ELFA Technical Description

Industrial Plants Marine Solutions Yacht Solutions Revision: 2.0 Propulsion System General

SIEMENS ELFA Propulsion

Propulsion Drive System

Table Of Contents 1. DRIVE SYSTEM GENERAL ............................................................................................... 2 2. PROPULSION GENERATORS/MOTORS.......................................................................... 5

2.1 GENERAL ..................................................................................................................................... 5 2.2 CONSTRUCTION FEATURES ..................................................................................................... 5

2.2.1 TERMINALS ...........................................................................................................................................................5 2.2.2 MISCELLANEOUS .................................................................................................................................................5

3. PROPULSION CONVERTER ............................................................................................. 5 4. REACTOR CIRCUIT ........................................................................................................... 6 5. PROPULSION CONTROL SYSTEM .................................................................................. 6

5.1 GENERAL ..................................................................................................................................... 6 5.2 HYBRID SYSTEM MODES........................................................................................................... 7

5.2.1 DIESEL ELECTRIC MODE ....................................................................................................................................8 5.2.2 PURE ELECTRIC MODE .......................................................................................................................................8 5.2.3 HYBRID MODE ......................................................................................................................................................8

5.3 CONTROLS AND PROTECTION................................................................................................. 8 5.3.1 CONTROL-INDEPENDENT PROTECTIVE FUNCTIONS.....................................................................................8 5.3.2 TEMPERATURE MONITORING ............................................................................................................................8 5.3.3 PROTECTIVE FUNCTIONS OF THE GATING MODULE .....................................................................................8

6. COMBINATION GEARS ................................................................................................... 10 6.1 GENERAL ................................................................................................................................... 10 6.2 SPIRAL BEVEL GEARS............................................................................................................. 12

6.2.1 CONSTRUCTION FEATURES ............................................................................................................................12 7. CABLE SYSTEM .............................................................................................................. 12

7.1 GENERAL ................................................................................................................................... 12 7.2 EXAMPLE OF CABLE HARNESSES ........................................................................................ 13

Created: Thomas Orberger

Author: SE & A Marine

General Description Page B - 1


1. DRIVE SYSTEM GENERAL

Siemens Yacht Propulsion System consists of frequency converters with drive control system (DICO), ELFA generators and ELFA drive motors. The Siemens ELFA drive components can be used in any electric propelled vessel with power supplies such as batteries, generators, solar cells, fuel cells or shore power. Based on different machine types and different drive configurations, the ELFA system can support applications in the power range from 60 kW – 900 kW. The propulsion solution is essentially build up by a combination of various ELFA DUO Inverter connected via the common DC link connections P and M as shown in Fig. 1, 2 and 3.

M3~G

3~

L11

L41

L12

Brakeresistor

Driveconverter

P1 M1 P2

Diesel

Fig. 1 General





Converter

M3~

Brakeresistor

M3~

Battery or fuel cell withprotection- and switchingelements

P M

M P

L12 L11

L41

P

Fig. 2 General





M3~

Diesel

M3~

DieselG(SYN)

G(TFM)

L11

L41

L12

L15

P

MP

Brakeresistor

Duoconverter

L45

Converter

Fig . 3 General





2. PROPULSION GENERATORS/MOTORS

2.1 GENERAL

The Generators/Motors are designed for IGBT PWM converter operation.

2.2 CONSTRUCTION FEATURES

The machines are designed according to the mechanical and electrical requirements of the propulsion application and correspond to the latest IGBT drive technology of the DUO Inverters. The machines are designed and tested in accordance with the requirements of the standards VDE and IEC.

2.2.1 TERMINALS

Separate terminal boxes will be provided on the ND end for power cables and auxiliary/signal wiring. The terminal boxes are wide enough for cable bending and connection. Terminal boxes will be fitted with an drilled cable entrance plate.

2.2.2 MISCELLANEOUS

The machines are used and primarily designed for installation in electric powered vehicles. Core and winding assembly are equipped with temperature sensors integrated into the stator winding for measuring the temperature response, as well as for regulation and preventing the generator from overheating. Siemens machines are supplied with lifting eyebolts. Motors and Generators are maintenance free during its lifetime. It is recommended after 20.000 hours or at least 5 years to replace the bearings.

3. PROPULSION CONVERTER

The ELFA PWM converter is a water-cooled fuse-less converter. In this fuse-less converter, the thermal capability of the semiconductors is chosen such way that the converter is still ready for operation after a short circuit, without changing of any fuses. The system is capable for 4-quadrant operation for driving and braking in both directions as an option with a chopper and braking resistor. The inverter on the motor side will provide the motor with a Pulse Width Modulated (PWM) output voltage, which will result in a sinusoidal output current. The PWM inverter comprises IGBT modules and provides 2 three phase systems and a single phase system for auxiliary systems





4. REACTOR CIRCUIT

In ELFA propulsion systems with battery banks is an adaptation of the DC link voltage to the varying battery voltage necessary. The adaptation will be realized with an inductive coupling.

5. PROPULSION CONTROL SYSTEM

5.1 GENERAL

The Drive control system (DICO) includes the interface of the ELFA propulsion system to the vessel, the Drive Control Unit and the Hybrid Control Software, separated into the power distribution logic and the power source control, i.e. the control of the power generation units itself. The performance of the drive system for acceleration and deceleration can be calibrated within the ELFA system in a very flexible way. There are many time functions, in order to tune the system to the required dynamic response. Power and torque limits are foreseen to adapt the system to the required stationary performance levels of the vessel. This functionality is described in the ELFA Drive Control Unit specification. The Hybrid Control functions, implemented in the DICO, determine the power of the power source units and if available the respective generator. This can be done with a broad flexibility, supporting different philosophies like constant generation mode, diesel electric mode, pure electric mode and a mixed hybrid mode. The interface to the vessel should be preferably done via SAE-CAN bus J1939. It is also possible to incorporate the Diesel(s) into the propulsion control system by discrete analog and digital signals, however with reduced performance in operation and diagnostics. The functions of the different inverters are the control of the drive motors, the generator control, the control of the auxiliary systems. In order to achieve this functionality Siemens components receive the command values from the DICO on the DCAN bus and perform this command with the assigned machine. In addition, the inverters also receive some system limits like voltage and current and support the DICO to keep the system within these limits. To support a dynamic system control within the DICO, the inverters provides feedback values of the respective components on the DCAN bus.





DCAN Reference Command

for Drive Motors

Hybrid control software: -Hybrid Control -Power Source Unit -Auxiliary control

Hybrid Control -Electric mode -Diesel electric mode -Charge mode

PSU -ICE point -Generator torque -Braking resistor

SAE CAN Bus Interface DICO

Drive Control Unit (DCU)

Helm station

Auxiliary System

Diesel Battery

Energy Storage

Generator Control

Auxiliary System

Drive System References -Drive Motor Power-Drive Motor Speed -Bus voltage reference

P,V

P,V, Speed

Drive Motor

Control

Fig. 4 Propulsion control

5.2 HYBRID SYSTEM MODES

Siemens Hybrid Control Software is physically embedded into the DICO, the Hybrid Control Software communicates with the application on SAE CAN bus and /or discrete input and output lines and thus controls the propeller drives, generators and the engines in the power source unit (PSU). Siemens hybrid control software supports different modes also called Hybrid System Modes (HSM)

• Diesel Electric Mode (DEM)

• Pure Electric Mode (PEM)

• Hybrid Mode (PHYM)





5.2.1 DIESEL ELECTRIC MODE

In the diesel electric mode a diesel engine is driving an ELFA generator that supplies the propulsion motors via the inverters.

5.2.2 PURE ELECTRIC MODE

The Pure Electric Mode is a pure battery mode, fuel cell or solar cell mode.

5.2.3 HYBRID MODE

In this mode the electric drive motors and at least one diesel or gasoline engine are connected to the propellers.

5.3 CONTROLS AND PROTECTION

5.3.1 CONTROL-INDEPENDENT PROTECTIVE FUNCTIONS

Following protective functions are implemented in the converter (independent of the motor control board (MCB), drive control module):

• Transient over voltages are smoothed (load fluctuations) by the DC link capacitors. • Discharging of DC link capacitors via the continuous discharge resistors in the powered-down

condition. • Protects against IGBT de-saturation.

5.3.2 TEMPERATURE MONITORING

The converter has temperature sensors close to IGBT modules. The drive control module evaluates the generated signals. Once the permissible temperature range is exceeded, then:

• The power is reduced (de-rating), and if necessary, the equipment will shut down.

5.3.3 PROTECTIVE FUNCTIONS OF THE GATING MODULE

• Under voltage protection When the internal power supply for the gating channels falls below a specific value, the driver transistors are prevented from turning-on, which in turn prevents the IGBT transistor from being turned-on in undefined fashion.

• Over voltage protection The suppressor diodes prevent the collector of the IGBT transistor having an excessive voltage with respect to the emitter-related IGBT gate





• Short-circuit current protection If the collector voltage VCE increases to impermissible values during the IGBT conduction phase due to over currents, then the IGBT is turned-off for 10 ms.

• Short-circuit signal For short-circuit trips, a signal is output for 10 ms which is converted by the MCB drive control module A100 into a general pulse inhibit.





6. COMBINATION GEARS

6.1 GENERAL

Siemens ELFA yacht propulsion system offers a high modularity and flexibility. The modularity is achieved by combining motors or generators to a generator unit or propulsion unit Fig. 1 and 2

Generator gearboxes increase the Diesel speed And Propulsion gearboxes reduce to the propeller speed

Fig. 5





Fig .6





6.2 SPIRAL BEVEL GEARS

Rated power per diesel/propeller: 112 kW – 450 kW Generator ratios: 1/1.25;1/1.5;1/1.75;1/2;1/2.3;1/3 Motor ratios: 5/1;4/1;3/1;2/1; or double 5.25/1;7/1;8/1;10.5/1;14/1;16/1 Medium duty: 25000 hrs life expectancy Efficiency: 98 % per connected unit Cooling-method: Water/Glycol (60/40) Ambient temperature: -30°C- 70°C Each gear will be delivered with:

• One set of mounting flanges & support pads • Gearbox temperature & level gauge

6.2.1 CONSTRUCTION FEATURES

Spiral Bevels are for systems requiring a high degree of reliability. The gears are fabricated of quality materials and proven for Marine applications. Spiral bevel gears with optimized tooth profile offer the best gear accuracy, backlash and silent running. One-piece spiral bevel input shafts and oversized output with press fit mating gear allow high resistance to dynamic cycling and load reversing. The integral machined bearing support flange with high quality tapered roller bearings provides high shaft radial load capacity. The modular one piece housing constructed of high quality aluminum ensure high torsional rigidity.

7. CABLE SYSTEM

7.1 GENERAL

Siemens ELFA yacht propulsion systems will be delivered with a pre-manufactured cable harness. The cable harness includes power cables, control cables, connectors and a junction box. Siemens pre-manufactured cable harness shortens installation time and the occurrence of malfunctions in the wiring of the propulsion system. Cables and connectors are rated for Marine environment. Cables are rated according to the expected operating loads and the mode of operation. Where short-term loads are possible, for instance starting loads, Siemens ensures that the voltage droop does not cause any malfunctions.





Motors and generators are connected to the inverter by means of three shielded, freely installed power cables that have a diameter of at least 35 mm². The cables, fitted with conduit threads PG 21, can be connected to the motor/generator terminal box as well as to the inverter terminal box via crimping cable lugs. Signal cables will be delivered with two signal connectors to connect motor, generator and inverter, helm station and diesel. Power and communication cables are shielded.

7.2 EXAMPLE OF CABLE HARNESSES

ELFAInverter

422.055.9003.03TYPE DUO

1

Driver seat

ICE

X1.2 29 Pol.

X1.1 29 Pol.

cable 2 (5459/19C)

I1, cable 1 ( 5136C)

cable 3 ( 5139/9C )

cable 4 ( 5136C )

Power Supply, Key On, KeyStart, Throttle Levers Starboard& Portside, Hotel Power On,Emergency System On, others

SAE-CAN Speed controlAnalogue Speed Control

Sub-D 9 Pol.

JunctionBox

CANconnector

RS 232

DICO

X1 42 Pol.

I2, cable 1 ( 5136C )

RS 232connector

ELFAInverter

422.055.9003.03TYPE DUO

2

PG Fitting

788158-2

C3

C4

C1-L1 C1-L2 C1-L3 C1-L4 C1-L5 C1-L6

C2

1-962366-1

1-962366-1

796188-1

788157-2

Fig.7 Control Cables





ELFA INVERTERTYPE DUO

9003.03I 1

ELFAGENERATOR

11FV5139

ELFADRIVE

MOTOR 11FV5139

G1 WG1 VG1 U

G1 X2

L32L22L12

I1 L32I1 L22I1 L12

M1 WM1 VM1 U

M1 X3

L11L21L31L41

I1 L31I1 L21I1 L11

X1X2X3

I1 X2I1 X3

WVU

WVU

ELFA INVERTERTYPE DUO

9003.03I 2

Cable 1 / I2X1X2X3

I2 X2I2 X3

JunctionBox

M1P1

P2

I1 P1I1 M1

ELFADRIVE

MOTOR 21FV5139

WVU

ELFAGENERATOR

21FV5139

WVU

Cable 1

Control cable, shielded

Power cable, shielded

Cable 1 / I1

M2I1 P2I1 M2

L42 I1 L42

I1 L41

L32L22L12

I2 L32I2 L22I2 L12

L11L21L31L41 I2 L31

I2 L21I2 L11

M1P1

P2

I2 P1I2 M1

M2I2 P2I2 M2

L42 I2 L42

I2 L41 G2 X2G2 WG2 VG2 U

M2 X3M2 W

M2 UM2 V

110/220V ACHotel Power

(Filter/Transformer)

Fig. 8 Power Cables




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ELFA Technical Description