STATIC CONVERTER

18 KV
 INTRODUCTION OF STATIC CONVERTER IN INDIAN
RAILWAY

The first Static converter was used in WCAM – 3 locomotives jointly developed
by RDSO and BHEL in 1997. The Static Converter converters the DC / AC
voltage into 3 phase, 415 volts for running auxiliary machines.

This converter was supplied by ACEC. In late 19s, SIEMENS provided 8 nos. 180
KVA Static Converter in conventional Locomotive at ELS / NCR / CNB.

Presently CLW manufactures only Static Converter fitted locomotive and till date,
the total population of Static Converters fitted locos are more than 750.

Advantages of Static Converter

i. Very steady output voltage with maximum regulation of ± 5%.

ii. All the three phases output voltages are balanced resulting in balanced
supply to the loads.
iii. Very high system efficiency.
iv. Soft starting of loads possible resulting in reduced system over loading.
v. In-built fault management system with storage of faults and traces.
vi. Various problems of auxiliary machines are reduced due to regulated and
balanced supply voltage.

Working Principal

The converter generates 415V, 3 phase, 50Hz output from 760V / 830V, 1 phase,
50Hz input which is available from the main locomotive transformer. The static
converter is made using a half controlled single phase bridge rectifier at the input, a
DC link filter and a three phase IGBT based PWM inverter. All functions of the
converter are controlled through 32 bits Digital signal processor (DSP) together
with an EPLD & host of digital gates and analog amplifiers.

THE CONVERTER CONSISTS OF FOLLOWING SUB-MODULES:

A.Input Section

The input section consists of input fuse (MF), Metal oxide varistors and input bus
bar. Input fuse is used to protect the converter and for ensuring safe operation of
the converter under worst input conditions. Metal oxide varistors (MOV) are used
to protect the converter from surges.

B.Rectifier Section

The rectifier section is made using a half controlled single phase bridge rectifier.
This consists of a half controlled bridge rectifier, made up of 2 thyristors and 2
diodes.
When the input AC voltage is positive, one of the thyristors is fired with a
predetermined delay. It starts conducting and the voltage of the DC link rises.

Fig. Rectified Waveform

The current continues to flow due to the DC link reactor, until the input voltage
changes polarity and the other thyristor is fired.

Now, the other thyristor with the corresponding diode takes over the current.

The main controller maintains the DC link voltage at a preset value by controlling
the firing angle of the thyristors.

A PI (proportional integral) controller is used to determine the firing angle. If the

DC link voltage is lower than desired voltage, the firing angle will be small and if
the DC link voltage is higher than the desired voltage, the firing angle will be
increased.

RC snubber circuits are provided across each thyristors and Diode’s to protect
against high “dv / dt”(rate of change of voltage with time) experience by devices.

C.Dc Link Filter & Over Voltage Chopper

The DC link filter consist of DC link Choke (FL) and DC link Capacitors (FC). DC
link Choke and Capacitors provided at the output of the rectifier to reduce the
ripples in the DC link voltage that is fed to the inverter.

The over voltage chopper is made-up of an IGBT switch with a resistor and an
anti-parallel diode. The IGBT switches the resistor on and off in the DC circuit if
the DC voltage exceeds a preset value.

The chopper dissipates the extra energy and protects the system from over voltage,
especially during transients at start-up.

D.Inverter Circuit
The Inverter consists of six IGBT modules. IGBT modules are configured as a 3-
phase bridge circuits. The bridge is made up of three identical phase branches and
each branch consists of two IGBTs.

The DC link voltage is converted into PWM sinusoidal waves by switching IGBTs
at a high frequency. The width of the individual pulses in the PWM wave
determines the amplitude of the output voltage and the width of the pulse block
determines the output frequency.

As the system is a constant voltage, constant frequency system, the output

frequency is maintained at 50Hz and the PI controller receives an output voltage
feedback in order to keep the voltage constant, too. The final stage is responsible
for generation of switching signals utilizing Space Vector Pulse Width Modulation
(SVPWM) technology.
State-of-the-art space vector PWM technique has been adopted in the design of
inverter software as this technology is more flexible & adapts to wider variations in
the input DC link voltages. For better regulation of the output voltage, proportional
integrated control has been used.

E.OUTPUT LC FILTER

The Inverter output voltage is PWM, which is converter into sine wave by using
output filter. It consists of 3 phases AC Choke (ACL) and 3 phases Capacitor
(ACC).

Brief Technical Specification

Input

i. Nominal voltage : AC single phase, 760V or 830V.

(corresponding to catenary voltage of 22.5KV)

ii. Min. voltage continuous : 642V AC.

iii. Max. Voltage continuous : 1014V AC.

iv. Min. voltage at which converter

trips on under voltage : < 591V AC.

v. Max. Voltage beyond which

converter trips on over voltage : 1150V AC.

vi. Input voltage range for which

guaranteed converter performance : 642V to 1014V AC.

is available
 vii. Input voltage range for which
guaranteed converter performance : 591V to 642V on lower side.

is not available but converter will : 1014V to 1150V on higher side.

not trip on either under voltage

or over voltage

viii. Power factor : 0.8 (At rated conditions).

ix. Input frequency : 50±3Hz.

Output

i. Output power : 180kVA, 0.8pf (at nominal operation).

ii. Overload : 200% for 5sec. (360KVA & current

Limit of 600A).

iii. Voltage 1 : AC 415V±5%, 3 phase system

between 642 - 1014V.

iv. Frequency : 50 Hz ±1% .

v. Waveform : Sine wave.

vi. THD in voltage : 10% (up to 20th harmonic).

vii. Efficiency : 92% (At nominal input voltage

And at rated load).

viii. Voltage 2 : DC 110V±5%,

[±5% ripple (rms) at full load and at nominal
continuous rated input voltage of 642 - 1014V].
Mechanical

i. Size (approx.) : Cubicle 1- 670mm(L)×1805mm(W)×1650mm(H).

: Cubicle 2 -850mm(L)×670mm(W)×390mm(H).

ii. Weight : Approx. 1440 kg (1320 kg + 120 kg).

iii. Cooling : Forced air cooling for Cubicle-1.

General

i. Ambient temperature : 0ºC to 70ºC (max. 55ºC inside loco).

ii. Humidity : 100% in rainy season (90% at 55ºC).

iii. Altitude : 160m above mean sea level.

iv. Dust : 1.6mg/cubic m, max. Ph 8.5.

v. Audible noise : 80dB (A) at 1m distance from

Cubicle as per IEC-1287-1.

vi. Display & communication : Vacuum fluorescent display and RS-232

Port for data logging.

vii. Control voltage : DC 110

As an effort towards continuous improvement, the present stage of the static

converter incorporates:
 Modular control unit

Battery Charger Input/output

Description of Static Converter

The static converter is made using a half controlled single phase bridge rectifier at
the input, a DC link filter and a three phase IGBT based PWM inverter. All
functions of the converter are controlled through 32 bits. Digital signal processor
(DSP) together with a EPLD & host of digital gates and analog amplifiers.

Input Module

The input section consist of input fuse ( MF ) , Metal oxide varistors and input bus
bar. Input fuse is used to protect the converter and for ensuring safe operation of
the converter under worst input conditions. Metal oxide varistors ( MOV ) are used
to protect the converter from surges.
 A. Rectifier Section

The input stage of the static converter consists of the main switch, input fuse and
rectifier circuit. The input fuse protects the circuit against input over current. The
rectifier circuit converts AC input voltage into DC voltage of desired level.

The configuration of the rectifier circuit is a semi-controlled rectifier bridge.

When the input voltage is positive, one of the thyristors is fired with a
predetermined delay. It starts conducting and the voltage of the DC link rises.
The current continues to flow due to the DC link reactor, until the input voltage
changes polarity and the other thyristor is fired. Now, this other thyristor with the
corresponding diode takes over the current. The main controller maintains the DC
link voltage at a preset value by controlling the firing angle of the thyristors. A PI
controller is used to determine the firing angle .

If the DC link voltage is lower than desired voltage, the firing angle will be small
and if the DC link voltage is higher than desired value, the firing angle will be
increased.

Fig. Block Diagram of Rectifier Control

 Rectifier Section

GDU CARD

A. DC link filter & Chopper Module

The DC link filter consist of DC link Choke ( FL ) and DC link Capacitors ( FC ). DC link
Choke and Capacitors provided at the output of the rectifier to reduces the ripples in the DC link
voltage which is fed to the inverter.
The over voltage chopper is made up of an IGBT switch with a resistor and an anti-parallel
diode. The IGBT switches the resistor on and off in the DC circuit if the DC voltage exceeds a
preset value. The chopper dissipates the extra energy and protects the system from over voltage,
especially during transients at start-up.

B. SMPS battery charger

It is made up of uncontrolled rectifier single phase IGBT inverter and filtering

circuit for providing boost and float mode charging.

C. Inverter Section

The inverter consists of six IGBT modules. IGBT are configured as a 3-phase bridge circuits.
The bridge is made up of three identical phase branches and each branch consists of two IGBTs.

The dc link voltage is converted into PWM sinusoidal waves by switching IGBTs at a high
frequency.

The width of individual pulses in the PWM wave determines the amplitude of the O/P voltage
and the width of the pulse block determines the O/P frequency.

As the system is a constant voltage, constant frequency system, the O/P frequency is maintain at
50 Hz and the PI controller receives an O/P voltage feedback in order to keep the voltage
constant too.

The final stage is responsible for generation of switching signals utilizing space vector pulse
width modulation (SVPWM) technology.
 Fig. Inverter Module

F. Output LC Filter
 The Inverter output voltage is PWM , which is converter into sine wave by using output
filter. It consist of 3 phase AC Choke(ACL) and 3 phase Capacitor(ACC ).

G. Main Controller Unit ( MCU )

 The main controller card consists of 32 bits digital signal processor (DSP) together with
a EPLD, host of digital gates and analog amplifiers, controlled the function of the
converter. It generates switching pulses to drive the IGBTs and thyristors.

It also monitors sensor signals to detect faults and abnormal operation of the static
converter. Status of various parameters are monitored and compared with the reference
levels. Desired preventive and corrective actions are initiated through the respective
controllers in the event of abnormal conditions.

Faults, if any are identified, stored in the fault memory and also can be displayed through
display panel. A communication port with RS-232 interface is provided on the front
panel for control gain setting, fault information and real time monitoring through a
Notebook PC.

A keyboard and Vacuum Fluorescent Display (VFD) is provided on the front panel for
selection of operation mode & text display of monitoring status, voltage, current level &
fault messages.

Main Control Card ( MCU ): Main Control Card ( MCU ):

KIT-2 KIT-3

H. Thyristor Gate Drive Card ( TGDU)

 The gate driver circuit receives switching pulses from the MCU card. The opto-coupler in
the gate driver provides the perfect isolation between the power circuit and the control
circuit for these pulses.

After further amplification, these switching pulses are sent to the Thyristors.

I. Chopper Gate Drive Card

The gate driver circuit receives switching pulses from the MCU card. The opto-coupler in
the gate driver provides the perfect isolation between the power circuit and the control
circuit for these pulses.

After further amplification, these switching pulses are sent to the Chopper IGBT. In case
of over-current of the chopper, the gate driver blocks the gate pulses to protect the IGBT
and feeds the information back to the main control card.

J. Inverter Gate Driver Card

 The gate driver circuit receives switching pulses from the MCU card. The opto-coupler in
the gate driver provides the perfect isolation between the power circuit and the control
circuit for these pulses.

After further amplification, these switching pulses are sent to the Inverter IGBTs. In case
of over-current of the inverter, the gate driver blocks the gate pulses to protect the IGBTs
and feeds the information back to the main control card.

K. Display card ( DCU )

A Vacuum Fluorescent Display ( VFD) is provided for display parameters and fault data
along with its associated keys / push buttons.

Display is provided on the front panel for selection of operation mode & text display of
monitoring status, voltage, current level & fault messages.

The display card also provide LED indications of various faults.

 A communication port with RS-232 interface is provided on the front panel for fault
information and real time monitoring through a Notebook PC.

L. Power Supply Card

M. Input Current Transformer ( ACCT )

The Input Current Transformer (ACCT ) is use to measure the input current. It is located
near to input section / Fuse.

Its ratio is 800 / 1 Amp. A burden resistor of 6 Ώ is always connected across its terminal.
N. Input Potential Transformer ( ACPT 1 )

The Input Potential Transformer ( ACPT 1 ) is use to measure the input voltage. It is
located at RFU section area. Its ratio is 1300/7.22 volts.

O.DC Link Current Transducer ( DCCT )

The DC Link Current Transducer ( DCCT ) is use to measure the DC link current.

P. DC Link Voltage Transducer ( DCPT )

The DC Link Voltage Transducer ( DCPT ) is use to measure the DC link voltage. It is
located at RFU section area.

Q. Chopper Current Transducer ( CHCT )

The Chopper Current Transducer ( CHCT ) is use to measure the Chopper current.

R.Output Current Transformer

 The Output Current Transformer ( ACCT1 / ACCT2 / ACCT3 ) are use to measure the
output current. It is located output section.

Its ratio is 800 / 1 Amp. A burden resistor of 6 Ώ is always connected across its
terminals.

S. Output Potential Transformer

The Output Potential Transformer ( ACPT 2) is use to measure the output voltage. It is
located at RFU section area. Its ratio is 600/7.22 volts.

T.Zero Current Transformer

The Zero Current Transformers are use to measure the Input leakage current
( ZCT 1) and Output leakage current ( ZCT 2 ).

They are located near Input section and Output section respectively.

Protection & Settings

The Static converter is equipped with circuits to protect itself and its load from all disturbances.
Its operation is stopped by all fault conditions.

1. Open Circuit in Auxiliary Winding

This circuit detects that input voltage is too low or completely absent. It is practically the
protection from input under voltage.

2. Fuse Failure in Converter

 This circuit monitors the signals from the fuse contacts and if a fuse blows the converter
is tripped.

3. Thermal Overloading

Temperature sensors are mounted on the heat sinks of the rectifier unit and the inverter
unit. If the temperature of the heat sink exceeds a predetermined level, a fault signal is sent
to the main controller.

The operation of inverter is stopped. The circuit resumes operation automatically when the
temperature returns to normal.

4. High/Low Voltage in DC Link

A voltage sensor monitors the DC link voltage. If DC link voltage is too high or too low, the
main controller shuts down the converter.

5. Failure of Power Supply to Control Electronics

The main controller monitors the power supply. If a failure is detected, the main controller
blocks the gate signals of IGBTs and thyristors.

6. Transient & Surge Protection

Voltage surge suppressor is provided at the input.

7. Input Over/Under Voltage

The main controller monitors input voltage continuously. The sensor is located at the input
of the rectifier circuit.

In case the input voltage exceeds the predetermined value of under voltage or over voltage,
an alarm signal is given to the main controller, which initiates adequate protective
operation. When the input voltage returns to normal, the inverter resumes normal
operation.

8. Input Over Current

The current sensors are also installed at the input of the rectifier circuit. Whenever the
input current exceeds the predetermined value, a fault signal is sent to the main controller
to initiate required protection.

9. Output Over/Under Voltage

The voltage exceeds the predetermined value of over voltage or under voltage, a fault signal
is sent to the main controller to initiate the protective operation. The main controller
immediately switches off the inverter.

10. Output Over Current

The output of the inverter is protected against overload. Whenever the output current
exceeds the predetermined value, a fault signal is sent to the main controller to initiate
required protection.

11. Short Circuit at Output

The output of the inverter is protected against short circuit. Whenever the output current
exceeds the predetermined value, the main controller initiate required protection. Under
short circuit conditions, a fast current limit protects the power semi-conductors in the 3-
phase Inverter Bridge.

12. Earth Leakage

In case the earth leakage detector has detected an earth leakage current, an earth fault is
initiated and the inverter trips.

13. Single Phasing

The single phasing protection is automatically available in the inverter through the over
current protection. If the output current of the inverter exceeds the predetermined limit
due to single phasing, then the inverter will trip.