4B Device Manual Parts

Gate Unit (GU):
Device Names: A101-A3, A102-A3, A103-A3, A204-A3 [Inverter A Section]
A201-A3, A202-A3, A203-A2, A204-A3 [Inverter B Section]
Siemens P/N: Generation 2 (black in color): 429 901 9006.50
Generation 4 (silver in color): 429 910 9031.00
Gate Unit modules, Generation 2 (black), Generation 4 (silver)
Description:
The Gate Unit is used to control the gates of the GTOs inside the phase and chopper modules.
This is the interface between the control unit and the power part of the Inverter.
Each Gate Unit consists of:

♦1 two-channel controller (DST, left housing)
♦2 high-voltage units (HST, middle and right housing)
The two-channel controller provides the signals and the energy for the high-voltage unit. Each high-
voltage-unit can drive one GTO They are locked against each other, so that only one GTO can be
switched 'on' at a time.
Copyright Siemens Energy & Automation, Inc. All Rights Reserved

Application:
In the control cabinet there a total of 8 gate units. The ones used on the inverter A components
are labeled A101-A3, A102-A3, A103-A3, A104-A3. The ones used on the inverter B are labeled A201-
A3, A202-A3, A203-A3, A240-A3.
The gate units mount on the front of the module and connect to terminals 9 ,10, 11, and 12 with
small bus bars. The gate units supply voltage is 140VDC which is supplied by the DC-DC converter
called the Gate Unit power Supply.
The SiBAS interfaces with the gate units through the pulse amplifier cards. Signals are sent to
turn each GTO “ON” or “OFF”. In turn feedback is sent from the gate unit to the SiBAS when the GTOs
are “ON” or “OFF”.
The GTO is fired over terminals G and K of the high voltage parts (terminals 9,10,11,12 of the module)
The connection to the GTO module is made by low-inductive bus bars.
UG-K ~ +2 V ⇒ GTO is 'on' (100% modulation)
UG-K ~ −15 V ⇒ GTO is 'off' (0% modulation)
The LEDs located on the bottom mean:
Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.

Red LED: ON - positive pulse current available, G - K circuit functional
Front gate
terminals
9-10 11-12
Power LEM connector
From GUPS 140VDC
I t
Grounding bolt E-prom plug

(Prom Stecker)
Signal LEM connector

(Communication signals)

WARNING
In operation mode of the TCU, the high-voltage units, even the covers of them, are under high
voltage!
Working, measuring and servicing on this component is only permitted, when the TCC is switched
'off' and grounded!
NOTE
For exchange of the GU, the supply-voltage has to be switched 'off'!
Technical Data:
Supply: Rated voltage: 140VDC (From Gate Unit Power Supply)

terminal 1 +140 V
terminal 2 ground
ripple: maximum 5 %
Current consumption during operation(one GU):
at 140 V DC
Temp. > 0 °C ... 55 < 0 °C
Range °C
Typically 5A 7A
Max. 8A 12 A
Tab. II - 1.2
Ripple: Iripple = 0.5 A (aver. peak)

fripple = 50 kHz
Starting current: 35 A for 2 ms
Type: Short - circuit current (1 or 2 GTO defective) 15 A ... 25 A at 140VDC
CAUTION
The gate unit is not short-circuit proof! When short-circuit occurs, the supply must be switched off
within 10 s!
Signals: The GU is connected to the TCU with a 10-pole AMP-plug at the two-channel controller A3
– A1, A2
NOTE
After removing and re-installing the plug-in connector, this connector must be locked with the
provided clamps on each side. It is locked only when the inserted plug ‘clicks’.
The GU is connected to the phase module by installing and tightening the screws.
Triggering: See Circuit Diagram GTO A/B – Inverter control Signals

terminal 3 Y11 (70 mA ⇒ channel 1 'on')
terminal 4 Y12 (70 mA ⇒ channel 1 'off')
terminal 5 Y22 (70 mA ⇒ channel 2 'off')
terminal 6 Y21 (70 mA ⇒ channel 2 'on')
(power supply 24 V term. 1)
(ground for triggering term. 2)
Feedback signals TCU:
terminal 7 channel 2 (Ri = 330 Ω)
(U = +12 V ⇒ storage time exceeded)
(U = 0 V ⇒ triggering o.k.)
Storage time channel 1 or 2 exceeded:

output gets low-resistance
I8,max < 10 mA
U8-9 < 5 V at I8,max
Storage time not exceeded:
output gets high-resistance
I8,max > 8 mA
U8-9 = +70 V
Output:
The GTO-thyristor is fired over terminals G and K of the high voltage part.
The connection to the cover of the evaporation bath module is made by low-inductive busbars.
UG-K ~ +2 V ⇒ GTO is 'on'
UG-K ~ −15 V ⇒ GTO is 'off'
Simple check by LEDs:
Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.

Red LED: ON - positive pulse current available, G - K circuit functional

Gate Unit E-Prom (prom Stecker):
Siemens P/N: For Generation 2 Gate units on Phase module: 429 811 9100.00
For Generation 2 Gate units on Chopper module: 429 821 9100.00
For Generation 4 Gate units on Phase module: 429 800 9001.07
For Generation 4 Gate units on Chopper module: 429 800 9001.03
Description:
The Prom Stecker is a program chip installed in a LIMO style male connector. The program installed on
the chip controls whether the gate unit functions as a phase or chopper gating device.
Gen 2 prom Steckers will not physically fit in Gen 4 gate units. If a chopper prom Stecker is plugged into
a gate unit connected to a phase module the start up sequence will report a fault during the GTO pulse
test. Until the start up sequence completes without faulting the system held in a protected state.

Inverter Protection Thyristor
Device Names: V101
Siemens P/N: A20 360 7032.00
Protection
Thyristor
Mounting
Left Hand Side
Cubicle from
the front
Application:
The Inverter Protection Thyristor is used so the DC bus voltage can be dissipated quickly in the event of
a serious system fault. Discharge of the DC-Bus is normally taken care of by the choppers at shutdown
and in certain systems the choppers have been optimized to replace the need for the Thyristor during
serious system faults as well.
The Thyristor is mounted in a assembly that facilitates connection of power cables and secure mounting.
It is located below the DC link capacitors in the far left compartment.

Firing Pulse Transformer
Device Names: A113
Siemens P/N: 359 554
Application:
The pulse transformer is used to fire the Inverter protection Thyristor. This device is labeled A113 and
located in the lower portion of the far left compartment (next to Thyristor). It works together with the
Thyristor control board (A112) to fire the Thyristor after receiving a signal from the SiBAS.
The pulse transformer and the respective Thyristor control board work as an oscillator, generating gate
pulses for the crowbar Thyristor. When working correctly, they provide a gate current to fire the Inverter
Protection Thyristor.
Technical Data:
Input:
From thyristor control board -A112 connected to pulse transformer -A113,
Pulse transformer: terminal 22, red connected to terminal -X1 (Thyristor control board)
terminal 21, blue connected to terminal -X2
terminal 24 yellow connected to terminal -X3
terminal 23, orange connected to terminal -X4
Output:
The pulse transformers are wired to gate/cathode of the Thyristors.
Dimensions: approx. 100 mm x 100 mm x 100 mm (L x W x H)
Weight: Approx. 0.5 kg

Thyristor control card (Software Trigger (Schutzzundelektronic))
Device Names: A112
Siemens P/N: 422 903 9022.20
Application:
The Thyristor control card is used to fire the Inverter protection Thyristor. This device is labeled A112
and located in the lower portion of the far left compartment (next to Thyristor). It works together with the
Pulse Transformer (A113) to fire the Thyristor after receiving a signal from the SiBAS. The control card
also provides a signal to SiBAS constantly reporting if Thyristor is “On” or “OFF” The connection to
SiBAS is done via a 6 pin Amp connector labeled X8. In addition there should be a jumper plug (Siemens
p/n: 394809) installed in connector X7 for proper operation of this card.
Thyristor Plug X8:

Pin: Signal: Connected to:
1 +24V LO87 Analog I/O
2 Off command L119 Output pulse card d6
3 ON command L119 Output pulse card d8
4 GND L087 Analog I/O
5 ON status signal L119 Output pulse card z8
6 Off status signal L119 Output pulse card b8
Because the Thyristor control card is always sending a feedback to Sibas, removal of plug
X8 will cause SiBAS to believe the Thyristor is on and the system will not be allowed to establish
bus voltage.

Current Transformer
Device Names: T103
Application:
The current transformer is used to indicated when the Inverter Protection Thyristor has fired. It is labeled
T103 and located along the inside wall of the far left compartment. It changes the current passing through
the IPM cable to a lower value. This lower current is passed to the Thyristor control card for proper
reaction and so that SiBAS is notified. The ratio is 400:1 and a small resistor (R114) ~1.2 Ohms is
placed across the output terminals in parallel with the input to the control card. This resistor is necessary
so a scaled voltage is properly applied to the control card’s input terminals.

COMPLETE Inverter Protection Module panel:
T103
Current Transformer Pulse
Thyristor
Thyristor Control Card
Plugs X8 and X7

DC Grid Blower Constant Speed Panel.
K191
K181.
X900
U171
Application:
The DC Grid Blower constant speed panel is installed into the cabinet in the place of the IPM
panel. Without the IPM panel installed the choppers are designated as the primary way to discharge the
voltage in the event of a serious fault.
The constant speed panel holds the components used to control the application of the DC voltage
to the grid blower. Contactor K191 completes the power circuit that applies DC bus voltage across the
DC grid motor and motor control resistors, also called MCRs. This contactor K191 closes when 24V is
applied across to it’s coil from K181. The cotactor K181 decreases the amount of current needed from
the Sibas digital output card (C019) to close contactor K191.
Also on the constant speed panel is a current transducer (U171) used for feedback to Sibas.
Finally the panel contains a terminal block that allows for the installation of a diode (35V 1A) and resistor
(50 Ohm 5W) needed for the current transducer’s feedback to Sibas.

Grid Blower DC-Contactor
Device Names: K191
Siemens P/N: 14-193-110-521
Insulating
Sheet
Application:
This is a high power DC contactor; it’s used as a control point to allow application of the DC Bus voltage
across the motor control resistors and grid blower motor. During installation it is extremely important to
install the included insulating sheet prior to mounting on the bracket.
Technical Data:
2800V, 1250A

Grid Blower 24V Relay
Device Names: K181
Siemens P/N: 3TF2010- 0BB4
Application:
This relay is used to limit the amount of current needed to close the larger DC contactor K191. The Sibas
digital output card C019 is current limited and without this relay it would not be possible to close K191.
The relay should be mounted on Din rail. To remove it from the Din rail place a flat screwdriver into the
release tab on the side of the relay.
Technical Data:
AC-3: 4kW 400V
24V coil

Grid Blower Monitoring Current Transducer
Device Names: U171
Siemens P/N: A1 110 199 441
Application:
This current transducer is used to monitor the grid blower constant speed circuit. It provides a measured
value to Sibas card L095 for analysis. Based on the feedback from this transducer Sibas can determine if
everything is working properly.
The transducer is direction sensitive, the arrow must be pointing in the direction of current flow. On the
grid blower constant speed panel the arrow should point toward the large DC contactor, K191. Also for
the proper feedback scale to Sibas a diode (V71) and resistor (R71) must be added at terminal block
X900 on the constant speed panel, see schematics for proper wiring.
Pin 1 : Supply voltage +12….15V

Pin 2 : Measure
Pin 3 : Supply voltage minus.
Pin 4 : No Connection
Technical Data:
15V, 300A
Diode V71 : 35V, 1A

Resistor R71 : 50 Ohm, 5W

DC-Link Capacitors
Device Names: C101, C102, C103, C104, C105, C106
Siemens P/N: 638619 [1100uF version on systems with 6 total capacitors]
A1110 201 382 [2200uF version on systems with 3 total capacitors]
Application:
The DC-link capacitors stabilize the DC-link voltage, which improves the operation of the inverter by
providing a more stable DC-BUS Voltage. On the systems with three 2200uF capacitors they are labeled
C101, C102, C103 and located in the upper portion of the far left compartment. While the systems that
have six 1100uF capacitors are labeled C101, C102, C103, C104, C105, C106 and located in the upper
portion of the far left compartment.
Note
Dc link capacitors may be charged to high voltage. Always be sure that they are discharged before
handling. Stored / disconnected capacitors have to be short-circuited by wires.

Temperature Probes, PT100 Style
Device Names: F101, F102, F106, F107, F201, F202, F205, F206, F301, F302
PT100 Temperature Probe
Application:
The temperature probe contains a temperature-sensitive resistor (PT100, according to IEC 751). This
enables the TCU to detect either a fault in the cooling system or excessive temperature of the device it is
mounted near. These are used through out the system to monitor the grid box, Snubber resistors.
Inverter compartment.
Technical Data:
The probe has two non-deferrable terminals:
1: + supply (+ 2 mA)
+ M (measured voltage)
2: − supply (− 2 mA)
− M (measured voltage)
Resistance values: 108.5 Ω at 22 °C / 100 Ω at 0 °C.

Motor module for DCL contactor
Device Name: M6
Siemens P/N: 14-192-625-503
Application:
The DCL motor module is labeled M6 and located on the rear left compartment. It is used to move the
DCL switch module (K104). On the top of the motor module are terminals for connection the that motor
as well as feedback contacts which indicate the motor’s current position. The feedback contacts are used
to indicate the position of the DCL switch since it is mechanically coupled to the motor module.
The motor is fed with 24 V DC battery voltage from contactors K161 and K162. Depending on which one
is made the DCL switch (K104) opens (K161) or closes (162). Currently one NO and one NC contactor
are connected to SiBAS for feedback whether K104 is closed (connected to DC link) or Open (DC-link
grounded).
Note: If power is cutoff irregularly (not using the ignition switch) the motor remains in the state it was at
when power was lost. When power is restored the TCU will move the motor/switch to the correct position.
Technical Data:
24VDC, 15A Dimensions: approx., 400 mm x 300 mm x 400 mm (L x W, H)
Weight: approx. 14 kg

Main Contactor DCL Switch
Device Name: K104, K204
Siemens P/N: 14-192-626-502 (entire switch)
14-192-626-801 (contact replacement kit)
Application:
The main contactor K104 connects the DC link voltage from the alternator, already rectified, to the
inverters and consequently the motors. This contactor is a double throw non-interrupting switch it takes
approximately 2 seconds to close but will NOT try to open or close when the voltage is > 30VDC on the contacts.
The closing action is done by M6 mounted to the side a mechanically coupled. The TCU uses K161 (opens) and
K162 (closes) to operate K104. In the open position the system is grounded, this can be seen either from the top of
the contactor or by looking at the position indicator in front of K104. If looking at it from the top the contacts inside
K104 should be to the rear, which is the grounded position. If looking at it from the front the position indicator should
be pointing to “1”. Inversely, if the contactor is closed the DC link is connected to the inverters. In the closed position
the contacts are to the front as seen from the top and the position indicator is pointing to position “2”. There are two
signals fed back to the TCU via two digital inputs (one for closed, one for open) telling it whether K104 is closed or
open. On systems with 4 contacts, two DCL switches have been but together (K204/K104). In these systems there
is still only one motor (M6) used, the system reports the location of only one of the switches, K104.
Technical Data:
1600A, 1500VDC
Note: If power is cut off irregularly (not using the ignition switch) the DCL switch remains in the state it
was at when power was lost. When power is restored the TCU will move to the correct position.

Snubber Capacitors
Device Names: C121-C126 (Inverter A section)
C221-C226 (Inverter B section)
Siemens P/N: 1006173 (Single capacitor)
A203360700600 (Inverter A section assembly)
A203360700700 (Inverter B section assembly)
Snubber capacitor assembly
Application:
The Snubber capacitors are used to prevent over-voltages at the phase and chopper modules caused by
switching. The inverter A section has a assembly of six capacitors labeled C121 – C126 and mounted
just behind the vertical bus bars in a cubby hole next to the chopper module. The Inverter B section has a
assembly of six capacitors labeled C221 – C226 and mounted just behind the vertical bus bars in a
cubby hole next to the chopper module
Technical Data (1 Capacitor):

42 µF, 700 V

Buffer Capacitor
Device Name: C107
Buffer Capacitor
Application:
The capacitor buffers and filters the SiBAS supply voltage (+ 24 V). It is labeled C107 and located in
the far right top compartment. Because of the capacitor SiBAS has enough time in the event of a sudden loss of
24V to immediately trigger the protection Thyristor.
Technical Data:
33 µF, 63 V DC

SiBAS Input power Filter
Device Name: Z102
Application:
The Input power filter helps to provide the SiBAS with a constant input voltage. The filter is
labeled Z102 and located in the front top right compartment. Z102 is mounted on the 24V distribution
panel just below the SiBAS computer. The filter has three channels that are used to filter the P& N input
power as well as the ON signal sent to the SIBAS card G163.
Technical Data:
36VDC
15A

Input power Filter
Device Name: Z101
Siemens P/N: 1000486
Application:
The input power filter helps to smooth out the 24V power before it is sent to the rest of the devices
in the cabinet, except SiBAS. The filter is labeled Z101 and located in the upper right front compartment.
Z101 is mounted on the 24V distribution panel just below the SiBAS computer and next to the SiBAS
input filter, Z102.
Technical Data:
250V
36A

Latching Diodes
Device Name: V111, V113
Application:
The latching diodes allow multiple sources to be used for the SiBAS ON signal. The diodes labeled V111
and V113 are located on the 24V distribution panel below the SiBAS computer.
Technical Data:

Blocking Diodes
Device Name: V110

Application:
The blocking diode prevents the positive 24V input to the SIBAS Filter from energizing the wrong portion
of the circuit. The blocking diode is labeled V110 and located on the 24V distribution panel just behind
the buffer capacitor.
Technical Data:

Complete 24V Distribution panel:
Latching diodes
Z102
Z101
X103 (GND)
X100 T.B. X102 (+24v)

Reactor Core Assembly
Device Names: L101 – L104 (Inverter A)
L201 – L204 (Inverter B)
Siemens P/N: A20 360 700200
Reactor Core, from back of cabinet
Application:
di
The reactor cores are necessary to limit of the GTOs during operation. The reactor cores connected to inverter A
dt
are labeled L101 – L104 and located in the left rear compartment. The reactor cores connected to inverter B are
labeled L201 – L204 and located in the middle rear compartment.
Technical Data:
54 torroid cores are mounted on each reactor core assembly

Snubber Resistor
Device Names: R113 (Inverter A)
R213 (Inverter B)
Application:
The Snubber resistor is used to dissipate the commutation losses of phase and chopper modules. The
resistor connected to inverter A is labeled R113 and located in the lower portion of the left rear
compartment. The resistor connected to inverter B is labeled R213 and located in the lower right middle
compartment. These resistors are located directly in the cooling airflow, their temperature is measured by
PT100s and sent to SiBAS
Technical Data:
0.18 Ohms, 30 kW.

Current Transducers
Device Names: U101 – Phase R current to motor A U201 – Phase R current to motor B
U102 – Phase S current to motor A U202 – Phase S current to motor B
U103 – Phase T current to motor A U203 – Phase T current to motor B
U104 – Chopper current Inverter A U204 – Chopper current Inverter B
U107 – DC Link current.
Siemens P/N: 1007213

Current Transducer
Current Transducers, monitoring chopper current Monitoring motor current
Application:
The current transducers are used through out the drive to monitor the current and give constant
information to SiBAS for proper control. The transducers for Inverter A output are labeled U101, U102, U103, these
are located at the bottom of the far right front compartment. The transducers for Inverter B output are labeled U201,
U202, U203, these are located at the top of the far right front compartment. The transducer monitoring the current
from chopper A is labeled U104 and located at the very bottom of the far left front compartment. The transducer
monitoring the current from chopper B is labeled U204 and located at the very bottom of the far left front
compartment. The transducer monitoring the DC-Link current is labeled U107 and located in the middle section of
the far left front compartment. Each transducer has a male LIMO type connector

Gate Unit power supply
Device Name: A115
Siemens P/N: A1 110 199 014
X1 View from top with out

Input power
X2 Input
X1
Yellow
X2
Green
Gate Unit power supply
Application:
The Gate unit power supply is just that, the power supply for the gate units. It is labeled A115 and located along
the wall in the bottom far right front compartment. Connectors X1 and X2 contain the outputs that go to the front of each gate
unit. The Gate unit power supply is a DC-DC power supply that supplies the large amount of current needed by the gate units to
fire the GTOs. A signal to enable this device is sent from SiBAS to X1 pin 2. The Unit gives its “ok “status by closing a normally
open contact between pins 10 and 11 of X1 after given the enable command. Consequently pin 11 has been attached to 24 V so
that the status read from pin 10 can be inputted into a digital input card and used by the TCU to know if the Gate unit Power
supply is functioning, a very important fact to know.
For visual verification of its operation one can look at the two LED’s near X2. If the green one is illuminated
then everything is okay. If the yellow one is illuminated, then there is a short circuit some where, either in the output or internally
to the gate unit power supply. These LED’s should be referenced only after giving the unit 20 seconds to finish start up.
Technical Data:
26VDC IN - 140 VDC Out

3TF41 Style Contactors
Device Name: K161, K162, K105
Siemens P/N: 3TF4122-0LB4
Application:
These contactors are used to power devices that the SiBAS can not power directly. The contactor K161 is used to operate
the motor M6 and in turn move K104. K161 is located in the rear right compartment (above K104). The contactor K162 is used to
operate the motor M6 and in turn move K104. K161 is located in the rear right compartment (above K104). The contactor K161
opens K104 and contactor K162 closes K104. These contactors can be momentarily made by pushing the black button on the
front of the contactor.
Contactor K105 is used to turn the GTO heaters on and off. It can also be momentarily closed by pushing the black button.
Contactor K105 is located just below K161 and K162 in the rear right compartment (above K104).
NOTE: Never close or open the contactor manually (using K161 or K162) when the DC-link has power on it (i.e. engine running
or Dc-link not discharged). The TCU moves K104 only after it is sure there is no power coming from the Dc-link. This
operation (by the TCU) protects the contactor from arcing and subsequently burning up the contacts.
Technical Data:
24V, 15ADC

3TF47, 3TF48 Style Contactors
Device Name: K141 , K142, K143, K101
Siemens P/N: 3TF4722-OLB4 (K101, K143)
3TB4817-OBB4 (K141, K142)
Application:
The 3TF47 and 3TB48 Style contactors are used to properly apply power to a device based on outputs from the SiBAS. The
contactor labeled K141 controls the application of voltage to the Auxiliary rectifier from the 1.6 tap on the auxiliary transformer.
K141 is located in the right rear compartment just above K104. The contactor labeled K142 controls the application of voltage to
the Auxiliary rectifier from the 2.4 tap of the auxiliary transformer . K142 is located in the right rear compartment just above K104.
. The contactor labeled K143 allows for the connection of a precharge resistor (R143) so the capacitors inside the Auxiliary
inverter are not damaged by sudden voltage changes. K143 is located in the right rear compartment just above K104. These
contactor CAN NOT be operated by pushing the black button on the front. The front black button can serve as a visual indication
that the contactor is closed/open but pressing it in WILL NOT to make the contactor.
The contactor K101 applies +24V power from the connector 1XF to the rest of the cabinet. K101 is located in the bottom front
right compartment. When the system if first turned ON K101 receives it's coil voltage from the key switch input. After the SiBAS
finishes the internal check of the SiBAS cards a digital output keeps the contactor K101 ON even if the Key switch if turned off.
Only when the key if OFF and the truck in the proper state will the system shutdown and open K101, removing +24V from the
devices in the cabinet.
Note: The 3TB48 style contactors are only present when a 60Hz main blower is installed. The 3TB48
style has a higher current capacity.
Technical Data:
480V, 80A (3TF47 style)
480V, 100A (3TB48 style)

Complete rear contactor panel:
K143 K142 K141

K105
K161
K162

Circuit Breakers
Device Name: CB141, CB142, CB105, CB102
Siemens P/N: ED43M070 (CB141 & CB142) used with 120Hz Main Blower
ED63B100 (CB141 & CB142) used with 60Hz Main Blower
3VU1600-1MM00 (CB105)
3VU1600-1MR00 (CB102)
Application:
The circuit breakers labeled CB141 and CB142 are used as protection for K141 and K142 and subsequently the auxiliary
inverter. These Circuit Breakers are located in the far left front compartment on a small swing panel. These are just like standard
circuit breakers, they can be switched on/off or reset using the switch on the front of each. The circuit breaker labeled CB105
protects the heating circuit. The circuit breaker CB102 protects the input to the field regulator.
Technical Data:
480V, 70Arms (CB141, CB142) used with 120Hz Main blower
480V, 100Arms (CB141, CB142) used with 60Hz Main Blower
480V, 10Arms (CB105)
480V, 21Arms (CB102)

Heat Exchanger
Device Name: B301
Siemens P/N: A1 110 201 323
Application:
The heat exchanger provides circulated air to the inverter compartments. The heat exchanger is labeled B301
and located on the door of the Inverter B compartment. When the control power is ON (K101 closed) then the heat
exchanger is running. There is no switching on or off by the TCU. Power is fed directly from the control power to a
terminal block (TP301) located on the door of the inverter B compartment.
Technical Data:
24V DC

Pressurizing Blower
Device Name: B302
Siemens P/N: A1 110 199 117 (Entire kit for field retrofit)
A1 110 199 118 (Pressurizing fan/motor, 24VDC)
A1 110 199 121 (Filter and pre-filter)
Outside view with Filter and cover Outside view Fan (Filter removed) Filter
Application:
The pressurizing blower is installed to add filtered air to the control cabinet. With the doors properly closed and
the cable fittings tight the addition of the air keeps dust out. The blower is a 24V circular fan wired directly to the
24V supply inside the cabinet. The blower runs as long as K101 is closed.
Note: The fan should never run unless the filter, pre-filter, and cover are installed.
Technical Data:
24V DC, 3A

Field Regulator – Three Phase AC INPUT style
Device Name: A107
Siemens P/N: A1 110 201 288
Input Battery
Input AC power
J4 J5
Application:
The Field regulator is used to effectively control the current being put into the field of the alternator thus
controlling the amount of AC power generated by the alternator. The field regulator is labeled A107 and located
along the right wall of the far left front compartment.
At start up after the engine is running and the control system is ready for high voltage the enable command is
sent to the field regulator from the TCU. This signal closes relays on the field regulator board sending and enabled
status back to the TCU and putting a diode in series with the field of the alternator and the batteries. This completes
the circuit and causes the field of the alternator to be energized. With the field now energized the rotating alternator
generates AC voltage. Once the AC voltage reaches a certain level the field regulator switches over and uses the
incoming three phase ac voltage from the 1:1 winding on the auxiliary transformer.
Technical Data:
Variable frequency field controller

24VDC Battery flash input
Three Phase AC input
Max output voltage = 80VDC
Field Regulator – 24V Input Style
Device Name: A107
Siemens P/N: A1 110 199 834
Output to alternator field
Input 24V from FU107
J1, 10 pin plug (Phoenix)
Application:
The Field regulator is used to effectively control the current being put into the field of the alternator thus
controlling the amount of AC power generated by the alternator. The field regulator is labeled A107 and located
along the right wall of the far left front compartment.
The 24V style is the latest version of this device. It uses ONLY 24VDC and outputs current to the alternator field
based on the setting received from SiBAS.
Pin out:
Technical Data:
24VDC, Max output voltage = 80VDC

Instruction for replacing the Three Phase style Field Regulator with the 24V style
Parts needed
Besides a Syko field regulator a updating kit is also required, the Siemens part number for this kit is: A1
110 199 115, this kit includes the following parts:
No. Name Part Number Quantity

1 Instruction A1 110 199 116 1
2 New fuse A1 110 199 031 1
3 Phoenix connector, MC1.5/10-STF-3.81 A1 110 199 032 1
4 Pin for Phoenix connector A1 110 199 033 12
5 Cable for power supply: 9 AWG, 1x6 mm sq, 319 830 15 Meters
44-56A, BK
6 M5 ring lug 052 647 4
7 Pin terminal for connection to fuse holder 340 109 2
Unplug J4 and J5, Disconnect all the wirings on the old style unit.
Install the new style unit.
Make wiring changes:
Compare the schematics attached for both field regulators. The following table can be used when
changing from the old style field regulator to the current style. If the truck schematic is SXXXXXX, the
wire label will be in the second column, if the truck schematic is A20360900X, the wire label will be in first
column.
Schema
Schematic A1 110
tic A1 110
A2036090 201 288 Comment
SXXXX 199 834
0X
XX
Cable # Cable # Color Old style New style
A107- A107- Cut the pin and put new item 4 pin,
1504 X102-2 BK
J4:1 J1:10 then make connection
A107- Cut the pin and put new item 4 pin,
1504 X102-2 WH A107-J1:9
J4:2 then make connection
A107-
1012 A107-11 BK J4:1 to Remove the jumper
J5-1
A107-
A107-J1:9 Cut the pin and put new item 4 pin,
1013 A107-12 BK J4:2
to J1:8 then make connection
to J5-3
1007 A107-14 BK A107-J1:7
3808 A107-13 BK A107-J1:7
1011 A107-15 BK A107-J1:6
1011 A107-15 WH A107-J1:5
A107:
A107- BK,R A107:
1001 OUTPUT Connect directly
8/9 D (+)
(+)
A107:
A107- OG,B
1001 A107: (-) OUTPUT Connect directly
8/9 N
(-)
1503 X103-1 WH A107: (-) Remove this wire
A107: Add a item 5, 5 meters new cable,
1611 1611 BK
INPUT(-) connect from A115 (-) to A107:INPUT(-)
Replace this wire with item 5, 5 meters,
BK/W
1405 A107-5 FU107:1 FU107:1 connect at same point at both end. Use
H
Item 7 for connecting to FU107.
Replace this wire with item 5, 2 meters,
BK/W A107:(+ A107:
1003 A107-4 Connect it from FU107:2 to
H B) INPUT(+)
A107:INPUT(+)
1004 A107-1 BK A107-R Remove this cable
1005 A107-2 BK A107-S Remove this cable
1006 A107-3 BK A107-T Remove this cable
Please note: Machines built with the current style regulator have wire 3005 but this wire is not
required for the retrofit unit.
Change the fuse with item 2 at FU107.

Change the field regulator type from Old Style to New style with monitor program under the “User-
parameter” menu.

Auxiliary Inverter
Device Name: A118
Siemens P/N: 456 901 9020.10
Power and
Covered Heat Sink communication
connections
(behind door)
Application:
The auxiliary inverter takes input power from the Auxiliary transformer and uses it to control the main blower
motor (AC). It receives a set of points from the SiBAS then outputs the proper blower motor frequency. The
Auxiliary inverter is labeled A118 and located on the side on the inverter cabinet of inside the far left compartment.
Technical Data:
Max power 70 kVA
Max Frequency 128 Hz

Auxiliary Rectifier
Device Name: A117
Siemens P/N: A1 110 231 129
Application:
The Auxiliary rectifier changes the input voltage to the Aux inverter from AC to DC before it reaches the
DC capacitors inside the Auxiliary Inverter. The Aux Rectifier is labeled A117 and located just inside the
far left front compartment.
Technical Data:
1200V
2 X 70A

Voltage Transducers
Device Name: U105, U106
Siemens P/N: A1 110 199 303
Application:
The voltage transducers monitor the DC-link and ground voltage. The value seen by the
transducers is fed back to SiBAS for proper control of the inverters and fault reaction. The transducer
labeled U105 monitors the DC-Link voltage at the input to K104. U105 is located on a panel above the
contactor in the right rear compartment. The transducer labeled U106 monitors the ground voltage. U106
is also located on the panel above the contactors in the right rear compartment. The values seen by
these transducers are constantly sent to SiBAS. If the ratio of the value seen at U106 to the value seen at
U105 is not correct then a ground fault is reported.
Technical Data:
4200V

Ground voltage monitoring resistors:
Device Name: R118 (30k Ohms)
R119 (90k Ohms)
Siemens P/N: A1-110-201-434 (30K, R118)
A1-110-201-435 (90K, R119)
Application:
The ground voltage monitoring resistors are used to establish the proper ratio of the DC-link
voltage seen by U106 in reference to the frame. The resistor labeled R118 is mounted on the panel
above the contactors in the right rear compartment. The resistor labeled R119 is also located on the
panel above the contactors in the right rear compartment.
Technical Data:
R118:
30 K Ohms
300W
R119:
90K Ohms
300W

Ground Tie Capacitor
Device Name: C131
Siemens P/N: 614685
Application:
The ground tie capacitor is used as a small filtering portion of the ground fault circuit. The
capacitor is labeled C131 and located on the panel above the contactors in the right rear compartment.
Technical Data:
0.22uF
2500V
Complete DC-link / Ground monitoring Panel
R118 R119
U106
U105
C131

Precharge resistor
Device Name: R143
Siemens P/N: A1-110-199-300
Application:
This precharge resistor is used to protect the Auxiliary inverter capacitors. The resistor is Labeled R143 and
located in the bottom of the right rear compartment (below K104).
Technical Data:
5 Ohm
300 W

Protocol Switch (Serial Interface Controller)
Device Name: A860
Siemens P/N: A20 360 702 900
EPROM on top board
P1
U1, U2, U3, U4
P3 On bottom board
Application:
The protocol switch, also called serial interface controller is used to change the format of the data coming from
Sibas card G063. The data transmitted from G063 is in RS232 format and the serial interface controller is needed to
convert this RS232 data to RS485 format.
The final device is a combination of various parts and a pre-programmed EPROM. These parts are assembled
during production and make up the final shipped product.
The production steps are included below for reference:
1). To enable the RS485 ports you must remove the LT1180 ICs from sockets U1 and U2 and install the 75175 in
U3 and 75174 in socket U4 (the nose of the ICs must look to the ports P3, P4).
2). Pull out the blank EPROM (no label) from the socket U6 and put the EPROM with the Part number A1 110 201
491 in this socket. The nose of the EPROM facing the nose of the socket with 4 pins on the side of the nose
unused.
3). Change the jumper J5 (Size of the EPROM) from 32k to 64k+
4). Check the jumper J6 (Pins in EPROM), must be on 28pin
Technical Data:
24VDC, 100mA

Discharge resistors
Device Name: R111, R112
Application:
The discharge resistors are used to discharge the high voltage in the DC Link capacitors if the other methods of
discharging do not operate. The resistor labeled R111 is located in the left rear compartment. The resistor labeled
R112 is located in the middle rear compartment. These resistors are wired in series with each other but in parallel
directly across the DC link. Therefore power is not longer coming into K104 the capacitive voltage begins to lower. If
the discharge resistors are correctly connected maximum bus voltage will be zero in approximately five minutes.
However, the Bus voltage should always be checked before work begins in the cabinet!!
Technical Data:
1.5 K Ohms (6 x 250 Ohms)

Rear view of the cabinet with the door removed.

Main Blower (120hz)
Siemens P/N: See OEM
Application:
The main blowers mounts under the rear portion of the control cabinet. It cools the GTO modules by drawing air
from the front intakes across the heat sinks of all the modules. This air then passes through the blower and is forced
into the alternator/rectifier and wheel motors. The speed of the AC blower motor is controlled by the Auxiliary
inverter. The proper V/Hz are outputted based on a set point from the Sibas control computer.
Technical Data:
12000 cfm

Main Blower (60hz)
Siemens P/N: See OEM
3-BOLTED
LIFTING LUGS
LIFT
HERE
TYP
INLET
ACCESS DOOR FAN

L
C BOTH SIDES
FAN D
HANDLING
LUG
HQ1
HQ1
HQ1
445 L25
400 L25
L
C
SIEMENS PART NO: A1210199509
Application:
The main blower mounts under the rear portion of the control cabinet. It cools the GTO
modules by drawing air from the front intakes across the heat sinks of all the modules. This air
then passes through the blower and is forced into the alternator/rectifier and wheel motors. The
speed of the AC blower motor is controlled by the Auxiliary inverter. The proper V/Hz are
outputted based on a set point from the Sibas control computer.
Technical Data:
12000 cfm

Main Rectifier
Siemens P/N: A1 210 231 125
Application:
The main rectifier converts the AC voltage coming out of the main alternator winding into DC
voltage. It is located in the enclosure on top of the alternator.
Technical Data:
Diode rating :
4400V

Alternator
Siemens P/N: see Truck OEM
Rectifier enclosure
AC Alternator
Application:
The alternator allows for the production of electricity from mechanical power. The alternator is a
AC generator using the interaction of magnetic fields to produce voltage when coupled to a rotating
engine. See the section in the alternator section of the manual for further information.
On the rotating shaft of the alternator there is a rectifier assembly consisting of 3 black diodes and
3 red diodes, the color indicates which end is the cathode and anode.
Siemens part numbers= Red diode: A1 104 080 010, Black diode: A1 104 080 009
Technical data:
Alternator Max power = 2800Hp
Rotating diodes (Red & Black) = 1200V, 125A

Speed Sensors
Device Name: E101, E201, E301
Siemens P/N: A1 110 201 331
Application:
The speed sensor monitors speed and direction and sends this information back to SiBAS in the
form of pulses. The speed sensor labeled E101 monitors motor A and is located on motor A. The speed
sensor labeled E201 monitors motor A and is located on motor B. The speed sensor labeled E301
monitors the alternator and is located end bell area of the alternator.
Each speed sensor has two channels which allows for the determination of direction. For the
sensors on the wheel motors both channels are used. For the speed sensor on the alternator only one
channel is used. The motors run in a closed loop control scheme so the speed sensor feedback must be
the correct direction and with in a defined limit otherwise the motors will not rotate properly.
Technical Data:
Speed Sensor Type: Channel 1 Channel 2 15VDC GND Shield
KRAUSS-MATTEI = KMG-24 Blue White Orange Green Black
LEONARD BAUER = GEL247 Yellow White Red Blue
Proper gap between the sensor tip and wheel:

[KMG-24= 0.7mm +/- 0.2mm] [GEL 247= 0.4mm +/- 0.1mm]

Wheel Motor
Siemens P/N: see Truck OEM
Application:
Each truck contains two Siemens wheel motors mounted at the rear of the truck. The motor
labeled Motor A is located on the grid box side of the truck. The motor labeled Motor B is located on the
driver side of the truck. Each motor drives a gear box which the tires mount to. For control of the motors a
speed sensor is mounted to each. The speed and direction is constantly sent to SiBAS and monitored.
See motor manual section for more information including maintenance procedure/intervals.

Technical Data, 1250kW motor :
Four-pole, three-phase, asynchronous motor for transverse mounting in the vehicle.
Mechanical motor data

Force ventilation: .......................................................................... 1.3 (1.5) m3/s
Diameter of the rotor: ............................................................................. 495 mm
Diameter of the stator bore: ................................................................... 500 mm
Length of the core assembly: ................................................................. 450 mm
Air gap: ................................................................................................... 2.5 mm
Electrical motor data
Continuous point
Rated voltage: ......................................................................................... 1800 V
Rated current: ........................................................................................... 475 A
Rated power: ........................................................................................ 1250 kW
Rated speed: ........................................................................................ 1480 rpm
Displacement factor cos phi:........................................................................... 0.90
Rated frequency: ........................................................................................ 50 Hz
Temperature class: ....................................................................................... 200
Rated insulation voltage: ........................................................................ 2300 V
Maximum voltage: ................................................................................... 2183 V
Maximum current: ................................................................................... 1000 A
Maximum speed: .................................................................................. 3465 rpm
Circuit: ............................................................................................................... Y
Supply cables: ................................................................ 1x 240 mm2 per phase
Standards: ............................................................................. VDE 0535 - 03 / 83
Motor weights
Motor complete: ..................................................................................... 3400 kg
Rotor complete (balancing unit): ............................................................ 1100 kg
Stator complete (core assembly with winding and frame): .................... 2012 kg
Bearing (D-end): . Deep-groove ball bearing DIN 625 - 6236 M / C5H (insulated)
Bearing (N-end): Cylindrical roller bearing DIN 43283 - NU 232-ECM / C4H012 (insulated)
Rolling-contact bearing grease: Shell Retinax LX (corresponding to "H3.5" Appendix A1)
Initial/new grease quantity
Bearing (D-end): ..................................................................................... 1300 g
Bearing (N-end): ..................................................................................... 1150 g
Regreasing quantity:
Bearing (D-end): .................................................................................... 120 g
Bearing (N-end): ................................................................................... . 120 g

Technical Data, 1500kW motor :
Four-pole, three-phase, asynchronous motor for transverse mounting in the vehicle.
Mechanical motor data

Force ventilation: ................................................................................ 1.3 (1.5) m3/s
Diameter of the rotor: .................................................................................. 495 mm
Diameter of the stator bore: ........................................................................ 500 mm
Length of the core assembly: ...................................................................... 450 mm
Air gap: ........................................................................................................ 2.5 mm
Electrical motor data
Continuous point
Rated voltage: .............................................................................................. 1760 V
Rated current: ................................................................................................ 575 A
Rated power: ............................................................................................. 1500 kW
Rated speed: ............................................................................................. 1480 rpm
Displacement factor cos phi:.............................................................................. 0.91
Rated frequency: ............................................................................................. 50 Hz
Temperature class: ............................................................................................ 200
Rated insulation voltage: ............................................................................. 2300 V
Maximum voltage: ........................................................................................ 2183 V
Maximum current: ........................................................................................ 1200 A
Maximum speed: ....................................................................................... 3465 rpm
Circuit: .................................................................................................................... Y
Supply cables: ..................................................................... 1x 240 mm2 per phase
Standards: .................................................................................. VDE 0535 - 03 / 83
Motor weights
Motor complete: ........................................................................................... 3800 kg
Rotor complete (balancing unit): .................................................................. 1110 kg
Stator complete (core assembly with winding and frame): .......................... 2175 kg
Bearing
Bearing (D-end): . Deep-groove ball bearing DIN 625 - 6236 M / C5H (insulated)
Bearing (N-end): Cylindrical roller bearing DIN 43283 - NU 232-ECM / C (insulated)
Rolling-contact bearing grease: ............................ Shell Retinax LX or SKF GLWA2
...................................................................... (corresponding to "H3.5" Appendix A1)
Initial/new grease quantity
Bearing (D-end): .......................................................................................... 1300 g
Bearing (N-end): .......................................................................................... 1050 g
Regreasing quantity:
Bearing (D-end): ......................................................................................... 120 g
Bearing (N-end): ........................................................................................ . 120 g

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Gate Unit (GU):

Device Names: A101-A3, A102-A3, A103-A3, A204-A3 [Inverter A Section]

A201-A3, A202-A3, A203-A2, A204-A3 [Inverter B Section]

Siemens P/N: Generation 2 (black in color): 429 901 9006.50

Generation 4 (silver in color): 429 910 9031.00

Gate Unit modules, Generation 2 (black), Generation 4 (silver)

Each Gate Unit consists of:

Copyright Siemens Energy & Automation, Inc. All Rights Reserved

The LEDs located on the bottom mean:

Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.

Grounding bolt E-prom plug

Signal LEM connector

Copyright Siemens Energy & Automation, Inc. All Rights Reserved

Supply: Rated voltage: 140VDC (From Gate Unit Power Supply)

Current consumption during operation(one GU):

Ripple: Iripple = 0.5 A (aver. peak)

Triggering: See Circuit Diagram GTO A/B – Inverter control Signals

Storage time channel 1 or 2 exceeded:

Simple check by LEDs:

Green LED: ON - negative G - K voltage available, G - K circuit is not short circuit.

Copyright Siemens Energy & Automation, Inc. All Rights Reserved

For Generation 2 Gate units on Chopper module: 429 821 9100.00

For Generation 4 Gate units on Phase module: 429 800 9001.07

For Generation 4 Gate units on Chopper module: 429 800 9001.03

Copyright Siemens Energy & Automation, Inc. All Rights Reserved

Device Names: V101

Siemens P/N: A20 360 7032.00

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Device Names: A113

Siemens P/N: 359 554

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Device Names: A112

Siemens P/N: 422 903 9022.20

Thyristor Plug X8:

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Device Names: T103

Siemens P/N: 373 431

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Thyristor Control Card

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Device Names: K191

Siemens P/N: 14-193-110-521

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Device Names: K181

Siemens P/N: 3TF2010- 0BB4

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Device Names: U171

Siemens P/N: A1 110 199 441

Pin 1 : Supply voltage +12….15V

Diode V71 : 35V, 1A

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Device Names: C101, C102, C103, C104, C105, C106

Siemens P/N: 638619 [1100uF version on systems with 6 total capacitors]

A1110 201 382 [2200uF version on systems with 3 total capacitors]

Copyright Siemens Energy & Automation, Inc. All Rights Reserved

Siemens P/N: 279 729

PT100 Temperature Probe

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