – 2 15 KW
Battery charger 12 KVA
Total Load 73.4 KW
 BUR-2 Isolated
Load on BUR-1
Traction motor blower -1 25 KW
Traction motor blower -2 25 KW
Oil cooler blower – 1 25 KW
Oil cooler blower – 2 25 KW
Scavenge blower – 1 3 KW
Scavenge blower – 2 3 KW
Total Load 106 KW

Load on BUR-3
Oil pump transformer – 1 4.7 KW
Oil pump transformer – 2 4.7 KW
Oil pump converter – 1 11 KW
Oil pump converter – 2 11 KW
Compressor – 1 15 KW
Compressor – 2 15 KW
Battery charger 12 KVA
Total Load 73.4 KW
 BUR-3 Isolated
Load on BUR-1
Traction motor blower -1 25 KW
Traction motor blower -2 25 KW
Oil cooler blower – 1 25 KW
Oil cooler blower – 2 25 KW
Scavenge blower – 1 3 KW
Scavenge blower – 2 3 KW
Total 106 KW
Load on BUR-2
Oil pump transformer – 1 4.7 KW
Oil pump transformer – 2 4.7 KW
Oil pump converter – 1 11 KW
Oil pump converter – 2 11 KW
Compressor – 1 15 KW
Compressor – 2 15 KW
Battery charger 12 KVA
Total 73.4 KW
Sharing of Loads of BURs and Contactor’s Status
Auxiliary Converter Circuit Diagram
Cab AC Circuit Diagram
Cabling Control Circuit
Cabling Auxiliary Circuit
 Protection of Auxiliary Converter.
The devices used in the auxiliary converter shall be protected against high rate of rise of
voltage & current, line transient surge, switching surges etc. The converters shall be
protected against:-
• Open circuit in auxiliary winding
• Ground fault in AC input circuit
• Ground fault in 3-phase load
• Auxiliary converter phase fault
• Line to line short circuit due to dead short at motor terminals
• Thermal over loading
• Fuse failure in converter
• High / low voltage in DC link
• Failures of power supply to control electronics
• DC link short circuit
• Input over voltage / under voltage
• Input over current
• Single phasing in load
• Output over current
 Cooling of Auxiliary Converter
• The GTO/IGBT based Auxiliary Cubical -1 Front Rear
Converter uses force air
cooling from machine room
Air Flow Rate 1100 m3/h 550 m3/h
blowers.
• A part of the cooling air is Air Speed 2.5 m/s 5.0 m/s
guided to the Auxiliary
Converter. The heat losses in Air Pressure 30 Pa 6 Pa
the BUR’s are carried away
through the heat exchanger. Cubicle- 2 Front Rear
• The ventilation air guiding
ducts from the machine room Air Flow Rate 1700 m3/h 1100 m3/h
to Auxiliary Converter Cubicle
1 & 2 shall be provided the Air Speed 5.0 m/s 5.0 m/s
following air values as
Air Pressure 30 Pa 20 Pa
appended below:
Thanks