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A300 SERIES MOTOR CONTROLLER USER MANUAL Revision 5.3

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2. 65 7 1 LOG ut a me PR ER M id e o M m LE UL a i Q 65 7 2 Fault Finding Guide eene eene 65 7 3 DIrou bleshootlngis eite iti Up P er sed Fd Idi 65 8 Customer Support ii a 66 Appendix A Parts List 1 1 u 67 Appendix B 70 Page 4 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Table of Figures Figure 1 Main Components Module 11 Figure 2 A300 Series Motor Controller Configuration sene 12 Figure 3 Pulse Width Modulation for Armature Current a 13 Figure 4 Pulse Width Modulation for Field 13 Figure 5 Mounting Connection Drawing emen nennen 14 Figure 6 Appearance of CON1 Viewed From the Outside of the A300 System Enclosure 15 Figure 7 Appearance of CN2 and CN3 viewed from the outside of the enclosure 18 Figure 8 Speed Sensor Connections UU nanna nanna nn anna 18 Figure 9 VO Control Connections eene dentata th nana auth nat 19 Figure 10 High Power Connection 20 Figure 11 Digital Display u
3. N zo NI MODONQONINVSOOJNINVS IVN NOILVIADHD Sei im eo gt ZOSL 19S 16 Xv4 1961 106 196 30830 Gav MILNIQUNODe m Mod quyu 288 228 s gt I6EE 14 SYW 14 OYOY QOOMNJENY OFOOL d 00100 EA in 87 S25 Jo fuo LUVd T3A31 4OL memo runny 28 ge2 OONINWS InP zi OSNINVE 8 383 a zo Wr zi ONS Ol svg 38 59 gef 9350 1577 SJJBWAN 39VI10 7 0350 1577 SH38NDN 39VLIOA 7 NOILOSNNO3 G13IHS 218 2 01553 Qzu M3ddOHO MOLSIS3M SINVNAG SANA 696008V id Lo gi G l 9 9L Gl c he NOLLO3NNO2 2 SIESVHO m P B GT3IHS FERE Pl pq Oy 6 qua qui sol tj TN 2 YOLOW 1 HOLON zl d zs LJ is zs Uis T eni aK gt zr HOLON 31536 Eh ve 09 Way Way Tr LOZOOEV YOLOW L YOLOW eris 080 10061 990719081 od ES 4 d n VoSz lv
4. U1001 011 CRIMPER DISCONN AND SPLICES 1 1001 028 CRIMP DISCONNECT FEMALE RED 50 1001 029 CRIMP DISCONNECT MALE RED 50 U1001 049 SILICONE HEATSINK COMPOUND 507 1 Page 69 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Appendix B Schematics This section is a compilation of all the electrical schematics for the A300 svstem as of this document release date Updated drawings mav be published after this date and can acquired through a Saminco Representative The drawings in this section are outlined in Table 32 below Table 32 Drawings in Appendix B Drawing Number Drawing Description Revision Release Level Date 300100 1of 2 120HP STREETCAR PROPULSION 1 24 Oct 02 A300100 Page 2 of 2 UNIT INSTALLATION DIAGRAM A300201 Page 1of 2 PCC STREETCAR SERIES 1 18 Nov 02 A300201 Page 2of2 MOTOR CONTROLLER A800969 1of 1 BRAKE MODULE 600V 1 24 Sep 02 Page 70 of 78 TRACTION 00100 V 00100 71 1334s ava aiv G ANDEK 3903 DL Cn 1 1 Cao SENG D ARIC Aone db sav nesses JB ONT QUY Em mo engl og 159905 40 CX DS 5155802 QNV SINLI GIU 39 TN gng rng TT WV49VIG
5. w AMAL a z gt 7 219 lt E z 9 inuro e SETT pM M 27 3199 ES e v L 8ZZVW nt CX I afa s D e e ae w amnor e mn et IOHLNOQ e 8 jima HOSSJOJOHHOHDIW aons q 6SCCcVW a e 25954 9 ze pese s e ames anv dota Ws fag 9e IX sibe i g ae 5 28 5 25 gt HIE iin ku 3 li tnt BRSERRRII oe 9 d e J Di 660241 2002 90 01010 Page 74 of 78 ELECTRIC TRACTION DRI SAMINCO A300 SERIES MOTOR CONTROLLER 69600 __ OPT apna amam wanana f 20 Lave TS avo CTUM OL AI B NV SIU ws Kom 104 saw 70 A009 QAN NOS WY ONY rcc AUST ONS V POET RIVER 2000000 EENS NIES C3HADN3H JE OI LON ST ORV Q m p No ae E 2061 196 176 XV4 1961 196 176 321440 set IVILN3OINOO
6. 0 H7 Fault 4 Time 0 H8 Fault 5 0 H9 Fault 5 Time 0 H10 Fault 6 0 H11 Fault 6 Time 0 H12 Fault 7 0 H13 Fault 7 Time 0 H14 Fault 8 0 H15 Fault 8 Time 0 H16 Fault 9 0 H17 Fault 9 Time 0 H18 Fault 10 0 H19 Fault 10 Time 0 H20 Fault 11 0 H21 Fault 11 Time 0 Page 33 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Parameter Parameter User Min Unit Access Level No Name Setting H22 Fault 12 0 23 Fault 12 Time 0 24 Fault 13 0 H25 Fault 13 Time 0 H26 Fault 14 0 27 Fault 14 Time 0 28 Fault 15 0 29 Fault 15 Time 0 H30 Fault HistoryReset 0 34 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 4 Maintenance and Repair 4 1 Fuses F9002 093 and F9002 080 The A300 contains two main power fuses rated at 250A 700V F9002 093 and a fuse in the pre charge circuit rated at 15A 1000V F9002 080 The fuses are high speed semiconductor fuses with DC interrupting capability 4 1 1 Testing Before testing fuses ensure that e Main power has been switched off e Control power has been switched off e The filter capacitors have had sufficient time 5 minutes to discharge to a very low resi
7. FT E e gt 185 U SUZAN LJ OVON QOOMU3SWV 02001 5 STI x iwi AH S3WVN LMvd T3A31 401 pem OONINVS 20 dis ec Gu 2 20 das vc arv JNA WALSAS Ol SSND138 adr H r 10 9 9 5 A00S A006 I ME 0 20082 T 010 006 ES HOLIMS 10 4 OMAS R a t i 5 230 0060 ILEZVIN NODOL H dh Hh f 5 e a THAI 9 zal 9 9 gr 09 8 9s 035 9 3LIHM n o aves 8 Jana iE 2 02 91 FOOZ IM ig3L1074 Page 75 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Page intentionallv left blank 76 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Page 77 of 78 SERIES MOTOR CONTROLLER Rev 5 3 SAMINCO ELECTRIC TRACTION DRIVES Eersel Netherlands Lavalette West Virginia Castle Hill NSW Australia Fort Mvers Florida Johannesburg South Africa Saminco Inc 10030 Amberwood Road Ft Mvers FL 33913 USA Telephone 239 561 1561 Facsimile
8. TE ova BE Ino ICT 3311051400 YOLOW 531035 CE ioi 23 flow 880 SAUTE COMINGS V WS ROLY THY IMNO 590 009 ELE arg alse PCM HVOLJ3HIS 93 SXSWiHd IHL WOHI 38 OL LON ST ORV Si id i ee ON 20 11932054 SI SNWVS0 SIAL mana NOLVINIMA SETA m 87180 m ZOSI 1I9S 622 XV4 1961 1096 662 32430 MILNAQIJNOD a ag 8 gt 1666 713 L3 OVOY 05001 CONS 10200 8 en 6 1494 T3431 401 mama mm OONINVS 20 so Gu ig zo onv 90 JNA YGISXS Ol SONO GG avo 2 M38WnN 133HS 74 317 05009 2721 3 aivNiauo09 Hd Old 6d L 133HS assn 1sv1 7 Bd SZZNW 4 88ccVW d 660211 2002 90 AON 0211010 AOZL 00 s 5 od Page 73 of 78 SERIES MOTOR CONTROLLER Rev 5 3
9. This parameter defines an instant speed reference to the drive speed control loop without applying the acceleration time ramp Setting this parameter permits a faster response on starting but will also increase the shock load to the mechanical system Care should be taken to make sure that the value does not introduce damaging shock loads to the mechanical drive train The Stop Speed is set to zero in this application E08 Start Delay This parameter allows time for the main contactor to close before the control loops activate and accelerate the motor In this application an auxiliary contact delays the activation of the controller until the main poles are closed E11 Stop Delay This parameter allows time for the main contactor to open before the control loops de activate and stop the motor E17 Economy Field This parameter determines the light load field current and may be used to minimize motor heating when full accelerating or braking torque is not needed Increasing the economy field level allows the full motor torque to be produced more quickly E18 Minimum Field This parameter establishes the minimum field reference This places an upper limit on the speed of the motor The maximum speed is almost inversely proportional to the value of minimum field A value of 40 allows approximately twice base speed to be achieved when the line voltage is at 600V E21 Field RoC This parameter controls the maximum rate of c
10. 239 561 1502 http www samincoinc com Page 78 of 78
11. Values C01 Voltage Class Set By Manufacturer This parameter defines the measurement scaling for the DC bus voltage and the motor armature voltage and must match the nameplate rating of the controller and is not modifiable by the customer C02 Current Class Set By Manufacturer This parameter defines the measurement scaling for motor armature current and motor field current It must match the nameplate rating of the controller and is not modifiable by the customer C04 Armature Setup Set By Manufacturer This parameter defines the total number of times the output current passes through the eye of the current sensors including the existing bus bar and is not modifiable by the customer Page 26 of 78 A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES C05 Input Voltage Parameter specifies the nominal bus voltage of the DC supply system It also sets the under voltage trip point 50 and the Over voltage trip point 140 If the input voltage is set higher than 600V the over voltage trip point is limited to 840V Between 710V and 840V the dump resistor PWM signal goes from 0 to 100 C06 Field Setup Set By Manufacturer This parameter defines the type of motor It must match the nameplate rating and is not modifiable by the customer C07 Default Values Provides the ability to store and restore the user parameter set up into the e prom of the drive Als
12. 1 Time H2 Fault 2 H3 Fault 2 Time H4 Fault 3 H5 Fault 3 Time H6 Fault 4 H7 Fault 4 Time H8 Fault 5 H9 Fault 5 Time H10 Fault 6 H11 Fault 6 Time H12 Fault 7 H13 Fault 7 Time H14 Fault 8 H15 Fault 8 Time H16 Fault 9 H17 Fault 9 Time H18 Fault 10 H19 Fault 10 Time H20 Fault 11 H21 Fault 11 Time H22 Fault 12 H23 Fault 12 Time H24 Fault 13 H25 Fault 13 Time H26 Fault 14 H27 Fault 14 Time H28 Fault 15 H29 Fault 15 Time H30 Fault History Reset G00 Analog IP1 Type G01 Analog IP1 Gain G02 Analog 1 Bias G04 Analog IP2 Type G05 Analog IP2 Gain G06 Analog IP2 Bias Page 22 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Attach the LCD module to the remote serial port connector 2 Confirm that all of the control inputs are in the inactive state equivalent to no direction selected and the drivers control in the COAST position and regenerative braking disabled 3 Apply a control supply voltage of between 16V and 30V DC to the A300 propulsion unit The supply must have a peak output capability of 10A 4 Confirm that the LCD initially displays Brookville Initialization and changes after approximately 10 seconds to Brookville Streetcar If the display continues to show the Initialization message it is not receiving data from the main propulsion unit Refer to section 7 Diagnostics and Fault Finding if this cannot be corrected either by momentarily applying the RESET switch or
13. 3 19001 051 Main Contactor RFI Module Filter Module fo B J J e 8 Figure 1 Main Components Module Layout 1 4 Storage of the A300 In order to protect the equipment against humidity and contaminants during storage the A300 unit should be fully enclosed The shipping container or plastic wrap is recommended for extended periods of storage All units should be stored away from possible liquid contamination Failure to keep the unit dry and sealed can cause many of the components to deteriorate which can become very dangerous under running conditions Also ensuring cleanliness of the unit will prolong the useable life of the unit The A300 has a maximum storage altitude of 3000m from Sea Level It is important not to exceed this as some internal components i e capacitors could leak and cease to function correctly The acceptable temperature range for storage is between 40 and 70 C 1 5 Principal of operation 1 5 1 Solid State Control The A300 can control series field DC motors using power IGBTs Insulated Gate Bipolar Transistors These IGBTs are given controlled duty cycles which control the speed and torque of the drive motor s Controlling a motor in this fashion yields high efficiencies with percentages in Page 11 of 78 SERIES MOTOR CONTROLLER Rev 5 3 the mid to high 90 s Using the IGBTs the A300 controls mo
14. Capacitor Removal 1 Remove the DC bus bar assembly The output busbars connected to T1 T2 and T3 may be left in place 2 Remove the balancing resistor assembly see Figure 52 3 Remove the M12 nylon retaining nut from the bottom of the capacitor and withdraw the capacitor see Figure 53 Filter Capacitor Replacement Figure 52 Removing the 1 Install the replacement capacitors and the nylon Balancing Resistor Assembly retaining nuts Ensure that all of the positive marked terminals are oriented towards the output terminals T1 through T4 end of the module Ensure that the pilot on the nylon nuts engages with the hole in the supporting bracket Keep the nut sufficiently slack for the can to rotate slightly during alignment with the busbars 2 Fit the balancing resistor assembly Do not tighten the screws 3 Fit the DC busbar assembly Ensure that the capacitor terminals align with the busbar holes before inserting the screws Do not tighten the screws until all are inserted 4 Fully tighten all of the terminal screws using a torque of 40 in Ib 5 Tighten the nylon retaining nuts DO NOT OVERTIGHTEN Figure 53 Removing the Capacitor Page 53 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Voltage Transducer Board MA2288 The voltage transducer board consists of four closed loop Hall Effect transducers These produce output currents from the secondary circuit proportional to
15. Supply Bus Voltage 420V to 720V DC continuous Maximum Peak Voltage 1000V for 1sec transient 10 000V for 50ys transient Supply Current Required 600A continuous Table 4 Control I O Specification Description Specification Logic Inputs 24V DC 5mA Communication RS232 Onboard Display or Laptop Channel Control Power Supply 18 to 34 VDC 5A Table 5 Protective Characteristics Description Specification Undervoltage 300V DC Overvoltage 850V DC Overload Motor thermal overload calculation 15096 current for 2 minutes 20096 current for 20 seconds Current limit Adjustable up to 20096 Thermal Heatsink temperature alarm Heatsink temperature shutdown Reverse Polarity Not damaged by reverse connection of main DC supply Power Loss One second ride through on loss of main DC supply Short Circuit IGBT junction voltage monitoring approx 1500A Line circuit fuse Armature circuit fuse Pre charge circuit fuse Motor Continuity Motor Connections are verified at the start of each cycle Page 9 of 78 SERIES MOTOR CONTROLLER Rev 5 3 1 3 Table 6 EMC Specification Description Specification Immunitv Designed to meet Requirements of EN50081 2 Emissions Designed to meet Requirements of EN50081 2 Equipment List Before accepting the A300 please ensure the contents of the package correspond with the items on the packing slip and the purchase order Discrepancies should be discus
16. TRACTION DRIVES Parameter Parameter User Min Max Unit Access No Name Setting Level G02 Analog IP1 Bias 0 0 10 10 0 1 2 G04 Analog IP2 Type 0 10 V N A 1 2 GO5 Analog IP2 Gain 1 00 0 00 10 00 10 01 2 G06 Analog IP2 Bias 0 0 10 10 0 1 2 G00 and G04 Analog IP1 and 1 2 These parameters define the signal format for the analog inputs IP1 is a bipolar signal used for sensing line current and voltage across the line contactor and must be 10V type IP2 is a unipolar signal used for slip spin measurement and must be 0 10V type G01 and G05 Analog IP1 and IP2 Gain Set the input scaling gain factor for IP1 and 1 2 must be set to 1 67 in order to correctly scale 600 line voltage to 100 IP2 must be set to 1 in order to scale the slip spin signal to a range of 100 for a 500V difference in armature voltages G02 and 606 Analog IP1 and IP2 Bias This parameter allows the input signal to be offset by plus or minus 10 The bias compensates for signal variances These parameters are set to zero in this application GROUP H Fault Log Table 19 Group H Fault Log Parameter Parameter User Min Max Unit Access Level No Name Setting HO Fault 1 0 H1 Fault 1 Time 0 H2 Fault 2 0 H3 Fault 2 Time 0 H4 Fault 3 0 H5 Fault 3 Time 0 H6 Fault 4
17. ab cart Ri ned IR e abd Le aede 42 Figure 30 Removing the Fan Fixing Screws sss eene eene nennen 43 Figure 31 Removal id aka 43 Figure 32 Fan Installation Complete U l enemies 43 Figure 33 Pre charge Resistors Installed sse nennen 44 Page 5 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Figure 34 Bottom Fixing Screws for the Pre charge 44 Figure 35 Removing the Pre charge Resistors 44 Figure 36 Removing the Pre Charge Resistors 45 Figure 37 Pre charge Resistor Assembly A300302 a 45 Figure 38 Tightening the Pre charge Resistor 46 Figure 39 Pre charge L u u u a a A a 46 Figure 40 Connectors Unplugged from MA2287 and MA2287 for PCB Tray Removal 47 Figure 41 Removing the A300 Control Board 47 Figure 42 PCB Tray Remowal eese tenete tenent innen tenant intesa dem na Pennant nnn ind 47 Figure 43 Pre Charge Diode rerien iaieiiea iia ie a iae eraa aiaiai 48 Figure 44 Balancing Resistors sse A RAE E E E RE 48 Figure 45 Snubber Capacitor Current Sensor and Busbar Fixing 49 Figure 46 CT1 and CT3 F
18. by cycling the control supply power 5 Confirm that the fan on the motor control module starts when the RESET switch is applied and held Confirm that the fan stops after the RESET switch is released The heatsink temperature must be below 50 deg C 122 deg F for the fan to turn off 6 Use the B key of the LCD module to select the menu Use the A key to select 21 Logic Inputs Confirm that the value indicated is 00000000 00000000 7 Operate the auxiliary contacts of the line contactor by hand Confirm that the value of A21 changes to 00000001 00000000 8 Confirm operation of the traction command inputs Enable A21 00000000 00000001 Forward 21 00000000 00000010 Reverse 21 00000000 00000100 Traction level code 1 21 00000000 00001000 Traction level code 2 21 00000000 00010000 Traction level code 3 21 00000000 00100000 Brake Release 21 00000000 01000000 Regen Enable 21 00000000 10000000 9 Confirm that the following parameters in the A menu are as shown in Table 11 Table 11 Startup Requirements 02 Armature Voltage Less than 5V A03 DC Bus Voltage Less than 20V A11 Line Voltage Less than 20V A23 Heatsink Temperature Approximate actual value A30 Fault Status No Fault A31 Sequence Status Initialization 10 Connect line supply Confirm that A03 and A11 both indicate values approximately the same as the line voltage 11 Briefly apply a traction comm
19. from cracks and large chips The arc chute material and the arcing horns must not be excessivelv burnt The arc chute connecting wire must be free from abrasion or cuts The auxiliarv contacts must move freelv See Figure 23 Ensure the armature gap circled in Figure 23 is no less than 0 03 inches when contactor is depressed Figure 22 Contact tips and blowout poles Figure 23 Checking Auxiliarv Contact Operation 4 4 2 Removal and Replacement 1 2 3 A 5 Remove the arc chute Disconnect the coil and auxiliarv contact connections Disconnect the line side cables 104 from the top terminals Disconnect the load side cable 105 from the bottom busbar Remove the remaining three nuts that secure the busbar to the stand offs Page 39 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Unbolt the contactor bodv from the mounting bracket If replacing the contactor unbolt and remove the bottom busbar from the contactor and attach to the replacement Follow the same sequence in reverse to re install After installation check that the connections to the coil and the auxiliarv contacts are secure necessary squeeze together the quick connect terminals or replace them to ensure that thev have a firm grip on the tags 4 4 3 Replacing Parts Please refer to Table 30 in Appendix A Parts List for a list of contactor replacement parts that can be ordered 4 4 4 Specifications 4 5 Table 22 Li
20. is 4 25mph Note that differences in wheel diameter on the same truck will cause the wheel slip detection to be more sensitive in one direction and less sensitive in the other D19 Slip Disable Lim This parameter sets the level of wheel slip at which normal traction or braking is resumed after anti slip action has been taken The following formula should be used Slip recovery threshold mph 0 0167 x Slip Disable Lim x mph at motor base speed Example If the vehicle speed is 17mph when the motor is at its base speed and Slip Disable Lim is set to 5 recovery from anti slip action will occur when the wheel rim velocity difference is 1 42mph Note that differences in wheel diameter on the same truck will cause the wheel slip detection to be more sensitive in one direction and less sensitive in the other Note also that if there is a large difference in wheel diameters and Slip Disable Lim is set too low it is possible that recovery is delayed indefinitely resulting in loss of traction or electric braking until the vehicle is brought to a lower speed by mechanical brakes 022 Antilock Enable This parameter sets the deceleration rate that will trigger the slip spin anti slip action in the event that both wheels of a truck slip without causing a significant difference in speed between the wheels Deceleration trigger level mph sec 0 00117 x Antilock Enable x mph at motor base speed Page 29 of 78 SERIES
21. lt lt mas gt e ONF 31504 OL wa lt lt 55080 ZNO 3 0123130 lt lt nsa lt 3 Z HOSNAS L 395435 auas ashes navna ce 3402 lt lt 2 2002 BAR 1 x09 AN lt 09 09 ISVITIU lt lt pk 2 A38 lt 5 Q HOLMS HOLMS HOLMS lt lt O1nv NYA IWNI JAVNI HOLMS NRI 3 93 lt lt 13538 NAOG dns HSWLI 2 17 3503 228388883 aw S522 8R RR EB fi S 295 8 926 nO i IL te 00100 km INN 24 A009 9 1 914 80 FOOZ 021074 00 SERIES MOTOR CONTROLLER Page 71 of 78 300 SERIES MOTOR CONTROLLER Rev 5 3 G IT DEE ZENERE PERETE AILO OL ALANAS ISNA 103 05 Od OL Qe io 4 vxo eu eee SHAR gt gt AR SON Sh IL GONINVE 20 410 0 0 QUY E 2 26 1530 505060 515802 INV SILI TN 22 reng OILVW3HOS 3MOd 2 u SAUTEI3X3 UONINVS ROLY ADANY N gt NILSAS NOISINdOYd 599133515 dHOZL vus ROE GONG ST OL TST ORY ae sd 2858228 8 OINAS 20 XIN3dONd JHI SI
22. reverse if brake release signal is high and drive forward signal is low See Note 1 below Compatible with 24V PLC logic outputs low inactive 24 high active 15 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Pin Signal Name Description Remark BRAKE RELEASE Brake release signal Low controller decelerates to stop High controller responds to forward reverse commands See Note 1 below 1 Grav code traction level input 1 See Note 2 below CODE2 Grav code traction level input 2 See Note 2 below CODE3 Grav code traction level input 3 See Note 2 below 10 REGEN ENABLE Regen enable input Low controller not permitted to return current to supplv network High controller permitted to return current to supplv network 11 RESET Controller reset input Low controller reset not active High controller reset active See Note 3 below 12 SLIP SPIN ENABLE Slip spin detector enable Low slip spin conditions ignored High slip spin conditions detected and recoverv action applied 13 FAULT Controller fault indication Low fault or propulsion unit not readv High propulsion unit readv and no fault 14 SLIP SPIN Slip spin indication Low slip spin not detected High slip spin condition detected See Note 4 below 15 SPEED Buffer
23. the current in the secondary circuit in the same manner as a current transformer High voltage resistors the primary side are used to determine the ratio of current to voltage The four transducers are used to measure respectively 1 Motor 1 Armature Voltage 2 Motor 2 Armature Voltage 3 Line Voltage to DC Bus Voltage Difference Figure 54 MA2288 Voltage Transducer Board 4 DC Bus Voltage Removal 1 Unplug the ribbon cable from MA2288 J4 see Figure 54 2 Withdraw the high voltage circuit connections from P4 P5 P6 P7 P8 P9 P1 and P11 3 Remove the four fixing screws 4 Withdraw the board complete with nylon insulators Installation Install the board by carrying out the above steps in reverse order Ensure that the high voltage connections are firm Squeeze together the receptacles to ensure that they grip tightly Gate Drive Board MA2287 The gate drive board contains many interface circuits as well as the gate drives If an IGBT failure has occurred it is possible for the associated gat drive circuit to be damaged as well If it is suspected that this has happened proceed as follows 1 Apply a 24V supply to pins 1 and 15 of J15 2 Confirm that all four power supply indicator LEDs are lit 3 Check that the voltage gate voltages applied to all IGBT gate terminals white wires relative to their emitters red wires is between 6V and 8V These voltages can be measured at the foll
24. up the equivalent of a single large capacitor The capacitors are arranged in groups of four Each group has two parallel pairs connected in series A voltage balancing resistor connected across each pair ensures that the bus voltage is divided equally between the two pairs By using four separate groups the damage caused by failure of a capacitor is limited to the capacitors within the group The life of electrolytic capacitors is a complex function of temperature applied voltage and ripple current In the A300 application under normal operating conditions the life of the capacitors is expected to exceed 50 000 hours of active usage or 200 000 hours of inactive usage with line voltage applied Capacitors that have been in storage for more than five years without voltage applied to them exhibit higher than normal leakage If a controller or a vehicle has been in storage for an extended period of time precautions should be taken to ensure that damage will not occur Table 23 Filter Capacitor Long Term Storage Requirements Storage Period Storage Requirements Up to 1 year No precautions necessary 1 year to 3 years Apply line voltage to vehicle for 2 hours before driving Apply 2 3 of normal line voltage to vehicle for 2 hours and then More than 3 years normal line voltage for 2 hours before driving Capacitor Inspection and Testing Capacitors should be replaced if fluid is leaking from the vent or if the can is swo
25. zy T zv iv gor 10 d 00 00 150 10061 n L 4 T ovo s 55 4 s S s S s C s ss s rs 6 6 s lt lt lt S sS lt lt lt lt A Q 9 GG Y an gt 4 1115 L B N s fe E 5 w a o ja j 8 8 la a 5 la e o 2 Jo l t 5 140060 d l o o o o 9 5 so as s nr S51 6 9 Per n 6 9 5 5 5 5 5 8 318 2 NOO 9 52 41 SMVOL x18 9 2 wo 055455002 22222582202 06 6 ERR bb 5 2 2 gt EN SWV9L am mmm UDR VPANNRASERIEXFRSRA RES aid gt gt gt K 33 D lt Z r r r m qr vog mou xx x lt x m 2 2 BEEBE 5758 28888 5 o2 a 2 83583 3 2222 h mo gt e TKUEBO LOOC CO T3104 2 a Page 72 of 78 SAMINCO TRIC TRACTION DET LEC A300 SERIES MOTOR CONTROLLER QNO BBZZVW 2007 zn3u i0zootv
26. 0mA Maximum Heatsink Temperature 90 deg C Maximum Ambient Temperature 55 deg C Minimum Temperature 20 deg C Figure 64 Brake Module Circuit Board MA2289 Page 61 of 78 SERIES MOTOR CONTROLLER Rev 5 3 5 Firmware Firmware is the programmed memorv device or devices used to permanentiv hold an executable program in a computer based system In the A300 system executable programs are found in three locations 1 The on chip Read Memorv found in the micro controller of the MA2259 control board This is a small program built into the micro controller chip used for the purpose of loading other programs through the serial port This program is embedded into the chip during manufacture and cannot be changed 2 Flash EPROM Erasable Programmable Read Only Memory located on the MA2259 control board This is the program that controls the operating sequence and many control functions of the A300 propulsion system It is created by Saminco Inc using high level language compiler loaded into the MA2259 board serial communication Flash EPROM is erased electricallv without removing the memorv from the board After it has been erased the A300 will not function until a new program is installed 3 The EPROM Erasable Programmable Read Only Memory located in the MA2263 board in the LCD module This program converts message received from the main propulsion unit to text that is displaved on t
27. 1 051 IGBT DUAL 800A 1200V 80C 1 Y9002126 BACK PLATE DELRIN A401 2 Y9002127 PC SUPPORT DELRIN A401 2 Y9002130 TOP COVER DELRIN 1 Y9003207 BOTTOM PLATE AL 14PEM 4BND 6H 1 Y9004051 HEAT SINK AL 13H 1 Y9007166 BRK ALUM 16G 4PEM SUB D PUNCH 1 Y9007168 SIDE COVER SS 3BND 4PEM 6H 2 Y9008142 BUS BAR 1H 2PEM 1BND 4 Y9008152 BUS BAR TCU 3H 2BND 1 Y9008153 BUS BAR TCU 2BND 2H 1 Y9008159 BUS BAR TCU 2BND 2H 1PEM 1 Page 68 of 78 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Saminco Part Number Description Quantity Y9008160 BUS BAR TCU OBND 2H 1PEM 1 Table 30 K9009 049 CON DC 1000V 28V DC Replacement Parts Saminco Part Number Description Quantity K9010 001 DPM L 67 AUX CONTACT 1 K9010 002 DPM L 67 REPLACEMENT COIL 1 K9010 003 DPM L 67 MOVING CONTACT 1 K9010 004 DPM L 67 STAT CONTACT 2 K9010 005 DPM L 67 ARCING CONTACT 1 K9010 006 DPM L 67 SHUNT 2 K9010 007 DPM L 67 COIL RETAINING O RING 1 K9010 008 DPM L 67 AUX BLOWOUT COIL 1 K9010 009 DPM L 67 ARC CHUTE 1 K9010 010 DPM L 67 MOVING CONTACT SPRING 1 K9010 011 DPM L 67 SPRING 1 9010 012 DPM L 67 KICKOUT SPRING 1 K9010 013 DPM L 67 LOAD ARC HORN SPRING 1 K9010 014 DPM L 67 LATCH CAL SPRING 1 K9010 015 DPM L 67 LATCH BIAS SPRING 1 Table 31 Miscellaneou s Components Saminco Part Number Description Min Quantitv Order
28. 120 in 16 connecting the positive and negative DC busbars to the filter capacitors It is not necessary to remove the balancing resistors Figure 46 CT1 and CT3 Fixing Screws 7 Withdraw the DC positive and negative busbar assembly Page 49 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Heatsink Thermistor A300301 The heatsink thermistor has a resistance of 10 kQ at 25 77 F As the temperature increases the resistance gradually falls At 87 189 F the resistance is 1 The thermistor is shown in Figure 47 Removal 1 Cut the cable ties to free the thermistor lead from the harness 2 Unscrew and withdraw the thermistor from the heatsink Figure 47 Heatsink Thermistor Installation 1 Ensure that the heat shrink sleeve protects the fragile leads of the thermistor 2 Fit the thermistor to the heatsink Do not tighten more than 10 in Ib 3 Tie the lead into the wiring harness using new cable ties Insulated Gate Bipolar Transistor IGBT Removal 6001 051 1 Remove the 5 control connections from the IGBT gate emitter and collector terminals 2 Remove the six fixing screws the blue arrows in Figure 48 3 Withdraw the IGBT see Figure 49 If the IGBT is to be saved for future attach two wire links or self adhesive copper strips from terminals E1 to G1 and from E2 to G2 Without these connections the IGBT is vulnerable to damage from static discharge when handled in an en
29. 300 1V 2 D18 Slip Enable Lim 8 0 0 0 50 0 0 1 2 D19 Slip Disable Lim 6 0 0 0 50 0 0 1 2 D22 Antilock Enable 700 0 32767 1 2 Page 27 of 78 SERIES MOTOR CONTROLLER Rev 5 3 000 Motor Rated Current This parameter must be set to the full load motor nameplate rating multiplied bv the number of parallel motor paths per controller output 001 Motor Rated Voltage This parameter is normallv set to the motor nameplate voltage rating multiplied bv the number of motors connected in series between the controller outputs This parameter is important to obtain the proper speed control from the drive as it influences the CEMF calculation 002 Motor Base Speed Parameter to be set to the motor nameplate rated RPM This parameter is used to calculate the A06 Motor RPM display value If this value is incorrect the display reading will not be accurate but the drive will operate properly 005 Current Limit Forward and Current Limit Reverse These parameters set the maximum current limit in the forward direction and reverse direction during acceleration and deceleration 006 Armature Field This parameter limits the maximum ratio of armature current to field current in order to ensure that the commutation capabilitv of the motor is not exceeded at high speeds Operation of the motor above its base speed requires the field to be weakened in order to maintain the armature voltage at
30. 87 1 GATE DRIVE INTERFACE 1 MA2288 MA2288 HIGH VOLTAGE ISOLATION 1 Page 67 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Saminco Part Number Description Quantitv N6001 051 IGBT DUAL 800A 1200V 80C 3 9005 023 RES 5W 5 WIREWOUND 1 R9120 001 RES 120W DUAL 10K 5 SOT227 4 9003 013 600 1 OPEN LOOP 3 V9001 004 STAND OFF PCB ROUND AL 8mm 6mm 4 W6002 028 RB 16CON 6IN PAN PAN 1 W6002 029 RB 14CON 4IN PAN PAN 1 W6002 035 RB 34CON 5 75IN PAN PAN 1 W6002 036 RB 10CON 11 5IN PAN PAN 1 W6004 176 CABLE 4CON 22AWG 10IN DCCT 2 W6004 180 CABLE CT 6CON 41IN 1 Y9004010 HEATSINK ALUM 8H 1 Y9005054 BASE PLATE ALUM 35H 1 Y9007507 BRK SS 14G 12BND 47H 6PEM 1 Y9007508 BRK SS 18G 8H 2BND 1 Y9007509 BRK SS 16G 1H 3BND 5PEM 2 Y9007510 PC TRAY SS 16G 5BND 5H 43PEM 1 Y9007511 BRK SS 16G 22H 2BND 6PEM 1 Y9007512 BRK SS 18G 6BND 21H 19PEM 1 Y9007512A FAN BRCK 18G SS 12BND 6H 4PEM 1 Y9007513 BRK SS 16G 6BND 2H 18PEM 1 Y9007514 BRK SS 16G 6BND 20PEM 1 Y9007517 STEEL 5H OBND ZINC 4 Y9007518 COVER 14G 4BND 6PEM 1 Y9008125 BUS BAR 25 4 X 7 5mm X 1mm 4 Y9008163 BUS BAR TCU 4H 2PEM OBND 4 Table 29 A800969 BM302 3 400V 750V 400A BRAKE Saminco Part Number Description Quantity C9002 002 PCAP 2 5uF 850WV OTH RAD BB 1 MA2289 1 MA2289 1 650V BRAKE CHOP CTRL 1 N600
31. 9120 001 In the A300 Motor Controller Module there are four balancing resistor assemblies which are fitted to the filler capacitor terminals Each resistor contains two separate 10 kO elements Disconnecting the leads from the terminals removing the fixing screws and withdrawing the component will allow the balancing resistors to be removed ig When replacing balancing resistor that the busbar link between two of the resistor terminals is present The fixing screws should be installed with 40 in Ib of torque Figure 44 Balancing Resistors Busbar Removal 1 Remove the 12 8 hexagon socket screws from the IGBT terminals re installation torque 85 in Ib these are labeled with red arrows Figure 45 2 Withdraw the three snubber capacitors C9002 002 Page 48 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Figure 45 Snubber Capacitor Current Sensor and Busbar Fixing Screws 3 Remove the 13 9 16 nuts from the stand offs shown in the yellow arrows in Figure 45 4 Remove the four fixing screws securing the current sensors near terminals T1 and see Figure 46 These fixing screws have a re installation torque of 40 in Ib 5 Withdraw the three output busbars with the two current sensors you can leave the current sensors attached 6 Remove 16 screws labeled by the blue arrows in Figure 45 with a re install torque of
32. AKE SYNC FLASH ENABLE RS485A RS232 TX CROSS CONNECTION TO OPPOSITE END ED RS485B RS232 RX FEMALE DISPLAY 5V PC COMMS DISPLAY RESET DISPLAY TX DISPLAY RX DISPLAY OV SHIELD DIAGNOSTICS Figure 9 Control Connections Page 19 of 78 SERIES MOTOR CONTROLLER Rev 5 3 2 3 High Power Connections Please refer to Figure 1 Main Components Module Lavout on page 11 for the phvsical locations of each module The full power schematic with cable number labels is shown in Figure 10 600V DC MIN 1 0 0 5 0 5 mH i 102 CHASSIS Oa CONNECTION Figure 10 MOTOR 1 MOTOR 2 ARMATURE ARMATURE MOTOR 2 FIELD MOTOR 1 FIELD MIN 1 0 AWG MOTOR CABLE SHIELD CONNECTION P A800969 mil CHOPPER R24 RESISTOR CABLE SHIELD CONNECTION High Power Connection Schematic Page 20 of 78 A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 3 Operation This chapter describes how to verify the correct operation of an A300 unit how to access monitoring information using the LCD module and how to carry out parameter adjustments if these are necessary 3 1 Start Up and Commissioning A digital display module may be connected to the serial port for the purpose of monitoring functions during the commissioning process This module is powered from the serial port connector The display becomes active when the 26V control supply is connec
33. Board MA2289 1 Remove the six lid fixing screws Withdraw the lid Figure 62 should show this 2 Unplug J1 J2 and P1 harnesses from the control board 3 Withdraw the control board see Figure 63 When re installing the board ensure that the connector for P1 is tight Figure 64 shows the control dure board IGBT Removal 1 Remove the lid and the control board 2 Remove the connecting busbars and the snubber capacitor 3 Remove the IGBT mounting screws Withdraw the IGBT module 4 Remove the gate lead harness Installation 1 Attach the gate lead harness 2 Applv heatsink compound to the IGBT base see Figure 50 on page 51 of this document Figure 63 Brake Module with Circuit 3 Install the IGBT See Figure 51 on page 52 Board Removed of this document Half tighten the screws before applving the full tightening torque Page 60 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 4 Fit the busbars and the snubber capacitor 5 Fit the control board and the lid 4 6 4 Specifications See Table 25 for the Brake Module specifications Table 25 Brake Chopper Module Specifications Nominal System Voltage 600V Minimum Operating Voltage 550V Maximum Operating Voltage 1100V Continuous Operating Current 200A Peak Operating Current 800A Minimum Resistor Value 800V input 1 0 ohm Standby Current 800V input 4
34. ELECTRIC TRACTION DRIVES 00 SERIES MOTOR CONTROLLER USER MANUAL Revision 5 3 December 2004 SERIES MOTOR CONTROLLER Rev 5 3 On Cover A300 Series Motor Controller Saminco Inc Contents of this document are the propertv of Saminco Electric Traction Drives Inc For technical assistance please contact Saminco Inc 10030 Amberwood Road Ft Mvers FL 33913 USA Telephone 239 561 1561 Facsimile 239 561 1502 http www samincoinc com 2 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Table of Contents 1 General Information 8 DNE iiL 8 1 2 iii E 8 1 3 Equipment List 7 10 14 iStorage of the A3DO ED tbe um E Ga dien i 11 1 5 Principalof Operation u u ia i a ids 11 1 5 1 Solid State Control a be 11 1 5 2 Four Quadrant Operation and Dynamic Braking sees 12 1 5 3 Controller Configuration decia etie rat acd dete a ecd 12 1 5 4 Pulse Width Modulatlom uiii tcrtio rho bateria eerie oa a 12 2 installation a ee 14 2 1 Mounting and Mechanical 14 2 2 Control Connection and Harn
35. EST OR MEGGER TEST ON ANY PART OF THE A300 THIS ELECTRONIC EQUIPMENT USES SEMICONDUCTORS AND IS VULNERABLE TO HIGH VOLTAGE 1 2 Specifications The specifications are outlined in Table 1 to Table 6 below Table 1 Mechanical and Environmental Requirements A300510 DUAL SHUNT MOTOR CONTROLLER SPECIFICATIONS Description Specification Operation Unit Weight 600lbs External Dimensions See Figure 5 Mounting Connection Drawing for details Ingress Protection Level NEMA 12 Ambient Operating Temperature 20 C to 50 Operating Altitude 1000 m De Rate 1 Power for each additional 100 m Page 8 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Description Specification Relative Humidity 100 Vibration 3g 10Hz to 500hz Shock 50g 10ms Storage See Section 1 4 for other Storage Details Storage Altitude Maximum 3000m Storage Temperature Range 40 C to 70 C Table 2 Output Ratings Description Specification Current 600A DC continuous 1 Minute Overload Capability 900A DC Grounding Configurations Grounded Negative Output terminal dV dt 1500 volts per microsecond maximum Switching Frequency 1kHz Thermal Dissipation Standby 120 watts At rated output current 800A 5096 Duty Cycle 1410W Table 3 Main Power Supply Description Specification
36. IES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Figure 36 Removing the Pre Charge Resistors Testing Measure the resistance between wires 21 and 22 The correct value of resistance is 64 ohms between the points shown in Figure 37 The value measured should be between 52 and 76 A high value of resistance indicates that a resistor is open circuit A low value of resistance indicates that a resistor has become short circuit Replace all of the resistor elements if damage has occurred Figure 37 Pre charge Resistor Assembly A300302 Page 45 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Installation 1 Before installation ensure that terminal studs of the resistors are tight see Figure 38 This is especially important if replacing a resistor that has been removed as the stud mav have loosened when the connecting wire was disconnected Insert the half into the module Connect wires 21 and 22 Slide the assembiv to its final position Insert the four pre charge resistor fixing screws into the side of the module with a Figure 38 Tightening the Pre charge torque of 28 Resistor Studs Insert the two fixing screws from the bottom of the module and retain with nuts with a torque of 28 in lb Pre Charge Contactor K9009 028 The pre charge contactor is a sealed DC contactor with permanent magnet blowout No maintenance is required picture is
37. Lied 18 d FRONT VIEW SIDE VIEW Figure 5 Mounting Connection Drawing 2 2 Control Connection and Harnesses This section outlines the control wiring harnesses and connections Cable and connector types are listed For further installation information of these harnesses and connectors please contact the vendor of this product Page 14 of 78 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 2 2 1 Control Connector Pin Outs Connector CON1 The I O connector is a Harting Box mounted receptacle with 16 AWG male pins The pin out details are shown in Figure 6 and Table 8 Table 8 OOOOOOO 1 e e e e e e e 7 N Figure 6 Appearance of CON1 Viewed From the Outside of the A300 System Enclosure CON1 Main Control Connector Pin Signal Name Description Remark 1 BATT 26V low voltage supply positive 2 BATT 26V low voltage supply negative Consumption 40W typical 60W maximum 3 ENABLE Controller enable signal Low controller inactive High controller responds to drive and brake commands See Note 1 below FWD Drive forward signal Low controller does not drive forward High controller drives forward if brake release signal is high and drives reverse signal is low See Note 1 below REV Drive reverse signal Low controller does not drive reverse High controller drives
38. MOTOR CONTROLLER Rev 5 3 Example If the vehicle speed is 17 when the motor is at its base speed and Antilock Enable is set to 500 anti slip action will occur if the rate of deceleration exceeds 9 95 mph sec GROUP E Drive Control Set Up Table 16 Group E Drive Control Set Up Parameter Parameter USER Min Max Unit Access No Name SETTING Level E00 Accel Time 0 0 sec 0 0 20 0 0 1 1 201 0 0 0 2 20 0 0 1 1 202 Current Gain 0 3 0 1 2 0 0 1 2 E03 Speed P Gain 10 0 1 0 10 0 0 1 2 E04 Speed Gain 0 02 0 02 0 20 0 01 2 05 0 00 0 00 0 20 0 01 2 06 Stop Speed 0 0 0 0 400 0 0 1 2 E07 Bypass Speed 0 0 0 25 0 1 2 E08 Start Delay 100 ms 50 2000 1ms 2 E11 Stop Delay Oms 0 2500 1 ms 2 E17 Economy Field 5096 50 100 0 1 2 E18 Minimum Field 40 25 100 0 1 2 E21 Field RoC 2FFF 0 FFFF 1 hex 2 E22 Armature RoC FFFF 0 FFFF 1 hex 2 E00 and E01 Accel Time and Decel Time These parameters set the minimum times for a speed increase or decrease of a magnitude equal to the base speed of the motor If either parameter is set to zero the acceleration control is disabled E02 Current Gain This parameter specifies the scaling factor gain for the armature and field control loops This parameter simultaneously adjusts the proportional and integral gain for both armature and field T
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40. TRACTION DRIVES 4 3 Filter 19001 051 The EMC filter is a 3 phase high attenuation filter Two phases are used for the line supply and return paths The third phase is not connected 4 3 1 Inspection Remove the slotted front cover which is secured by six screws shown in Figure 16 Figure 17 shows the EMC filter with the cover removed Check that the inductor cores and the two printed circuit boards are secure Ensure the power connections are tight Replace the front cover The component should replaced if any damage has occured as a result of sustained overloading or loose connections 4 3 2 Removal and Replacement 1 Disconnect power cable from input and output Disconnect ground cable Remove the mounting hardware and withdraw the component Figure 17 Filter with Cover Removed 4 Fit the new component Ensure that the mountings are secure 5 Reconnect ground and power cables Ensure that connections are tight Page 37 of 78 SERIES MOTOR CONTROLLER Rev 5 3 4 3 3 Specifications This is MTE 150CE5 150A 600V 3 phase High dB 100 TIM TIM T attenuation filter E The printed circuit boards used in this filter must be coated 70 HH A eM LLL with a conformal lacquer or an electrical insulating varnish 60 eme ING suitable for printed circuit boards before the filter can be used in this applic
41. U etae en DE 38 4 4 1 Inspection and 38 4 4 2 Removal and Replacement 39 4 4 3 Replacing Tue et ec dt 40 4 4 4 Specification LEE 40 45 Motor Control Module 300201 40 4 5 1 Inspection and Testing n u ans uu ipa 42 4 5 2 Removal and Replacement a 42 4 5 3 Replacing E RU EE eta ee Ee E B 42 4 5 4 Specifications A e n 58 4 6 Brake Chopper Module 800969 59 4 6 1 Inspection and Testing ei eH ed a M p gps 59 4 6 2 Removal and Replacement 60 4 6 3 Replacing Pants ede em tet l A 60 4 6 4 Specifi ationis iri fa e E e e e et SA ti 61 Xa FIrmWar i ua H 62 5 1 Identifying Installed Firmware sse nennen 63 5 2 Installing New 63 6 Parameters and Adjustments 64 6 1 BlocleDiagiatm uie ete a ete e e dae cett 64 62 Traction RM eet Se ee erai 64 6 3 Brake Lovel a ata m tita rtt ett 64 64 Slip Spini Sensitivity u n dare P Pen i A 64 Diagnostics and Fault Finding
42. VES Tio f E TE _ T2 Voltage J Gite T1 T2 Voltage Current Figure 3 Pulse Width Modulation for Armature Current Similarly the field voltage is the difference between terminals T4 and T3 See Figure 4 below T3 Voltage T4 Voltage T4 T3 Voltage d Figure 4 Pulse Width Modulation for Field Current Page 13 of 78 SERIES MOTOR CONTROLLER Rev 5 3 2 2 1 Installation This section outlines the installation procedures required for safe use of the A300 DANGER UP TO 800V MAY EXIST IN THIS CONTROLLER USE EXTREME CAUTION TO AVOID SHOCK DISCONNECT INPUT POWER BEFORE WIRING OR SERVICING THE MOTOR Mounting and Mechanical Connections Figure 5 below shows a general dimensioned drawing of the enclosure for mechanical mounting 54 REF 52 5 2 3125 10 N G 4 gt 80 2188 4 L 17 U VIEW Ground Stud Power Power Inputs Outputs N 0 5 22 m El X 35 1 10 085 gr 35 i q nr N 90 307 18 5 8 PLACES bi pod 3 1 E o o o 05 d Lus 10 5 uM 1 0 5 05 kE 151
43. ad Page 24 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES Parameter No Parameter Name Function Unit A19 Upper Control Displays the forward current limit applied to the 0 1 Limit speed controller A20 Lower Control Displays the reverse current limit applied to the 0 196 Limit speed controller Logic I O Status A21 Logic Inputs Displays the status of the logic inputs 16 bit A22 Logic Outputs Displays the status of the logic outputs 16 bit Controller Status A23 Heatsink Displays the temperature of the semiconductor 0 1 C Temperature heatsink A24 Ambient Displays the ambient temperature inside the N A Temperature A300 Enclosure Not Used at this Time A25 Overload Level Displays the accumulated value of armature 0 or 1 current overload above 110 A26 T1 Duty Cycle Displays the PWM duty cycle at terminal T1 0 196 27 2 Cvcle Displays the PWM duty cycle terminal 2 0 1 28 T3 Duty Cycle Displays the PWM duty cycle at terminal T3 0 1 A29 Control Status Displays control status register flags 16 bit A30 Fault Status Displays the active trip before reset N A 0 No Fault 1 Control Supply Under Voltage CUV 2 Under Voltage UV1 3 Heatsink Over temp Alarm OH1 4 Heatsink Over temp Trip OT 1 5 Short Circuit SC IGBT Driver Module 6 Over Voltage Trip OV 7 External Fault 8 Pa
44. and Confirm that the vehicle jogs in the correct direction 12 Select the opposite direction Confirm that the vehicle jogs in the correct direction 13 Accelerate the vehicle to approximately 10 mph and apply a brake command Confirm that the vehicle brakes electrically and that A03 is between 700V and 720V during deceleration Page 23 of 78 SERIES MOTOR CONTROLLER Rev 5 3 14 Select regenerative braking Accelerate the vehicle to approximatelv 10 mph and applv a brake command Confirm that the vehicle brakes electricallv and that A12 Line Current shows a negative value during deceleration 15 Enable Slip Spin detection Run the vehicle at an approximatelv constant speed of 20 mph that A15 Analog Input 2 Slip spin signal does not exceed 5 3 1 3 Digital Displav Menu Tables This section outlines the functions of each parameter in the display menu All parameters are pre set at the factorv and should not be modified unless specified bv Saminco Group A Monitoring Table 12 Group A Monitoring Parameter No Parameter Name Function Unit Motor Current and Voltage A00 Armature Current Displays the value of motor armature current 0 1A derived from controller terminal T1 current measurement A01 Field Current Displays the value of motor field current derived 0 1A from controller terminal T3 measureme
45. approximatelv the same level as the supplv voltage The controller weakens the field automaticallv when speeds in excess of the base speed are required 008 OH Alarm Level This parameter sets the temperature level at which the semiconductor heat sink provides a warning of possible shutdown When this temperature level is reached the drive will cut back the current and allow 150 maximum current for the one minute cvcle and not the 200 for three seconds The level is adjustable from 70 to 85 C 009 Trip Level This parameter sets the heatsink temperature where the drive will fault and shut down until the heatsink cools below the set level The level is adjustable from 85 to 115 D15 Brake Level This parameter controls the analog brake level signal applied to the dynamic brake chopper This determines the DC bus voltage level at which the brake chopper turns on The voltage impressed upon the supply network during regenerative braking is limited to this level provided the impedance of the brake resistor is low enough to absorb the difference between the total DC bus current and the current that can be absorbed by the supply The brake level must not be set so low as to cause the brake chopper to become active normal line voltage conditions or become active when nearbv vehicles are regenerating Page 28 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES D16 Regen Level When re
46. ast Forward direction is defined as that for which terminal T1 of the controller becomes positive with respect to T2 Direction of tractive effort may be reversed by motor connections or gearing Note 2 Truth table for Gray code traction level inputs CODE 1 CODE 2 CODE 3 CONTROLLER RESPONSE Run at Creep Speed Drive or brake level 1 Drive or brake level 2 Drive or brake level 3 Drive or brake level 4 Drive or brake level 5 Drive or brake level 6 O O O O O Drive or brake level 7 Note 3 Reset Signals momentarilv high reset signal can be used to re initialize the controller to power on state e Reset signal must be released low for controller to operate normally e The reset signal must be manually accessible in order to execute the flash download procedure Note 4 Slip Spin Indication The slip spin indication remains active for two seconds following detection of a slip spin condition or will remain active as long as the condition exists Page 17 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Speed Sensor Connectors CN2 and CN3 The speed sensor connector is 5 MIL C 5015 wall mount receptacle with 16 AWG female sockets using 22 AWG wire 2 is the active speed sensor input The speed sensor from either axle may be connected to 2 CN3 is not wired inte
47. ation Figure 18 shows the typical TATA i S attenuation characteristic of this EMC filter LLI ro LIL LI L LIU 0 01 1 10 30 MHz Figure 18 EMC Filter 4 4 Line Contactor K9009 049 Attenuation Characteristic The line contactor is a solenoid operated switch rated at 1000V and 1000A The design of the A300 control system is such that the power semiconductors normally control current and voltage before the contactor is operated a picture of the line contactor is shown in Figure 19 The wear of the contact surfaces is therefore minimized and regular replacement of the tips will not be necessarv 4 4 1 Inspection and Testing The arc chute should be removed to inspect the condition of the contact tips arcing horns and the mechanism see Figure 20 and Figure 19 Line Contactor Figure 21 It is not necessary to remove the contactor from the equipment in order to carrv out this procedure Figure 20 Arc Chute Retaining Screw Figure 21 Removal of the Arc Chute Page 38 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Inspection items 1 Contact tips must not excessivelv worn burnt See Figure 22 Contact tips must have adequate surface in contact when thev are closed and have adequate lift and wipe The leading center contact must be free to move against the pressure spring The arc chute must be free
48. complete with connecting lead Installation 1 Fit the connecting lead 2 Mount the current sensor on the busbar using a torque of 28 in Ib The arrow on the body must be in the direction shown by Figure 46 and Figure 60 3 Re install the busbars installation torque of 85 in Ib and pcb tray Figure 60 CT2 4 5 4 Specifications Table 24 A300201 Specifications Specification Type Specification Maximum Motor Power 2 x 75HP Motor Voltage 2 x 300V Nominal Supply Voltage 600V Undervoltage Trip Level 300V Overvoltage Trip Level 840V Absolute Maximum Voltage not operating 1040V Continuous Output Current armature and field 200A Peak Armature Current 400A Peak Field Current 300A Control Supply Voltage Range 16V to 30V Control Supply Current at Minimum Control Supply Voltage 3A Maximum Heatsink Temperature 90 deg C Maximum Ambient Temperature 55 deg C Page 58 of 78 A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Specification Type Specification Minimum Temperature 20 deg C 4 6 Brake Chopper Module A800969 The brake chopper module uses a single IGBT module to switch the externally mounted brake resistor directly across the DC bus of the propulsion unit when it is necessary to dump energy recovered from the motors during braking The brake chopper module has its own power supply gate drive circuit and control circuit and is able to
49. dual voltage Test fuses with an ohmmeter continuity tester or a digital multi meter set to the diode test range A good fuse will always indicate a zero resistance path in both directions It is sometimes possible for a small residual voltage from the filter capacitors to produce a false indication of good continuity through the fuse Reverse the leads of the instrument and confirm good continuity in both directions 4 1 2 Removal and Replacement 1 Remove failed fuses by removing the nuts from the retaining studs of the fuse holder Figure 14 shows the fuses in the A300 system From Left to Right F9002 093 and F9002 080 Withdraw lugs of attached cables if necessary Withdraw the fuse 4 Check the tightness of the fuse holder mountings 5 Install the replacement fuse Ensure that attached cable connections are replaced at the same end of the fuse holder from which they were withdrawn 4 1 3 Specifications Figure 14 Fuses in the A300 System Table 20 A300 System Fuse Specifications Fuse Location Fuse Characteristics Approved types Line supply and High speed semiconductor fuse GOULD SHAWMUT armature 250A 700V A70QS250 4 F9002 093 Pre charge circuit High speed semiconductor fuse GOULD SHAWMUT F9002 080 15A 1000V A100P15 1 Page 35 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Written approval must be obtained from Saminco Inc before alternative tvpes are used for t
50. e 16 Group E Drive Control Set Up 30 Table 17 Group F Speed and Torque Settings 32 Table 18 Group G I O Configuration nn nanna anna ann tan 32 Table 19 Group H Fault Log L 33 Table 20 A300 System Fuse Specifications nt 35 Table 21 Line Filter Specifications 36 Table 22 Line Contactor Specifications 40 Table 23 Filter Capacitor Long Term Storage Requirements 52 Table 24 A300201 rr 58 Table 25 Brake Chopper Module Specifications 61 Table 26 Fault Codes and Corrective 65 Table 27 A300110 A300 Motor Controller Parts List nn 67 Table 28 A300201 SERIES MOTOR CONTROLLER MODULE 67 Table 29 A800969 BM302 3 400V 750V 400A 68 Table 30 K9009 049 CON DC 1000V 28V DC Replacement 5 69 Table 31 Miscellaneous Components nnne 69 Table 32 Drawings in Appendix 7 70 7 of 78 SERIES MOTOR CONTROLLER Rev 5 3 1 General Information This document outlines the installation operation and troubleshooti
51. e chopper which then also turns on The Brake Chopper Module is shown in Figure 61 4 6 1 Inspection and Testing CAUTION THE HEATSINKS PROTRUDING THROUGH THE LID APERTURES ARE AT A HIGH POTENTIAL WHEN THE MODULE IS CONNECTED TO THE A SUPPLV DO NOT TOUCH THE HEATSINKS The brake chopper module has a preset potentiometer for switching voltage adjustment This is factorv set and does not normallv require adjustment Page 59 of 78 SERIES MOTOR CONTROLLER Rev 5 3 To test the brake chopper voltage threshold it is necessarv to provide an adjustable DC supplv of 850V DC at a current of 1A and a resistive load of approximately 1 000 ohms Six 120V 100W light bulbs connected in series is recommended Connect the variable DC power supply to and Connect the resistive load to R1 and 2 Ensure that an interface lead containing a link between pins 5 and 17 of the control connector is fitted Gradually increase the power supply voltage to 850V The brake chopper should turn on at between 790V and 820V Graduallv reduce the power supplv voltage The brake chopper should turn off at between 770V 800V Adjust the preset potentiometer to obtain switching points within these ranges 4 6 2 Removal and Replacement 1 Disconnect from power terminals from P N R1 and R2 2 Disconnect the sub D control connector 3 Remove the fixing screws and withdraw the module 4 6 3 Replacing Parts Control
52. ed speed detector signal 0 24 square wave output 9Hz per mph Compatible with 24V PLC inputs OV low inactive 24V high active 16 BRAKE_SYNC Brake chopper synchronization signal Bi directional 24V logic signal Low brake chopper off High brake chopper on Links to opposite end controller to balance brake resistor loads 17 FLASH_ENABLE Flash download enable Low normal operation High select flash download on next controller reset 24V signal Temporary use for software installation RS232 TX RS232 RX Multi function serial data lines Use for software installation or data logging DISPLAY 5V Monitor display keypad 5V supply DISPLAY RESET Monitor display keypad reset signal DISPLAY TX Data to monitor display keypad DISPLAY RX Data from monitor display keypad DISPLAY Monitor display keypad ground Temporary connection to monitoring and programming unit SHIELD Connection for cable shield drain wire Page 16 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES Note 1 Truth table for ENABLE BRAKE_RELEASE FWD and REV inputs ENABLE BRAKE FWD REV CONTROLLER REPSONSE RELEASE 0 x X X Coast 1 0 X X Brake to standstill 1 1 0 0 Coast 1 1 0 1 Drive in reverse direction 1 1 1 0 Drive in forward direction 1 1 1 1 Co
53. embly The following section covers replacement of power semiconductors current sensors precharge diode filter capacitors and voltage balancing resistors Removing the PCB Tray 1 From the MA2287 gate drive board disconnect J1 J2 43 1 2 J8 J9 J10 J11 J12 and J14 From the MA2288 voltage transducer board disconnect P4 P5 P6 P7 P8 P9 P10 and P11 Figure 40 shows the A300 Motor Controller with the top level removed and the cables mentioned above disconnected Remove the PCB fixing screws from the side of the module see Figure 41 reinstallation torque 28 in Ib Completely withdraw the PCB tray assembly Ensure that no cables or connectors get snagged torn see Figure 42 Figure 40 Connectors Unplugged from MA2287 and MA2287 for PCB Tray Removal Figure 41 Removing the A300 Control Board Layer Figure 42 PCB Tray Removal Page 47 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Pre charge Diode D9002 003 The pre charge diode is a 25A 1600 3 phase rectifier The AC terminals are never connected in this assembly Disconnecting wires 22 23 and removing the fixing screw will allow the diode to be removed When replacing the diode it is not necessary to use any heatsink compound Ensure that wire 23 is connected to the positive side of the rectifier A torque of 40 in lb is required for remounting of this device Balancing Resistors R
54. esses U 14 2 2 1 Control Connector u s 15 2 2 2 Control Wiring 19 2 3 High Power Conrnectlons odii eiie besten tite eid iL e ek eite eb i 20 3 21 3 1 Start Up and 0 21 3 1 1 Digital Display and Keypad Navigation a 21 3 1 2 Start Up Procedure 22 3 1 3 Digital Display Menu Tables UU u treten edes tede nea dd 24 4 Maintenance and Repaair 35 4 1 Fuses F9002 093 and 9002 080 35 4 1 1 Tes ing uuu 35 4 1 2 Removal and Replacement naa 35 4 1 3 Sere 35 42 Line Filter Chokes 19001 050 36 4 2 1 INSPEC 36 4 2 2 Removal and Replacement sss enne nnn 36 4 2 3 Specifications 36 4 3 EMC Filter 9001 051 ente d teet etaed ee du veda a akaqa aq 37 Page 3 of 78 SERIES MOTOR CONTROLLER Rev 5 3 4 3 1 Inspection E 37 4 3 2 Removal and Replacement 37 4 3 3 itt A ee a a en eg le ires 38 4 4 Line Contactor K9009 049
55. evel code inputs are zero The setting is in percent of motor base speed F21 Creep Speed Bias This parameter is used to trim out the analog offset in the armature voltage measurement circuit in order to obtain exactly equal creep speeds in both directions A positive creep speed bias increases the creep speed in the forward direction and decreases the creep speed in the reverse direction The correct value of creep speed bias can be determined bv setting the creep speed F13 to zero and adjusting F21 to hold the vehicle at standstill during creep speed operation F14 to 220 and 221 Travel Torque 1 through 7 These parameters set up the acceleration and braking levels based upon the displacement of the driver s control Various levels of torque can be set for each of the switch positions F22 Neutral Torque Neutral Torque used to applv a small stopping torque when the driver selects the coast position The purpose of this is to ensure that the vehicle speed will not remain the same or slowlv increase if the controller is still enabled while the coast position has been selected GROUP I O Configuration Table 18 Group G Configuration Parameter Parameter User Min Max Unit Access No Name Setting Level GOO Analog IP1 10V N A 1 2 G01 Analog IP1 Gain 1 67 0 00 10 00 0 01 2 Page 32 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC
56. function without any connection to the motor control module A 6 wire interface to the main motor control module allows the characteristic of the brake chopper to be adjusted or modified to suit operating conditions and allows brake chopper faults to be detected and logged When the brake chopper is disconnected from the motor control module the switching voltage is set so that the IGBT turns on when the DC bus voltage is 800V Figure 61 Brake Chopper Module When the motor control module interface is 800969 connected an analog signal from the main controller is used to depress the switching voltage up to 200V When the input signal is 10V the IGBT turns on at a bus voltage of 600V While the propulsion unit is not enabled the controller sets the switching level to its maximum of 800V in order to avoid unwanted operation of the brake chopper yet still provide good protection from line transients above 800 While the propulsion svstem is enabled the switching level is depressed to a lower level tvpicallv 700V so that regenerating cars cannot impress high voltages on the network The brake chopper has a svnchronization signal for the purpose of balancing the braking load of the other propulsion unit The svnchronization signal is a bi directional 24V signal and is linked to the same signal of the other brake chopper The first brake chopper to switch drives the synchronization line to 24V This is detected by the other brak
57. generative braking is not enabled the line contactor in the propulsion unit is opened when the reverse line current exceeds this parameter Current is then diverted to the on board brake chopper Regen Level is typically set at 10 Increasing this level results in more current returned to the line before the contactor opens Reducing this level may result in unnecessarily frequent cycles of the contactor D17 Bus Threshold This parameter controls the point at which the line contactor returns to the closed position during non regenerative braking The Bus Threshold is the amount by which the DC bus voltage must fall below the line voltage before re closure is initiated Bus Threshold is typically set at 50V Increasing this level causes a larger inrush current and delays the transition to the driving mode Reducing this level may result in unnecessarily frequent cycles of the contactor 018 Slip Enable Lim This parameter sets the amount of wheel slip that must be detected before the anti slip action is initiated Slip detection is based upon measurement of the difference in armature voltage between the two series connected armatures on the same truck The following formula should be used Slip threshold mph 0 0167 x Slip Enable Lim x mph at motor base speed Example If the vehicle speed is 17mph when the motor is at its base speed and Slip Enable Lim is set to 15 anti slip action will occur when the wheel rim velocity difference
58. hange of field current This is a hexadecimal value The maximum value of FFFFH corresponds to a 400 change per second This is the recommended value E22 Armature RoC This parameter controls the maximum rate of change of armature current This is a hexadecimal value The maximum value of FFFFH corresponds to a 400 change per second The recommended value is 2FFFH This allows 75 change per second Page 31 of 78 SERIES MOTOR CONTROLLER Rev 5 3 GROUP F Speed and Torque Settings Table 17 Group F Speed and Torque Settings Parameter Parameter Name User Min Max Unit Access No Setting Level F12 Travel Speed 200 0 300 0 1 1 F13 Creep Speed 5 5 0 10 0 1 1 F14 Travel Torque 1 3090 0 200 0 1 1 F15 Travel Torque 2 60 0 200 0 1 1 F16 Travel Torque 3 75 0 200 0 1 1 F17 Travel Torque 4 9090 0 200 0 1 1 F18 Travel Torque 5 105 0 200 0 1 1 F19 Travel Torque 6 120 0 200 0 1 1 220 7 140 0 200 0 1 1 F21 Creep Speed Bias 0 2 2 0 1 1 F22 Neutral Torque 0 1 0 200 0 1 1 212 Travel Speed This parameter defines the maximum operating speed Setting is in percent of motor base speed F13 Creep Speed This parameter defines the speed at which the vehicle runs when the creep speed mode is selected bv applving a forward or reverse command to the controller while all three traction l
59. he LCD and converts push button operations into messages that are transmitted to the main propulsion module The device used to store this program is erased bv exposing to strong ultra violet light After exposure it can be reprogrammed The EPROM fitted mav be a one time programmable OTP tvpe This has the same UV erasable chip inside has no window to permit UV exposure The firmware in this location is created bv Saminco Inc using a high level language compiler affects operation of the only when the display is connected for checks and parameter adjustment Page 62 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES 5 1 Identifying Installed Firmware 1 Connect the LCD module 2 Cycle the control supply power or momentarily apply the RESET input 3 Wait until the display changes from Brookville initialization to Brookville Streetcar Figure 65 Press the A key once more to indicate the software version installed in the main propulsion unit see Figure 66 oU 5 2 Installing New Firmware Software updates can be installed using a laptop PC connected to the serial port Consult Saminco Inc before attempting to make any changes to the installed firmware of the main propulsion unit Display Software BV DU v1 18 E A v Figure 65 LCD Module Software Version Display Example Motor Control SW Brookville v 103 E A v Figure 66 Motor Control Sof
60. his application 4 2 Line Filter Chokes 19001 050 Two identical inductors of 0 5mH each are connected in series to vield a total inductance of 1mH See Figure 15 4 2 1 Inspection Check the tightness of the mounting hardware Check the tightness of the connections Do not re tighten the connection screws without using a wrench on the back nut to restrain the movement of the connecting lug If a choke shows signs of overheating either as a result of sustained operation at very high currents or as a result of loose connections it should be replaced 4 2 2 Removal and Replacement 1 Disconnect all power connections 2 Disconnect choke connections e Unplug control connections from motor Figure 15 Line Filter Choke control module Remove the retaining screws from the baseplate Withdraw the baseplate complete with attached components Disconnect the series link Remove the mounting hardware and withdraw the component Fit and the replacement choke Ensure mountings and connections are secure Reconnect the series link Do not strain the connecting lugs when tightening MN Oa Install the baseplate assembiv Replace the retaining screws 10 Reconnect the choke connections 4 2 3 Specifications Table 21 Line Filter Specifications Rating Description Rating Inductance 0 5mH Current Rating 100A DC continuous Page 36 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC
61. his parameter is set to match the inductance of the traction motor E03 Speed P Gain This parameter sets the amount of proportional action for the speed loop This has an effect on the stability of braking performance when operating close to zero speed The Speed P Gain is set to a value of 10 Reducing the Speed P Gain will give smoother running if the system is to be tested off the vehicle or with the wheels lifted clear of the rails but under actual driving conditions E04 Speed Gain This parameter sets the amount of integral action for the speed loop The presence of some integral gain ensures that the braking effort is maintained down to a very low speed that is within the normal range at which the mechanical brakes are set E05 IR Comp Gain The speed loop IR compensation gain tightens up the speed regulation from no load to full load This parameter affects the dynamic response of the speed loop IR compensation should be set to zero whenever fast speed loops are necessary IR compensation is set to zero in this application Page 30 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES E06 Stop Speed This parameter sets the speed value that will initiate the stop sequence in the software When the controlled speed reference A18 reaches this value the DB contactor is de energized and the DB Delay Time E08 begins The Stop Speed is set to zero in this application E07 Bypass Speed
62. ircuit Wait for the center OFF position OV e Disable IGBTs Indicates excessive DC input voltage Overvoltage e Wait for the center OFF position or supply no able to accept reverse current flow during regeneration FL Disable IGBTs Indicates that the motor field loop is Field Loss e Wait for the center OFF position open or that IGBTs Q2 or Q3 are not conducting MOL e Disable IGBTs Wait for motor or check motor Motor Overload Wait for the center OFF position EXT Disable IGBTs Slack Cable condition detected Only External Limit e Wait for the center OFF position hoisting is permitted until reset Switch e Lowering Disabled MS e Disable Drive Master switch not in OFF position Master Switch Page 65 of 78 SERIES MOTOR CONTROLLER Rev 5 3 8 Customer Support For customer support or help with this manual please contact Saminco Inc 10030 Amberwood Road Ft Mvers FL 33913 USA Telephone 239 561 1561 Facsimile 239 561 1502 http www samincoinc com Page 66 of 78 ELECTRIC TRACTION DRIVES A300 SERIES MOTOR CONTROLLER Appendix A Parts List In order to obtain spare parts for maintenance please refer to Table 27 through Table 31 The quantities of an entire module are given for reference Table 27 shows the top level assembly of the A300 Motor controller Bolts and easily obtained equipment is not listed Any of
63. ixing Screws u E A EAA A AER enne 49 Figure 47 Heatsink 50 Figure IGBT Fixing 5 u ia auqa al m usq hot 51 Fi ure 49 IGBT Removal usut g aed Wend ae qapas 51 Figure 50 Applying Heatsink Compound I 51 Figure 51 Installing the 1 52 Figure 52 Removing the Balancing Resistor Assembly 53 Figure 53 Removing the Capacitor u L uD 53 Figure 54 2288 Voltage Transducer 54 Figure 55 Gate Driver Board iii sas ine 55 Figure 56 Main Control 56 Figure 57 Main Control Board with Connectors 56 Figure 58 Control Board Link Positions eene nemen 57 Figure 59 Control Board DIP Switch 57 Fowo CVA i rit t oet bai usi tis tha of e es 58 Figure 61 Brake Chopper Module A800969 sss eene 59 Figure 62 Removing the Brake Module 60 Figure 63 Brake Module with Circuit Board Removed sss eee 60 Figure 64 Brake Module Circuit Board MA2289 a 61 Figure 65 LCD Module Software Versi
64. ket The fan sucks air from the heatsink and the surfaces of the fan blades will be visible when it is installed 3 Leaving the fan guard unattached secure the fan with fixing screws A see Figure 32 Position the fan guard as shown ensuring that it is the right wav round Secure with fixing screws B Ensure that the fan blades rotate freelv after all screws have been tightened 4 Attach 2 connector to J14 on the MA2287 gate drive board Figure 32 Fan Installation Complete Page 43 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Pre Charge Resistor Assembly A300302 The pre charge resistor is a network of six strip heater resistor elements attached to a insulating base Removal 1 Position the module so that access to the bottom fixing screws is possible Remove the two screws and nuts that secure the inside corners of the pre charge resistor Remove the four pre charge resistor fixing screws from the side of the module Partly withdraw the assembly far enough to provide access to the terminals for wires 21 Figure 33 Pre charge Resistors and 22 Installed Disconnect wires 21 and 22 Take care not to allow the resistor terminal studs to unscrew from the body of the resistor element Completely withdraw the assembly Figure 34 Bottom Fixing Screws Figure 35 Removing the Pre charge Resistors for the Pre charge Resistor Page 44 of 78 SAMINCO A300 SER
65. llen or ruptured is common to find trace of fluid around the vent of a new capacitor remaining from the filling process This should be ignored if no more fluid appears after it has been cleaned off If itis suspected that there is a faulty capacitor in the group proceed as follows Connect a high voltage low current supply across one pair DC busbar connections of a group The polarity of the supply must agree with the markings on the capacitor can DO NOT APPLY Page 52 of 78 A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES REVERSE VOLTAGE A resistor of 1 kilohm should be used in series with the supply to limit the current in the event of a capacitor failure Measure the DC voltage across each capacitor in the circuit The difference in voltage measurements across each capacitor should not exceed 3 of the total Example If 600V is applied to the pair the lower voltage should not be less than 291V and the higher voltage should not exceed 309V Repeat for the other pair of DC bus connections CAUTION ALWAVS ALLOW CAPACITORS TO DISCHARGE TO A SAFE VOLTAGE BEFORE TOUCHING THE TERMINALS OR OTHER PARTS OF THE TEST CIRCUIT If a group of filter capacitors has failed the voltage balance test ALL OF THE CAPACITORS IN THE GROUP SHOULD BE REPLACED It is important that all of the capacitors have identical leakage characteristics If possible the replacement capacitors should have the same or very similar date codes Filter
66. ne Contactor Specifications Specification Description Specification Maximum Inline Voltage 1000 VDC Continuous Current Rating 1250 A Interrupt Current Rating 1250 A Motor Control Module A300201 Figure 24 through Figure 27 shows several views of the A300 Motor Controller Module Figure 24 A300 Motor Controller Module Page 40 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Figure 25 A300 Line Side Terminals Figure 26 A300 Load Side Terminals Figure 27 A300 Motor Controller with Top Cover Removed Page 41 of 78 SERIES MOTOR CONTROLLER Rev 5 3 4 5 1 Inspection and Testing Ensure that the heatsink see Figure 28 is not obstructed bv accumulated dirt Inserting a small brush between gt the fins and blowing with compressed air can remove dirt Isopropyl alcohol mav be used to remove greasv or stickv residues IMPORTANT DO NOT USE WATER OR CHLORINATED SOLVENTS Ensure that the fan G9005 022 can rotate freelv and that electrical connections and mounting hardware are secure gt Execution of the test procedure for the A i pu Series Motor Control module requires complete test fixture with a motor load stand If a module requires Figure 28 9004010 00 Motor Control Module Heat Sink retesting or recalibration it should be returned to Saminco 4 5 2 Removal and Re
67. ng of the Saminco A300 Series Motor Controller Please read and understand this manual before carrving out installation inspection maintenance operation or repair of this equipment or its components Within this document the product known as the Saminco A300 Motor Controller shall be referred to as the A300 Some exceptional features of the A300 are listed below Adjustable traction control Modular construction High efficiencv power conversion Safetv circuits for maximum protection of personnel and components External drive displav for ease of monitoring and troubleshooting Power semiconductors used wherever possible to replace electro mechanical switchgear Stepless acceleration and braking Selectable dvnamic braking or line regenerative braking blended with dvnamic braking Wheel slip and slide detection 1 1 Safetv THE A300 IS A HIGH POWER UNIT THAT CAN CAUSE SEVERE INJURV OR DEATH IF NOT USED PROPERLV FOR YOUR OWN SAFETV PLEASE REVIEW THE FOLLOWING WARNINGS FULLV BEFORE PROCEEDING 1 READ THIS MANUAL ENTIRELY BEFORE INSTALLING OR OPERATING THE A300 2 DO NOT CONNECT OR DISCONNECT WIRING CONNECT OR DISCONNECT WHILE THE HIGH VOLTAGE POWER SUPPLY IS TURNED ON 3 THE A300 HAS INTERNAL CAPACITORS THAT ARE STILL CHARGED EVEN AFTER THE POWER SUPPLY IS TURNED OFF TO PREVENT ELECTRICAL SHOCK DISCONNECT ALL POWER AND WAIT A MINIMUM OF FIVE MINUTES BEFORE TOUCHING INTERNAL COMPONENTS 4 DO NOT PERFORM A WITHSTAND VOLTAGE T
68. nt A02 Armature Voltage Displays the value of the armature voltage 0 1V measurement derived from controller terminals 1 2 A03 DC Bus Voltage Displays the voltage on the controller DC bus 0 1 capacitors Motor Speed and Torque Calculation A04 Armature CEMF Displays the motor counter EMF as a 0 1 percentage of the motor rated voltage A05 Flux Calculated motor flux as percentage of the full 0 1 field value A06 Motor RPM Calculated motor speed in RPM 1 RPM A07 Motor Torque Displays the calculated motor torque as a 0 1 percentage A11 Line Voltage Displays the voltage at the line side of the line 0 1V contactor A12 Line Current Displays the input current to the propulsion unit 0 1 as a percentage of the motor rated current Power Energy and Operation Cycles A13 Elapsed Hours Accumulated time controller is enabled 1hr Analog Input Status A14 Analog Input 1 Displays the full scale of analog input 1 0 1 A15 Analog Input 2 Displays the full scale of analog input 2 0 1 Current and Speed A16 Armature Current Displays the armature calculated current 0 1 Reference reference as a percentage of the motor rated current A17 Field Current Displays the field calculated current reference 0 1 Reference as a percentage of the motor rated current A18 Speed Reference Displays the calculated speed reference after 0 1 acceleration and deceleration control as a percentage of the motor rated speed at full lo
69. o provides the ability to load factory default settings Access to store and restore is provided by the user or engineer password level To store the user settings select Store User Setting after all of the parameters are set and checked for accuracy To restore the user settings enter password and select Restore User Setting To restore the factory settings select the Restore Factory Setting It will be necessary to reset the parameters for proper operation for the specific drive and motor used since the default settings are not drive specific as the user settings are The default settings will not become effective until the controller is powered down or reset Warning Before installing a control board whether from another drive or from inventory follow the proper set up procedure Incorrect drive set up can cause equipment damage or personnel injury GROUP D Protection Table 15 Group Protection Parameter Parameter Name User Minimum Maximum Unit Access No Setting Level DOO Motor Rated Current 170 1 2000 1A 2 001 Motor Rated Volts 600 200 700 1V 2 002 Motor Base Speed 1600 0 5000 1RPM 2 003 Current Limit Fwd 100 50 200 0 1 2 005 Current Limit Rev 100 50 200 0 1 2 006 Armature Field 2 0 1 1 3 0 0 1 2 008 OH Alarm Level 85 70 85 1 2 009 Trip Level 105 85 115 1C 2 D15 Brake Level 705 600 800 1V 2 D16 Regen Level 10 0 0 100 0 0 1 2 D17 Bus Threshold 50 0
70. on Display 63 Figure 66 Motor Control Software Version Display 63 Page 6 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES Index of Tables Table 1 Mechanical and Environmental 8 Table 2 uuu sl ea cg deb m br d ld tea adds 9 Table 3 Main Power u u a 9 Table 4 Control Specification na 9 Table 5 Protective 9 Table 6 Specification rr 10 Table 7 A300 10 Table 8 CON1 Control 15 Table 9 CN2 Speed Sensor 18 Table 10 Keypad Button Descriptions 21 Table 11 Startup Requirements 23 Table 12 Group Monitoring 24 Table 13 Group B ACCESS iii ip id ka da nad cies ad 26 Table 14 Group Controller Rating Set Up a 26 Table 15 Group D Protections u nida bd due 27 Tabl
71. owing points J1 pin 1 to J1 pin 2 J1 pin 6 to J1 5 J2 pin 1 to J1 pin 2 J2 pin 6 to J2 pin 5 J3 pin 1 to J3 pin 2 54 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 6 J3 pin 6 to J3 pin 5This test may be carried out with the IGBT gate leads connected or unplugged Note that this test is not a complete test of the gate drive circuits It merely serves to ensure that the gate drive circuit produces a negative bias that on all of the IGBT gates so that it is safe to apply voltage to the DC bus Figure 55 Gate Driver Board Removal 1 Unplug all of the connectors from the gate drive board 2 Remove all of the fixing screws 3 Withdraw the gate drive board Installation Install the board by carrying out the removal steps in reverse order Page 55 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Control Board MA2259 The MA2259 control board for the uses a microcontroller to read digital and analog input and feedback signals and deliver output signals for controlling the power semiconductors and other hardware of the A300 system The MA2259 board uses flash memorv to store the microcontroller executable program This allows the program to be erased and updated remotely using a serial communication port The MA2259 board also uses a similar but separate device for storage of adjustable settings All adjustments are carried out remotel
72. placement 1 N Disconnect all external power connections from the propulsion module Remove the baseplate retaining screws Slide out the baseplate ensuring that the front edge is supported Disconnect power cables 106 107 108 111 ans 114 refer to Figure 10 for the connection schematic Disconnect control cables 36 37 and 38 Loosen the six cover retaining screws Remove the cover Disconnect plugs from J15 J16 J18 and J19 Remove the four fixing screws that secure the module to the baseplate Withdraw the module The module be installed reversing these steps 4 5 3 Replacing Parts Fan Removal A300303 1 Unplug the 2 pin connector from J14 on the MA2287 gate drive board Figure 29 shows the location of this connector Figure 29 Location of J14 on MA2287 Page 42 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 2 Detach the fan guard by removing the four fan fixing screws see Figure 30 3 Withdraw the fan guard withdraw the fan complete with the attached lead 4 Remove the Fan see Figure 31 Fan Installation Figure 30 Removing the Fan Fixing Screws 1 Pass the 2 pin connector from the lead attached to the fan between the current sensor mounting bracket and the wall of the module L a z a gt Ce x 2 Position the fan so that the label is visible when it is placed against the fan brac
73. rameter Exceeds Rating PER 9 Not Implemented 10 Not Implemented 11 Not Implemented 12 Not Implemented 13 Motor Overload MOL 14 Not Implemented 15 Change of Configuration COC Locks out drive immediate operation if configuration is changed Also see Table 26 Fault Codes and Corrective Action in Section 7 3 Troubleshooting Page 25 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Group B Access Table 13 Group B Access Parameter Parameter FACTORV Range Access No Name DEFAULT Level 00 Password 0 0 0 65535 0 Monitor Only 212 Plant User BO1 Access Level Monitor 0 Monitor Only 0 1 Plant User 2 Engineer 802 Software N A N A 0 Version THIS PRODUCT REQUIRES PASSWORDS TO MAKE PARAMETER CHANGES IT IS THE RESPONSIBILITV OF THE PURCHASER USER TO SECURE THESE PASSWORDS AND MAKE THEM AVAILABLE ONLV TO QUALIFIED TRAINED PERSONNEL IMPROPER PARAMETER SET UP CAN DAMAGE EQUIPMENT AND CAN POSE A HAZARD TO PERSONNEL GROUP C Controller Rating Set Up Table 14 Group C Controller Rating Set Up Parameter Parameter User Setting Min Max Unit Access No Name Level C01 Voltage Class 1 400 720 400 720V 1 C02 Current Class N4 200A 200A 200A 1 C04 Armature Int CT Setup C05 Input Bus 600 200 700 1V 2 Voltage C06 Field Setup Int CT C07 Default No Action 1 2
74. replace fit the relay link between LK and J13 of the gate drive board Connect the short wires of the contact side to the control board DO NOT FIT A SIMPLE 2 WIRE LINK WITHOUT A RELAY WHEN USING MA2259 Secure the relay to the MA2259 board with silicone RTV If fitting MA2259 1 replace the link between J1 and the gate drive board with a straight 2 wire jumper without a relay ENSURE THAT THE BOARD 1 MA2259 1 OR LATER BEFORE FITTING A SIMPLE 2 WIRE LINK Figure 58 Control Board Link Positions Figure 59 Control Board DIP Switch Positions Page 57 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Current Sensors T9003 013 The current sensors consist of a high permeabilitv magnetic core that is fitted around the conductor carrving the current to be measured A small Hall Effect magnetic field sensor located in a gap of the core produces a small output voltage proportional to the core flux which in turn is proportional to the current passing through the core An amplifier converts the small Hall Effect signal to a larger signal such that 4V corresponds to the 600 nominal specification of the device Removal and CT3 Refer to Figure 46 on page 49 of this document 1 Remove the pcb trav 2 Remove busbars connected to T1 and T3 3 Withdraw the current sensors complete with connecting leads CT2 1 Remove the 9 16 nuts securing the busbar link shown in Figure 60 2 Withdraw the current sensor
75. rnallv to the controller input and serves only as a termination point for the spare speed sensor signal Figure 7 Figure 8 and Table 9 describes the signal for each pin SENSOR CONNECTOR CN2 12V CHA CHB Figure 7 Appearance of CN2 and CN3 viewed from the outside of the enclosure Figure 8 Speed Sensor Connections Table 9 2 Speed Sensor Connectors Pin Signal Name Description Remark A 15V 15V speed sensor supply Protected by 0 5A self resetting PTC fuse B CHA Speed sensor channel A Open collector Speed sensor channel outputs D OV Speed sensor ground E SHIELD Speed sensor cable shield Connect to drain wire of cable shield Page 18 of 78 A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 2 2 2 Control Wiring Harnesses Figure 9 outlines the connections required for control of the A300 The cable connector is a Harting style with 16 AWG female crimped pins The speed sensor cable connector CN2 requires a 5 way MIL C 5015 in line receptacle with 16 AWG male sockets PLC I O BRAKE RELEASE REV CONNECTOR CON1 SPEED SIGNAL SLIP SPIN SIGNA FAULT SIGNAL RESET CODE 3 CODE 2 CODE 1 FWD ENABLE CONTROL SWITCH SWITCH SWITCH REV BRAKE RELEASE LEVEL CODE 1 LEVEL CODE 2 LEVEL CODE 3 REGEN ENABLE RESET SLIP SPIN DET ENABLE FAULT SLIP SPIN SPEED BR
76. s Voltage A04 Armature A05 Flux A06 Motor RPM A07 Motor Torque A11 Line Voltage A12 Line Current A13 Elapsed Hours A14 Analog Input 1 A15 Analog Input 2 A16 Armature Current Reference A17 Field Current Reference A18 Speed Reference A19 Upper Control Limit A20 Lower Control Limit A21 Logic Inputs A22 Logic Outputs A23 Heatsink Temperature A24 Ambient Temperature A25 Overload Level A26 T1 Duty Cycle 27 2 Duty Cycle A28 T3 Duty Cycle A29 Control Status A30 Fault Status 3 1 2 Start Up Procedure Group D Group E Group F Drive Control Protection F12 Travel Speed F13 Creep Speed F14 Travel Torque 1 F15 Travel Torque 2 F16 Travel Torque 3 F17 Travel Torque 4 F18 Travel Torque 5 F19 Travel Torque 6 F20 Travel Torque 7 F21 Creep Speed Bias F22 Neutral Torque E00 Accel Time E01 Decel Time E02 Current Gain E03 Speed P Gain E04 Speed Gain E05 IR Comp Gain EO6 Stop Speed E07 Bypass Speed E08 Start Delay E11 Stop Delay E17 Economy Field E18 Minimum Field E21 Field RoC E22 Armature RoC DOO Motor Rated Current D01 Motor Rated Volts D02 Motor Base Speed DO3 Current Limit Fwd D05 Current Limit Rev D06 Armature Field D08 OH Alarm Level D09 OH1 Trip Level D15 Brake Level D16 Regen Level D17 Bus Threshold D18 Slip Enable Lim D19 Slip Disable Lim D22 Antilock Enable Figure 13 Menu Map Speed and Torque Group G Group H Configuration Fault Log HO Fault 1 H1 Fault
77. sed with the vendor of this product immediatelv for resolution Also please refer to the terms and conditions of sale Anv damages due to shipping should be immediatelv claimed against the shipping carrier Each A300 is made up of the following modular sub components inside the main enclosure Table 7 and Figure 1 below are given for reference purposes and outline the approximate location and underlying principal of each modular sub component For terminal locations see Figure 10 High Power Connection Schematic For Mounting information see sections 2 1 and 2 2 of this document Table 7 A300 Sub Components Item Qty Part Description 1 1 A800969 Brake Chopper Module 2 1 A300201 Series Motor Controller Module 3 1 I9001 051 RFI EMC Filter 4 2 19001 050 Choke DC 5mh 150A 5 1 K9009 049 Main DC Contactor 1000V 28V DC Control CH 2120A7G01 6 1 F9002 080 15A 1000V Semiconductor Fuse 7 2 F9002 093 250A 700V Semiconductor Fuse Page 10 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRIVES 19001 050 2 1504 DC Choke Mounted gt 2 a A300201 9 Motor Controller Module OF9002 093 250A 700V Fuse o F9002 080 15A 750V Fuse 1 800969 Brake Chopper 5 K9009 049 Module
78. shown in Figure 39 Removal 1 Disconnect the coil leads For units with no in line connectors in the coil leads cut the leads 4 inches from the contactor body shown by a yellow line in Figure 39 Install 74 inch female quick connect terminals on the leads attached to the harness See Table 31 for part numbers of the crimp utility and quick connect terminals Figure 39 Pre charge Contactor 2 Disconnect wires 20 and 21 from the contact terminals see the blue arrows in Figure 39 3 Remove the fixing screws labeled with red arrows in Figure 39 and withdraw the contactor Testing A 24V power supply that is able to supply a peak output of 10A is required to test the contactor Apply 24V to the coil The red lead must be connected to the positive side Confirm that the contact resistance is near zero when the coil is activated and infinite when the coil is inactive Distinct clicks will be heard when the coil is activated and deactivated Page 46 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES Installation Reverse all steps of the removal procedure If replacing a contactor that does not have in line connectors install two inch male quick connect terminals to the contactor leads The install torques for the fixing screws and contact terminals should be 28 and 85 in Ib respectively Ensure that the polarity of the coil and the contact leads is correct Power Semiconductor Ass
79. ted to the A300 3 1 1 Digital Display and Keypad Navigation This display is software specific and can be attained using Saminco Reference Part MA2263 Display Board with Keypad There is a 2 line LCD to display information and four pushbuttons to control the display and carry out adjustments Figure 11 Figure 12 and Table 10 below shows the appearance and function of the LCD module and buttons The menu structure is outlined in Figure 13 Logic inputs A21 0000000000000000 E A Y gt Figure 11 Digital Display Figure 12 Digital Display Module Table 10 Keypad Button Descriptions Key Symbol Key Name Description E ENTER Use this key to accept or select the current entry UP Increment to the next parameter or menu item If at the last parameter or menu item it will move back to the first DOWN Increment to the previous parameter or menu item If at the first parameter or menu item it will move back to the last gt RIGHT This kev is used to select the menu to be displaved Page 21 of 78 SERIES MOTOR CONTROLLER Rev 5 3 Group Group B Access Group C Controller Rating Monitoring C01 Voltage Class C02 Current Class C04 Armature Setup C05 Input Bus Voltage C06 Field Setup C07 Default Values B00 Password B01 Access Level B02 Software Version 00 Current A01 Field Current 02 Voltage A03 DC Bu
80. these parts can be ordered by contacting a Saminco Inc sales representative See Section lt LINKREF gt for contact information Table 27 A300110 A300 Motor Controller Parts List Saminco Part Number Description Quantity A300201 Table 28 SERIES MOTOR CONTROLLER MODULE 1 A800969 Table 29 BM302 3 400V 750V 400A BRAKE 1 E9001 207 ENC PCC 1 F9001 007 HOLDER FUSE 1 60 250V 1 F9001 013 HOLDER FUSE 400A FERRAZ 3 F9002 080 FUSE 15A 1000VAC 750VDC 1 F9002 093 FUSE 250A 700V 2 F9004 004 CLIP FUSE PCB 5 DIA 2 19001 050 5mh 150 W NOMEX 2 19001 051 RFI EMC FILTER 1 J9004 046 JUNC BLK 3 8 16 STUD 4 K9009 049 Table 30 JCON DC 1000V 28V DC 1 W6004 175 CABLE 6CON 25PIN SUB D PLUG 1 W6004 178 CABLE 42PIN CONTROL 1 Y9002128 MIDDLE SLIDE UHMW PE 2 Y9002129 SLIDE UHMW PE 2 Y9008052 BUS BAR TCU 8 8 2 Y9008161 BUS BAR ALUMINUM 1 Table 28 A300201 SERIES MOTOR CONTROLLER MODULE Saminco Part Number Description Quantity 300301 HEATSINK THERMISTOR ASM 1 A300302 A300 PRE CHARGE RES ASM 1 A300303 A300 FAN ASM 1 C9001 121 CAP 6 8uF 400VDC OTH 1 C9002 002 PCAP 2 5uF 850WV OTH RAD BB 3 C9002 032 PCAP 1800uF 500VDC 16 D9002 003 PWR DIODE BRIDGE 3PH 25A 1200V 1 HM100 004 M10 NYLON CAP STUD INSUL NUT 16 K9009 028 CON 200A 320DC N O 9 36V ECON 1 MA2259 3 MA2259 3 CONTROL BOARD 1 MA2287 1 MA22
81. tor and braking functions with a PWM pulse width modulation signal PWM is described in more detail in Section 1 5 4 of this document 1 5 2 Four Quadrant Operation and Dvnamic Braking The is a four quadrant motor controller which allows it to be used to produce negative torque regardless of the drive motor s rotational direction That said this controller has the ability to provide dynamic braking dissipating energy in outboard resistors as heath or returning the energy to the DC Supply 1 5 3 Controller Configuration The configuration of the A300 system is shown in Figure 2 The A300 System supplies armature current through T1 and T2 and field current through T3 and T4 This arrangement results in equal capabilities in either motor direction A300 Enclosure SUPPLY K 400 720 DC Figure 2 A300 Series Motor Controller Configuration 1 5 4 Pulse Width Modulation A Pulse Width Modulation PWM signal is used to produce an output voltage on each terminal bv controlling the dutv cvcles of each half bridge The voltage across the motor winding is the difference between the two input voltages 1 2 Voltage in Figure 3 below and mav be made positive or negative as desired The currents that flow have a small amount of high frequencv ripple but are almost the same as if thev had been derived from a smooth DC source 12 of 78 SAMINCO A300 SERIES MOTOR CONTROLLER ELECTRIC TRACTION DRI
82. tware Version Display Example Press the A key indicate the software version installed in the LCD module EPROM see Page 63 of 78 SERIES MOTOR CONTROLLER Rev 5 3 6 Parameters and Adjustments 6 1 Block Diagram 6 2 Traction Control 6 3 Brake Level 6 4 Slip Spin Sensitivitv Page 64 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES 7 Diagnostics and Fault Finding 7 1 7 2 7 3 Fault Log Fault Finding Guide Flowchart Troubleshooting Table 26 Fault Codes and Corrective Action Fault Code Drive Action Comment Text Message CUV e Disable IGBTs Indicates that the 24V power supply Control Pwr Loss e Disable parameter adjustment e Wait for PSU ready signal to become low has fallen below 19V If the fault occurred while a movement was in progress Restart movement power restored within 1 second then wait for center OFF position if power restored after more than 1 second UV1 Disable IGBTs Indicates that the main DC supply Undervoltage e Wait for the center OFF position voltage is too low or that the M contactor did not close OH1 Over Temp Alarm OT1 Heatsink Temp Trip e Disable IGBTs e Wait for the center OFF position and heatsink temperature to drop below 90 C Indicates that an excessive heatsink temperature rise has occurred 5 e Disable IGBTs Short C
83. uu blc S 21 Figure 12 Digital Display Module nanna kanna 21 Foure T Menu uuu lu 22 Figure 14 Fuses in the A300 35 Figure 15 Line Fiter Choke i iii a b d A fa 36 Fig re 46 Filter 9004 051 1 a 37 Figure 17 EMC Filter with Cover nennen nennen 37 Figure 18 EMC Filter Attenuation 38 Figure 19 Line Contactor U 38 Figure 20 Arc Chute Retaining annoa 38 Figure 21 Removal of the Arc 122001 38 Figure 22 Contact tips and blowout poles 000001 39 Figure 23 Checking Auxiliary Contact Operation 39 Figure 24 A300 Motor Controller 40 Figure 25 A300 Line Side Terminals ennt nnne 41 Figure 26 A300 Load Side 41 Figure 27 A300 Motor Controller with Top Cover Removed eee 41 Figure 28 Y9004010 A300 Motor Control Module Heat 42 Figure 29 Location of J14 on 2287 eiii etes
84. vironment that is not static controlled Page 50 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES Figure 48 IGBT Fixing Screws IGBT Replacement 1 Thoroughly clean the site of the IGBT ensuring that all residue of old heatsink compound is removed WD40 be used to remove remaining smears DO NOT TRY TO INSTALL AN IGBT USING THE RESIDUAL HEATSINK COMPOUND The heatsink compound has a solvent that allows it to flow easily into small gaps when it is fresh This solvent is lost over time Apply heatsink compound U1001 049 to the base of the IGBT as shown in Figure 50 Only a thin layer is required Take care to ensure that no foreign material adheres to the heatsink compound after it has been applied Figure 49 IGBT Removal Figure 50 Applying Heatsink Compound Page 51 of 78 SERIES MOTOR CONTROLLER Rev 5 3 3 Position the IGBT in the correct the same as originallv placed orientation and install as shown in Figure 51 4 Install the fixing screws looselv Half tighten the screws and then tighten diagonally and diametrically opposite Screws to maintain even pressure on the base use a final torque of 45 in Ib 5 Reconnect gate emitter and collector leads 6 Remove any excess heatsink compound Figure 51 Installing the IGBT Filter Capacitors C9002 032 The A300 module uses a bank of electrolytic capacitors to make
85. y using the LCD programming module The board is constructed using surface mount technology which allows a high level of functionality to be achieved in a small space on a single board Figure 56 shows this board as it is in the A300 Motor Controller Removal 1 Unplug connectors X1 X6 X7 and X5060 Refer to Figure 57 2 On earlier control boards MA2259 disconnect the flash programming control relay from J13 of the gate drive board Figure 57 Main Control Board with Connectors Unplugged 3 On later boards MA2259 1 and greater disconnect the 2 pin connector from J1 of the control board 4 Remove fixing nuts and withdraw the board Page 56 of 78 SERIES MOTOR CONTROLLER SAMINCO ELECTRIC TRACTION DRIVES Installation 1 Check that the position of the movable links shown in Figure 58 a LK2 links pins 1 to 2 b LK3 links pins 1 to 2 LK4 links pins 2 to 3 Check that the position of the DIP switches shown in Figure 59 are from position 1 to 8 respectively OFF ON OFF ON OFF OFF OFF OFF Check that all of the S1 switches are in the OFF position Install the board and fit the four retaining nuts For the MA2259 version use insulating washers for the two fixings opposite to the green connectors For the MA2259 1 version shown it is permissible to use non insulating hardware for all fixings Reconnect the plugs to X1 X3 X6 X7 and X5060 If fitting MA2259

A300 SERIES MOTOR CONTROLLER USER MANUAL Revision 5.3

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