We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express authority is strictly forbidden.  Copyright 2009 ABB. All rights reserved. Traction Converter BORDLINE® CC400 with Energy Storage Preliminary Technical Specification Customer: Inekon We reserve the right to make technical changes Based on. Prep.. Appr P. Scherrer K. Shokoofh Technical Specification 31.03.2011 BORDLINE® CC400 14.03.2012 Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Pages 28 Language Rev. en E Page 1 ® Technical Specification - Traction converter BORDLINE CC400 TABLE OF CONTENTS 1 VEHICLE MAIN DATA 1.1 Overview 4 1.2 Vehicle overview 4 COMPONENTS 7 1.2.2 2 4 Streetcar Performance 5 2.1 BORDLINE CC400 Traction and auxiliary converter 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8 8 8 8 9 9 9 10 12 2.2 Traction package 14 2.3 ABB Scope of supply 15 2.4 BORDLINE® CC400 - Technical Data 16 2.5 Traction Motor AST 90-4 22 2.6 Brake resistor 24 2.3.1 2.3.2 2.3.3 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.4.6 2.4.7 2.4.8 2.4.9 2.4.10 2.4.11 2.4.12 2.4.13 2.4.14 2.4.15 2.5.1 2.6.1 2.6.2 3 7 Functional units of BORDLINE CC400 Line contactor and fuse Line filter Propulsion Converter 24V DC output and onboard battery charger Auxiliary converter Converter control (Drive control) ® Diagnostic tool: Bordline -View Included Optional Not included 15 15 15 Input Data Propulsion Converter (INV) Braking chopper ESS charger Auxiliary converter Onboard battery charger Control Voltage (for Electronics) Control HW interface Test voltages Environmental conditions Cooling circuit Supply for cooling equipment Maintenance interval of CC400 Maintenance interval of HEX Mechanical Layout 16 16 16 16 16 16 17 17 17 17 17 17 17 18 18 Main data 22 Main data Drawing 24 24 TYPE TEST AND ROUTINE TEST (ABB POWER LABORATORY) Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 25 Language Rev. en E Seite 2 ® Technical Specification - Traction converter BORDLINE CC400 4 APPLICABLE STANDARDS 27 Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 3 Technical Specification - Traction converter BORDLINE® CC400 1 Vehicle main data 1.1 Overview The ABB Traction Package shall be installed to motorize the Streetcars, double articulated unit, with three body sections, each end has a fully equipped operator’s position. The vehicles are designed to operate with 750V DC and maximum operation speed of 70km/h. Each ABB traction package consists of 2 traction converter BORDLINE® CC400 liquid cooled and 4 asynchronous traction motors totally enclosed self ventilated. Optional a battery box can be provided to fulfill the overhead less driving requirements. 1.2 Vehicle overview Four axle Double-Ended Low-Floor Streetcar Figure 1: Low-floor streetcar. The yellow marked components are in scope of supply of ABB. CC400 Traction converter with integrated auxiliary inverter and battery charger HEX Cooling unit for CC400 with integrated braking resistors T-BAT High voltage traction battery for ESS Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 4 Technical Specification - Traction converter BORDLINE® CC400 1.2.1 Main data for one Streetcar Starting tractive effort Maximum power at the wheels Dynamic braking power at wheels 60 kN 525 kW (DC-link voltage 750 Vdc) 725 kW (regenerative) 725 kW (dissipative) 4 610 mm (new) 530 mm (fully worn) 6.841 :1 30.7 t, AW0 (Including battery of 1300 kg) 39.3 t, AW2 45.1 t, AW4 Bo`Bo` 70 km/h (80 km/h design speed) 750 V DC 925 V DC 525 V DC Number of driving motors Wheel diameter Gear ratio Vehicle weight Bogie Maximum speed Nominal line voltage Max. line voltage Min. line voltage 1.2.2 Streetcar Performance The required traction performance is that vehicles under load AW2 shall have a minimum acceleration rate of 1.34m/s2 between speeds 0 and 32km/h. Additionally, for 100% traction power, at maximum speed under load AW2 the residual acceleration is required to be at least 0.2 m/s2. ZV Diagram Max Tractive Effort [kN] 80 60 40 20 0 -20 -40 -60 -80 Figure 2 0 10 20 30 40 Speed [km/h] 50 60 70 80 Traction effort diagram Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 5 Technical Specification - Traction converter BORDLINE® CC400 Acceleration / Braking Capability Max Acceleration [m/s2] 1.5 1 0.5 0 -0.5 -1 -1.5 Figure 3 0 10 20 30 40 Speed [km/h] 50 60 70 80 Acceleration & Braking Capability. The required braking performance is that vehicles under all load (up to AW4) must have the average braking rate, measured by the entry speed divided by stopping time as following: • 1.34m/s² ± 5% with all dynamic brakes functional, from any entry speed to zero • 1.34m/s² ± 10% with one or more dynamic brake units inoperative, from any entry speed to zero, this means that also the friction braking must be used. Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 6 Technical Specification - Traction converter BORDLINE® CC400 2 Components 2.1 BORDLINE CC400 Traction and auxiliary converter The BORDLINE CC400 series converters are compact rugged units with modern IGBT technology, designed for applications in rail vehicles. The equipment is efficiently cooled using liquid cooling, making possible a very compact construction. The temperature of the coolant is lowered using an external heat exchanger which is included in ABB`s scope of supply. The BORDLINE CC400 power electronics system is designed to be installed on the roof of streetcars. The system serves to convert the 750Vdc line voltage into a 3-phase, driving power for the traction motors. One complete unit contains two propulsion converters, two braking choppers and two choppers for the energy storage unit, a three-phase converter to supply the on-board auxiliary power systems and a battery charging unit. An internal blower and an air/water heat exchanger are built in to allow air circulation and to cool the internal part of the converter, in order to prevent it from hot spots and to achieve a long life span. Motor control functions, converter supervision, diagnostics and monitoring are carried out using a built-in control module, which is also part of the delivery package. Control IT AC 800PEC Control System The equipment has been developed and designed according to IEC 61373 and following European standards EN 61287-1 (power part) and EN 50155 (electronic part). Further railway standards have been taken into consideration as far as they are relevant for this equipment. All plastic materials which are used in any significant quantity comply with the requirements of UL94-V0 and NFPA 130 standards. With respect to the electromagnetic compatibility (EMC) a specific concept was developed for this equipment. Also existing guidelines, as laid down by EMC specialists from ABB, have been complied with, which are based on IEC 61000-4 and EN 50121-3-2 (electromagnetic compatibility for rolling stock-apparatus). Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 7 Technical Specification - Traction converter BORDLINE® CC400 2.1.1 Functional units of BORDLINE CC400 BORDLINE CC400 traction and auxiliary converter includes the following functional units: • 2 x Line contactor and fuses for propulsion inverter • 2 x Input filter and capacitor bank (DC-link): Filtering • 2 x Propulsion converters (INV) to allow single-axle control: Convert DC link voltage into variable frequency motor voltage. • 2 x Braking choppers (Chopper): limit the DC-link voltage and control the dissipation of the braking energy in the resistor, in case the line is not able to take recuperative energy. • 2 x Choppers with LC-filter for energy storage system: Battery charger for ESS battery • 1 x Fuse, pre-charging circuit and line filter inductor for auxiliary power system • 1 x Auxiliary converter: Supply onboard consumers – galvanic insulated • 1 x Onboard battery charger unit, with two 24V DC outputs. One to feed the DC bus and one to charge the battery – galvanic insulated • 1 x Control unit: The standard ABB PEC 800 control platform is used to control the converter. It’s programmable in MATLAB/Simulink. • Control HW and SW • Fiber-optic connections from the power section to the control system • Drive control SW • CANopen bus interface for communication with the vehicle control system • I/Os for direct sensor signals and protection commands (temperature, speed encoder, primary current / voltage and emergency trip line...) The complete converter is housed in an aluminum cabinet, which is designed for installation on the vehicle roof. 2.1.2 Line contactor and fuse At the input of each propulsion converter there is a line contactor and a fuse to make and interrupt power during normal or faulted conditions and to isolate the inverter from primary power. During emergency braking the line contactor is opened and the DC link voltage is raised up to 1000 Vdc to maximize the dynamic brake effort. The inrush current is limited by the line choke and the DC link capacitors. In order to avoid any oscillation of the voltage as a consequence of the L-C-filter the braking chopper on the MSR module is starting working. 2.1.3 Line filter Each propulsion converter is equipped with a line filter consisting of a line choke and DC link capacitors. The resonant frequency of the line filter is below 60 Hz. Film capacitors with a high life time are used for the DC link. A bleeder resistor is permanently connected to the DC link capacitor bank, so that the voltage at the terminals of the capacitor bank is Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 8 Technical Specification - Traction converter BORDLINE® CC400 discharged to 50 V or less within 3 min after primary voltage is removed from the bank. A permanent sign is positioned at the cover of the CC400 to warn maintenance personnel of the presence of high voltage and the procedure to be used to discharge the capacitor bank before commencing work. 2.1.4 Propulsion Converter The MSR modules contain the actual drive consisting of the DC input capacitor, the traction inverter, the braking chopper and the energy storage chopper to charge / discharge ESS battery. The traction inverter transforms the DC voltage of the intermediate DC circuit into a 3 phase AC voltage of variable magnitude and frequency to be fed to the traction motors. Operation in all 4 quadrants is possible (forward/reverse and drive/brake). The traction inverter is controlled by means of pulse width modulation with a constant modulation frequency. The braking chopper is located in parallel to the traction inverter. The braking chopper limits dynamic overvoltages in the intermediate DC circuit and provides – together with the braking resistor – the electrical braking function. This is necessary in cases where no energy recuperation to the catenary is possible. The energy storage chopper is located in parallel to the traction inverter. The energy storage with filter allows to control the charge current of the ESS battery. The traction inverter, braking chopper and energy storage chopper consist of standard 1700V IGBT modules arranged in a 2 level topology. Beside of ABB’s own IGBT’s, there are other mayor semiconductor-suppliers qualified. The IGBT’s are controlled by the traction control unit via gate drivers. Each MSR can operate independently, such that in case of an outage of one module the CC400 compact converter can still operate with 50% power output. 2.1.5 24V DC output and onboard battery charger The isolated DC / DC converter producing the DC voltage operates with high pulse frequency. The galvanic separation is realized by applying an IGBT full-bridge circuit, medium frequency transformer, output rectifier and an output filter. The rectified and smoothed output voltage feeds the bus-bars of the vehicle via decoupling diodes, which are connected to the DC loads. A separate output with current limiting is provided for the battery charging. 2.1.6 Auxiliary converter Like for the battery charger, the galvanic separation is realized by applying an IGBT fullbridge circuit, medium frequency transformer and an output rectifier. The auxiliary converter generates a current limited three-phase output voltage directly from this galvanically separated DC-link. A sine filter smoothes the PWM modulated output voltage, so that a sine wave voltage waveform is available at the output terminals of the auxiliary converter. The start-up of heavy loads such as air compressors is made possible by the overload capability. If the limits are exceeded during overload operation then Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 9 Technical Specification - Traction converter BORDLINE® CC400 the amplitude of the output current is limited, and the output voltage is slightly reduced dynamically. 2.1.7 Converter control (Drive control) The standard ABB PEC 800 Control platform is used to control the converter. This unit is programmable via standard MATLAB and Simulink SW tools, commercially available The converter controls fulfills the following tasks: • Traction motor electrical torque control • Traction motor flux control • • • • Adhesion control and anti-slip/slide protection Control of 3 phase auxiliary voltage Control of onboard battery charging Control of traction battery charging • • • • Fault current monitoring Ride-through function for transient grid voltages (e.g. pantograph bouncing) Converter protection and diagnostics “Traction safe signal”, to safely disable the propulsion inverter Slip Slide Control The speed of the four motors of the driving bogies are measured and transmitted to the TCU of the CC400 compact converter. The measurements are compared in the TCU in order to counteract slipping and sliding by means of torque limitation. Traction safe signal The traction safe signal is a failsafe hardware signal to disable the pulsing of the propulsion inverter. The brake chopper is still operational, so that the over voltage protection is working. And also the traction battery charger is operational to charge the ESS battery. In case of shop power supply the propulsion converter can be safely disabled by the traction safe signal, thus allowing to charge the ESS battery in the shop. Base principle: Whenever the circuit "Traction Safe" is interrupted outside the converter, any kind of torque from the motor is prohibited. • The security circuit of the vehicle interrupts the circuit “Traction Safe“. • With an open circuit the pulsing commands of the IGBT become interrupted in two different ways. The “Enable” driver entry for the transmitter is set to FALSE and the circuit of the transmitter gets interrupted. This is a hardware path. The interlock cannot be influenced by neither SW nor FPGA. • The command for locking the pulses via FPGA is entered via input I01_3_[1] of OM4 and OM5. If anyone of these signals demands a lock, all linked signals are locked over the FPGA as well. This path cannot be influenced by the SW. Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 10 Technical Specification - Traction converter BORDLINE® CC400 • The 4 signals I01_3_[1] of OM4 (direct lock) I01_3_[1] of OM5 (direct lock) I01_[1] of OM4 (confirmed lock) I01_[1] of OM5 (confirmed lock) are transmitted via FPGA to the TCU where it becomes cross-examined. Examination of this setup with FMEA and failure tree analysis leads to following results: Failure Frequency w [h-1] 3.9 E-09 FIT 4 Non-availability Q [-] 4.6 E-06 Based on this analysis the board can be assumed to fulfill SIL4 for the above mentioned base principle. This traction safe signal is used in all ABB compact converter and has showed its safety and reliability in over 3000 converters. Dynamic brake control The dynamic brake is combined regenerative and rheostatic and is continuously available from maximum vehicle speed down to a vehicle speed of 3 km/h. The dynamic brake control system is continuously monitoring the line voltage. It is supplying to the line the maximum amount of energy possible within the line voltage limits. If the line is not receptive the generated energy is used for the auxiliary power converter and to charge the ESS battery, only the excess of the energy is dissipated by the braking resistors. Dynamic braking is available independent of the presence of line voltage. Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 11 Technical Specification - Traction converter BORDLINE® CC400 ® 2.1.8 Diagnostic tool: Bordline -View BORDLINE ®-View is a diagnostic tool for visualization of signals, parameters and states of converters. BORDLINE ®-View can be installed on usual laptops and the communication with converter controller AC 800PEC is done via Ethernet protocol. The program view is subdivided in five windows: o Window for State Display o Window for PEC Information / Maintenance o Functions window o Window with Value Tables o Plot window o Window for State Display In this window the actual state of the converter is displayed. For fast recognition the visualization of the states is made with colors, green for normal operation, orange for warnings and red for malfunction. If necessary other colors are available. It’s possible to display two times 48 states. o Window for PEC Information / Maintenance For the service engineer are two modes available. The message window, where the coded binary output is displayed decoded and a direct function window with soft buttons for parameter changes. o Functions window In the function window information about project and the configuration is displayed. The soft buttons for printing the value tables, for setup, for exit and log off are placed in the function area. o Window with Value Tables Signals, parameters and coded binary output are displayed. Signals and parameters with green selection field can be plotted in the plot window. o Plot window It’s possible to plot signals and parameters in a graph or display the values analogical in a meter window. Five graph windows are available. Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 12 Technical Specification - Traction converter BORDLINE® CC400 Window for PEC Information / Maintenance Window for State Display Functions window Window with Value Tables Plot window The detailed list of failures that will be sent by the converters to the BORDLINE - View tool will be defined in the design stage of this project. Typical failures/signals that are detected are: • Overcurrent/short-circuit of the motor phases, brake chopper, traction battery charger, auxiliary phase and battery charger • Grid overvoltage • Input overcurrent • DC link overvoltage • IGBT faults • Supply faults • Faults of the circuit breakers • Motor temperature and speed Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 13 Technical Specification - Traction converter BORDLINE® CC400 2.2 Traction package The yellow components are part of ABB scope of supply. The main power circuit of BORDLINE® CC400 traction and auxiliary converter is shown in the following schematic. The battery is needed for operation without catenary. System Schematic Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 14 Technical Specification - Traction converter BORDLINE® CC400 2.3 ABB Scope of supply 2.3.1 Included One Traction package suitable for one streetcar consisting of: ® • 2 x Traction converters BORDLINE CC400 including software • 2 x Cooling system HEX integrated with CC400: including brake resistors • Windows based diagnostic tool • Documentation: ABB standard User manuals, Block diagram & Dimensional drawing • 3D STEP file of traction converter & motor • Type test according to specification • 2 x Dead battery start unit (included in CC400): Battery power is not required to start the LVPS • Counterparts to all used connectors on CC400 2.3.2 Optional • Traction battery 2.3.3 Not included System components or functions which are not included within the ABB’s scope of supply: • Pantograph • Ground speed sensors • Third party certification or certification tests in the field • Cables & wiring between drive chain components • Vehicle control functions like: pneumatic pressure control, global state machine,(start up, shut down), speed & acceleration control, friction brake control controller • Safety related software functions • TCMS system and TCMS interface are specified separately. • Any other item, service, functions or devices not covered in the ABB scope of supply or explicitly not mentioned in our specification Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 15 Technical Specification - Traction converter BORDLINE® CC400 2.4 BORDLINE® CC400 - Technical Data 2.4.1 Input Data Nominal line voltage Voltage range for nominal power Emergency braking 750 VDC 525 ... 925 VDC up to 1000 VDC Self discharge time for Ud < 50 V DC (passive) Active discharge with braking chopper < 3 min. <2s 2.4.2 Propulsion Converter (INV) Nominal voltage / frequency Phase current (per inverter), continuous Pulse pattern Voltage rise, max. 0…500 Vrms / 0…170 Hz 347 Arms PWM < 4 kV/µs 2.4.3 Braking chopper Power to be dissipated, service braking Power to be dissipated, emergency braking Braking chopper resistor Voltage rise 2 x 200 kW @ 720 Vdc 2 x 300kW @ 900 Vdc 2 x 2 Ω +/- 5% < 4 kV/µs 2.4.4 ESS charger Battery voltage Phase current, continuous 400…550 VDC 2 x 320 Arms Output is smoothed by LC filter. 2.4.5 Auxiliary converter Voltage Power Connections Max asymmetric load Voltage shape Voltage distortion factor 3 x 460 Vrms / 60 Hz 33 kVA 3P+N 10A Sinus < 8% 2.4.6 Onboard battery charger Voltage Power Charging curve Temperature compensation Temperature sensor 24 VDC 8 kW @ 24V to be defined Yes NTC Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 16 Technical Specification - Traction converter BORDLINE® CC400 2.4.7 Control Voltage (for Electronics) Externally backed-up, without galvanic isolation Control voltage, nominal Power dissipation 24 VDC ≈ 350 W , 500W (transient) 2.4.8 Control HW interface The hardware signal and communication interface is realized with specially configured Harting connectors. The definite configuration will be defined in the next project phase. Communication with the vehicle electronics Serial bus protocol CAN Connector Harting Isolation voltage 500 Vrms Supply voltage for controls 24 V (Battery) Speed sensor type to be defined 2.4.9 Test voltages (according to EN50124) Traction converter versus GND Auxiliary converter (three-phase output) versus GND Battery charger and DC output versus GND 3.3 kVrms 2.5 kVrms 1.2 kVrms 2.4.10 Environmental conditions Ambient temperature Max. cooling liquid inlet temperature (to converter) Water temperature for MTBF calculation Operating altitude -25 to 45°C (standard) +50°C +30°C max. 1000 m 2.4.11 Cooling circuit Coolant Coolant flow rate Pressure drop, maximum Coolant volume System test pressure water-glycol mixture 60 l/min 700 mbar ca. 6 l. 6 bar 2.4.12 Supply for cooling equipment Voltage Water pump Internal fan 3 x 460 Vrms / 60 Hz 1200 VA 700 VA Voltage Two fans for heat exchanger 24 VDC 2 x 300 W 2.4.13 Maintenance interval of CC400 Visual inspection of the CC400 interior 1 year Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 17 Technical Specification - Traction converter BORDLINE® CC400 Replacement of ventilators Replacement of electrolytic capacitors 6 years 15 years 2.4.14 Maintenance interval of HEX Replacement of ventilators Replacement of water pump Filling-up the cooling liquid (e.g. after water level alarm or trip) Cleaning and visual inspection of heat exchanger 6 years 6 years When required 1 year 2.4.15 Mechanical Layout Dimensions (without mounting points) – see drawing: Figure 8 CC400 converter Dimensions (L x W x H) without brackets Dimensions (L x W x H) with brackets Converter weight Protection degree CC400 Brake resistors Vibration capability (modules) Mechanical strength (structure) 1554 x 1800 x 720 mm 1594.5 x 1886 x 720 mm < 720 kg IP65 IP20 IEC 61373, Cat 1, Class B EN 12663-1, Cat P-II Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 18 Technical Specification - Traction converter BORDLINE® CC400 Mechanical drawings Figure 4 converter ISO mode view Figure 5 converter top view Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 19 Technical Specification - Traction converter BORDLINE® CC400 Figure 6 Converter overall view Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 20 Technical Specification - Traction converter BORDLINE® CC400 Figure 8 BORDLINE® CC400 DC dimensional drawing Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 21 Technical Specification - Traction converter BORDLINE® CC400 2.5 Traction Motor AST 90-4 2.5.1 Main data Motor type Number of poles Nominal voltage Short time power (acceleration) Nominal power (S1) Nominal torque Starting torque Max. speed Test speed (2 min) Speed sensor for TCU Speed sensor for friction brake three phase asynchronous machine 4 480 Vrms 145 kW 90 kW 432 Nm 705 Nm 4800 rpm 5760 rpm GEL247 X1FM 300.1 GI5-S Basic characteristics of the motor AST 90-4: Frequency Voltage Power Speed Current Torque Breakdown torque Off-load current f (Hz) U (V) P (kW) n (1/min) I1 (A) M (Nm) Mzv (Nm) Im (A) 67 425 145 1965 241 705 1658 71,8 80 480 145 2360 208,5 587 1503 61,7 100 480 145 2949 203 470 964 39,3 120 480 145 3536 205 392 664 30,9 140 480 125 4137 176 288 487 26,2 160 480 110 4736 154,6 222 373 22,8 160 Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 22 Technical Specification - Traction converter BORDLINE® CC400 Basic characteristics of the motor AST 90-4 (generator): Frequency Voltage Shaft horsepower Speed Current Torque Breakdown torque Off-load current Line voltage f (Hz) U (Vac) Pmech (kW) n (1/min) I1 (A) M (Nm) Mzv (Nm) Im (A) U (Vdc) 155,9 140 120 100 98,3 620 620 620 620 620 200 200 200 200 200 4736 4252 3644 3037 2985 196 195,2 196,6 204,5 205,3 403 449 524 631 640 772 975 1372 2051 2127 30,7 35,0 44,5 67,2 70,6 900 900 900 900 900 Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 23 Technical Specification - Traction converter BORDLINE® CC400 2.6 Brake resistor 2.6.1 Main data Nominal Resistance RN Max. Resistance Rmax Rmin (-30 °C) P1 Max. Voltage UNm Inductance Creepage Distance Air Distance Insulation Protection Degree Energy Absorption Capacity Thermal Resistance Thermal Capacity Resistance Material Active Mass Active Surface Max. Resistance Temperature Max. Air Temperature Ambient Temperature Cooling Connection Terminals Mass Dimensions (L x B x H) 1,8 +7 %, -5 % 2,45 @ 650°C 1,65 15 kW Continuous Power 1100 V < 20 µH 2 x 27,5 mm (PD4) 2 x 10 mm (OV2 / PD4) double IP 00 – with Enclosure IP 21 1127 kJ (650 °C) Rth =13 * 10-3 K/W Cth = 1,8 kJ/K CrNi2521, Band 3.9 kg 22324 cm² Continuous Power: approx. 300°C approx. 400 °C (Braking at 50 °C Ambient) -32 °C ... + 50 °C Forced Air M10 < 19 kg 695 x 355 x 230 mm incl. Air Distance 2.6.2 Drawing Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 24 Technical Specification - Traction converter BORDLINE® CC400 3 Type test and routine test (ABB Power laboratory) ® The table gives a survey of the type and routine-test to be performed on BORDLINE CC400. They will be performed at ABB`s power laboratory. The following standards are applied: • EN 61287-1 for the power part (replacement for EN50207 since 2007) • IEC 61287-1 for the power part • EN 50155 for the control electronics and the battery voltage. Test step EN 61287-1 EN50155 chapter type EN61287-1 test EN50155 routine test remarks visual inspection 4.5.3.1 air/creepage distances, cable shift, surface, cable marking dimension and tolerances 4.5.3.2 pre-testing at manufacturer of mechanical components weighing 4.5.3.3 marking 4.5.3.4 specifications on identification plate cooling 4.5.3.5 combined with temperature rise test protection and measuring device 4.5.3.6 light load test nominal load test 4.5.3.7 sealing 4.5.3.8 Commutation overload capability test 4.5.3.9 acoustic noise 4.5.3.10 temperature rise 4.5.3.11 7.4.5 replaced by a nominal load test for auxiliary converters overload capability 7.4.6 7.4.7 dry heat test 10.2.4 start controls at high temperature low temperature test 10.2.3 start controls at low temperature Power loss determination 4.5.3.12 supply overvoltage and transient energy 4.5.3.13 Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 25 Technical Specification - Traction converter BORDLINE® CC400 sudden load variation short-circuit test load-break test 4.5.3.14 performance test starting and restarting test 10.2.2 insulation, isolation resistance 4.5.3.15 dielectric test 4.5.3.16 safety requirements 4.5.3.18 shock and vibrations 4.5.3.19 EMI test 4.5.3.20 line voltage variation 4.5.3.21 short time supply interruption test 4.5.3.22 7.4.3 7.4.8 electronics supply test , including power consumption measurement 7.4.2 output characteristics test 7.4.1 voltage and frequency ranges verification 7.4.4 signaling Housing is done by FEM calculation, power modules are tested ( ) Together with whole Vehicle , not in ABB scope Test of alarm and fault indication Burn-in Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 26 Technical Specification - Traction converter BORDLINE® CC400 4 Applicable standards The following railway standards have been taken into consideration as far as they are relevant for this equipment: EN 50121-3-2 EN 50124-1 EN 50125-1 EN 50153 EN 50155 EN 50163 EN 61287-1 EN 61000-4-4 EN 61000-4-5 EN 61373 IEC 61287-1 IEEE 519-1992 Railway applications – Electromagnetic compatibility – Rolling stock – Part 3-2: Rolling stock apparatus Railway applications – Insulation coordination – Part 1: Basic requirements – Clearances and creepage distances for all electrical and electronic equipment Railway applications – Environmental conditions for equipment – Part 1: Equipment on board rolling stock Railway Applications – Rolling Stock – Protective Provisions relating to Electrical Hazards Railway applications – Electronic equipment used on rolling stock Railway applications – Supply voltages of traction systems Railway Applications – Power convertors installed on board rolling stock – Part 1: Characteristics and test methods Electromagnetic compatibility (EMC) – Part 4-4: Testing and measurement techniques: Electrical fast transient/burst immunity test Electromagnetic compatibility (EMC) – Part 4-5: Testing and measurement techniques: Surge immunity test Railway applications – Rolling stock equipment – Shock and vibration tests Power converters installed on board rolling stock - Part 1: Characteristics and test methods, First edition IEEE Recommended Practices and Requirements for Harmonic Control in Electrical Power Systems Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 27 Technical Specification - Traction converter BORDLINE® CC400 Document Index Rev. Page chapt A 16, 13 Description Date / responsible Draft Elvis Dzindo 06.01.2010 Elvis Dzindo 13.01.2010 Elvis Dzindo 15.01.2010 Patrik Scherrer Patrik Scherrer 14.03.2012 Patrik Scherrer 22.03.2012 dwg in English, IP55 for traction motor B Traction motor characteristics, step – up box. C D Inserted battery for overheadline less operation Completely revised version E Chp. 1.2.1 Chp. 2.5 Chp. 2.6 Chp 3 Changed max. power to 525 kW, and braking power to 725kW Inserted traction motor AST 90-4 Inserted brake resistor Removed traction battery, The traction battery is specified in a separate document Document Nr. ABB Switzerland Ltd. 3BHS396008 E01 Language Rev. en E Seite 28