IGBT User Manual - Advanced Rail Controls
Contents
1. Bias magnet Hall sensors Output S 90 degree Output S 90 degree V 8V to 32V DC 3 pinco nnector 5 pin connector Direction of Rotation 1 Direction of Rotation 2 FIGURE 1 x15 PITCH FIGURE 2 ADVANCED RAIL CONTROLS PRIVATE LIMITED BANGALURU FIGURE 3 ADVANCED RAIL CONTROLS PRIVATE LIMITED BANGALURU 5 PROCEDURE FOR COMMISSIONING For retrofitment in older locomotives IGBT converter fed remove the dust cover and replace the old pulse generating wheel with new pulse generating wheel if the old wheel is damaged in the traction motor and check the tightening Fix the dust cover Remove the old sensor assembly from the dust cover and connector end from the terminal box Fix the new speed sensor and connect as per loco side wiring diagram PRECAUTIONS TO BE TAKEN WHILE COMMISIONING e 5 pin connector have signals and SHOULD NOT be connected to high voltage 3 pin connector is a power connector and SHOULD be connected to the respective male connector A positive and B negative Check the gap before mounting using a suitable test gauge Mounting surface SHOULD be clean and if the gap is too narrow use shims The air gap ideally has to be above 1mm and below 1 5 mm Before connecting to the Power connector check and verify the voltage at the terminals on loco side using a Multimeter 6 PROCEDURE FOR CONN2. HALL EFFECT ACTIVE SPEED SENSOR FOR IGBT TRACTION CONVERTER USER MANUAL i Release 1 1 bf r AAA A December 2014 advanced rail controls ADVANCED RAIL CONTROLS PRIVATE LIMITED 59 1 2 2nd FLOOR ABOVE BANK OF INDIA G BLOCK SAHAKARANAGAR BANGALORE 560092 CONTENTS INTRODUCTION APPLICATION TECHNICAL DESCRIPTION MECHANICAL CONSTRUCTION PROCEDURE FOR COMMISSIONING PROCEDURE FOR CONNECTION OF SENSOR AND CRO SETTING FOR THE TEST DATA SHEET OF THE SPEED SENSOR TROUBLE SHOOTING SCOPE OF SUPPLY CONTACT DETAILS 1 INTRODUCTION This document provides the technical details and usage of Hall Effect based Active Speed Sensor which is used to measure the speed of traction motor fed by IGBT converter in Electric Locomotives 2 APPLICATION There are two cables coming out from the speed sensor One is signal cable and other one is power cable The signal cable is of 2x1x1 mm2 and power cable is 2x1 mm2 both are twisted shielded pair type cable All the connectors for interfacing with the loco side remains the same as that of Wiegond TM Sensors In the signal cable two 90 Phase shifted pulses are fed to IGBT converter viz channel 1 and channel 2 Using these 90 phase shifted pulses direction is resolved within the converter electronics The output pulses are open collector type and hence amplitude depends upon the supply voltage The pulses have a duty ratio of 5
3. conforming to MIL C 26482 ITT Cannon Make Part No KPSE06E14 5SDZ Can be Identified by BLUE color sleeve Huber Suhner make Part No 12583003 270 cm each Signal Connector Cable Signal amp Power TABLE 1 8 TROUBLE SHOOTING Likely problems and solutions for the problems are listed in TABLE 2 No DDS MESSAGES LIKELY REASONS 1 Error Tachogenerator 8 Sensor output Frequency not matching Rotational Speed greater with that of the other sensors than Maximum b Absence of pulses whereas other Ill Error rotational Speed sensor delivers normal pulses Exceeds Maximum C Rotational direction doesn t match with IV Speed Disturbance the other sensors Suggested Remedial Actions 1 Check the air gap between sensor and toothwheel It should be between 1mm and 1 5 mm 2 Check the pulses on a test zig with air gap adjusted to less than 1 5 mm If the pulses are found disturbed change the sensor with a new If pulses are GOOD refit the sensor with proper air gap as mentioned above and check the connections wiring AS peri card and AS controller TABLE 2 9 SCOPE OF SUPPLY SI DESCRIPTION OF QUANTITY No SUB ASSEMBLY SPEED SENSOR Rotational Speed Sensor 1 Ferrous Toothed Wheel for Traction Motor Cable Type H S part number 12583003 RADOX TENUIS TW S EMC SC 600 1000V 2x1 mm2 18AWG cable will be
4. connected with the sensor and crimped with the specified female connector Signal Cable 270 cm Power Cable 270 cm Fixing Boltfor Sensor amp Toothed Wheel 1 Hex Hd Screw M8x25 Zn plated Grade 8 8 1 02 Nos to IS 1364 Pt2 92 ISO 4017 88 for fixing sensor II Hex socket Hd Cap screw M6x16 12 9 Zn 1 06 Nos plated to 1S 2269 95 and machined washer 6 4 to IS 2016 67 amp Steel to IS 2062 99 Gr A Type M6x16 Allen Screws for fixing the toothed wheel TABLE 3 CONTACT DETAILS Mr Srinivasan P C Incharge Customer Care 9845920790 ADVANCED RAIL CONTROLS PRIVATE LIMITED 59 1 2 II FLOOR ABOVE BANK OF INDIA G BLOCK SAHAKARANAGAR BANGALORE 560 092 Tel 080 42401212 Fax 080 42401213 E mail mail arc net in ADVANCED RAIL CONTROLS PRIVATE LIMITED BANGALURU
5. 0 and frequency proportional to speed 3 TECHNICAL DESCRIPTION The working principle is illustrated in FIGURE 1 Two Hall Effect Sensors are placed closely in the sensor housing such that it is very close to the toothed wheel Associated with the Hall Sensors is a biasing magnet placed in the very close proximity An iron toothed wheel having a uniform tooth pattern is mounted on the motor shaft The toothed wheel has 120 teeth When the toothed wheel moves under the Hall Effect sensors the magnetic field linking with the sensors vary according to the tooth and trough of the wheel The flux variation is measured by the sensor and amplified Two sensors are mounted with a shift such that the outputs of these two sensors are 90 electrical degrees phase shifted which are conditioned and brought out through suitable cable amp connectors The power supply needed for the sensor circuitis derived from the electronic rack itself For every revolution of the tooth wheel means motor shaft 120 pulses are generated The sensor reliably reproduces the pulses from near zero speed to above 3000 rpm which has been tested and validated The sensors conform to IEC 60571 amp IEC 61373 The output signals are taken using signal cables intended for traction application The cable used is of 2x1 mm EB irradiated cross linked type shielded with reinforcement for outdoor traction applications like that of speed sensor The length of the
6. ECTION OF SPEED SENSOR AND CRO SETTINGS FOR TESTING ON THE TEST BENCH Connect 3 pin female connector to dc power supply pin A to be connected to positive of the DC power supply and pin B to be connected to negative of the DC power supply Connect signal cable to CRO probes In signal connector pin A and B are to be connected to positive probes of the CRO Ground probes and negative of the power supply are shorted CRO settings are given bellow Channel 1 set the voltage div as 5 V Channel 2 set the voltage div as 5 V Time div 100us Trig d Pos 0 000 SAVE REC Tek ATE m Action 1 JPEG Images 24 Select Folder Save TEKOO0S JPG CH1 5 00 CH2 5 00 10005 CH1 5 60 25 Aug 12 10 43 5 83334kHz FIGURE 5 7 DATA SHEET OF THE SPEED SENSOR The salient data sheet of the speed sensor is given in TABLE 1 Si PARAMETER VALUE No Type Active Hall Effect Sensor Type Sensor Input 8V to 32V DC from Converter Rack 90 degree phase shifted square Pulses Output Signal 51 amp 2 50 duty ratio open collector short circuit protected Signal ground common to power supply ground Pulse Frequency 120 pulses per revolution of motor shaft Impulse Ring ib S Tooth Wheel Zinc Plated 120 ee 3 PIN circular conforming to MIL C 26482 Power connector ITT Cannon Make Part No KPSE06E12 3SDZ Can be Identified by RED color sleeve 5 PIN circular
7. cable is 270 cmeach The salient data sheet of the speed sensor is givenin TABLE 1 The signal outputs are terminated on 5 PIN circular connector Female bearing ITT Cannon part number KPSEOGE14 5SDZ These connectors have a special termination arrangement for providing a heat shrinkable boot shield termination which takes care of the stress relieving and ingress protection These female connectors can be directly plugged into the 5 PIN male receptacles provided on the locomotive under frame The power supply cable is terminated in a 3 PIN circular connector of ITT Cannon part number KPSEOG6E12 3SDZ The corresponding panel mount male receptacle bearing ITT Cannon part Number KPSEO7F 12 3P is supplied as loose item along with the sensor These connectors conform to MIL C 26482 standard The sensor is totally sealed to comply with IP68 ingress protection class according to IEC 60529 4 MECHANICAL CONSTRUCTION The Speed Sensor is mechanically 100 compatible to the original Wiegand type speed sensor provided in the traction motors of Indian Railways needing no modifications in the mechanical housing The toothed wheel also has the same fixing dimensions and diameter The sensor has two output cables one is used for sensor signals S1 amp S2 and the other is used for deriving rack power supply from Converter rack The shield of the cable is connected to pin E The mechanical drawings of the speed sensor are given at FIGURE 2
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