Min 184 Rev. 6

Operation and Maintenance Manual
SINGLE PHASE TO
THREE PHASE
STATIC CONVERTER
As Per
RDSO Specification No.ELRS/Spec/SI/0018
(Rev.1.0) March, 2006
Amendment No: 1
TYPE MIN184
IM - 41 rev 6 MEDHA SERVO DRIVES PVT. LTD.

Information in this document is subject to change without notice.
Copyright © 2022 Medha Servo Drives Pvt. Ltd. All rights reserved.
This document contains confidential, proprietary information of

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Medha logo is registered of Medha Servo Drives Pvt. Ltd. Any other
trademarks are the property of their respective owners.
Document No: IM - 41 rev 6

Released: April, 2022
Table of Contents
Chapter 1
Safety Messages 7
Chapter 2
System description 9
General Description 9
Mechanical Arrangement 9
Technical Specifications 10
System Specifications 11
Terminologies Used 12
Load And Load Pattern 12
Chapter 3
Block diagram 15
Block 1 – Input Section 16
Block 2 – Rectifier Assembly 16
Block 3 – LC Filter and Brake Chopper 17
Block 4 – Inverter Assembly 18
Block 5 – Output Filtering and C.T’s 19
Block 6 – 3 Phase Output 19
Block 7 – Step down Transformer 20
Block 8 – Battery Charger Assembly 20
Block 9 – Battery load 20
Block 9 – Battery Load 20
Chapter 4
Main cards in Converter Section, Battery Charger
21
Section & Description
Card Level Description of MIN184 21
Transducer Card 22
Display Card with VFD 22
Thyristor Angle Firing Control Card 23
Power Supply Card 23
Main Control Card 23
Analog Card 23
Gate Drive Card 23
PWM card 24
Capacitor High Voltage Card 24
Brake Chopper Card 24
Charger MC Card 24
Charger CC Card 24
Reverse Polarity LED Card 24
Volt Free Contactor Card (VFC Card) 24
Analog Current Sensor Card 25
Chapter 5
Details of Main Components 27
Front View & Rear View 28
H - Sectional View 29
Rectifier Section 29
Connection Terminal Section 30
Inverter Section 30
Blower Transformer Section 31
Display on Front Panel 31
Table of Contents
Chapter 6
Types of faults and protections 33
Internal Faults 33
External Faults 35
Chapter 7
Commissioning 37
Handling 37
Installation 37
Earthing 37
Connections 37
Operating the Converter 38
Chapter 8
Application and Data Analysis Software 41
RS232 Interfacing 41
Cable Connection 41
Opening Application 42
Chapter 9
Maintenance 49
Maintenance Precautions 49
Routine Maintenance 49
List of Recommended Spares 51
User Interface to the System 54
Chapter 10
Troubleshooting Procedure 57
Trouble Shooting Procedure 57
Feedback Form 70
ANNEXURE 1 :
Electrical Schematic for 180kVA Static Converter Part-1
ANNEXURE 2 :
Electrical Schematic for 180kVA Static Converter Part-2
ANNEXURE 3 :
Outline and Mounting Details 180kVA Inverter - MIN184KVA
ANNEXURE 4 :
Static Converter Frame Stage 7 - 184kVA
IMPORTANT
The procedures in this manual have been compiled on the

assumption that personnel following them will have
received adequate technical technical training. Such
persons are therefore deemed to be competent to act at all
times with due regard to the safety of themselves, the
equipment and others working on it, and employ good
engineering practices.
This equipment is not to be used in the

residential, commercial and light industrial
environment.
WARNING !
HIGH LEAKAGE CURRENT
Earth Connection essential
Before connecting supply.
DANGER
High Voltage Working area.
Equipment contains hazardous voltages and
Controls, hazardous rotating mechanical parts(fans)
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Chapter 1
SAFETY MESSAGES
For the best results with the MIN184 converter, carefully read this manual
and all of the warning labels attached to the converter before installing and
operating it and follow the instructions exactly. Keep this manual handy for
quick reference.
DEFINITIONS AND SYMBOLS :

A safety instruction (message) includes a hazard alert symbol and a signal
word, WARNING or CAUTION. Each signal word has the following meaning:
HIGH VOLTAGE:
This symbol indicates high voltage. It calls your attention to items or
operations that could be dangerous to you and other persons operation on
this equipment. Read the message and follow the instructions carefully.
This symbol is the “Safety Alert Symbol.” It occurs with either of the two signal
words : CAUTION or WARNING, as described below.
WARNING:
Indicates a potentially hazardous situation which, if not avoided, can result in
serious injury or death.
CAUTION:
Indicates a potentially hazardous situation which,if not avoided, can result in
minor to moderate injury, or serious damage to the product. The situation
described in the CAUTION, if not avoided, may lead to serious results.
Important safety measures are described in CAUTION (as well as
WARNING), so be sure to observe them.
NOTE: Notes indicate an area or subject of special merit, emphasizing either

the product’s capabilities or common errors in operation or maintenance.
TIP: Tips give a special instruction that can save time or provide other
benefits while installing or using the product. The tip calls attention to an idea
that may not be obvious to first-time users of the product.
HAZARDOUS HIGH VOLTAGE :
HIGH VOLTAGE: Rectifier and Inverter assemblies are connected to

hazardous line voltages. When servicing these assemblies, there may be
exposed components with housings or protrusions at or above line potential.
Extreme care should be taken to protect against shock. Stand on an
insulating pad and make it a habit to use only one hand when checking
components. Always work with another person in case an emergency occurs.
Chapter 1 - Safety Messages Medha Servo Drives Pvt. Ltd.
Disconnect power before checking controllers or performing maintenance. Be

sure that the equipment is properly grounded.
GENERAL PRECAUTIONS - READ THESE FIRST
WARNING: This equipment should be installed, adjusted, and serviced by

qualified electrical maintenance personnel familiar with the construction and
operation of the equipment and the hazards involved. Failure to observe this
precaution may result in bodily injury.
HIGH VOLTAGE: Hazard of electrical shock. Disconnect incoming power

before working on this control.
WARNING: Wait at least five (5) minutes after turning off the input power
supply before performing maintenance or an inspection. Otherwise, there is
a danger of electric shock due to residual power.
CAUTION: These instructions should be read and clearly understood before

working on MIN184 type Converters.
WARNING: This equipment has high leakage current and must be

permanently (fixed) hard-wired to earth via two independent cables.
CAUTION: Hazardous voltages for input (main) connections, must be

inaccessible up to the final installation.
CAUTION: Connection to field wiring terminals must be reliably fixed having

two independent means of mechanical support, using a termination with
cable clamp.
HIGH VOLTAGE: Be careful not to touch the wiring or connector terminals

while working with the inverters and taking measurements. Be sure to follow
all the above instructions while taking measurements in an insulating housing.
8 IM - 41 rev 6
Chapter 2
SYSTEM DESCRIPTION
2.1 General Description

MIN184 is a single phase to three phase static converter, which takes a
nominal 830 V AC supply from the locomotive main transformer auxiliary
winding. It employs a phase controlled thyristor rectifier to drive a stable DC
link voltage, which is unaffected by input supply voltage variations. The DC
link voltage is used as input to 3-phase Inverter with IGBTs to synthesize a
set of three phase sine weighted PWM output waveforms, with a fundamental
frequency of 50 Hz at 415 V line to line. The output voltage is filtered to
reduce the voltage and current harmonics. The output of inverter is
connected to all the distributed loads and is switched as per clause 2.3.1 of
the specification.
The battery charger is powered from the auxiliary winding of the main
transformer directly, followed by a step down transformer and IGBT based
SMPS battery charger to ensure better regulation, protection and very less
ripple in battery charging current.
2.2 Mechanical Arrangement

The 180 kVA converter is built into a fabricated CRCA sheet enclosure, which
is mounted inside the locomotive. This cubicle has two doors for accessing
and it is a “H – type” construction.
Thyristors and diodes in rectifier section and IGBT modules in inverter section
are mounted on heat sinks. These heat sinks are used to cool the power
semiconductor devices and to dissipate the heat to outside of the cubicle. A
duct encloses the fins of the heat sink with four blower fans at the bottom to
dissipate the heat and to achieve high reliability, by keeping semiconductor
device junction temperatures well below their maximum safe levels.
A display is mounted on the front panel, with alpha numeric VFD panel and
an array of LEDs to provide visual indication of the status of the unit and as
an aid for fault diagnosis.
The unit is mounted in the locomotive via eight fixing points on the base at the
rear and front corners. It is important to check that the unit is fixed at all the
eight points.
Cable is passed through a gland plate at the bottom side of the base, located
at the rear side of the unit for ease of access. All connections to the train
electrical system are located in this area.
Chapter 2 - System Description Medha Servo Drives Pvt. Ltd.
2.3 Technical Specifications

2.3.1 Reference to various Specifications
1. RDSO Specification ELRS/SPEC/SI/0018 REV.”1” DATED MARCH 2006
& Amendment No.1
2. IEC61287-1(1995) : Power Converters installed on board rolling stock :
Characteristics and Test methods
3. RDSO Specification no. ELRS/SPEC/SI/0015 for reliability of electronics
used in rolling stock applications
2.3.2 INPUT Specifications

Input to the Converter is supplied from the auxiliary winding of the Loco
Transformer.
The details of the transformer are mentioned in Table 3.1(a) and (b).
Details HETT3900 5400KVA

4170kVA 5670kVA
Primary 185.3 A 252 A
22.5kV 22.5kV
3900kVA 5400kVA
Secondary (Traction Winding) 2 x 2250 A 2 x 2700 A
865V 1000V
Auxiliary windings (A82 windings
270kVA 760V 270kVA 760V
of 380 V or 415 V are connected
or 830V or 830V
in series)
Table 3.1(a)
Details HETT3900 5400KVA
Percentage Impedance
1. Main Circuit 12% 12%
2. Auxiliary Circuit 4% 3% to 5%
Magnetizing Current at 22.5 kV 2.25A 2.5A
Table 3.1(b)
Other input parameters are mentioned in Table 3.2.
Nominal Catenary voltage : 22.5kV
Corresponding transformer auxiliary winding voltage : 760V or 830V
Input Voltage Catenary voltage can vary from 19kV to 31kV under normal conditions
Under abnormal conditions, this voltage may dip down up to 16.5kV for
about 30 minutes.
Input Frequency 50 Hz ± 6%
> 0.8 (at Full-load) for catenary voltages between 19kV and 25kV
Input Power Factor > 0.55 (at Full-load) for catenary voltage above 27.5 kV
Table 3.2
10 IM- 41 rev 6
Medha Servo Drives Pvt. Ltd. MIN184 - Operation & Maintenance Manual
2.3.3 DC Voltage supply for Control Electronics

Control Electronics of the Converter is supplied by 110 V DC locomotive
battery. The nominal battery voltage is 110 V and it may vary from 77 V to
137 V. The locomotive battery is always connected to the battery charger
output. In case of battery fault or battery related problems, the locomotive
battery is isolated from the other circuitry. In this case, the battery charger
continues to supply all the locomotive DC loads and also the control
electronics of the converter. The battery supply is always available while the
converter starts up.
2.3.4 Climatic and Environmental conditions :

Static converter is fitted in locomotive machine room where temperature is,
a) Maximum Temperature Stabled Locomotive under SUN 70°C
On board working loco under SUN 55°C
b) Minimum Temperature 0°C
c) Average Temperature 47°C
Humidity : Up to 100% during rainy season
Altitude : Up to 1200 m above mean sea level
Rainfall : Very heavy in certain areas.
Atmosphere during hot weather :
Extremely dusty and desert terrain in certain areas. The dust concentration
in air may reach a high value of 1.6 mg per cubic meter.
2.4 System Specification
Parameter Design Value

Nominal Input Voltage 760 / 830 V AC at 22.5 kV
Operating Temperature Range -5°C to +55°C
Operating Humidity 98% non condensing
Audible Noise < 75 db
Efficiency (at nominal input) > 92% full load
Output Voltage LINE – LINE 415 V
Power Rating – Continuous 180kVA
Power Rating – Peak 400kVA for 5 seconds
Load Power Factor 0.8
Output Frequency 50 Hz
Output Frequency Tolerance ± 3%
Voltage Regulation (Load) ± 5%
VOTAGE THD <10%
CURRENT THD <3%
Weight < 1500Kg
Table 3.3(a)
IM- 41 rev 6 11
Parameter Design Value

DC 110V OUTPUT (Battery Charger)
Voltage 110V DC ± 5%
20A The Load Contains of 75AH battery & 6A
Nominal Current Inductive Load of locomotive control circuit,
headlights & flasher lights
Over Current Protection (with
25A
Current limiting feature)
Current ripple < 5 % at rated load
MECHANICAL DIMENSIONS
Width in mm 680
Depth in mm 1740
Height in mm 1650
Table 3.3(b)
2.5 Terminologies Used
MVSI Motor for silicon Rectifier Colling Blower
MVSL Motor for smoothening reactor cooling blower
MPH Motor for Transformer oil pump
MCP Motor for main Compressor
MVRH Motor for main Transformer cooling blower
MVMT Motor for Traction motor cooling blower
MVRF DBR Blower
Table 3.4
2.6 LOAD & LOAD Pattern
There are two different load patterns. One for the normal mode and another
for rheostatic braking mode. The details are given in tables 3.5(a) and 3.5(b).
Category Type of Load Rating Remarks

MVSI 1 2. 2kW Always connected
MVSL 1 2. 2kW Always connected
Load Pattern 1 MPH 3. 2kW Always connected
(Normal Mode) MVRH 22kW Always connected
MVMT 1 26kW Always connected
MCP 1 20.5kW Direct On Line starting
TOTAL 127kW
Table 3.5(a)
Ÿ Three MCPs with the ratings given in table 3.5(b) are used in certain
locomotives.
Starting
Name of the Rated
Rating current in
Sl.No. Code Auxiliary Current
(kW) Amps
Machine (at 415V)
(at 415V)
Motor for main
1 MCP 1, 2 &3 3 x 10.5kW 3 x 23.1 A 154.85
compressors
Table 3.5(b)
12 IM- 41 rev 6
Ÿ Once the Converter reaches up to a steady state voltage and frequency, the
Converter ON potential free contact is activated (LSCHBA on loco driver's
desk). MCP 1 and MCP 2, which are DOL (Direct On Line) can now be
switched ON or OFF, depending upon the compressed air level requirements
for the locomotive brake circuit.
Ÿ Time delay of 5 seconds is provided between switch ON of MCP 1 & MCP 2.
Ÿ When the locomotive stops for more than 20 minutes, MVRH, MVMT 1 and
MVMT 2 are switched OFF to save energy. This is done by first switching
OFF the Converter and then restarting it after reconfiguring the load
connections through the load contactors.
Category Type of Load Rating Remarks

Load Pattern 2 MPH 3. 2kW Always connected
(Rheostatic Braking Mode) MVRF 33kW Always connected
TOTAL 138kW
Table 3.5(c)
Ÿ When the locomotive goes into rheostatic braking mode, the converter is first
switched OFF, MVRH is disconnected, MVRF is connected and the Con-
verter is restarted again (all other loads remain connected as before).
Ÿ Once the Converter output reaches to the steady state voltage and
frequency, the Converter ON potential free contact is activated (LSCHBA on
loco driver's desk). MCP 1 and MCP 2 can now be switched ON or OFF, DOL
(Direct On Line), Depending upon the compressed air level requirements for
the locomotive brake circuit.
Ÿ Time delay of 5 seconds is provided between switch ON of MCP 1 & MCP 2.
IM- 41 rev 6 13
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Chapter 3
BLOCK DIAGRAM
830 V / 760 V
Single Phase 830 V AC
50 Hz at
1 7 7
Step Down
Input Section
Transformer
2 8
Battery
Rectifier
Charger
Assembly
Assembly
3
LC Filter &
Brake
Chopper 9 10
Lights Load &
4 Battery Baby
Load Compressor
Inverter
Assembly
5
Output Sine
Filter and
CT's
6
3 Phase
Output
415V(L-L)50Hz Fig 3.1
Chapter 3 - Block Diagram Medha Servo Drives Pvt. Ltd.
3.1 Block 1 – Input Section

Input section contains the input protection circuits for the converter and a
1200/(50 - 0 -50 ) & (0 -12) step down transformer.
F1
680V
680V
R1 R2
MOV1
MOV3
15 mf/1700 V
C1
680V
680V
C2
C3
MOV2
MOV4
F2 T1 T2
R26 1200V R27
0V
T3
12V 50V
0V
12V
50V
0V
Fig 3.2
Input Protection circuits
(a) Input Fuses
(b) Snubber
(c) Metal Oxide Varistors
The input terminals are directly wired to 650 A fast blow semiconductor
fuses. These fuses disconnect the converter in the event of input side short
circuit (after the fuses) or over current. Two micro switches are mounted on
both the fuses. With these switches, the status of fuses are continuously
monitored by the main control card.
While locomotive is running, there is a chance of getting voltage surges on
the transformer secondary i.e., on input to 180 kVA unit due to pantograph
bouncing. Snubber circuit and metal oxide varistors protect the converter
from the external voltage surges.
Current transformers are used in the input section to measure the input
current.
Step down input voltage is used for zero crossing detection, which is
internally used in the thyristor angle firing control card for measuring and
displaying the input voltage.
3.2 Block 2 – Rectifier Assembly

Rectifier Assembly section is the main power stage for the input rectifier and
comprises of a single phase half - controlled thyristor bridge (Semi
Converter).
16 IM- 41 rev 6
The half controlled thyristor bridge operates at an improved power factor with
almost equally distributed heat loss in thyristors and diodes. Freewheeling
action in semi converters ensures the continuous load current and improved
power factor.
R R
TH1 D1
C C
DC Link
INPUT
R R
TH2 D2
C C
TAFC Card
Fig 3.3
Thyristor and diode modules are mounted on a forced cooled aluminum heat
sink. Each thyristor and diode has their own suppression network for transient
voltage sharing. All of these components are mounted on the heat sink to
make complete rectifier sub assembly. Heat sink is galvanically isolated from
high voltage.
Fins of the heat sinks are external to the rectifier cubicle and are cooled by
two blowers. Over temperature of the rectifier heat sink is sensed by main
controller through a thermal switch with over temperature limit at 90°C. The
semiconductor side of the heat sink assembly is protected from the
locomotive environment with proper shielding.
Once the input voltage is within allowable range and command is ON,
thyristor trigger pulses are issued by thyristor angle firing control card through
the thyristor drive circuit. These thyristor trigger pulses are controlled
according to input voltage variation and the output load variation in order to
maintain invariable DC Link.
3.3 Block 3 – LC Filter and Brake Chopper

3.3.1 LC Filter
LC filter is used to filter the 100 Hz AC component, which appears at the
output of the rectifier, to produce a stable and low impedance voltage source
to the inverter. The firing of the rectifier thyristor is controlled to generate a
constant 620 V DC at the output of the filter, which is independent of load and
supply voltage variations.
The output of single-phase half – controlled thyristor bridge is very high in
voltage ripple. It is therefore essential to have substantial filtering on the
output to filter out the average DC component. The filter comprises an iron
cored inductor, polypropylene and electrolytic capacitors. The inductor and
IM- 41 rev 6 17
L2
5.5mH / 600A
R
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T C C9 C10 C29 C
1 E
I T T
R
F I I
6 T
I O O
7 E
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R
R
BRAKE CHOPPER
CARD
Fig 3.4
polypropylene capacitors are mounted in the mid section of the cubicle. The
electrolytic capacitors bank is mounted in the inverter cubicle, since they
need to be physically close to the inverter bridge for safe operation of the
IGBT switches. The inductor and polypropylene capacitors are mounted in an
IP21 enclosure to allow the unnecessary heat from this component to
disperse to ambient without heating up the rectifier cubicle.
The capacitor bank is made up of 450 V electrolytic capacitors with two
devices connected in series to give a voltage rating of 900 V for the DC link.
3.3.2 Brake Chopper

Brake chopper part of the circuit operates only when the DC link voltage is
higher than the threshold limit (680 V). At this condition, brake chopper is
made ON by the brake chopper circuit, sensing the DC link over voltage and
protects the DC link capacitors and inverter section IGBTs from over voltage.
Brake chopper function stops once DC link voltage is back to the normal
working range.
3.4 Block 4 – Inverter Assembly

Inverter assembly uses IGBTs to synthesize a set of three-phase PWM
output waveforms by chopping up the 620 V DC link. The inverter
configuration is such that, it can be placed easily on the heat sink with least
lead inductance.
Heat sink is cooled by forced air cooling with a pair of blowers. Fins of the
heat sink are mounted external to the inverter cubicle.
Heat sink is sensed by main controller through a thermal switch with over
temperature limit at 90°C. The assembly has low inductance laminar bus bar
assembly with part of the DC link capacitor being integral to the assembly,
thus providing a low source impedance for the safe switching of the IGBTs
and free wheel diodes. The IGBT gate drive is also mounted on the assembly
in order to minimize the gate lead length and to produce a complete self-
contained inverter arm.
Three identical assemblies are mounted on the rear wall of the inverter cubicle.
Fig 3.5 shows the simplified circuit diagram of the inverter (for clarity, each
arm of the bridge is shown as only one IGBT module).
18 IM- 41 rev 6
T1 D1 T3 D3 T5 D5
3 Phase IM
W Load
DC Link V
Vs C
Voltage U
T4 D4 T6 D6 T2 D2
Fig 3.5
The inverter IGBTs are switched at high frequency, giving a total harmonic
current distortion of less than 3% for an induction motor type load, whilst
optimizing semiconductor switching losses and overall efficiency. Each of the
semiconductor has a voltage rating of 1700 V and the parallel combination of
modules per phase has sufficient current rating and thermal capacity to cope
up with all of the specified combinations of direct on line starting currents.
3.5 Block 5 – Output Filtering and C.Ts

Output terminals of IGBT modules, after filtering are passed through current
transformer and then taken to the outgoing terminals of the inverter.
I C33 – C35 T4
S S
N O
E E
V U
C C39-C41 C
E T5 T
T T
R P
I I
T U
O O
E T6 T
N N
R
L3 C36 – C38
Fig 3.6
The inductors, in conjunction with output RFI capacitors, limit the rate of rise
of voltage at the output terminals during IGBTs switching. As stated in the
above paragraph, current transformers are fitted in each output phase, to
provide feedback signal for displaying all three-phase currents, for phase
current imbalance detection. Sensing of output current is also used in
maintaining adequate output voltage with various load conditions and to
ensure the protection against the output side faults.
3.6 Block 6 – 3 Phase Output

After filtering, 3-phase output is made available at the output section of the
unit. A step down transformer is connected between two lines of the output.
This transformer output is used to run the blowers (used for cooling the
Rectifier and Inverter heat sinks) and to run few loads in locomotive like cab
fans and heaters.
IM- 41 rev 6 19
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3 PHASE
OUTPUT Y 3 PHASE
after OUTPUT
FILTERING B
F9
440V
0V
T8
0V 110V
230V
0V
L4
C43 C42
BLOWER-1
2 1
TB7
F5
BAT CHAR MC
2 1
TB7
BLOWER-2
F6
2 1
TB7
BLOWER-3
F7
2 1
TB7
BLOWER-4
F8
Fig 3.7
3.7 Block 7 – Step down Transformer

The battery charger is fed from the auxiliary winding of the main transformer,
via a step down transformer to provide the most appropriate voltage level and
to provide galvanic isolation between the main power circuits and the battery.
3.8 Block 8 – Battery Charger Assembly

The secondary of the transformer is rectified, filtered and fed to the IGBT
based buck chopper to regulate the DC output voltage level of the locomotive
battery. An LC filter circuit at the output of the chopper smoothens the output
and eliminates the ripple.
3.9 Block 9 – Battery Load

Battery load is supplied from the battery charger. This load consists of 75 AH
battery.
3.10 Block 10 – Lights Load

Lights load consists of 6 A inductive load of locomotive control circuit, header
lights and flasher lights.
20 IM- 41 rev 6
Chapter 4
MAIN CARDS IN CONVERTER SECTION,

BATTERY CHARGER SECTION & DESCRIPTION
4.1 Card Level Description of MIN184
830V AC
INPUT
Step down Transformer & Batteries &
Battery Charger Load
Circuit
I/P Fuse
Traction
Snubber MOV Step Down Transducer
Traction
Motors
circuit VF Display RS 232
Transformer Card
Motors
Thyristor Angle
1f Traction
Firing Control MC Card
= Motors
Card 110V
Analog
Card
Traction
DC Link
PS3 PS2 PS1
LC Filter
Motors
Power Supply
Card
Brake Chopper
= Gate Drive PWM Card

3f Card
O/P Filtering Transducer

& C.T's Card
415 AC
OUTPUT
Chapter 4 - Main cards in Converter section, Medha Servo Drives Pvt. Ltd.
Battery Charger section &
Description
4.2 Transducer Card

Transducer card contains input, output, DC link, battery charger output,
battery control voltage, current feedback circuits, output voltages and
currents which are scaled and provided to the main control card for
displaying and taking action under faulty conditions. This module also
detects the fuse failure of the two main input fuses and over temperature of
rectifier heat sink. These circuits pass the status of the fuses and
temperature of heat sink to the micro control card.
The output of the inverter section are fed to the output terminals of the unit
after filtering. Filtered output feedback is sensed by transducer card sensing
circuit. This PCB contains isolated voltage transducers and current
transformers, to provide the control circuits with scaled and isolated
feedback signals, which represents the three output currents and three line
to line output voltages.
4.3 Display Card with VFD

Display card with VFD is mounted on the front cubicle behind a transparent
window, to provide the maintenance personnel with status of Inverter and
diagnostic data. It has a Vacuum Fluorescent Display (VFD), which displays
the status of the unit, the three output voltages and phase currents, input
voltage and input current, battery charger output voltage and current, battery
voltage and current.
In addition to these, display card also displays fault diagnostic data when two
status buttons are pressed simultaneously for few seconds.
Display card contains a RESET switch to reset buzzer that sounds under
faulty conditions.
Input voltage
LED Color By Default Internal fault External fault CHBA fault
fault for LED
SI OK Green ON OFF OFF ON OFF
Input Voltage
Red OFF OFF OFF OFF ON
in Range
Internal Fault Red OFF ON OFF ON OFF
External Fault Red OFF OFF ON OFF OFF
CHBA -OK Green ON ON OFF OFF OFF
Earth bypass Red OFF OFF OFF OFF OFF
Table 4.1
DISPLAY SW1
SW2
SI UNIT OK
INTERNAL FAULT EARTH BYPASS
EXTERNAL FAULT
INPUT VOLTAGE IN RANGE
CHBA O.K
RS232
ALARM RESET
22 IM- 41 rev 6
There are five LEDs, which indicate the status and fault conditions as given
below,
The display board receives data from the main control card and drives the
VFD display and LEDs.
SW1 and SW2 are used to check the values of input voltage
and input current, 3-Ph output voltages, 3-Ph currents, Battery
charger voltage, current and battery voltage.
RESET SW is used for BUZZER reset under faulty conditions only.
It is possible to connect a PC to the display card via an RS232 link, to retrieve

the fault data to view the system status.
4.4 Thyristor Angle Firing Control Card

The second output from the transformer (T3) is directly connected to the
Thyristor Angle Firing Card (TAFC), used for zero crossing detection and
generating firing pulses for thyristors. This card has voltage feedback from
the DC link, input current feedback and output current feedback. With these
feedbacks, TAFC card regulates the DC link voltage by varying firing angle of
the thyristor. Under all load conditions, DC link is maintained constant with
the THYRISTOR ANGLE FIRING card.
4.5 Power Supply Card

The batteries supply 110 V DC, which is connected to the 5 & 6 terminal of
the static converter via the CCINV fuse. With this, different isolated voltages
are generated as per the control electronics requirements. Each and every
power supply has input over voltage, input under voltage, reverse polarity and
output short circuit protections.
4.6 Main Control Card

Main control card is responsible for overall system control, status monitoring,
and fault diagnostics. When the input voltage to the system is within limits and
if system is found healthy, control card enables the angle firing card. It
monitors the data which is fed back from various cards (like TAFC card,
TDC_IF card, etc) for delivering information to the operating staff via the VFD
and LED displays mounted on the display card. It enforces the output current
limit of the inverter and checks for sustained short circuit operation.
4.7 Analog Card

Analog card detects the earth leakage current, battery voltage, DC link
current, brake chopper current and the heat sink temperature feedback
(charger and inverter) and passes them to the control system that compares
with a preset trip threshold. This circuit passes the resultant information to the
control card.
4.8 Gate Drive Card

Gate Drive Card receives the drive signals from PWM card and
communicates the same to IGBTs.
Since the individual IGBT emitters are referenced to different power circuit
voltages, it is necessary to provide galvanic isolation between the control
IM- 41 rev 6 23
Description
circuits and the drive signals. It is necessary to derive an isolated power

supply for each driver. This is done by specially designed SMPS.
The gate drivers generate appropriate gate drive signal to the IGBT in
response to the demand, received from the PWM card. The input is isolated
from the control circuit by an opto-coupler.
The drivers also monitor the Vce voltage of the IGBT, to ensure that the IGBT
is not carrying excess current. Once this Vce voltage exceeds a
predetermined threshold, the gate drive signal is terminated to prevent
excessive loss in the IGBT.
4.9 PWM Card

The PWM card is responsible for PWM waveform generation for the inverter
IGBTs at high frequency to synthesize a set of three phase, sine weighted
PWM waveforms with a fundamental frequency of 50 Hz. This card has
separate SMPS for ensuring isolation from the power circuit.
4.10 Capacitor High Voltage Card

Capacitor High Voltage card detects the voltage imbalance in the two series
connected DC Link capacitor banks (C11-C19 & C20-C28). Normally, DC link
voltage is equally distributed over these two capacitor banks. This card
monitors the two capacitor bank voltage levels. If any one of them exceeds
the other value with some preset voltage difference, then stops the angle
firing of the rectifier.
4.11 Brake Chopper Card

Brake chopper card operates only when the DC link voltage increases
beyond certain specified value. This card activates the brake chopper IGBT,
which in turn decreases the DC link voltage to the normal working voltage.
4.12 Charger MC card

Charger MC card monitors the healthiness of the heat sink cooling blowers
and charger section. This card sends the signal to the main controller as per
the events occurred regarding heat sink cooling blowers and charger section.
4.13 Charger CC card

Battery charger section is controlled by charger CC card. By monitoring the
battery charging voltage and current, this card controls the battery charger
section.
4.14 Reverse Polarity LED card

Reverse polarity LED card detects the reverse polarity connection of the
batteries. An LED indication is provided in the card to display the reverse
polarity connection.
4.15 VOLT Free Contactor Card (VFC Card)

VFC card inside 4 relays are using and details are mentioned below.
Q1:- CHBA OK health monitoring and this relay drives the QV61 relay in loco
Q2:- SI OK health monitoring and this relay drives the QCON relay in loco
Q3:- CONV. TRIP health monitoring and this relay drives the QSIT relay in
loco
24 IM- 41 rev 6
Q4:- BLSI signal (ON COMMAND FOR SIV) received from MPCS through
QVSM relay and Relay output signal given to MC card for BLSI enable.
4.16 Analog Current sensor Card (ACS card)

This card was using charger section. Three current sensors are using in this
card. This card is used to monitor the total charger current, loco control circuit
current and battery charging current.
IM- 41 rev 6 25
Description
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26 IM- 41 rev 6
Chapter 5
DETAILS OF MAIN COMPONENTS
Sl. No. COMPONENT MAKE TYPE RATING

1 Fuses Bussman / Ferraz A130URD73L10630 630Amps.
2 Thyristor ABB / WESTCODE 5STP12F4200 4200V/1150A
3 Diodes ABB / WESTCODE 5SDA14F5007 5000V/1410A
4 DC Link Capacitors VISHAY / DUCATI Polypropylene/ Electrolytic 12mF / 900V
5 Input filter capacitor EPCOS/API Polypropylene 15mF/ 1700V
6 IGBT Eupec / Semikron Single 600A / 1700V.
7 L2 Inductor Medha ---- 6mH / 600A
8 L3 Inductor Medha ---- 240uH / 300A
9 Transformer (T10) 1200 V/ 200V,
Medha ----
20A
10 Transformer (T8) 415 V / 230 V &
Medha ----
110 V
11 Angle firing card Medha MIN184_TAFC_PS NA
12 Break Chopper card Medha MIN184_BRK_CHOP NA
13 Inverter Gate Drive Medha MIN184_INV_GD NA
14 Inverter Power supply Medha MIN184_INVPS NA
15 Gate Drive child card Medha MIN184_GD_CHLD NA
16 PWM card Medha MIN184_PWM NA
Isolation Power
17 Medha MIN184_ISOPS NA
supply card
18 Display Power supply Medha MIN184_DSP_PS NA
19 Display card Medha MIN184_DSP NA
20 Transducer card Medha MIN184_TDCIF NA
21 Volt free contact Medha MIN184_VFC NA
22 Cap. High Voltage Medha MIN184_CAPHV NA
23 Power supply Medha MIN184_PS NA
24 Current Sensor card Medha MIN184_ACS NA
Batt. Char. Control NA
25 Medha MIN184_BAT_CHAR_CC
card
Batt. Char. Micro Medha MIN184_BAT_CHAR_MC NA
26
Controller card
27 Micro controller card Medha MIN184_MC NA
28 Reverse Polarity card Medha MIN184_REV_POL NA
29 Analog Card Medha MIN184_AN NA
30 Blower Terminal Card Medha MIN184_BL_TB NA
31 Blower Cap CARD Medha MIN184_BL_CAP NA
32 Transformer(T3) Medha ------------- 1200/50-0-50 &
0-12V.
Note : NA – Not Applicable

Chapter 5 - Details of Main Components Medha Servo Drives Pvt. Ltd.
5.1 Front View & Rear View
3 2
15 14
Front View Rear View

Fig 5.1
From Fig 5.1:
1. VF Display (Including LED, audible BUZZER indication )

2. Earth fault by pass switch
3. Power reset switch.
14. Blower – 3
15. Blower - 4
28 IM- 41 rev 6
5.2 H - Sectional View
6
7
12 8
13 5
11
Fig 5.2(a)
10
9
Fig 5.2(b)
From Fig 5.2(a) and (b) :
4. Input RC snubber Circuit – Resistors (R1, R2)

5. Input RC snubber Circuit – Capacitors (C1)
6. DC Link Capacitor (C9, C10)
7. Battery Charger Inductor (L5)
8. Battery Charger Transformer (T10)
9. Brake Chopper Resistors (R16 - R23)
10. DC Link Inductor (L2)
11. Output di/dt Inductor (L3)
12. Output dv/dt Capacitors (C33 - C41)
13. Blower - 1&2
5.3 Rectifier Section

From Fig 5.3 : 16 18
20
16. Thyristor – 1
17. Thyristor – 2
18. Diode - 1
19. Diode - 2
20. Snubber Circuits for Thyristors and Diodes
17 20 19
Fig 5.3
IM- 41 rev 6 29
5.4 Connection Terminal Section
21 21
22
26
24 23
25 25
Fig 5.4
From Fig 5.4 :
21. Input Fuses with Micro Switches
22. Input Connections
23. Output Connections
24. Reverse Polarity LED
25. Earth Leak Current sensors
26. SIV to Loco inter Connections
5.5 Inverter Section
28. GD CARD-1
28 29
29. GD CARD-2
30. GD CARD-3
30 31
31. GD CARD-4
32 33 32. GD CARD-5
33. GD CARD-6
34 34. DC LINK Capacitor Bank

(C11-C28)
Fig 5.5
30 IM- 41 rev 6
5.6 Blower (Heat Sink Cooling) Transformer Section
36
35
Fig 5.6
From Fig 5.6 :
35. Blower transformer sine filter inductor
36. Blower transformer
5.7 Display on Front Panel
37
38
Fig 5.7
As shown in Fig 5.7, Display unit is the user interface to the system.
37. Push Button – 1
38. Push Button – 2
Above mentioned buttons are used to scroll through various parameters such
as input voltage, input current, output voltages, output currents, charger
voltages, charger currents. By pressing these two push buttons at a time for
a while, displays the latest fault details.
Fault log data is downloaded from the main controller via RS232 connection.
Reset acknowledgment switch is used for the alarm (buzzer) reset.
In addition to these, textual display and LED indication show the status of the
converter.
IM- 41 rev 6 31
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32 IM- 41 rev 6
Chapter 6
TYPES OF FAULTS AND PROTECTIONS
According to the location of fault occurrence, faults are mainly categorized as,
● Internal faults
● External faults
These are useful in predicting the fault cause whether it is internal to the
converter system or outside of the converter system.
Depending on the fault severity, converter may trip at one time

occurrence of fault or may restart itself automatically for two times of
fault and the 3rd time, it shuts down permanently. Permanent shut
down is due to continuous occurrence of a fault.
Fault is displayed on the VF Display in text format relevant to the fault

event. In addition to the display, LED indication and buzzer (audible)
signal are also provided. To reset the buzzer, reset SW be used.
6.1 Internal Faults

6.1.1 Input Current Fault
Whenever the input current exceeds 385 A for a duration of 10 seconds, input
current high fault occurs. If it happens for two times, system restarts itself but
for the third time, it shuts down under latched. Once input current becomes
less than 300 A, fault gets cleared and system works normally.
For operating the unit under latched shutdown, user has to reset the control
power or use the switch on the front panel.
6.1.2 DC Link Voltage Fault

DC link voltage fault is categorized as DC link voltage high and
DC link voltage low
● If DC link voltage is more than 760 V for a duration of 100 msec with input
voltage at 830 V, then it is declared as DC link voltage high. For DC link
voltage high fault, system does not reset automatically. It resets only with
power interrupt or pressing the reset switch in the front panel.
● If DC link voltage is less than 500 V for a duration of 30 seconds with input
voltage at 830 V, then it is declared as DC link voltage low. Once DC link
voltage becomes greater than 550 V, fault gets cleared. But in DC link
voltage low fault condition, the system gets reset for two times and latch
at third time.
6.1.3 Rectifier Fault

If DC link voltage is less than 100 V for a duration of ten seconds with input
voltage at 830 V, then the fault is declared as rectifier fault. System gets
restarted for two times when fault occurs continuously and for the third time
its a latched shutdown.
Chapter 6 - Types of Faults Medha Servo Drives Pvt. Ltd.
and Protections
6.1.4 DC Link Current High Fault

If DC link current is greater than 600 A for a duration of two seconds, system
is declared as DC link current high fault. In this fault condition, the system
does not reset automatically. It gets reset with control supply interruption only
or by pressing the reset switch in the front panel. This fault is declared as
internal fault.
6.1.5 Output Voltage Fault

Output voltage fault is categorized as output voltage high and output voltage
low
● Whenever the output voltage is more than 455 V for a duration of
3 seconds, it is declared as output voltage high fault.
● If the output voltage is less than 350 V for a duration of 32 seconds, it is
declared as output voltage low fault.
In both the cases, system shuts down on declaration of fault. If the output
voltage recovery is less than 455 V and greater than 370 V, then fault gets
cleared. System restarts itself for two times and for the third time it is a
latched shut down, if the fault occurs continuously.
6.1.6 Single Phase Voltage Fault

If any one phase voltage difference is greater than or equal to 50 V for a
duration of 9 seconds, it is announced as single phase voltage fault with
immediate shutdown of the unit. System gets restarted for two times, and for
the third time it’s a latched shutdown.
6.1.7 Inverter Fault

Inverter fault occurs when any one of the output phase voltage is less than
50 V for a duration of 20 seconds, with sufficient DC link voltage. System gets
restarted for two times and for the third time its a latched shutdown.
6.1.8 Input/internal Earth Fault

If earth leakage current is more than 350 mA with external earth
leakage current less than 300 mA for a duration of ten seconds, then it is
declared that the input/ internal earth fault and system shuts down. System
gets restarted for two times automatically and for the third time it’s a latched
shutdown.
6.1.9 Blower Fault

With failure of blowers for a duration of 5 seconds, which are used to cool the
heat sinks, blower fault is declared. This fault is just showed, but no action will
be taken immediately.
6.1.10 Over Temperature

If heat sink temperature increases beyond 90°C for a duration of five seconds,
according to over temperature section, it is declared as inverter over
temperature.
If inverter over temperature or rectifier over temperature or CHBA over
temperature fault occurs, unit shuts down immediately and it gets restarted
again on reaching low heat sink temperatures.
34 IM- 41 rev 6
6.1.11 Input Fuse Fail

If fuse fail circuit output is found low for a period of five seconds, it is declared
as input fuse fail. System does not reset until and unless the recovery of fault
output is high.
6.1.12 Control Supply Fail

If control supply feedback is not available for a period of five seconds, it
results in control supply failure it results in control supply failure. Immediately
unit shutdowns and it gets restarted again on getting significant control supply
voltage.
6.1.13 Brake Chopper Current Fault

Brake chopper current fault occurs when current is greater than 35 A for a
duration of five seconds with DC link voltage greater than 650 V. System gets
restarted for two times automatically and for the third time its a latched
shutdown and fault is cleared with chopper current gets below the set limit.
6.1.14 Brake Chopper Fault

If chopper current is above 10 A with DC link voltage less than 650 V for a
duration of five seconds, then it results in chopper fault system shutdown.
System gets restarted for two times automatically and for the third time its a
latched shutdown.
BATTERY CHARGER SECTION FAULTS
6.1.15 Battery Charger Voltage Fault

Battery charger voltage fault is categorized as charger voltage high fault and
charger voltage low fault
● If the charger voltage is more than 140 V for a duration of one second,
then it is declared as charger voltage high fault.
● If the charger voltage is less than 90 V for a duration of ten seconds, then
it is declared as charger voltage low fault.
In both the cases, fault gets cleared if the charger voltage is maintained
between 95 V and 134 V.
6.1.16 Charger Fault

If charger voltage is less than 20 V for a duration of eight seconds with Input
voltage in specified range, then the micro controller declares it as CHBA fault.
6.2 External Faults

6.2.1 Battery Charger Current Fault
Occurrence of battery charger current fault does not cause any action except
fault logging. This fault occurs when the charger current is more than 25 A
for a duration of eight seconds. It gets cleared when charger current is less
than 25 A.
6.2.2 Output Short Circuit

If output short circuit occurs for more than a period of six seconds, then
output short circuit fault is declared with immediate unit latched shut down.
Unit gets restarted on power reset.
IM- 41 rev 6 35
Chapter 6 - Types of Faults Medha Servo Drives Pvt. Ltd.
and Protections
6.2.3 Output Current High Fault

Whenever the output current is more than the 400 A for 20 seconds, it is
declared as output current high fault and the system shuts down. System
restarts itself for two times and for the third time it is a latched shut down.
6.2.4 Single Phase Current Fault

If any one of the phase current difference is greater than or equal to 50 A for
a duration of nine seconds, then the controller declares it as single phase
current fault. System restarts itself for two times and for the third time it’s a
latched shut down.
6.2.5 External Earth Leakage Fault

If external earth leakage current is more than 300 mA for a duration of
ten seconds with earth fault bypass disable, then it leads to external earth
fault system shutdown. System gets restarted for two times automatically and
for the third time it is latched shutdown, if the fault occurs continuously.
Earth fault bypass switch is used to run the system with the existence of earth
fault condition.
For both the earth leakage faults, system accepts earth fault bypass switch
input, only after sensing the earth fault at least once, i.e. earth fault by pass
switch function is made active from the first time earth fault is detected and
up to 30 minutes from the first earth fault sensing. Main controller reads the
bypass switch input for 30 minutes from first earth fault sensing, even with the
control supply interruption (with failure of 110 V supply). Internally, RTC is
used to maintain these timing logics.
If the system is in bypass mode, the leakage current trip level is changed to
1.5 A. Hence in this mode, system does not trip, if the earth fault current is
greater than 300 mA and less than 1.5 A. It trips in either of the following two
conditions :
● If 45 minutes time duration has completed since ‘Earth fault bypass
switch’ is being activated by displaying a message, “Earth fault by
pass>45 minutes”
● Earth fault current is greater than 1.5 A even if the system is in bypass
mode.
6.2.6 Input Voltage Fault

Input voltage fault is categorized as input voltage high and input voltage low
Whenever the input voltage from transformer is more than 1180 V for a
duration of 1 sec, then it is declared as input voltage high fault and if the input
voltage from transformer is less than 555 V for a duration of three seconds,
then it is declared as input voltage low fault. System immediately shuts down
and will be in OFF state till supply recovers to the normal operating range.
Input voltage feedback is taken from TDC_IF card.
36 IM- 41 rev 6
Chapter 7
COMMISSIONING
7.1 Handling
● Lift only with adequate equipment and trained persons. Lift always upright
position and do not overturn.
● Improper lifting and handling can cause serious or fatal personal injury
and substantial property damage.
● While lifting the equipment, use all the four eye bolts. Do not try to lift with
any two of the eye bolts.
● Equipment center of gravity is offset from center line.
7.2 Installation
● The static converter cubicle is designed to mount inside the locomotive
with eight bolts of M16 size.
● The converter unit should be installed inside the locomotive in vertical
position and fixed to solid surface from upper and lower sides.
● Position of the unit in locomotive should be adjusted such that its inlet and
outlet match with those in the locomotive.
● The converter shall be mounted in such a way that the front window
facilitates easy reading of status and faults.
7.3 Earthing
Connect the body of converter cubicle via earthling studs to the earthling
provided in the loco.
7.4 Connections
Fig 7.1 shows major connections of 180 kVA static converter unit to input
supply, output load and battery supply, charging sections and DC loads.
Fig 7.1
Chapter 7 - Commissioning Medha Servo Drives Pvt. Ltd.
Input connecting cables shall be able to take a continuous current of 350 A

and shall be suitable for 3 kV operating voltage and M-16 bolt at the
termination bus bar.
Output connecting cables shall be able to take a continuous current of 350 A
and shall be suitable for 1 kV operating voltage and with M-16 bolt at the
termination bus bar.
Cables connecting battery load and DC loads shall be able to take a
continuous current of 35 A and shall be suitable for 400 V operating voltage.
Following table gives the detailed description of the inter connections of
180 kVA static converter.
RELAY RELAY
BASED BASED
SL.NO MEDHA SIV Internal
WIRE LOCOS LOCOS
DESCRIPTION FERRULE
RAILWAY RAILWAY
FERRULE FERRULE
1 INPUT 830V -- 120 sq.mm A991 A991
2 INPUT OV -- 120 sq.mm A992 A992
3 OUTPUT “U” 16 120 sq.mm A965 A965
4 OUTPUT “V” 18 120 sq.mm A966 A966
5 OUTPUT “W” 20 120 sq.mm A967 A967
6 CON1 (Charger +Ve) 131 10 sq.mm X003 X003
7 CON2 (Charger -Ve) 108 10 sq.mm B-313 B-313
8 CON3 (Batt. –Ve) 108 10 sq.mm B-313 B-313
9 CON4 (Batt. +Ve) 120 10 sq.mm C003/1 C003/1
10 CON5 (110 VDC +Ve) 8 4 sq.mm K747 K747
11 CON6 (110 VDC –Ve) 2 4 sq.mm B-695 B-695
12 CON7 (Enable) 58 4 sq.mm F732 F035
13 CON8 (110 VDC +Ve) 54 4 sq.mm L747 L747
14 CON9 (S.I.OK) 55 4 sq.mm A188 A018
15 CON10 -- -- NC NC
16 CON11 (S.I.FAULT) 57 4 sq.mm A734 A017
17 CON12 (CHARG. OK) 56 4 sq.mm A973 A973
18 CON13 (110 VAC) 59 4 sq.mm J169 J968
19 CON14 (110 VAC) 61 4 sq.mm A170 A984
7.5 Operating the Converter

Once all the supply input and output connections are made, make sure that
the status of the ‘Enable’ switch on the front panel should be in OFF position.
Switch ON battery switches on the B.D panel and ensure that the reverse
polarity LED is OFF and, the VFD illuminates. If reverse polarity LED is ON,
check the polarity of the battery supply connections or CON 3 & CON 4
connections of the static converter cubicle.
Measure all power supply voltages and observe the LEDs on the display
panel. When the converter is in OFF condition, the status of the LEDs shall
be as mentioned below.
38 IM- 41 rev 6
● S.I OK - GREEN (should be OFF)

● Input Voltage in Range - RED (should be OFF)
● Internal Fault - RED (should be OFF)
● External Fault - RED (should be OFF)
● CHBA - OK - GREEN (should be OFF)
● Earth Bypass - RED (should be OFF)
● Alarm - NO SOUND
Turn ON the baby compressor switch in CAB1 and wait until the pressure
needle reaches to 6 kg/cm2. Then raise the pantograph of the engine.
Switch ON BL key on the driver desk and then close the BLRDJ. Make sure
that all the load switches of the static converter are in OFF condition. Then
observe the input voltage on the display panel. If input voltage is within the
range, then switch ON the ‘Enable’ switch and observe the DC link voltage
with DMM. This voltage should be around 591 V DC. The DC link voltage built
up time should be less than 15 seconds. If the DC link voltage does not build
up within the specified time, then switch OFF the enable switch and analyze
the problem. If the DC link voltage builds up in specified time, then observe
the output voltages of U-phase, V-phase and W-phase. Simultaneously,
observe the charger output voltage and currents.
The system is now operational with the VFD displaying phase currents, line
voltage, input voltage and input current, charger voltage and currents. It also
displays “system healthy” message in normal operating condition. Then
switch ON the load switches of MVSL1, MVSL2, MVSI1, and MVSI2 and
MPH one by one and observe the status on the VFD. There should not be
any deviations on the display parameters. If deviations are found, turn off the
loads. Check the VFD for fault information and react according to that. If the
static converter unit runs normally with switching of loads, run the unit with all
loads for five minutes.
Later switch ON the BLCP (automatic) switch located on the driver’s desk and
observe the currents on the VFD. The two compressors switch ON with five
seconds time delay. Then run the unit for 5-10 minutes.
Switch OFF the BLCP switch on the driver’s desk and keep the HVMT1
switch in position '1' and HVMT2 switch in position '0'. These switches are
provided at topside of the fuse panel. Switch ON BLVMT switch on the
driver’s desk and observe the static converter. The ‘Enable’ switch of the
static converter resets and converter starts with soft start. If the ‘Enable’ does
not get reset, then ask the railway engineers to check the wiring of the
particular section.
Switch OFF the BLVMT switch on the driver’s desk. Then change the
switches of HVMT1 to position '0' and HVMT2 to position '1'. Switch ON
BLVMT switch on the driver’s desk and observe the static converter. The
enable of the static converter will reset and converter should start with soft
start. After that keep both the switches HVBT1&2 in position '1' and observe
the static converter.
Now keep the DJ switch in open condition and keep all the load switches in
ON position. Then observe the static converter. The system is now
IM- 41 rev 6 39
Chapter 7 - Commissioning Medha Servo Drives Pvt. Ltd.
In order to make the SI unit safe to work on, the battery supply must
be isolated externally and wait at least 5 minutes to allow capacitors
to discharge completely.
Status of converter is easily known by looking at the LED Indication

and textual display on front panel.
One can easily know the values of Input Voltage, Input Current,
Output Voltages, Output Currents, Battery Charging Voltage and
Battery Charging current by using the push buttons on the display
board.
operational with full load and display shows “system healthy” message in
normal operating condition. Run the static converter for 15 minutes.
40 IM- 41 rev 6
Chapter 8
APPLICATION & DATA ANALYSIS

SOFTWARE
SETTING-UP THE FAULT DIAGNOSIS SYSTEM
8.1 RS232 Interfacing

The unit’s status can be interrogated via the diagnostic connector, which is
located on the display panel. The port connector is a 9 way ‘D’ type female
plug. To access the diagnostics, attach the serial port of a terminal or PC,
running a terminal emulation package to the appropriate port, where the
diagnostic investigation needs to take place.
NOTE: The cable length must not exceed 15 meters from unit to the PC.
8.2 Cable Connection

● The serial cable used with the diagnostics shall be a 9 way male to female
cable. Only five pins are used in the cable and they shall be configured as
shown below:
Fig 8.1
Chapter 8 - Application & Data Analysis Software Medha Servo Drives Pvt. Ltd.
8.3 Opening Application

● Application can be opened by selecting
‘MIN184 Application Software Version 1.0.2’ from start menu folder or from
the desktop shortcut icon.
Fig 8.1
● By clicking on the software, main menu screen appears as shown in Fig 8.2.
Fig 8.2
42 IM - 41 rev 6
● By clicking on ‘COM port settings’ as shown in Fig 8.3, a screen appears as

shown in Fig 8.4
Fig 8.3
Fig 8.4
● Select the COM port and click on connect symbol as shown in Fig 8.5.
Fig 8.5
IM - 41 rev 6 43
● Now, select the ‘File’ option as shown in Fig 8.6.
Fig 8.6
● Click on ‘File’ and select ‘Download Memory Serial Port’ as shown in Fig 8.7
Fig 8.7
● By selecting ‘Download Memory Serial Port’ a screen appears as shown in
Fig 3.8. Select ‘Faults Only’ option and enter the Loco No, Unit No and Shed
Name and click on ‘Download’ as shown in Fig. 3.8.
44 Fig 8.8 IM - 41 rev 6

● By clicking on ‘Download’, faults screen appears as shown in Fig 8.9.
Fig 8.9
● By clicking on ‘Date Time Selection’, a prompt window appears to enter start
date & time and End date & time as shown in Fig 8.10.
Fig 8.10
● Click on Exit, to enter the main menu as shown in Fig 8.8
Fig 8.11
IM - 41 rev 6 45
● Select ‘Fault Messages with Data Pack’ and click on ‘Download’ as shown in
Fig 8.12.
Fig 8.12
● By clicking on ‘Download’, a screen appears as shown in Fig 8.13.
Fig 8.13
● By clicking on ‘FDP’, a sub fault data appears as shown in Fig 8.14.
Fig 8.14
46 IM - 41 rev 6
● Click on ‘Exit’ to exit the screen as shown in Fig 8.15.
Fig 8.15
● By clicking on ‘Exit’ in Fault log screen as shown in Fig 8.16, a default screen
appears as shown in Fig 8.17.
Fig 8.16
Fig 8.17
IM - 41 rev 6 47
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48 IM - 41 rev 6
Chapter 9
MAINTENANCE
9.1 Maintenance Precautions
Ÿ Only qualified service technicians are allowed to service the inverter.

Ÿ Ensure that the ‘Enable’ switch provided on the Display panel is in OFF
position.
Ÿ Ensure that the DC link capacitor is discharged completely before service
is made inside the inverter. Otherwise, wait for 5 minutes till capacitors
get discharged.
Ÿ Do not touch any electrical contacts when power is ON during testing and
measuring.
9.2 Routine Maintenance

Overall the unit is maintenance free.
During POH (once in 18 months), the following checks are to be carried out.
Ÿ Clean the dust from entire unit.
Ÿ Open the unit and check the connections of all assemblies.
Ÿ Check for the wear and tear of bolts, as vibrations may cause damage to
the threadings. If found, replace them and ensure tightness.
During POH, the work MUST be carried out with the equipment
switched OFF and isolated from the supply. Always allow at least 5
minutes for capacitors to discharge after isolating the equipment.
Chapter-9 Maintenance Medha Servo Drives Pvt. Ltd.
Inspection parameters during Schedule maintenance

During
S. No. Nature of Work Comm. or IA IB AOH IOH POH Remarks
IO
Fault log data download before
1 √ √ √ √ √ √
schedules
Check tightness of Connections at
2 √ 0 - √ √ √
I/P, O/P and Control cables
Blow air in Middle compartment for Use Dry
3 - - √ √ √ √
dust removing. air only
Clean the dust with brush or
vacuum cleaner (sucking) at
4 - - √ √ √ √
inverter section and rectifier
section.
Checking of the operation of
5 √ √ √ √ √ √
QCON, LSCHBA & LSIT.
Turn ON Battery supply and
6 √ √ √ √ √ √
Download FDP Before Schedule
After Schedule Inspection Erase
7 √ √ √ √ √ √
FDP memory
8 Check tightness of power cables √ - √ √ √ √
9 Check Healthiness of Blowers - - - √ √ √
Check Healthiness of Door Gasket
10 If required gasket shall be - - - √ √ √
replaced.
Check Para meters In SIV working
11 √ √ √ √ √ √
conditions
Check the earth leakage current of
12 - - - √ √ √
all the auxiliary motors.
Check the load currents of
13 - 0 - √ √ √
individual motors and total current.
After 6 years at the date of
commissioning, measure the
capacitor values for all electrolytic
14 - √ √ √ √ √
capacitors,DC link polypropylene
capacitors and AC capacitors
(Dv/Dt and Blower).
This point applicable for after 6
15 years locos. Replacement of 0 - - - - √
Electrolytic capacitors
Clean the dust in side of the
16 - √ √ √ √ √
blower
Verify the blowers working or not
17 - √ √ √ √ √
at SIV working condition.
Incase Blower fault is displayed,
18 verify the which blower is not - √ √ √ √ √
working.
Replace the new blower in place
19 0 √ √ √ √ √
of failure blower
50 IM- 41 rev 6
9.3 List of Recommended Spares

Price/Unit
S.No. CODE DESCRIPTION
Rs.
1 SP184101003 CAP HV CARD FOR DC LINK FOR INVERTER 3,000
2 SP184101004 ISOLATION POWERSUPPLY CARD FOR INVERTER 9,600
3 SP184101005 DISPLAY POWER SUPPLY CARD FOR INVERTER 8,800
4 SP184101006 VFD DISPLAY CARD FOR INVERTER 39,500
5 SP184101007 GATE DRIVE CARD FOR INVERTER 9,600
6 SP184101008 INVERTER POWER SUPPLY (INV-PS) 21,000
7 SP184101009 MAIN POWER SUPPLY CARD (PS) 8,300
8 SP184101010 PWM CARD FOR INVERTER 23,900
9 SP184101011 TAFC CARD FOR INVERTER 21,400
10 SP184101012 TRANSDUCER INTERFACE CARD FOR INVERTER 16,450
11 SP184101013 VOLT FREE CONTACTS CARD FOR INVERTER 5,250
12 SP184101014 GATE DRIVE CHILD CARD FOR INVERTER 3,500
13 SP184101015 REVERSE POLARITY CARD - CONTROL SUPPLY 650
14 SP184101016 MAIN CONTROL CARD FOR INVERTER 59,500
15 SP184101017 ANALOG SIGNALS CARD FOR INVERTER 14,300
16 SP184101018 BATTERY CHARGER CURRENT SENSING CARD 3,500
17 SP184101019 BATTERY CHARGER CC CARD 8,500
18 SP184101020 BATTERY CHARGER OVERLOAD CT CARD 1,600
19 SP184101021 BATTERY CHARGER CAPACITOR DISCHARGE CARD 1,200
20 SP184101022 BATTERY CHARGER MC CARD 24,500
21 SP184101023 BREAK CHOPPER CARD WITH GATE DRIVE CARD 17,500
22 SP184101024 SINE FILTER CAPACITOR CARD 2,400
23 SP184101025 BLOWER TB CARD 800
24 SP184111001 M10 SIZE BUS BAR INSULATOR 150
27 SP184121001 BAT-CHARGER DOOR HINGE SET 970
28 SP184121003 BAT-CHARGER DOOR SCREW 80
29 SP184121004 THYRISTOR HEAT SINK 14,200
30 SP184121005 THYRISTOR BUSBAR SET 9,800
31 SP184121008 INVERTER IGBT HEAT SINK 21,400
32 SP184121010 DC LINK BLEEDER RESISTOR HEAT SINK 2,100
33 SP184121011 SC MESH DOOR TOP SIDE 4,100
34 SP184121012 SC MESH DOOR BOTTOM SIDE 7,300
35 SP184121014 OUTPUT CAPACITOR BUSBAR 2 1,120
36 SP184121015 BREAK CHOPPER RESISTOR HEATSINK GASKET 550
37 SP184121016 I/P FUSE BUSBAR - SET 3,600
38 SP184121017 I/P TERMINAL BUSBAR SET 6,330
39 SP184121021 FRONT SIDE TOP DOOR FOR INVERTER 7,000
40 SP184121022 FRONT SIDE BOTTOM COVER FOR INVERTER 2,050
41 SP184121023 BACK SIDE TOP DOOR FOR INVERTER 5,700
42 SP184121024 BACK SIDE MIDDLE DOOR FOR INVERTER 1,650
43 SP184121025 BACK SIDE BOTTOM DOOR FOR INVERTER 2,050
44 SP184121026 DISPLAY UNIT BOX FOR INVERTER 1,670
45 SP184121029 IGBT / THYRISTOR HEATSINK GASKET 1,450
IM- 41 rev 6 51
Price/Unit
Sl.No. CODE DESCRIPTION
Rs.
46 SP184121030 BLOWER GASKET - 184 220
47 SP184121031 SNUB. RES. INSULATOR FOR THYRISTOR/DIODE 350
48 SP184121032 DOOR LOCK SCREW FOR INVERTER 45
49 SP184121033 DISPLAY DOOR FOR INVERTER 870
50 SP184121041 THYRISTOR HEAT SINK BOTTOM 14,200
51 SP184121042 INVERTER IGBT HEAT SINK BOTTOM 21,400
INVERTER IGBT BUSBAR SET WITH INSULATORS FOR
54 SP184121045 24,500
ONE PHASE
INVERTER IGBT & CAPACITOR BUSBAR SET WITH
55 SP184121046 25,100
INSULATOR
56 SP184121047 DISPLAY UNIT MIMIC FILTER ASSY. 1,500
57 SP184121048 DISPLAY UNIT BOX WITH MIMIC FILTER FOR INVERTER 3,100
58 SP184121049 DOOR GASKET FOR INVERTER 7,800
59 SP184121050 BATTERY CHARGER HEATSINK WITH GASKET 13,200
60 SP184141001 BAT-CHAR I/P START CURRENT LIMIT RESISTOR 180
61 SP184141003 THYRISTOR / DIODE SNUBBER RESISTOR 3,240
62 SP184141004 BREAK CHOPPER RESISTOR ASSY 15,300
63 SP184141005 I/P SURGE PROTECTOR SET 48,400
64 SP184141007 DC LINK CAPACITOR 1,42,500
65 SP184141009 IGBT SNUBBER FOR INVERTER 1,750
66 SP184141010 THYRISTOR / DIODE SNUBBER CAPACITOR 13,600
67 SP184141011 I/P RECTIFIER DIODE 29,500
68 SP184141012 BAT-CHARGER RECTIFIER DIODE 1,290
69 SP184141014 INVERTER IGBT 12,800
70 SP184141016 I/P RECTIFIER THYRISTOR 28,000
71 SP184141017 VOLT FREE CONTACTORS SET 1,900
72 SP184141018 HEAT SINK THERMAL SWITCH 320
73 SP184141019 OUTPUT CURRENT SENSOR 1,110
74 SP184141020 INPUT CURRENT SENSOR 920
75 SP184141021 DC LINK CURRENT SENSOR 13,400
76 SP184141022 BREAK CHOPPER CURRENT SENSOR 7,300
77 SP184141023 INT / EXT EARTH FAULT CURRENT SENSOR 2,500
78 SP184141024 HEAT SINK COOLING BLOWER 14,200
79 SP184141025 BLOWER FUSE 6
80 SP184141026 BLOWER FUSE HOLDER 45
81 SP184141027 BAT-CHARGER INPUT FUSE 120
82 SP184141028 INPUT FUSE FOR STATIC CONVERTER 8,100
83 SP184141029 BLOWER INPUT FUSE 150
84 SP184141030 110VAC INPUT FUSE 145
85 SP184141031 RESET SWITCH FOR STATIC CONVERTER 135
86 SP184141032 INPUT FUSE FAIL FEED BACK SWITCH FOR SIV 1,200
87 SP184141033 EARTH LEAKAGE BY PASS SWITCH 350
88 SP184141034 STATIC CONVERTER ENABLE SWITCH 350
89 SP184141035 BAT-CHARGER OUTPUT CONTACTOR 5,700
90 SP184141036 BAT-CHARGER IN PUT CONTACTOR 1,220
52 IM- 41 rev 6
Price/Unit
Sl.No. CODE DESCRIPTION
Rs.
91 SP184141037 ENABLE AND CHARGER SELECTION SWITCH 350
92 SP184141038 INVERTER SET WITH IGBTs PER PHASE 1,40,000
93 SP184141039 I/P SNUBBER RESISTOR ASSY. 8,800
94 SP184141040 BREAK CHOPPER RESISTOR SET 10,200
95 SP184141042 DC LINK BLEADER RESISTOR SET 17,500
96 SP184141043 DC LINK CAPACITOR BUSBAR SET 6,500
97 SP184141044 BAT-CHARGER IGBT WITH SNUBBER CAPACITOR 6,400
98 SP184141045 BREAK CHOPPER IGBT WITH SNUBBER CAPACITOR 14,200
99 SP184141047 BAT-CHARGER BLOCKING DIODE 950
100 SP184141048 DC LINK VOLTAGE SENSOR 20,500
101 SP184141049 I/P TERMINAL BLOCK S/A 1,200
102 SP184141050 O/P TERMINAL BLOCK S/A 1,500
103 SP184151001 DC LINK CAPACITOR BANK 1,10,000
104 SP184151002 BAT-CHARGER O/P FILTER S/A 2,600
105 SP184151003 DV/DT CAPACITOR BANK SET 1,00,500
106 SP184151004 BLOWER SINE FILTER S/A 3,500
107 SP184151005 INPUT SNUBBER CAPACITOR SET 21,000
108 SP184151006 BAT-CHARGER INDUCTOR 24,750
109 SP184151007 BLOWER SINE FILTER INDUCTOR 3,500
110 SP184151008 BLOWER TRASFORMER 9,200
111 SP184151009 INPUT VOLTAGE FEED BACK TRANSFORMER 3,200
112 SP184151010 BAT-CHARGER TRASFORMER 29,300
113 SP184151011 DC LINK INDUCTOR FOR MIN184 2,30,000
114 SP184151012 DI/DT INDUCTOR FOR MIN184 2,02,000
115 SP184201001 FLAT RIBBON CABLES SET 12,500
116 SP184201002 VOLTAGE / CURRENT SENSOR CABLES SET 4,200
117 SP184201003 CONTROL CABLES SET 56,600
118 SP184201004 BATTERY CHARGER CABLES SET 12,200
119 SP184201005 DC LINK POWER CABLES SET 27,900
120 SP184201006 INVERTER POWER CABLES SET 22,000
121 SP184201007 CABLE - I/P FUSE F1 TO TH1&TH2 JUNCTION 2,100
122 SP184201008 CABLE - I/P FUSE F2 TO D1&D2 JUNCTION 2,100
123 SP184201009 CABLE - TH1& D1 JUNCTION TO L2 2,700
124 SP184201010 CABLE FROM U-PH OF DI/DT TO OUTPUT 3,900
125 SP184201011 CABLE FROM V-PH OF DI/DT TO OUTPUT 3,700
126 SP184201012 CABLE FROM W-PH OF DI/DT TO OUTPUT 3,700
127 SP184201013 DATA DOWNLOADING CABLE 2,750
128 SP184201014 CABLE - TH2& D2 JUNCTION TO CAPACITOR 2,450
IM- 41 rev 6 53
9.4 User Interface to the System

Static converter activates all the protections according to the fault. Incase of
major faults like output overload, earth fault, etc., automatic restart attempts
(3 attempts) are provided and converter goes into latched shut down mode,
if the fault still persists. Battery reset (POWER reset switch) is required for
restarting the unit.
EARTH FAULT BYPASS and POWER RESET (used to reset the unit under
latched shut down condition) switches are provided on the front panel.
Power reset switch is provided on the front panel to reset the latched unit.
This switch is made active during latched shut down only. In other conditions,
functioning of power reset switch is disabled internally.
All the faults detected by the static converter are communicated to the
maintenance staff by several ways like LED indication, text display and
through Laptop / PC interface.
The information regarding the status of static converter is communicated to
the loco pilot through Volt free contactors. These contactors are driven by
specified relays according to the status of the converter.
Control Unit
with Static
Converter
54 IM- 41 rev 6
Following is the information on the fault display and indication.
MESSAGE IN DISPLAY LED INDICATION PROBABLE CAUSE

S.I. OK - GREEN
Input voltage range LED - OFF
Normal working conditions Internal fault LED - OFF (Healthy condition of unit)
external fault LED - OFF
CHBA OK LED - GREEN
Earth Bypass - OFF
S.I. OK - OFF
Input voltage range LED - RED
Input Over/Under Voltage OHE Over voltage
Internal Fault LED - OFF
external Fault LED - OFF
CHBA OK LED - OFF
Earth Bypass - OFF
S.I. OK - OFF
Input voltage range LED - OFF
Input Fuse Fail Fuse Fail
Internal Fault LED - RED
external Fault LED - OFF
CHBA OK LED - OFF
Input Over Current Internal Fault LED - RED Internal short circuit
Output Over Volts Internal Fault LED - RED Converter Fault
Output Over Current External Fault LED - RED Fault on load side
Output Phase current
External Fault LED - RED Fault on load side
Imbalance
Output Phase voltage
Internal Fault LED - RED Inverter fault
Imbalance
Output Short Circuit External Fault LED - RED Fault on load side
External Earth Fault External Fault LED - RED Fault on load side
Internal Earth Fault Internal Fault LED - RED Fault in the SIV
Blowers failure condition.
Over temperature in the
Over Temperature Internal Fault LED - RED rectifier / Inverter/charger
HEAT sink or thermal
switches failed.
Blower Fault Internal Fault LED - RED Cooling fan defective
DC Link over/under voltage Internal Fault LED - RED Rectifier section fault
Charger Input Fail Internal Fault LED - RED Charger Input Fuse
Charger Output Low / High Internal Fault LED - RED Charger Section Fault
Charger Load (verify the
Charger Over load External Fault LED - RED
batteries)
IM- 41 rev 6 55
K
AN
BL
FT
LE
Y
LL
NA
IO
NT
TE
IN
IS
GE
PA
I S
TH
56 IM- 41 rev 6
Chapter 10
TROUBLESHOOTING PROCEDURE
10.1 Troubleshooting Procedure

WARNING: Make sure that only qualified personnel will perform
maintenance, inspection and part replacement. Do not wear any metallic
objects like wristwatch, bracelet, etc. Be sure to use tools with insulated
handles. Otherwise, there is a danger of electric shock and / or injury to
personnel.
HIGH VOLTAGE: Be careful not to touch wiring or connector terminals while

working with the inverters and taking measurements. Be sure to place the
measurement circuitry above in an insulated housing before using them.
CAUTION: The heat sink fins have a high temperature. Be careful not to
touch them. Otherwise, there is danger of getting burned.
CAUTION: Converter and PCB cards contain components which can be

destroyed by electrostatic discharge. Hence necessary ESD precautions
should be taken while handling the components and PCBs.
CAUTION: Connection to field wiring terminals must be reliably fixed having

two independent means of mechanical support using a termination with cable
clamp.
HIGH VOLTAGE: Rectifier and Inverter assemblies are connected to

hazardous line voltages. When servicing these assemblies, there may be
exposed components with housings or protrusions at or above line potential.
Extreme care should be taken to protect against shock. Stand on an
insulating pad and make it a habit to use only one hand when checking
components. Always work with another person for support in case an
emergency occurs. Disconnect power before checking controllers or
performing maintenance. Be sure equipment is properly grounded.
Chapter-10 Troubleshooting Medha Servo Drives Pvt. Ltd.
Procedure
Occurrence of every fault leads to fault log entry (fault log data and various
parameter values are stored in main micro controller) and audible buzzer
indication with LED indication.
Status of
Message on
S.No. Converter on fault Probable Cause Action to be taken
Display
occurrence
INPUT SIDE
1. System functions from

16.5 kV to 31 kV.
2. Check the input
voltage, tripping at
>1180V (recovers at <
1140V)
3. Check input voltage
level and confirm it is
1. Rectifier OFF
less than 31kV
4. Check the voltage
2. Static converter Ÿ OHE over voltage
indication on driver's
awaits for Input
cabin, whether it is also
voltage to appear Ÿ Defect in loco
indicating the same
within the transformer
OHE voltage or not.
permissible limits.
5. Wait until Input voltage
Input Voltage Ÿ Defect in the input
1. stabilize within the
High 3. Converter starts section step down
working limits
itself on finding transformer.
6. Now converter will
the Input Voltage
function on it's own, if it
within range. Ÿ Defect in Input
is not functioning even
voltage sensing
after Input voltage
4. Indication of Input circuit
stabilizes, check for the
voltage in range
Input voltage sensing
LED (RED)
circuit (in Transducer
card) and the 12 V
section of the step
down transformer.
7.Even the fault condition
still persists,
communicate the same
to the service staff .
1. Rectifier OFF Ÿ OHE voltage

1. System will function
from 16.5 kV to 31 kV.
2. Static converter Ÿ Defect in loco
awaits for Input transformer
2. Check the input
voltage to appear
voltage, tripping at
Input Voltage within the Ÿ Defect in the input
2. <555V to >200V
low permissible limits. section step down
(recovers at <605V).
transformer.
3. Converter starts
3. Check input voltage
itself on finding Ÿ Defect in Input
level and confirm it is
the Input Voltage voltage sensing
greater than 16.5 kV
within range. circuit
58 IM- 41 rev 6
Status of
Message in
Sl.no Converter on fault Probable Cause Action to be taken
Display
occurrence
4. Check the voltage
indication on driver's
cabin, whether it is
also indicating the
same OHE voltage
or not.
5. Wait until input
voltage stabilize
within the working
limits
6. Now converter will
function on it's own,
4. Indication of Input if it is not functioning
voltage in range even after Input
LED (RED) voltage stabilizes,
check for the Input
voltage sensing
circuit (in Transducer
card) and the 12 V
section of the step
down transformer.
7. Even the fault
condition still
persists,
communicate the
same to the service
staff.
Ÿ Fuses (F1 &F2)
1. Do not switch ON
may be blown.
the converter with
input available till
Ÿ Dead short circuit
the fault is cleared.
on the auxiliary
2. Check micro switch
side.
connection (wire
93) of input fuse.
Ÿ Short circuit in
3. Check Input fuses
the DC Link filter
(F1, F2).
(LC) side.
1. Rectifier OFF 4. Check whether
short circuit exists
Ÿ Short circuit in
2. Converter in DC Link filter
the connecting
functions in the (LC ) Circuit of
cable between
normal way after converter.
3 Input Fuse Fail rectifier and
clearing the fault. 5. Check whether
inverter section.
short circuit exists
3. Indication of in the connecting
Ÿ High voltage
Input voltage in cable between
spikes on
range LED (RED) rectifier and
auxiliary
inverter section.
transformer
6. Check the OHE
secondary (MOV
voltage at the time
burnt).
of fuse fail from
fault log data.
Ÿ Loose contact in
7. Check the micro
the fuse fail
switches contact
detection circuit
and fuse fail
(contact of micro
sensing circuit.
switches)
IM- 41 rev 6 59
Procedure
Status of
Message in
Display
occurrence
8. If none of the above
things are noticed ,
then communicate
the same with
service staff.
1. Rectifier OFF.
2. Converter
restarts itself
(automatically) 1. Check the output
3. If the fault loads, load
condition is connections.
removed Ÿ Output Over load Rectify the problem
converter works if exists.
normally. Ÿ Overload due to 2. Check the DC Link
4. Input current DC Link LC filter LC filter of the
Input Current High fault is of converter(if converter.
4. counted by the
High any defect). 3. Check the rectifier
main controller. section and restart
5. However, if the Ÿ Defect in Input the system.
fault persists for Current sensing 4. If still the fault
more than 2 circuit. persists, don’t
times, 3rd time close the DJ and
it's a latched inform the condition
shut down. to the service staff.
6. Indication of
Internal fault
LED (RED).
RECTIFIER SECTION
1. Rectifier OFF.
2. Converter 1. This fault occurs ,
restarts it self When the DC Link
(automatically) voltage is < 500 V.
3. If the fault 2. Check the rectifier
Ÿ Fault in the
condition is assembly input and
rectifier section.
removed output connections.
converter works 3. Check the DC Link
Ÿ Over loading at
normally. filter circuit
the OUTPUT
4. DC Link Voltage connections
section
DC Link Voltage LOW fault is 4. Check the DC Link
5. LOW counted by the voltage sensor and
Ÿ DC Link voltage
(3 times) main controller. sensing circuit.
sensor and
5. However , if the 5. Check the Thyristor
sensing circuit
fault persists for angle firing control
more than 2 card and its
Ÿ Thyristor angle
connections.
times, 3rd time firing control card
6. If still the fault
it's a latched or connections.
persists, don’t
shut down. close the DJ and
6. Indication of inform the condition
Internal fault to the service staff.
LED (RED).
60 IM- 41 rev 6
Status of
Message in
Display
occurrence
1. This fault occurs ,

When the DC Link
voltage is > 760 V.
1. Rectifier OFF. 2. Check the rectifier
assembly input and
2. Converter will output connections.
trip with latched 3. Check the DC Link
shut down. Ÿ Fault in the filter circuit
rectifier section. connections.
3. Converter runs , 4. Check the DC Link
only after reset Ÿ DC Link voltage sensor, sensing
DC Link of the control sensor and circuit and
6.
Voltage HIGH supply (Reset sensing circuit. connections to
switch on the angle firing control
front panel is Ÿ Thyristor angle card.
used to reset firing control card 5. Check the Thyristor
the latched unit). or connections. angle firing control
card and its
4. Indication of connections.
Internal fault 6. If still the fault
LED (RED). persists, don’t
close the DJ and
inform the condition
to the service staff.
1. Rectifier OFF 1. Check loads and

their wiring
2. Converter will Ÿ Fault in the 2. Check healthiness
trip with latched rectifier section. of DC link filter (LC
shut down. filter) circuit.
Ÿ DC Link Current 3. Check the Inverter
3. Converter runs , sensor and assembly and
only after reset sensing circuit. inverter section
DC Link current of the control input and output
7.
HIGH supply (Reset Ÿ DC Link (LC) connections.
switch on the filter circuit. 4. Check the DC
front panel is current sensor
used to reset Ÿ Inverter section circuit.
the latched unit). 5. If still the fault
Ÿ Load side due to persists, don’t
4. Indication of faulty load. close the DJ and
Internal fault inform the condition
LED (RED). to the service staff.
1. Check the rectifier
Ÿ Fault in the
1. Rectifier OFF. assembly input and
rectifier section.
2. Converter output connections.
restarts itself 2. Check the DC Link
Ÿ DC Link Voltage
(automatically) filter circuit
sensor and
3. If the fault connections.
sensing circuit.
condition is 3. Check the DC Link
8. Rectifier fault
removed Voltage sensor,
Ÿ Thyristor angle
converter works sensing circuit and
firing control card
normally. connections.
or connections.
4. Rectifier fault is 4. Check the Thyristor
counted by the angle firing control
Ÿ Enable circuit
main controller. card and its
connections
connections.
IM- 41 rev 6 61
Procedure
Status of
Message in
Display
occurrence
5. However, if the
fault persists for
more than 2 5. If still the fault
times, 3rd time it's persists, don’t close
a latched shut the DJ and inform
down. the condition to the
6. Indication of service staff.
Internal fault LED
(RED).
1. Rectifier OFF.
2. Converter
restarts itself
(automatically)
3. If the fault 1. Check the loads
condition is and load
removed connections.
converter works Ÿ Fault in the
normally. rectifier section. 2. Check the
4. Chopper healthiness of the
Current HIGH Ÿ Out side due to DC Link.
Chopper fault is counted faulty load.
9.
Current high by the main 3. Check healthiness
controller. Ÿ Fault may be in of TAFC card.
5. However, if the TAFC card (due
fault persists for to unregulated 4. If still the fault
more than 2 DC link) persists, don’t
close the DJ and
times, 3rd time inform the condition
it's a latched to the service staff.
shut down.
6. Indication of
Internal fault
LED (RED).
1. Rectifier OFF.
2. Converter
restarts it self
(automatically) 1. Check the current
3. If the fault Ÿ Chopper current sensor feed back
condition is sensor or its and Analog card.
removed sensing circuit.
converter works 2. Check the
normally. Ÿ Brake chopper healthiness of
4. Chopper fault is card or Chopper Break chopper
10. Chopper fault counted by the IGBT. card, IGBT and
main controller. Chopper resistors.
5. However, if the
fault persists for Ÿ Chopper 3. If still the fault
more than 2 resistors or its persists, don’t
times, 3rd time connections. close the DJ and
it's a latched inform the condition
shut down. to the service staff.
6. Indication of
Internal fault
LED (RED).
62 IM- 41 rev 6
Status of
Message in
Display
occurrence
1. Check whether the
air flow path to the
rectifier is not
obstructed.
2. Check the heat
Ÿ Heat sink sink cooling blower.
Cooling blower 3. Check healthiness
of output loads,
1. Rectifier OFF. Ÿ Actual ambient which if faulty can
temperatures cause continuous
2. Converter overload of rectifier
restarts itself Ÿ Continuous and thus over
(automatically) overload of temperature.
on finding LOW rectifier due to 4. Check whether the
Rectifier over rectifier faulty load. ambient is less
11.
temperature temperature i.e than 55°C or not.
on clearance of Ÿ Thermal switch 5. Check the
the fault on rectifier heat healthiness of
sinks. thermal switch on
3. Indication of the rectifier heat
Internal fault Ÿ Chopper sink.
LED (RED). conduction or 6. Check the break
it's Thermal chopper current
switch on heat and heat sink
sink temperature.
persists, don’t
close the DJ and
INVERTER SECTION
1. Check the Inverter
assembly.
1. Rectifier OFF. 2. Check the
2. Converter healthiness of the
restarts it self Ÿ Inverter load and load
(automatically) assembly connections.
3. If the fault 3. Check the
condition is Ÿ Over loading at healthiness of
removed the OUTPUT PWM card
converter works section. 4. Check the voltage
normally. sensors and
4. Inverter fault is Ÿ PWM card or its sensing circuit
12. Inverter fault counted by the connections connections.
main controller. 5. Check the
5. However , if the Ÿ Inverter power healthiness of the
fault persists for supply output sine filter.
more than 2 6. Check the
times, 3rd time Ÿ Output Voltage healthiness of
it's a latched sensing circuit. inverter power
shut down. supply card.
6. Indication of Ÿ Output sine filter If still the fault
Internal fault persists, don’t close
LED (RED). the DJ and inform
the condition to the
service staff.
IM- 41 rev 6 63
Procedure
Status of
Message in
Display
occurrence
air flow path to the
inverter heat sink is
not obstructed.
2. Check the heat
sink cooling blower.
3. Check healthiness
Ÿ Heat sink
of output loads,
1. Rectifier OFF. Cooling blower
which if faulty can
cause continuous
2. Converter Ÿ Actual ambient
overload of inverter
restarts it self temperatures
and thus over
(automatically)
temperature.
on finding LOW Ÿ Continuous
Inverter Over inverter overload of
13. ambient is less
temperature temperature i.e inverter due to
than 55°C or not.
on clearance of faulty load.
5. Check the
the fault.
healthiness of
Ÿ Thermal switch
thermal switch on
3. Indication of on inverter heat
the inverter heat
Internal fault sink.
sinks.
LED (RED).
6. Ensure the sensing
Ÿ Analog card
circuit function and
connections in
Analog card.
persists and inform
the condition to the
service staff.
OUTPUT SECTION
1. Rectifier OFF. output and
2. Converter connections
restarts it self between DC Link
(automatically) filter to Inverter.
3. If the fault 2. Check the Inverter
condition is Ÿ Rectifier output assembly.
removed 3. Check the
converter works Ÿ TAFC card healthiness TAFC
normally. assembly card and its
4. Output voltage connections.
Output voltage high fault is Ÿ Inverter 4. Check the voltage
14. counted by the
HIGH assembly sensors and
main controller. sensing circuit
5. However , if the Ÿ Output Voltage connections in TDC
fault persists for sensing circuit. IF card.
times, 3rd time Ÿ Output sine filter healthiness of the
it's a latched output sine filter.
shut down. 6. If still the fault
6. Indication of persists, don’t
Internal fault close the DJ and
LED (RED). inform the condition
64 IM- 41 rev 6
Status of
Message in
Display
occurrence
output and
connections
1. Rectifier OFF. between DC Link
2. Converter filter to Inverter.
restarts it self 2. Check the Inverter
(automatically) assembly.
3. If the fault 3. Check the
condition is healthiness of the
Ÿ Rectifier output
removed load and load
converter works connections.
Ÿ Inverter
normally. 4. Check the Inverter
assembly
4. Output voltage output connections
low fault is to the load.
Output voltage Ÿ Load side due to
15. counted by the 5. Check the voltage
LOW faulty load.
main controller. sensors and
5. However, if the sensing circuit
Ÿ Output Voltage
fault persists for connections.
sensing circuit.
healthiness of the
times, 3rd time Ÿ Output sine filter
output sine filter.
it's a latched 7. Check the
shut down. healthiness of
6. Indication of TAFC card
Internal fault 8. If still the fault
LED (RED). persists, don’t
close the DJ and
2. Converter healthiness of
restarts it self loads and load
(automatically) connections.
3. If the fault
condition is 2. Check the Inverter
removed Ÿ Load side due to
output connections
converter works faulty load (high
to the loads.
normally. single phase
4. Single phase load).
3. Check Output
Single Phase voltage fault is voltage sensing
16. counted by the Ÿ Output voltage
voltage fault circuit.
main controller. sensing circuit.
5. However, if the 4. Check Inverter
fault persists for Ÿ Inverter
assembly.
more than 2 assembly.
times, 3rd time 5. If still the fault
it's a latched persists, don’t
Internal fault to the service staff.
LED (RED).
IM- 41 rev 6 65
Procedure
Status of
Message in
Display
occurrence
1. Rectifier OFF.
2. Converter 1. Check the
restarts it self healthiness of
(automatically) loads and load
3. If the fault connections.
condition is 2. Check the Inverter
removed Ÿ Load side due to output connections
converter works faulty load. to the loads.
normally. 3. Check Output
4. Output current Ÿ Output current current sensing
Output current high fault is sensing circuit. circuit.
17. counted by the
HIGH 4. Check Inverter
main controller. Ÿ Inverter assembly.
5. However, if the assembly. 5. Check the
fault persists for healthiness of
more than 2 Ÿ Output sine filter. output sine filter
times, 3rd time 6. If still the fault
it's a latched persists, don’t
external fault to the service staff.
LED (RED).
2. Converter healthiness of
restarts it self loads and load
(automatically) connections
3. If the fault (imbalances in the
condition is loads).
removed Ÿ Load side due to 2. Check the Inverter
converter works faulty load. output connections
normally. to the loads.
4. Single phase Ÿ Output current 3. Check the
Single phase current fault is sensing circuit. healthiness of
18. counted by the
current output sine filter.
main controller. Ÿ Inverter 4. Check Inverter
5. However, if the assembly. assembly.
fault persists for 5. Check Output
more than 2 Ÿ Output sine filter. current sensing
times, 3rd time circuit.
it's a latched 6. If still the fault
shut down. persists, don’t
6. Indication of close the DJ and
external fault inform the condition
LED (RED). to the service staff.
66 IM- 41 rev 6
Status of
Message in
Display
occurrence
2. Converter Ÿ Load side due to healthiness of the
permanently faulty load. loads.
shuts down 2. Check the load
Converter runs , Ÿ Cable cables connection
only after reset connections from static
of the control between static converter to loads.
OUTPUT short
19. supply (Reset converter output 3. Check the
circuit switch on the and loads. healthiness of
front panel is output sine filter.
used to reset Ÿ PWM card 4. Check the
the latched unit). functionality of
3. Indication of Ÿ Inv. gate drive PWM and Gate
external fault card drive card and it's
LED (RED). connections.
1. Check the blower
healthiness.
1. Audible buzzer
indication. 2. Check blower
Ÿ Blower function.
current sensor and
2. Indication of current sensing
Ÿ Blower current
internal fault circuit In charger
sensing circuit.
LED (RED). MC card.
20. Blower fault
Ÿ Blower fuses.
3. Static converter 3. Check the blower
functions transformer (step
Ÿ Blower sine filter
normally even down transformer
and Transformer
on detection of connected at the
this fault. static converter
output side)
healthiness.
EARTH FAULT
1. Rectifier OFF.
2. Converter waits
in by pass
mode.
3. Converter 1. Check the wiring at
restarts it self. DC Link output
4. If the fault side.
condition is 2. Check the wiring
removed between inverter
converter works input and output.
normally. 3. Check the
5. Internal earth Ÿ Earth fault at
Internal earth insulation levels of
21. fault is counted Rectifier, DC link
fault (3 times) DC link inductor
by the main or inverter side.
and di/dt inductor.
controller. 4. Check the
6. However, if the healthiness of
fault persists for Analog card
more than 2 5. Check the Blower
times, 3rd time transformer
it's a latched insulation levels.
shut down.
7. Indication of
internal fault LED
(RED).
IM- 41 rev 6 67
Procedure
Status of
Message in
Display
occurrence
1. Rectifier OFF.
2. Converter waits
in by pass
mode.
3. Converter
restarts it self
(automatically).
4. If the fault
condition is
removed
converter works 1. Check the Load
normally. side connections.
External earth 5. External earth Ÿ Earth fault at the
22.
fault fault is counted load side
2. Check the load
by the main insulation levels.
controller.
6. However, if the
fault persists for
more than 2
times, 3rd time
it's a latched
shut down.
7. Indication of
external fault
LED (RED).
BATTERY CHARGER SECTION
1. Audible buzzer
indication.
1. Check the
2. Visible LED healthiness of
indication. Charger CC card.
Charger voltage Ÿ Charger CC card
23. (CHBA LED –
HIGH Ÿ Feedback wiring
OFF(GREEN)) 2. Verify the all the
connections of CC
3. Indication card.
Internal fault
LED (RED)
1. Audible buzzer
indication.
2. Visible LED 1. Check the

indication. healthiness of
Charger voltage (CHBA - OK Ÿ Charger CC card Charger CC card.
24.
LOW green LED - Ÿ Feed back wiring 2. Verify the all the
OFF)) connections of CC
card.
3. Indication
Internal fault
LED (RED)
68 IM- 41 rev 6
Status of
Message in
Display
occurrence
Ÿ Indication
External fault Ÿ Check the battery
Ÿ Battery Charger
Charging LED (RED). charger section
25. section output
current HIGH output load and
load.
Ÿ Only fault battery.
logging.
1. Check the battery
1. Rectifier OFF.
charger assembly.
Ÿ Load side 2. Check the load
2. Converter
connections. side connections.
restarts it self
3. Check the Thermal
(automatically)
Ÿ Battery charger switch connections
on finding LOW
assembly. to the Analog card.
CHBA Over CHBA
26. 4. Check the
temperature temperature i.e
Ÿ Thermal switch healthiness of
on clearance of
on charger heat Thermal switch.
the fault.
sink. 5. If still the fault
persists, don’t
3. Indication of
Ÿ Analog card close the DJ and
Internal fault
LED (RED).
1. Rectifier OFF.
2. Converter
restarts it self Ÿ Control supply 1. Check the 110 V
(automatically) (110 V) connections to the
on recovery of converter.
Control supply
27. control supply Ÿ Power supply
failure
i.e on clearance cards 2. Check the control
of the fault. supply connections
Ÿ TDC IF card. at TDC IF card.
3. Indication of
Internal fault
LED (RED).
1. Audible buzzer 1. Check healthiness
indication. of Battery charger
CC and MC card,
2. Visible LED charger IGBT.
indication.
(CHBA -OK Ÿ Check charger 2. Check charger
28. CHBA fault
green LED - section load.
OFF))
3. Indication persists, inform the
Internal fault condition to the
LED (RED) service staff.
IM- 41 rev 6 69
Procedure
10.2 FEEDBACK FORM

(Kindly fill up this feedback form with your comments/suggestions, which will
direct us to improve the quality of the product as well as to take corrective
action if essential)
From:
To
M/S MEDHA SERVO DRIVES (P) LTD.
P-4/5B, I.D.A, NACHARAM
Hyderabad – 500 076
Phone: +91 40 27171101
Fax: +91 40 27174908
1. Type of Unit : 180KVA STATIC

CONVERTER (MIN184)
2. Serial No. of the Unit :
3. Year of the Manufacturing :
4. Name of the Manufacturer : MEDHA SERVO
DRIVES (P) LTD.
5. Specification No. : ELRS/SPEC/SI/0018
6. Date of dispatch :
7. Date of receipt of the Unit :
8. Condition of the Unit on receipt : GOOD / OK / POOR
9. All the accessories / spares as
Per the Packing Slip found : YES / NO
10. Commissioned on :
11. Any difficulty at time of installation:
12. Any suggestions to modify the
Unit for better performance. :
13. Performance Test : SATISFACTORY /
NOT SATISFACTORY
(If not satisfactory please give details)
Remarks :
Signature: Stamp:
Date:
70 IM- 41 rev 6
Annexure - 1 MIN184 - Operation and Maintenance Manual
IM - 41 rev 6
IM - 41 rev 6
IM - 41 rev 6
IM - 41 rev 6
Operation and Maintenance Manual
SINGLE PHASE TO THREE PHASE

STATIC CONVERTER
TYPE MIN184
Medha Servo Drives Pvt. Ltd.

P- 4/5 B, I.D.A., Nacharam, Hyderabad - 500076. India.
www.medha.com

Min 184 Rev. 6

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Min 184 Rev. 6

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Operation and Maintenance Manual

IM - 41 rev 6 MEDHA SERVO DRIVES PVT. LTD.

This document contains confidential, proprietary information of

Document No: IM - 41 rev 6

The procedures in this manual have been compiled on the

This equipment is not to be used in the

DEFINITIONS AND SYMBOLS :

NOTE: Notes indicate an area or subject of special merit, emphasizing either

HAZARDOUS HIGH VOLTAGE :

HIGH VOLTAGE: Rectifier and Inverter assemblies are connected to

Disconnect power before checking controllers or performing maintenance. Be

GENERAL PRECAUTIONS - READ THESE FIRST

WARNING: This equipment should be installed, adjusted, and serviced by

HIGH VOLTAGE: Hazard of electrical shock. Disconnect incoming power

CAUTION: These instructions should be read and clearly understood before

WARNING: This equipment has high leakage current and must be

CAUTION: Hazardous voltages for input (main) connections, must be

CAUTION: Connection to field wiring terminals must be reliably fixed having

HIGH VOLTAGE: Be careful not to touch the wiring or connector terminals

2.1 General Description

2.2 Mechanical Arrangement

2.3 Technical Specifications

2.3.2 INPUT Specifications

Details HETT3900 5400KVA

2.3.3 DC Voltage supply for Control Electronics

2.3.4 Climatic and Environmental conditions :

2.4 System Specification

Parameter Design Value

Parameter Design Value

Category Type of Load Rating Remarks

Category Type of Load Rating Remarks

MVSI 1 2. 2kW Always connected

3.1 Block 1 – Input Section

R26 1200V R27

3.2 Block 2 – Rectifier Assembly

3.3 Block 3 – LC Filter and Brake Chopper

3.3.2 Brake Chopper

3.4 Block 4 – Inverter Assembly

3.5 Block 5 – Output Filtering and C.Ts

3.6 Block 6 – 3 Phase Output

3.7 Block 7 – Step down Transformer

3.8 Block 8 – Battery Charger Assembly

3.9 Block 9 – Battery Load

3.10 Block 10 – Lights Load

MAIN CARDS IN CONVERTER SECTION,

4.1 Card Level Description of MIN184

= Gate Drive PWM Card

O/P Filtering Transducer

4.2 Transducer Card

4.3 Display Card with VFD

INTERNAL FAULT EARTH BYPASS

INPUT VOLTAGE IN RANGE

RESET SW is used for BUZZER reset under faulty conditions only.

It is possible to connect a PC to the display card via an RS232 link, to retrieve

4.4 Thyristor Angle Firing Control Card

4.5 Power Supply Card

4.6 Main Control Card

4.7 Analog Card

4.8 Gate Drive Card

circuits and the drive signals. It is necessary to derive an isolated power

4.9 PWM Card

4.10 Capacitor High Voltage Card

4.11 Brake Chopper Card