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DC to AC Inverter/Battery Charger
Release 1.1
12-Nov-02
Transtechnik Corp. USA P/N XXXXX
EXCERPTS
from
Freund Associates Technical Communication
Release History
Release
Date
Author
1.0
June 2002
John Freund
1.1
Nov. 2002
John Freund
Comment
Initial Release (MSWord 2000)
Copyright 2002
By transtechnik Corp. USA
All Rights Reserved
This manual and all contents within are the sole property of
transtechnik Corp. USA.
All rights of design or invention are reserved.
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Table of Contents
CHAPTER 1 INTRODUCTION ........................................................................................ 1-1
Safety Information............................................................................................................ 1-1
Unit Identification ............................................................................................................ 1-2
Function............................................................................................................................. 1-3
Inverter vs. Motor-Alternator .......................................................................................... 1-4
Operational Characteristics ............................................................................................ 1-5
System Features............................................................................................................... 1-5
Physical Description ......................................................................................................... 1-7
Service Access................................................................................................................. 1-8
Enclosure ......................................................................................................................... 1-9
Cooling of power converter........................................................................................... 1-10
Diagnostics .................................................................................................................... 1-10
Operational Specifications ............................................................................................. 1-11
Input Characteristics...................................................................................................... 1-11
Output Characteristics ................................................................................................... 1-11
Inverter .................................................................................................................................... 1-11
Battery Charging ..................................................................................................................... 1-11
Components................................................................................................................... 2-10
Inverter Modules A300 and A400 ........................................................................................... 2-10
Main output transformers ........................................................................................................ 2-12
Output Filtering ....................................................................................................................... 2-12
AC Regulation Board A38 ...................................................................................................... 2-13
LED array of the AC control board...................................................................................... 2-16
Feedback Transformer Boards A32 and A33 .......................................................................... 2-18
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Components................................................................................................................... 2-24
DC regulation board A78 ........................................................................................................ 2-27
-Regulating functions .............................................................................................................. 2-29
-LED array of the BC control board ........................................................................................ 2-31
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FIGURES
Figure 1. The Inverter/BC System....................................................................................................... 1-7
Figure 2. Orientation and mounting of Inverter/BC ............................................................................ 1-8
Figure 3. Internal Layout..................................................................................................................... 1-9
Figure 4. Input Protection Schematic .................................................................................................. 2-3
Figure 5. Dynamic Voltage Limitation (DVL).................................................................................... 2-4
Figure 6. Generation of 6-Step Waveform .......................................................................................... 2-7
Figure 7. Generation of the final (12-Step) AC waveform.................................................................. 2-8
Figure 8. Regulating Output Voltage with PWM................................................................................ 2-9
Figure 9. Inverter Sub-system ........................................................................................................... 2-11
Figure 10. Pulse-width modulation of the driver signal keeps the output voltage VAC constant....... 2-15
Figure 11. LED array of the AC control board A38.......................................................................... 2-17
Figure 12. Three Phase Full Bridge Rectifier and Output ................................................................. 2-20
Figure 13. Generating of the constant d.c. voltage in the dc-dc input stage ...................................... 2-22
Figure 14. Battery Temperature Compensation Curve...................................................................... 2-24
Figure 15. Battery Charger Sub-system ............................................................................................ 2-25
Figure 16. DC Chopper Module (A700) Control Signals.................................................................. 2-30
Figure 17. BC Control Board Status Indicators................................................................................. 2-31
Figure 18. Unit Control and Power Supply ....................................................................................... 2-37
Figure 19. View of the TTDiag WR and AUX Panels ........................................................................ 3-3
Figure 20. View of the TTDiag BC Panel ......................................................................................... 3-23
Figure 21. Bus Bar Connection Points ................................................................................................ 4-8
Figure 22. X100 Test Interface............................................................................................................ 4-9
Figure 23. Fan Connections............................................................................................................... 4-10
Figure 24. Test 1A Output................................................................................................................. 4-12
Figure 25. Test 1B Output................................................................................................................. 4-13
Figure 26. Test 1C Output................................................................................................................. 4-14
Figure 27. Inverter Dead Time rising edge........................................................................................ 4-31
Figure 28. Inverter Dead Time falling edge ...................................................................................... 4-32
Figure 29. Inverter IGBT Oscilloscope Probe Locations (A31 Board) ............................................. 4-32
Figure 30. Soft Start Pulses ............................................................................................................... 4-34
Figure 31. Phase Shift Measurement................................................................................................. 4-36
Figure 32. ........................................................................................................................................... 4-39
Figure 33. ........................................................................................................................................... 4-40
Figure 34. ........................................................................................................................................... 4-45
Figure 35. ........................................................................................................................................... 4-46
Figure 36. ........................................................................................................................................... 4-47
Figure 37 ............................................................................................................................................ 4-47
Figure 38. ........................................................................................................................................... 4-60
Figure 39. ........................................................................................................................................... 4-61
Figure 40. ........................................................................................................................................... 4-62
Figure 41. ........................................................................................................................................... 4-65
Figure 42. ........................................................................................................................................... 4-65
Figure 43. ........................................................................................................................................... 4-66
Figure 44. Rogofsky Probe on A700 Current Sense Line ................................................................. 4-68
Figure 45. ........................................................................................................................................... 4-69
Figure 46. ........................................................................................................................................... 4-70
Figure 47. Location of SCR Status Indicator .................................................................................... 4-73
Figure 48. X100 Test Interface.......................................................................................................... 4-78
Figure 49. External Load Contactor Indicator Lights........................................................................ 4-78
Figure 50. Time Delay for Phase Imbalance ..................................................................................... 4-87
Figure 51. Unit Orientation ................................................................................................................. 5-2
Figure 52. Compartments .................................................................................................................... 5-3
Figure 53. Unit Mounting.................................................................................................................... 5-6
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FIGURES
Figure 54. Inverter/BC Access Panels................................................................................................. 5-7
Figure 55. Bottom Access Panels........................................................................................................ 5-8
Figure 56. Top Panel Access............................................................................................................... 5-9
Figure 57. Front of Hinged Electronics Panel ................................................................................... 5-15
Figure 58. Rear of Hinged Electronics Panel .................................................................................... 5-15
Figure 59. Left-side of Electronic Bay .............................................................................................. 5-16
Figure 60. Right side of Electronics Bay........................................................................................... 5-17
Figure 61. Left Top Section of Electronics Bay ................................................................................ 5-17
Figure 62. Control Board Assembly.................................................................................................. 5-18
Figure 63. A10, A11, A09 Control Board Assembly ........................................................................ 5-19
Figure 64. Diode Snubber Circuit Boards (A14.1 A14.5) .............................................................. 5-21
Figure 65. Detailed View of the Diode Resistor Boards (A16 & A17)............................................. 5-22
Figure 66. Inverter Control Board (A38)........................................................................................... 5-23
Figure 67. Voltage Divider Boards (A74, A76 & A79) .................................................................... 5-25
Figure 68. Regulator Control Board (A78) ....................................................................................... 5-27
Figure 69. Diode Snubber (A15) ....................................................................................................... 5-29
Figure 70. 15V Power Supply Board (A07) ...................................................................................... 5-30
Figure 71. Phase Control Board (A34, middle)................................................................................. 5-32
Figure 72. Temperature Compensation Board (A75, far right) ......................................................... 5-33
Figure 73. Detailed View of the 5V DC Supply Board (A77) .......................................................... 5-34
Figure 74. Detailed View of C03 Capacitor ...................................................................................... 5-36
Figure 75. Crowbar Trigger Board (A02) ......................................................................................... 5-38
Figure 76. Dead Battery Start Board (A04)....................................................................................... 5-40
Figure 77. High Voltage Relay Board (A05) .................................................................................... 5-41
Figure 78. Capacitor Monitoring Board (A06).................................................................................. 5-42
Figure 79. Crowbar Assembly (L02)................................................................................................. 5-44
Figure 80 Capacitor Discharging Resistors (R01)............................................................................. 5-46
Figure 81. Input Filter Capacitor (C01)............................................................................................. 5-49
Figure 82. Inverter Heat Sink Module (A300) .................................................................................. 5-50
Figure 83 View of Bus Bar above A300 and A400........................................................................... 5-51
Figure 84. Inverter Heat Sink Module (A400) .................................................................................. 5-54
Figure 85 IGBT Driver Board (A31)................................................................................................. 5-57
Figure 86. Ring Core Assembly ........................................................................................................ 5-59
Figure 87. Actual Value Transformer Boards (A32, A33) ................................................................ 5-60
Figure 88. High Voltage Warning Light Board (A08.1) ................................................................... 5-62
Figure 89. Fault Light Board (A12) .................................................................................................. 5-63
Figure 90. Re-Start Switch (S01) ...................................................................................................... 5-65
Figure 91. Dynamic Voltage Resistor Assembly (R02) ..................................................................... 5-67
Figure 92. Dynamic Voltage Limiter Assembly (A100) Details....................................................... 5-69
Figure 93. LVPS Chopper (A700) Assembly Access ....................................................................... 5-72
Figure 94 LVPS Chopper (A700) Assembly Details ........................................................................ 5-73
Figure 95. A71 PC Board .................................................................................................................. 5-76
Figure 96. The Input Filter Choke (L01)........................................................................................... 5-78
Figure 97. The Fan Assembly (M30) ................................................................................................ 5-79
Figure 98 Transformers T310 and T410............................................................................................ 5-81
Figure 99. The Capacitor Assembly (C31-C36)................................................................................ 5-82
Figure 100. Capacitor Connections at the L1, L2, L3 Bus Bars........................................................ 5-83
Figure 101. Detailed View of Input Junction Box............................................................................. 5-85
Figure 102. LED Fuse Indicator (A08.2) .......................................................................................... 5-86
Figure 103. Output Terminals ........................................................................................................... 5-87
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Tables
Table 1. Observable Differences ......................................................................................................... 1-4
Table 2. Transformer Characteristics ................................................................................................ 2-12
Table 3. A38 Control Board Status Indicators .................................................................................. 2-17
Table 4. A78 Control Board Status Indicators .................................................................................. 2-32
Table 5. Load Management Timing .................................................................................................. 2-40
Table 6. WR Panel Status Indicator Summary .................................................................................... 3-4
Table 7. AUX Panel Status Indicator Summary.................................................................................. 3-7
Table 8. Troubleshooting based upon WR/AUX Status Indicators................................................... 3-11
Table 9. BC Panel Status Indicator Summary ................................................................................... 3-23
Table 10. Troubleshooting based upon BC Status Indicators............................................................ 3-26
Table 11. Troubleshooting based upon Functional Test Results ....................................................... 3-33
Table 12. Individual Tests Contained in the Functional Test .............................................................. 4-2
Table 13. Recommended Test Equipment........................................................................................... 4-4
Table 14. Inverter and BC Test Loads................................................................................................. 4-6
Table 15. Stardard Functional Test Setup ........................................................................................... 4-7
Table 16. Input Filter Test Setup....................................................................................................... 4-11
Table 17. Input Filter Test 1A (150V)............................................................................................... 4-12
Table 18. Input Filter Test 1B (300V)............................................................................................... 4-13
Table 19. Input Filter Test 1C (600V)............................................................................................... 4-14
Table 20. Preparing for Circuit Board Power Tests .......................................................................... 4-15
Table 21. Supply Voltages ................................................................................................................ 4-16
Table 22. Reference Voltages............................................................................................................ 4-17
Table 23. Record Data from TTDiag ................................................................................................ 4-18
Table 24. Diagnostic Checklist for Board A38 ................................................................................. 4-19
Table 25. Diagnostic Checklist for Board A78 ................................................................................. 4-21
Table 26. Temperature Failure simulated on the A38 board ............................................................. 4-23
Table 27. Saturation Voltage on Board A38 ..................................................................................... 4-25
Table 28. Temperature Failure on Board A78................................................................................... 4-27
Table 29. Saturation Voltage on Board A78 ..................................................................................... 4-28
Table 30. Procedure for Measuring Inverter Driver Dead Time ....................................................... 4-30
Table 31. Inverter Driver Dead Time Test Points ............................................................................. 4-33
Table 32. Soft Start Pulse Check....................................................................................................... 4-34
Table 33. Phase Shift at Module A300.............................................................................................. 4-35
Table 34. Phase Shift at Module A400.............................................................................................. 4-37
Table 35. AC Output Amplitude and Waveform Test Setup............................................................. 4-38
Table 36. AC Output Amplitude and Waveform Test (L1-L2)......................................................... 4-39
Table 37. AC Output Amplitude and Waveform Test (L2-L3)......................................................... 4-41
Table 38. AC Output Amplitude and Waveform Test (L1-L3)......................................................... 4-42
Table 39. AC Output Amplitude and Waveform Test (L1-N) .......................................................... 4-42
Table 40. AC Output Amplitude and Waveform Test (L2-N) .......................................................... 4-43
Table 41. AC Output Amplitude and Waveform Test (L3-N) .......................................................... 4-43
Table 42. Checking Actual Value of the Output Voltage.................................................................. 4-44
Table 43. Checking the Output Voltage with the Oscilloscope......................................................... 4-46
Table 44. Measuring Output Frequency ............................................................................................ 4-48
Table 45. Checking Phase Sequence ................................................................................................. 4-48
Table 46. Checking the Warning Lights (A08.1; A08.2) .................................................................. 4-49
Table 47. Checking the Output Under/Over Voltage Protection....................................................... 4-49
Table 48. Test Procedure for HV Relay ............................................................................................ 4-51
Table 49. Test Procedure for High-Low Input Voltage..................................................................... 4-52
Table 50. Checking the Capacitor Discharge Time........................................................................... 4-53
Table 51. Preparing for the Power Load Tests .................................................................................. 4-54
Table 52. Checking the Nominal Load.............................................................................................. 4-54
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Tables
Table 53. Testing for Overload ......................................................................................................... 4-56
Table 54. Testing Maximum and Minimum Voltage ........................................................................ 4-58
Table 55. Testing for Short Circuit on Nominal Output Load........................................................... 4-59
Table 56. Regulation Characteristic .................................................................................................. 4-61
Table 57. Load Switching ................................................................................................................. 4-62
Table 58. Checking BC Under-Voltage Control ............................................................................... 4-63
Table 59. Checking BC Over-Voltage Control ................................................................................. 4-64
Table 60. Checking the A700-Chopper Dead Time .......................................................................... 4-64
Table 61. Checking Input-Output Voltage ........................................................................................ 4-67
Table 62. Checking A700-Chopper Waveforms ............................................................................... 4-68
Table 63. Checking A700- Current Limitation ................................................................................. 4-71
Table 64. Battery Switchover Test .................................................................................................... 4-72
Table 65. TTDiag Tests..................................................................................................................... 4-75
Table 66. External Load Contactor Sequence ................................................................................... 4-77
Table 67. Warm-up Switch Test........................................................................................................ 4-79
Table 68. Simulating Over Temperature ........................................................................................... 4-83
Table 69. Simulating Open Voltage Sense Line to Battery............................................................... 4-84
Table 70. Checking External Enable Switch ..................................................................................... 4-85
Table 71. Checking Inverter Voltage Limitation and Imbalance Detection ...................................... 4-86
Table 72. Checking BC Operation in Final Configuration................................................................ 4-88
Table 73. Checking the Dead Battery Start.................................................................................... 4-89
Table 74. External Connection Torque Requirments .......................................................................... 5-6
Table 75. Breakdown of LRUs and Their Locations......................................................................... 5-10
Table 76. To Remove the Control Board Assembly (A09) ............................................................... 5-19
Table 77. To Install the Control Board Assembly (A09) .................................................................. 5-20
Table 78. To Remove the Diode Snubber Circuit Boards (A14.1 A14.5)...................................... 5-21
Table 79. To Install the Diode Snubber Circuit Boards (A14.1 A14.5) ......................................... 5-21
Table 80. To Remove the Diode Resistor Boards (A16 & A17) ....................................................... 5-22
Table 81. To Install the Diode Resistor Boards (A16 & A17) .......................................................... 5-22
Table 82. To Remove the Inverter Control Board (A38) .................................................................. 5-24
Table 83. To Install the Inverter Control Board (A38)...................................................................... 5-24
Table 84. To Remove the Voltage Divider Boards (A74, A76 & A79) ............................................ 5-25
Table 85. To Install the Voltage Divider Boards (A74, A76 & A79) ............................................... 5-26
Table 86. To Remove the Regulator Control Board (A78) ............................................................... 5-27
Table 87. To Install the Regulator Control Board (A78)................................................................... 5-28
Table 88. To Remove the Diode Snubber (A15)............................................................................... 5-29
Table 89. To Install the Diode Snubber (A15) .................................................................................. 5-29
Table 90. To Remove the 15V Power Supply Board (A07).............................................................. 5-30
Table 91. To Install the 15V Power Supply Board (A07) ................................................................. 5-31
Table 92. To Remove the Phase Control Board (A34)...................................................................... 5-32
Table 93. To Install the Phase Control Board (A34) ......................................................................... 5-32
Table 94. To Remove the Temperature Compensation Board (A75)................................................ 5-33
Table 95. To Install the Temperature Compensation Board (A75) ................................................... 5-34
Table 96. To Remove the 5V DC Supply Board (A77) .................................................................... 5-35
Table 97. To Install the 5V DC Supply Board (A77)........................................................................ 5-35
Table 98. To Remove the C03 Capacitor .......................................................................................... 5-36
Table 99. To Install the C03 Capacitor.............................................................................................. 5-36
Table 100. To Remove the R03 Resistor........................................................................................... 5-37
Table 101. To Install the R03 Resistor .............................................................................................. 5-37
Table 102. To Remove the Control Trigger Board (A02) ................................................................. 5-39
Table 103. To Install the Control Trigger Board (A02) .................................................................... 5-39
Table 104. To Remove the Dead Battery Start Board (A04)............................................................. 5-40
Table 105. To Replace the Dead Battery Start Board (A04) ............................................................. 5-40
Table 106. To Remove the High Voltage Relay Board (A05) .......................................................... 5-41
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Tables
Table 107.
Table 108.
Table 109.
Table 110.
Table 111.
Table 112.
Table 113.
Table 114.
Table 115.
Table 116.
Table 117.
Table 118.
Table 119.
Table 120.
Table 121.
Table 122.
Table 123.
Table 124.
Table 125.
Table 126.
Table 127.
Table 128.
Table 129.
Table 130.
Table 131.
Table 132.
Table 133.
Table 134.
Table 135.
Table 136.
Table 137.
Table 138.
Table 139.
Table 140.
Table 141.
Table 142.
Table 143.
Table 144.
Table 145.
Table 146.
Table 147.
Table 148.
Table 149.
Table 150.
Table 151.
Table 152.
Table 153.
Table 154.
Table 155.
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Chapter 1 Introduction
Service Access
Internal
Access:
The Inverter can be opened easily and quickly even when the unit is in place.
The Side Access Cover allows access to most of the electronic controls and most of
the modules that are likely to be replaced during servicing.
Bottom Access Covers allow access to the other compartments and improve access
to the inverter electronic assemblies.
The service covers are held by large thread captive fasteners and can be opened
using a Torx head (T30) driver.
Connections: All electrical connections are easily accessible from the exterior of the Inverter.
Simple Unit
Removal:
DC Input connections (L+ & L-) are located within the Input Junction Box
on the South side of the unit.
AC and Battery Output connections (L1,L2,L3,N,B+,B-,BN+) are located
within the Output Junction Box located on the west side of the unit.
Ground connections are located on the exterior of the unit on the east and
west sides of the unit
The X100 and X200 connectors for control and diagnostics are located on
the north side of the unit, adjacent to the Side Access Panel.
All routine maintenance work and the most repair service chores can be carried out
without dismounting the unit from the rail car. If removal is necessary, the unit can
be removed relatively easily at the LIRR maintenance facility.
NORTH
EAST
Side Access Panel
WEST
Input
Terminal
Box
Ouput
Terminal
Box
SOUTH
Bottom Access Panels
Bottom Panels
Hinged at Center
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A300
A400
RED
YELLOW
IDYN
GREEN
ENABLE
IMAX
GREEN
RUN
RED
V31/32
YELLOW
RED
V33/34
RED
UACMAX
RED
V35/36
RED
RED
T 100
RED
UIMAX
YELLOW
STDBY
COUTP
RED
ERROR
YELLOW
CACTIV
RED
RESET
RED
TTRANS
YELLOW
YELLOW
UIMIN
RED
T 80
UISYS
LED
Color
Description
Unit
Shutdown
Field in
TTDiag
WR Panel
ENABLE
Green
No
Enable
RUN
Green
No
Run
STDBY
Yellow
No
Ready
ERROR
Red
Yes
Error
A300
A400
Red
NA
NA
V31/32
Red
Yes
IGBT 31/32
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AC to DC Rectification
The Battery Charger uses the AC output of the Inverter as its source of input power.
This 3-phase AC output is converted to DC through a 3-phase Full Bridge Rectifier as
shown in Figure 12. The rectifier combines the 3 phases of the 230VAC input,
converting it into a single 700VDC current. The output (shown in Figure 12) has a
relatively high ripple (variation in voltage).
Rectifier Output
DC with Ripple
DC Output
L1
L2
L3
3 Phase AC
Input
Combined 3 Phase AC
- DC Output
Figure 13 outlines the steps taken in the Battery Charger (BC) to control the DC
output voltage. Note the reference number (1-5) on the right side. These are referred
to in the discussion below.
The BC must produce a constant low voltage output (5) from the varying higher input
voltage. The BC uses a Pulse Width Modulation (PWM) technique to control the
overall output voltage. By rapidly switching on and off the current flow, it is possible
to regulate the overall voltage. The timing of the pulses is affected by the input
voltage. To highlight the difference, Figure 13 is divided into two columns:
Input voltage at the upper limit of tolerance (left column)
Input voltage at the lower limit of tolerance (right column).
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Chapter 3 -Diagnostics
303
304
TTDiag Panel
Status Indicator
Ready
(WR)
Error
(WR)
Meaning of
Indication
No error present, but
input voltage VI of the
inverter is below
specified minimum.
Inverter is on standby.
Serious error (shut
down of inverter).
Possible Cause
Replace A38.
305
Enable
(WR)
No error present
306
VH err
(WR)
Error in electronics
voltage supply of AC
board A38
Replace C03
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Chapter 3 Diagnostics
Functional Test
Observed Failure
Short Circuit on
Nominal Output
Load.
Maximum and
Minimum
Voltage Tests.
FT23 Test 11
Probable Cause
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Warning
Do not run the inverter at moderate to high loads (>100A) for extended periods (>1
minute) with the bottom access panels open and/or the fan disconnected. The
transformers could over heat and be damaged.
Do not touch or handle printed circuit boards without proper grounding. Static
discharges can damage components.
Use a diode to protect the power supply.
Recommendations
Do not use conductive tools near boards while powered. Place jumpers by hand or use
non-conductive tools.
Keep a trusted voltmeter attached to BusBar+ and BusBar- at all times to verify
capacitor charge levels. See Figure 21.
Only low voltage DC power is present on the Hinged Electronics Panel. All other
areas should be considered as potentially containing high voltages. This includes the
Left and Right portions of the Electronics Bay behind the Hinged Electronics Panel.
STANDARD FUNCTIONAL TEST SETUP
The tests listed in this section are intended to be performed in order as they are
presented in this section. Each test is written to allow individual test to be performed
out of sequence, however all sub test should be performed in order ( In Test 1,
perform tests 1A, 1B & 1C). All test will assume that the unit has been setup for
testing as outlined in Table 15..
Table 15. Stardard Functional Test Setup
Step
1
2
3
4
5
Action
Open and remove the Side Access Cover .
Follow the instructions in Section 5.
Release the hinged panel behind the Side Access Panel
Follow the instructions in Section 5.
Open and remove the both Bottom Access Covers .
Follow the instructions in Section 5.
Connect Inputs
Connect the HVPS (defined in Table 13) on L+ and LThey should not be applied at this time, Switch should be open
Connect Ground to the ground terminals on the exterior of the Inverter/BC.
Connect Voltmeters
These voltmeters are used throughout testing, leave them in position
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Action
Connect a voltmeter to BusBar + and BusBar in electronics bay on plates
near A300/A400. as shown in Figure 21.
Figure 21. Bus Bar Connection Points
Recommendation
This voltmeter measures the voltage across the input capacitor.
Leave it in position throughout testing as a safety precaution. It will
provide confirmation that voltage in the capacitor has dissipated.
7
8
9
10
11
Connect a voltmeter to terminals B+ and BConnect a voltmeter to the output terminals at L1 and L2
Connect loads on L1, L2, L3
They should not be applied at this time, Switch should be open.
Connect the X100 Test Interface (Figure 22) to the X100 connector at the
exterior of the Inverter/BC.
Turn the Enable switch on.
Set S1 to the OK position (Up)
to simulate an normally closed Battery Temperature Switch
Set the Load Shed (Warm-up) switch to the on position (middle position
on X100 Interface). The K3 and K4 contacts will be energized during
operation.
Set Pot 1 switch to UP position
connected to the actual Battery Sensor on X100 Test Interface
Connect the battery sensor wires from the X100 Test Interface to:
Red
B+
Black BConnect a PC to connector X200.
Note: Requires a serial cable NOT a null modem specified in the TTDiag User
Manual and Table 13.
Start the program TTDiag at the PC with TTDiag..
Type O to set the TTDiag into online-mode.
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5
6
Action
Continue from Table 61.
Turn off the PSB ( to turn of power to the electronics)
Connect the Battery load bank to the B+ and B- terminals. Keep existing
connections at B+ and B-.
To Simulate BC operation:
Place a jumper on the J8 Freigabe jumper location on A78
Place a jumper on the J15 Ena jumper location on A78
Connect a 10:1 probes from CH1 to test point P9 (A2) on A78.
Connect a 10:1 probes from CH2 to test point P18 (D2) on A78.
Connect the Rogofsky current probe in the cables through current sense on A700.
Figure 44. Rogofsky Probe on A700 Current Sense Line
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8
9
10
11
Action
Connect the Differential Voltage Probe
Positive (Red) to B+
Minus (Black) to BAttach the probe to CH4
Turn on the PSB and set the voltage to 24VDC ( to power to the electronics)
Switch on a Nominal Battery load on B+.
Raise the input voltage from the HVPS to about 500V.
With output at 37.6V, compare your results with
Figure 45.
Figure 45.
2001/07/26 20:01:06
Stopped
NORM:50MS/s
20us/div
(20us/div)
CH1=10V
DC 10:1
CH2=10V
DC 10:1
CH3=200mV
DC 1:1
CH1 A2(P9)
CH2 D2(P18)
CH3 I prim 20A/div
GND (P7)
Time base: 20s/div
=Filter=
Smoothing : OFF
BW : FULL
12
=Offset=
CH1 : 0.0V
CH2 : 0.0V
CH3 : 0.000V
CH4 : 0.0V
=Record Length=
Main : 10K
Zoom : 10K
=Trigger=
Mode : AUTO
Type : EDGE CH1
Delay : 0.0ns
Holdoff : MINIMUM
Oscilloscope-Trigger:
Type: Normal
Source: CH1
Rising Edge
YES = OK
NO
Excerpt
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The procedure for removing the crowbar assembly is described in Table 110. The
procedure for installing the crowbar assembly is described in Table 111.
Table 110. To Remove the Crowbar Assembly (L02)
Step
Action
Cut the 2 cable ties (Item 1) from the tie mounts near the A02 board leading to
the A02/X10 connector. Move the cables out of the way
It may be necessary to remove cable ties (Item 2) on the wire leading to
A02/X11, X12, and X13.
Remove two hex head bolts (Item 3), each securing a cable marked VTH01AL, from the base plate, next to L02 . Move the two cables aside.
One of the L02 wires goes to A100 in the Right (West) Section (Item 4). Six
harness Ties will have to be cut in order to free this wire from the cable going
to the Right Section.
2
3
4
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Action
Remove a hex bolt from the VD01A terminal on the A100 heat sink (in the
Right Section) This terminal is just to the left of VD01. (See Figure 92, Item
4). As an alternative to cutting the six harness Ties, cut back the L02 wire from
A100 at its entrance to the wire bundle. Do the same at its exit point to L02.
Add additional Ties for the replacement L02 wire.
The other L02 wire is internal to the assembly.
Remove the yellow and red wires with push-on connectors from the A02 board
at the X1 and X2 (Item 5) connectors. A02 is on the Mounting Platform above
C01.
Remove the socket-head screw holding 2 gray wires with a yellow strip marked
VTH01-AL on base of the L02 assembly near the side access panel (Item 6).
Cut the first cable tie holding those two wires together.
Remove four socket head screws at the corners of the L02 Assembly base plate
(Item 7).
6
7
Action
Mount the assembly on the plastic mounting stand-offs with L02 closest to the
A400 module. Secure the base with four socket-head screws (Item 7 -inch
steel) with split-locks and flat washers and tighten to 48 in.-lbs.
Connect the two gray wires with a yellow stripe (marked VTH01-AL) directly
to the base near the side access panel (Item 6). One wire comes from the
A02/X8 connector and the other from the circuit board in the circuit board on
the L02 assembly. Secure with a socket-head screw with a split-lock and
washer.
Use a cable tie to secure these two wires together between the tie mount and
the socket head screw.
Connect the push-on connectors with red and yellow wires from X1 and X2
(Item 5) to A02. A02 is on the Mounting Platform above C01. Make sure all
connectors are securely in place. Use a cable tie to secure these wires to the
cable mount between the L02 assembly and the A02 board.
Replace the hex bolt on the A terminal on the A100 heat sink (in the Right,
West section). This terminal is just to the right of VD01. (See Figure 92, Item
4).Tighten the hex bolt until snug, and then add another turn.
Replace the six cable ties securing the L02 wire (Item 4) attached to the left
section of the A100 heat sink.
Connect the two cables marked VTH01-AL (Item 3) attached to the base plate
at the terminal locations next to L02. Secure with hex bolts, split-locks, and flat
washers and tighten until snug, and then add another turn.
Secure the cables with cables ties (Items 1 & 2).
Inspection: Make sure that all screws and nuts are properly torqued and that
they are marked by Glyptol.
5
6
7
8
Excerpt
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