GTO User Manual - Advanced Rail Controls
Contents
1. ADVANCED RAIL CONTROLS PVT LTD 9 13 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL pa 9 o GT v LI Cy re 2 FIGURE 3 _____1 1 1 1 _ ADVANCED RAIL CONTROLS PVT LTD 2 743 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL FIGURE 4 V ADVANCED RAIL CONTROLS PVT LTD 913 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL 6 PROCEDURE FOR CONNECTION OF SPEED SENSOR WITH CRO SETTINGS ON THE TEST BENCH Connect 3 pin female connector to dc power supply pin Ato be connected to positive of the DC power supply and pin B to be connected to negative of the DC power supply FIGURE 7 Connect signal cable to CRO probes In signal connector pin A to be connected to positive probe of the CRO and Pin B to the ground probe CRO settings are given bellow Channel 1 set the voltage div to 1volt Channel 2 set the voltage div to 1volt Time div 25us If motor runs in anti clockwise looking from wheel end direction of pulses should be in positive direction as shown in theFIGURE 5 Tek A Tria d Pos 0 0005 SAVEZREC Action File Format About sawing Images Select Folder Save TERKOOOS JPG CH1 1 00 CH2 1 00 25 0 us CH1 240m v2. HALL EFFECT ACTIVE SPEED SENSOR FOR 3 PHASE TRACTION MOTOR TYPES 6FRA6068 6FXA7059 FED FROM GTO CONVERTER USER MANUAL Release V 1 0 ADVANCED RAIL CONTROLS PRIVATE LIMITED 59 1 2 1 amp 2 FLOOR ABOVE BANK OF INDIA G BLOCK SAHAKARNAGAR BANGALORE 560092 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL INDEX NO CONTENTS PAGE 1 0 INTRODUCTION 2 2 0 TECHNICAL DESCRIPTION 2 3 0 MECHANICAL CONSTRUCTION 4 40 TESTS 4 5 0 MOUNTING 4 6 0 PROCEDURE FOR CONNECTION OF SENSOR AND CRO SETTINGS 8 70 CONNECTION DETAILS 10 8 0 TROUBLE SHOOTING 11 9 0 SCOPE OF SUPPLY 12 1 13 ADVANCED RAIL CONTROLS PVT LTD HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL 1 INTRODUCTION The Rotational Speed Sensor working on Hall Effect principle as per CLW specification is suitable for the traction motors used in WAG9 WAG9H WAP7 amp WAP5 class of locomotives TM type 6 6068 is used WAG9 WAP7 amp WAGS9H locomotives and type 6FXA7059 is used in WAP5 One set of Speed Sensor consists of the sub assemblies as mentioned in TABLE 2 2 TECHNICAL DESCRIPTION The working principle is illustrated in FIGURE 1 Two Hall Effect Sensors are placed closely in the sensor housing FIGURE 3 such that it is very close to the toothed wheel Associated with the Hall Sensors is a biasing magnet placed in the very close proximity An iro
3. 3 4 amp ug 12 20 11 5 32014kHz FIGURE 5 ADVANCED RAIL CONTROLS PVT LTD 9 13 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL E If motor runs in clockwise direction looking from wheel side pulses should be in negative direction as shown in the FIGURE 6 Tek Tria d Pas 0 000s SAVE REC Action Save Image File Format About Saving Images itt Select Folder 1 Save TEKO02Z3 JPG CH1 1 00 CH2 1 00 25 0 us CH1 7 200m 4 9 12 16 06 424 70SHz FIGURE 6 When the traction motor runs in maximum speed say 3000 RPM the frequency shown in CRO should be close to 6kHz Relation between frequency and RPM is mentioned in the below formula F RPM 120 60 in Hz For eg RPM 723000 then Frequency is F 3000 120 60 F 6000 Hz or 6 2 10 13 ADVANCED RAIL CONTROLS PVT LTD HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL 7 CONNECTION DETAILS DC POWER SOURCE SIGNAL 5 PIN CONNECTOR KPSE 5 PIN CONNECTOR RED KPSE 06E14 5SDZ BLUE KPSE06E14 5SDZ 3 PINCONNECTOR KPSE06E12 3SDZ FIGURE 7 PRECAUTIONS BE TAKEN WHILE MOUNTING 5 pin connector carries signal and should not be connected to High voltage connector is a power connector and is to be connected to 110 Volt Pin A to positive and pin B to negative Check the gap b
4. e receptacle bearing ITT Cannon part Number KPSEOT7F 12 3P is supplied as loose item along with the sensor These connectors conform to MIL C 26482 standard 3 13 ADVANCED RAIL CONTROLS PVT LTD y HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL In the present arrangement there is no provision for providing the power supply receptacle in the connector plate Hence a modified connector mounting plate is also supplied as part of each sensor The sensor is totally sealed to comply with IP68 ingress protection class according to IEC 60529 3 MECHANICAL CONSTRUCTION The Active Speed Sensor is mechanically 10096 compatible to Wiegand type speed sensor needing no modifications in the mechanical housing The toothed wheel also has the same fixing dimensions and diameter The sensor has three output cables two are for two sensor output channels and the third one is for the power supply 110 V DC from loco battery The drawings of the speed sensor and toothed wheel are given at FIGURE 3 amp FIGURE 4 4 TESTS The sensor has been type tested and passed according to IEC 60571 amp IEC 61373 5 MOUNTING Speed sensors have to be mounted on the housing which is part of the traction motor It is very important to notice that the speed sensors should not rub with the wheel and the air gap should not be more than 1 6mm for satisfactory performance ldeal air gap
5. efore mounting using suitable test gauge Mounting surface to be clean and if the gap is too less use shims ADVANCED RAIL CONTROLS PVT LTD 11 43 HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL 7 TROUBLE SHOOTING Likely problems and solutions to the problems are listed in TABLE 1 SL NO LIKELY PROBLEMS SOLUTIONS Error in tacho generator message Check the air gap and maintain 1 6mm and if the gap is too less then use shims Check the wheel version and it must be W 3 version opeed not increasing more than 1 kmph Check the air gap mount the sensor within the specified gap If the air gap Is correct and problem is not solved then Change the sub D connector from respective sensor on SR rack Speed exceed maximum Check the mounting of the sensor Place the sensor with suitable mounting specification Speed exceeds maximum motor damage possible Check the mounting of the sensor Place the sensor with suitable mounting specification Speed disturbance possible Check the sensor on test bench if no pulses are visible on CRO then change the sensor with new one TABLE 1 12 13 ADVANCED RAIL CONTROLS PVT LTD y MVB BASED GRAPHICAL DRIVER DISPLAY USER MANUAL 9 SCOPE OF SUPPLY SI EM Quantity nos No Description
6. is between 0 5mm and 1 5mm If the air gap is more than 1 6mm there may be a chance of missing the pulses so it is very important to take care ofthe air gap while mounting After adjusting to suitable air gap mount the speed sensor with m8 screws provided If the air gap is too low shims be used to increase the gap to safe levels ADVANCED RAIL CONTROLS PVT LTD 4 13 Hall Effect Sensor HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL Biasing Magnet Sensor Housing Pulse Galvanic Isolation Amplification wA dw wA o o a n ws Acn neon nO 44 TWO 4 Tw un DO How no o 110V DC FIGURE 1 Signal Output Signal Output 5 13 ADVANCED RAIL CONTROLS PVT LTD HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL T M SPEED SENSOR DATA SHEET M mano Connector 1 5 PIN Circuler lt 5406 14 5502 11 Sagnal Connector 2 5 PN Circulo Seo A RPSEOGE 14 5502 Signal Connector 3 PIN Circular KPSED6E 2 3502 ELECTRICAL INTERFACE EI 1107 DC Nomina Power Connector 77V 137 5 DC EX EN ADVANCED RAIL CONTROLS PVT LTD 59 1 2 2ND FLOOR G BLOCK 60FT MAIN ROAD SAHAKAR NAGAR BANGALORE 92 FIGURE 2 V
7. n tested and validated The sensor has been type tested and passed according to IEC 60571 amp IEC 61373 The data sheet of the speed sensor is given in FIGURE 2 The average pulse height is close to 2V which is compatible to the Wiegand Sensor The pulse width is also compatible to the Wiegand sensor Power supply to the sensor is provided from locomotive battery at 110V DC nominal This is permitted to a variation of 77V to 137 5V according to IEC 60571 The input is protected against any surges and transients to comply with IEC 60571 The output signals and power supply are taken using signal cables intended for traction application The cable used is of 2x1 mm EB irradiated cross linked type shielded with reinforcement for outdoor traction applications like that of speed sensor The length ofthe cable is approximately 270 cm each The signal outputs are terminated on 5 PIN circular connector Female bearing ITT Cannon part number KPSEOGE14 5SDZ These connectors have a special termination arrangement for providing a heat shrinkable boot shield termination which takes care of the stress relieving and ingress protection These female connectors can be direcery revolution of the tooth wheel means motor shaft 120 tly plugged into the 5 PIN male receptacles provided on the locomotive under frame The power supply cable is terminated in a 3 PIN circular connector of ITT Cannon part number KPSEOGE12 3SDZ The corresponding panel mount mal
8. n toothed wheel FIGURE 4 having a uniform tooth pattern is mounted on the motor shaft The toothed wheel has 120 teeth When the tooth wheel moves under the Hall Effect sensors the magnetic field linking with the sensors vary according to the tooth and trough of the wheel The flux variation is measured by the sensor and amplified Two sensors are mounted with a phase shift of 90 electrical degrees The outputs of these two sensors are used to resolve the direction of the tooth wheel The final output coming out of the sensor is galvanically isolated and contains the direction information The output waveform is compatible to the Wiegand type speed sensors used originally in the three phase locomotives There are two galvanically isolated output channels In WAG9 WAG9H WAP7 locomotives only one channel needs to be connected and the other channel is kept as spare In WAP5 locomotives both the channels of the same sensor are to be connected to the AS Peri card 2 13 ADVANCED RAIL CONTROLS PVT LTD HALL EFFECT ACTIVE SPEED SENSOR USER MANUAL For every revolution of the tooth wheel ie Motor shaft 120 pulses are generated which is exactly same as the originally used Wiegand sensors Due to this compatibility there is no need of any modifications in the electronics hardware and software ALG The sensor will reliably reproduce the pulses from near zero speed to above 3000 rpm which has bee
9. of Sub Assembly Speed 27 1 Active Speed Sensor 1 2 Tooth Wheel 1 Cable Type H S part number 12583003 RADOX TENUIS TW S EMC SC 3 600 1000V 2x1 mm2 18AWG cable will be connected with the sensor and crimped with the specified female connector 1 Signal Cable 270 cm 2 2 Power Supply Cable 270 cm 1 Fixing Bolt for Sensor amp Tooth Wheel 1 Hex Hd Screw M8x25 Zn plated 2 Grade 8 8 to IS 1364 Pt2 92 ISO 4017 88 4 for fixing sensor 2 Hex socket Hd Cap screw M6x16 12 9 Zn plated 6 to 15 2269 95 and machined washer 6 4 to 15 2016 67 amp Steel to 15 2062 99 Gr A Type M6x16 Allen Screws for fixing the Tooth Wheel 1 ITT Cannon Connector KPSE07F12 3P 1 Loose Supply with fasteners 5 2 SS Plate to accommodate connector receptacles 1 TABLE 2 Note In one WAG 9 WAG9H WAP7 locomotive 06 such sensors used In WAP5 locomotive 04 such sensors are used 3 13 13 ADVANCED RAIL CONTROLS PVT LTD MVB BASED GRAPHICAL DRIVER DISPLAY USER MANUAL E CONTACT DETAILS Mr Krishnaraj Sr DGM Technical ADVANCED RAIL CONTROLS PRIVATE LIMITED 59 1 2 FLOOR ABOVE BANK OF INDIA G BLOCK SAHAKARANAGAR BANGALORE 560 092 080 42401216 mail arc net in 13 13 3 ADVANCED RAIL CONTROLS LTD wy rm 16 J
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