Technica Main Tl Manual Sample Tt

Heavy Repair Manual

DC to AC Inverter/Battery Charger

Release 1.1 12-Nov-02

Transtechnik Corp. USA P/N XXXXX

EXCERPTSfrom

Freund Associates Technical Communication

Release History

Release Date Author Comment

1.0 June 2002 John Freund Initial Release (MSWord 2000)

1.1 Nov. 2002 John Freund

• Added TTDiag error messages to diagnostics • Amended 6-step & PWM descriptions and

diagrams • Amended unit to rail car installation

Copyright © 2002 By transtechnik Corp. USA

All Rights Reserved

This manual and all contents within are the sole property of transtechnik Corp. USA.

All rights of design or invention are reserved.

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ExcerptFreund Associates

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Table of Contents

CHAPTER 1 INTRODUCTION ........................................................................................ 1-1 Safety Information............................................................................................................ 1-1 Unit Identification ............................................................................................................ 1-2 Function............................................................................................................................. 1-3

Inverter vs. Motor-Alternator .......................................................................................... 1-4 Operational Characteristics ............................................................................................ 1-5

System Features............................................................................................................... 1-5 Physical Description ......................................................................................................... 1-7

Service Access................................................................................................................. 1-8 Enclosure ......................................................................................................................... 1-9 Cooling of power converter........................................................................................... 1-10 Diagnostics .................................................................................................................... 1-10

Operational Specifications ............................................................................................. 1-11 Input Characteristics...................................................................................................... 1-11 Output Characteristics ................................................................................................... 1-11

Inverter .................................................................................................................................... 1-11 Battery Charging ..................................................................................................................... 1-11

Diagnostics and external interfaces ............................................................................... 1-12 Status and fault indication ....................................................................................................... 1-12 External Interfaces................................................................................................................... 1-12

Environmental Conditions............................................................................................. 1-12 Mechanical Construction............................................................................................... 1-12 Dead Battery Start ......................................................................................................... 1-12 Related Standards .......................................................................................................... 1-12

CHAPTER 2 THEORY OF OPERATION....................................................................... 2-1 General Overview............................................................................................................. 2-1

Purpose ............................................................................................................................ 2-2 Components..................................................................................................................... 2-2

Dynamic voltage limitation ....................................................................................................... 2-3 Crowbar..................................................................................................................................... 2-4 Polarity reversal protection........................................................................................................ 2-4 EMI Protection .......................................................................................................................... 2-4 Capacitor Discharge .................................................................................................................. 2-5 Input Fuse.................................................................................................................................. 2-5

Inverter (DC-AC Conversion)......................................................................................... 2-6 Purpose ............................................................................................................................ 2-6 Techniques ...................................................................................................................... 2-6

AC Waveform Generation......................................................................................................... 2-7 Summary: How 12-step technology works................................................................................ 2-8 Regulation of the Output Voltage.............................................................................................. 2-9

Components................................................................................................................... 2-10 Inverter Modules A300 and A400 ........................................................................................... 2-10 Main output transformers ........................................................................................................ 2-12 Output Filtering ....................................................................................................................... 2-12 AC Regulation Board A38 ...................................................................................................... 2-13

LED array of the AC control board...................................................................................... 2-16 Feedback Transformer Boards A32 and A33 .......................................................................... 2-18

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Battery Charger.............................................................................................................. 2-19 Purpose .......................................................................................................................... 2-19 Techniques .................................................................................................................... 2-19

AC to DC Rectification ........................................................................................................... 2-20 Generating the DC output voltage ........................................................................................... 2-20 Why is a High-Frequency Switching Used?............................................................................ 2-22 Battery Charging Modes.......................................................................................................... 2-23 Battery Temperature Compensation........................................................................................ 2-24

Components................................................................................................................... 2-24 DC regulation board A78 ........................................................................................................ 2-27 -Regulating functions .............................................................................................................. 2-29 -LED array of the BC control board ........................................................................................ 2-31

Battery Switch-Over Circuit.......................................................................................... 2-34 Unit Control & Diagnostics ........................................................................................... 2-36

Purpose .......................................................................................................................... 2-36 Components................................................................................................................... 2-36

Unit Control Board (A09) ....................................................................................................... 2-38 Monitoring and Diagnostics................................................................................................. 2-38 Control Functions................................................................................................................. 2-39

Output Phase Monitoring ................................................................................................. 2-39 Repetitive Error Management (Lockout) ......................................................................... 2-39 Load management ............................................................................................................ 2-40 Current Limitation............................................................................................................ 2-40 Battery Temperature Compensation/Charging Mode....................................................... 2-41 Battery Temperature Limitation ....................................................................................... 2-41 External Enable ................................................................................................................ 2-41

Electronic Power Supply...................................................................................................... 2-41 High Voltage Relay.......................................................................................................... 2-41 Dead Battery Start (DBS)................................................................................................. 2-42

CHAPTER 3 DIAGNOSTICS ............................................................................................ 3-1 Diagnostics Philosophy..................................................................................................... 3-1 Using the Diagnostic Software......................................................................................... 3-2

Diagnostic Page 1............................................................................................................ 3-2 Diagnostic Page 2............................................................................................................ 3-2 Diagnostic Page 3............................................................................................................ 3-2 Diagnostic Page 4............................................................................................................ 3-2

Diagnosing Low Voltage Power Supply Problems ........................................................ 3-3 WR Panel Indicators........................................................................................................ 3-4 AUX Panel Indicators ..................................................................................................... 3-7 Inverter (WR/AUX) Diagnostic Chart .......................................................................... 3-11

Diagnosing Battery Charger Problems......................................................................... 3-23 BC Panel Indicators....................................................................................................... 3-23 BC Diagnostic Chart ..................................................................................................... 3-26

Diagnosing Problems Found During Functional Testing............................................ 3-33

CHAPTER 4 FUNCTIONAL TEST.................................................................................. 4-1 Checking All Major Components ................................................................................... 4-1

Individual Tests Contained in the Functional Test.......................................................... 4-2 Recommended Test Equipment....................................................................................... 4-4 LVPS and BC Test Loads ............................................................................................... 4-5 Location of Jumpers and Test Points............................................................................... 4-6

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Safety ................................................................................................................................. 4-6 Standard Functional Test Setup...................................................................................... 4-7

Disconnect Fan for Testing ........................................................................................... 4-10 Test No. 1 — Input Filter Test....................................................................................... 4-11

Input Filter Test 1A (150V Spike)................................................................................. 4-12 Input Filter Test 1B (300V Spike)................................................................................. 4-13 Input Filter Test 1C (600V Spike)................................................................................. 4-14

Test No. 2 — Circuit Board Power Tests ..................................................................... 4-15 Control Board Power Check (Test No. 2A) .................................................................. 4-15 Checking the Control Board Power Supply Voltages (Test No. 2B) ............................ 4-16 Checking the Reference Voltages (Test No. 2C) .......................................................... 4-17

Test No. 3 — Diagnostic Indicator Checks................................................................... 4-18 Record Reference Data (Test No. 3A) .......................................................................... 4-18 Diagnostic Indicator Checklists (Test No. 3B).............................................................. 4-19

Test No. 4 — Diagnostic Simulated Failure Checks.................................................... 4-23 Simulating a Temperature Failure on Board A38 (Test No. 4A) .................................. 4-23 Simulating Saturation Voltage (Vce) Failure on Board A38 (Test No. 4B) ................. 4-25 Simulating a Temperature Failure on Board A78 (Test No. 4C) .................................. 4-27 Simulating Saturation Voltage (Vce) Failure on Board A78 (Test No. 4D) ................. 4-28

Test No. 5 — Inverter Driver Tests............................................................................... 4-30 Dead Time (Test No. 5A).............................................................................................. 4-30 Soft Start Pulse Check (Test No. 5B)............................................................................ 4-34 Phase Shift at Module A300 (Test No. 5C)................................................................... 4-35 Phase Shift at Module A400 (Test No. 5D) .................................................................. 4-37

Test No. 6 — Output Voltage Tests............................................................................... 4-38 AC Output Amplitude and Waveform Test (Test No. 6A) ........................................... 4-38 Checking Actual Value of the Output Voltage (Test No. 6B)....................................... 4-44 Checking the Output Voltage with the Oscilloscope (Test No. 6C).............................. 4-46 Measuring Output Frequency (Test No. 6D)................................................................. 4-48 Checking the Phase Sequence (Test No. 6E) ................................................................ 4-48 Checking the Warning Lights (Test No. 6F) ................................................................. 4-49 Checking the Output Under/Over Voltage Protection (Test No. 6G) ........................... 4-49

Test No. 7 — High-Voltage Relay Test ......................................................................... 4-51 Test No. 8 — High-Low Input Voltage Range Test..................................................... 4-52 Test No. 9 — Capacitor Discharge Time Check .......................................................... 4-53 Test No. 10 — Power Load Tests .................................................................................. 4-54

Test Preparation............................................................................................................. 4-54 Nominal Load (Test No. 10A)....................................................................................... 4-54 Overload ( Test No. 10B) .............................................................................................. 4-56

Test No. 11 — Maximum and Minimum Voltage Tests.............................................. 4-58 Test No. 12 — Load Regulation Tests........................................................................... 4-59

Short Circuit on Nominal Output Load ( Test No. 12A)............................................... 4-59 Regulation Characteristic( Test No. 12B) ..................................................................... 4-61 Load Switching( Test No. 12C) .................................................................................... 4-62

Test No. 13 — Battery Charger Tests........................................................................... 4-63 Checking BC Under-Voltage Control (Test No. 13A) .................................................. 4-63 Checking BC Over-Voltage Control (Test No. 13B) .................................................... 4-64 Checking the A700-Chopper Dead Time (Test No. 13C) ............................................. 4-64 Checking Input-Output Voltage (Test No. 13D)........................................................... 4-67 Checking A700-Chopper Waveforms (Test No. 13E) .................................................. 4-68 Checking the Current Limitation (Test No. 13F) .......................................................... 4-71

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Test No. 14 — Battery Switchover Test........................................................................ 4-72 Test No. 15 — TTDiag Tests.......................................................................................... 4-75 Test No. 16 — Warm-up Switch Test ........................................................................... 4-77 Test No. 17 — Simulating Over Temperature ............................................................. 4-83 Test No. 18 — Simulating Open Voltage Sense Line to Battery ................................ 4-84 Test No. 19 — Checking External Enable Switch ....................................................... 4-85 Test No. 20 — AC Output Protection Tests ................................................................. 4-86 Test No. 21 — Checking BC Operation........................................................................ 4-88 Test No. 22 — Checking the “Dead Battery Start” ..................................................... 4-89

CHAPTER 5 REMOVING AND REPLACING LRUS................................................... 5-1 General Instructions and Guidelines .............................................................................. 5-1

Introduction ..................................................................................................................... 5-1 Inverter/Battery Charger Orientation .............................................................................. 5-1

Internal Compartments .............................................................................................................. 5-2 Component Handling ...................................................................................................... 5-3 Handling Printed Circuit Boards (PCBs) ........................................................................ 5-3 Cable Ties........................................................................................................................ 5-4 Hardware Retention......................................................................................................... 5-4 Torque Requirements ...................................................................................................... 5-4 Connectors....................................................................................................................... 5-5

Snap-on Connectors................................................................................................................... 5-5 Screw-on Connectors................................................................................................................. 5-5 Push-on Connectors................................................................................................................... 5-5 Clamp-on Connectors................................................................................................................ 5-5

Inverter/BC Mounting on Rail Car ................................................................................ 5-6 Internal Access.................................................................................................................. 5-6

Side Panel Access............................................................................................................ 5-6 Hinged Electronics Panel ................................................................................................ 5-7 Bottom Panel Access....................................................................................................... 5-7 Top Panel Access ............................................................................................................ 5-8 Input Junction Box Access .............................................................................................. 5-9 Output Junction Box Access ........................................................................................... 5-9

Lowest Replaceable Units (LRU) .................................................................................. 5-10 Locating Electronic LRUs ............................................................................................. 5-15 Hinged Panel – Front Side ............................................................................................. 5-18

Control Board Assembly (A09) .................................................................................... 5-18 Diode Snubber Circuit Boards (A14.1 – A14.5) ........................................................... 5-20 Diode Resistor Boards (A16 & A17) ............................................................................ 5-22 Inverter Control Board (A38)........................................................................................ 5-23 Voltage Divider Boards (A74, A76 & A79) ................................................................. 5-25 Regulator Control Board (A78)..................................................................................... 5-27

Hinged Panel – Rear Side .............................................................................................. 5-29 Electronic Power Supply Input Diode (A15) ................................................................ 5-29 15V Power Supply Board (A07) ................................................................................... 5-30 Phase Control Board (A34) ........................................................................................... 5-32 Temperature Compensation Board (A75) ..................................................................... 5-33 5V DC Supply Board (A77) .......................................................................................... 5-34 Capacitor (C03) ............................................................................................................. 5-36 Resistor (R03)................................................................................................................ 5-37

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Electronics Compartment – Left Top........................................................................... 5-38 Crowbar Trigger and Voltage Transducer Board (A02) ............................................... 5-38 Dead Battery Start Board (A04) .................................................................................... 5-40 High Voltage Relay Board (A05).................................................................................. 5-41 Capacitor Monitoring Board (A06) ............................................................................... 5-42 Crowbar Assembly (L02).............................................................................................. 5-44 Capacitor Discharging Resistors (R01) ......................................................................... 5-46 Input Filter Capacitor (C01) .......................................................................................... 5-49

Electronics Compartment – Left Side .......................................................................... 5-49 Inverter Heat Sink Module (A300)................................................................................ 5-49 Inverter Heat Sink Module (A400)................................................................................ 5-54 IGBT Driver Board (A31)............................................................................................. 5-57 Ring Core Assembly ..................................................................................................... 5-59 Actual Value Transformer Boards (A32, A33) ............................................................. 5-60 High Voltage Warning Light Board (A08.1) ................................................................ 5-62 Fault Light Board (A12)................................................................................................ 5-63 Re-Start Switch (S01).................................................................................................... 5-65 Main Wiring Harness .................................................................................................... 5-66

Electronics Compartment -- Right Side ....................................................................... 5-67 Dynamic Voltage Resistor Assembly (R02) ................................................................. 5-67 Dynamic Voltage Limiter Assembly (A100) ................................................................ 5-69 Dynamic Voltage Limitation Board (A01).................................................................... 5-71 LVPS Chopper Assembly (A700) ................................................................................. 5-72 A71 PC Board ............................................................................................................... 5-76

Choke Compartment...................................................................................................... 5-78 Input Filter Choke (L01) ............................................................................................... 5-78 Fan Assembly (M30)..................................................................................................... 5-79

Transformer Compartment........................................................................................... 5-81 Transformers (T310 and T410) ..................................................................................... 5-81 AC Output Filter Capacitor Assembly (C31-C36) ........................................................ 5-82

Input Junction Box ......................................................................................................... 5-84 Input Fuse (F01) ............................................................................................................ 5-84 High Voltage Warning Light Board (A08.2) ................................................................ 5-86

Output Junction Box ...................................................................................................... 5-87 AC EMI Filter Board (A35) .......................................................................................... 5-87 DC EMI Filter Board (A80) .......................................................................................... 5-88

CHAPTER 6 MAINTENANCE & SPARES..................................................................... 6-1 Periodic Maintenance....................................................................................................... 6-1 Recommend Spare Parts.................................................................................................. 6-2

APPENDIX A ACRONYMS ............................................................................................. A-1

APPENDIX B TORQUE REQUIREMENTS ...................................................................B-1

APPENDIX C JUMPER & TEST POINT LOCATIONS .............................................. C-1

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FIGURES

Figure 1. The Inverter/BC System....................................................................................................... 1-7 Figure 2. Orientation and mounting of Inverter/BC ............................................................................ 1-8 Figure 3. Internal Layout..................................................................................................................... 1-9 Figure 4. Input Protection Schematic .................................................................................................. 2-3 Figure 5. Dynamic Voltage Limitation (DVL).................................................................................... 2-4 Figure 6. Generation of 6-Step Waveform .......................................................................................... 2-7 Figure 7. Generation of the final (12-Step) AC waveform.................................................................. 2-8 Figure 8. Regulating Output Voltage with PWM................................................................................ 2-9 Figure 9. Inverter Sub-system ........................................................................................................... 2-11 Figure 10. Pulse-width modulation of the driver signal keeps the output voltage VAC constant ....... 2-15 Figure 11. LED array of the AC control board A38.......................................................................... 2-17 Figure 12. Three Phase Full Bridge Rectifier and Output ................................................................. 2-20 Figure 13. Generating of the constant d.c. voltage in the dc-dc input stage ...................................... 2-22 Figure 14. Battery Temperature Compensation Curve...................................................................... 2-24 Figure 15. Battery Charger Sub-system ............................................................................................ 2-25 Figure 16. DC Chopper Module (A700) Control Signals.................................................................. 2-30 Figure 17. BC Control Board Status Indicators................................................................................. 2-31 Figure 18. Unit Control and Power Supply ....................................................................................... 2-37 Figure 19. View of the TTDiag WR and AUX Panels ........................................................................ 3-3 Figure 20. View of the TTDiag BC Panel ......................................................................................... 3-23 Figure 21. Bus Bar Connection Points ................................................................................................ 4-8 Figure 22. X100 Test Interface............................................................................................................ 4-9 Figure 23. Fan Connections............................................................................................................... 4-10 Figure 24. Test 1A Output................................................................................................................. 4-12 Figure 25. Test 1B Output................................................................................................................. 4-13 Figure 26. Test 1C Output................................................................................................................. 4-14 Figure 27. Inverter Dead Time rising edge........................................................................................ 4-31 Figure 28. Inverter Dead Time falling edge ...................................................................................... 4-32 Figure 29. Inverter IGBT Oscilloscope Probe Locations (A31 Board) ............................................. 4-32 Figure 30. Soft Start Pulses ............................................................................................................... 4-34 Figure 31. Phase Shift Measurement................................................................................................. 4-36 Figure 32. ........................................................................................................................................... 4-39 Figure 33. ........................................................................................................................................... 4-40 Figure 34. ........................................................................................................................................... 4-45 Figure 35. ........................................................................................................................................... 4-46 Figure 36. ........................................................................................................................................... 4-47 Figure 37 ............................................................................................................................................ 4-47 Figure 38. ........................................................................................................................................... 4-60 Figure 39. ........................................................................................................................................... 4-61 Figure 40. ........................................................................................................................................... 4-62 Figure 41. ........................................................................................................................................... 4-65 Figure 42. ........................................................................................................................................... 4-65 Figure 43. ........................................................................................................................................... 4-66 Figure 44. Rogofsky Probe on A700 Current Sense Line ................................................................. 4-68 Figure 45. ........................................................................................................................................... 4-69 Figure 46. ........................................................................................................................................... 4-70 Figure 47. Location of SCR Status Indicator .................................................................................... 4-73 Figure 48. X100 Test Interface.......................................................................................................... 4-78 Figure 49. External Load Contactor Indicator Lights........................................................................ 4-78 Figure 50. Time Delay for Phase Imbalance ..................................................................................... 4-87 Figure 51. Unit Orientation ................................................................................................................. 5-2 Figure 52. Compartments .................................................................................................................... 5-3 Figure 53. Unit Mounting.................................................................................................................... 5-6

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FIGURES Figure 54. Inverter/BC Access Panels................................................................................................. 5-7 Figure 55. Bottom Access Panels........................................................................................................ 5-8 Figure 56. Top Panel Access............................................................................................................... 5-9 Figure 57. Front of Hinged Electronics Panel ................................................................................... 5-15 Figure 58. Rear of Hinged Electronics Panel .................................................................................... 5-15 Figure 59. Left-side of Electronic Bay .............................................................................................. 5-16 Figure 60. Right side of Electronics Bay........................................................................................... 5-17 Figure 61. Left Top Section of Electronics Bay................................................................................ 5-17 Figure 62. Control Board Assembly.................................................................................................. 5-18 Figure 63. A10, A11, A09 Control Board Assembly ........................................................................ 5-19 Figure 64. Diode Snubber Circuit Boards (A14.1 – A14.5) .............................................................. 5-21 Figure 65. Detailed View of the Diode Resistor Boards (A16 & A17)............................................. 5-22 Figure 66. Inverter Control Board (A38)........................................................................................... 5-23 Figure 67. Voltage Divider Boards (A74, A76 & A79) .................................................................... 5-25 Figure 68. Regulator Control Board (A78) ....................................................................................... 5-27 Figure 69. Diode Snubber (A15) ....................................................................................................... 5-29 Figure 70. 15V Power Supply Board (A07) ...................................................................................... 5-30 Figure 71. Phase Control Board (A34, middle)................................................................................. 5-32 Figure 72. Temperature Compensation Board (A75, far right) ......................................................... 5-33 Figure 73. Detailed View of the 5V DC Supply Board (A77) .......................................................... 5-34 Figure 74. Detailed View of C03 Capacitor ...................................................................................... 5-36 Figure 75. Crowbar Trigger Board (A02) ......................................................................................... 5-38 Figure 76. Dead Battery Start Board (A04)....................................................................................... 5-40 Figure 77. High Voltage Relay Board (A05) .................................................................................... 5-41 Figure 78. Capacitor Monitoring Board (A06).................................................................................. 5-42 Figure 79. Crowbar Assembly (L02)................................................................................................. 5-44 Figure 80 Capacitor Discharging Resistors (R01)............................................................................. 5-46 Figure 81. Input Filter Capacitor (C01)............................................................................................. 5-49 Figure 82. Inverter Heat Sink Module (A300) .................................................................................. 5-50 Figure 83 View of Bus Bar above A300 and A400........................................................................... 5-51 Figure 84. Inverter Heat Sink Module (A400) .................................................................................. 5-54 Figure 85 IGBT Driver Board (A31)................................................................................................. 5-57 Figure 86. Ring Core Assembly ........................................................................................................ 5-59 Figure 87. Actual Value Transformer Boards (A32, A33) ................................................................ 5-60 Figure 88. High Voltage Warning Light Board (A08.1) ................................................................... 5-62 Figure 89. Fault Light Board (A12) .................................................................................................. 5-63 Figure 90. Re-Start Switch (S01) ...................................................................................................... 5-65 Figure 91. Dynamic Voltage Resistor Assembly (R02) ..................................................................... 5-67 Figure 92. Dynamic Voltage Limiter Assembly (A100) Details....................................................... 5-69 Figure 93. LVPS Chopper (A700) Assembly Access ....................................................................... 5-72 Figure 94 LVPS Chopper (A700) Assembly Details ........................................................................ 5-73 Figure 95. A71 PC Board .................................................................................................................. 5-76 Figure 96. The Input Filter Choke (L01)........................................................................................... 5-78 Figure 97. The Fan Assembly (M30) ................................................................................................ 5-79 Figure 98 Transformers T310 and T410............................................................................................ 5-81 Figure 99. The Capacitor Assembly (C31-C36)................................................................................ 5-82 Figure 100. Capacitor Connections at the L1, L2, L3 Bus Bars........................................................ 5-83 Figure 101. Detailed View of Input Junction Box............................................................................. 5-85 Figure 102. LED Fuse Indicator (A08.2) .......................................................................................... 5-86 Figure 103. Output Terminals ........................................................................................................... 5-87

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Tables Table 1. Observable Differences ......................................................................................................... 1-4 Table 2. Transformer Characteristics ................................................................................................ 2-12 Table 3. A38 Control Board Status Indicators .................................................................................. 2-17 Table 4. A78 Control Board Status Indicators .................................................................................. 2-32 Table 5. Load Management Timing .................................................................................................. 2-40 Table 6. WR Panel Status Indicator Summary .................................................................................... 3-4 Table 7. AUX Panel Status Indicator Summary.................................................................................. 3-7 Table 8. Troubleshooting based upon WR/AUX Status Indicators................................................... 3-11 Table 9. BC Panel Status Indicator Summary ................................................................................... 3-23 Table 10. Troubleshooting based upon BC Status Indicators............................................................ 3-26 Table 11. Troubleshooting based upon Functional Test Results ....................................................... 3-33 Table 12. Individual Tests Contained in the Functional Test .............................................................. 4-2 Table 13. Recommended Test Equipment........................................................................................... 4-4 Table 14. Inverter and BC Test Loads................................................................................................. 4-6 Table 15. Stardard Functional Test Setup ........................................................................................... 4-7 Table 16. Input Filter Test Setup....................................................................................................... 4-11 Table 17. Input Filter Test 1A (150V)............................................................................................... 4-12 Table 18. Input Filter Test 1B (300V)............................................................................................... 4-13 Table 19. Input Filter Test 1C (600V)............................................................................................... 4-14 Table 20. Preparing for Circuit Board Power Tests .......................................................................... 4-15 Table 21. Supply Voltages ................................................................................................................ 4-16 Table 22. Reference Voltages............................................................................................................ 4-17 Table 23. Record Data from TTDiag ................................................................................................ 4-18 Table 24. Diagnostic Checklist for Board A38 ................................................................................. 4-19 Table 25. Diagnostic Checklist for Board A78 ................................................................................. 4-21 Table 26. Temperature Failure simulated on the A38 board ............................................................. 4-23 Table 27. Saturation Voltage on Board A38 ..................................................................................... 4-25 Table 28. Temperature Failure on Board A78................................................................................... 4-27 Table 29. Saturation Voltage on Board A78 ..................................................................................... 4-28 Table 30. Procedure for Measuring Inverter Driver Dead Time ....................................................... 4-30 Table 31. Inverter Driver Dead Time Test Points ............................................................................. 4-33 Table 32. Soft Start Pulse Check....................................................................................................... 4-34 Table 33. Phase Shift at Module A300.............................................................................................. 4-35 Table 34. Phase Shift at Module A400.............................................................................................. 4-37 Table 35. AC Output Amplitude and Waveform Test Setup............................................................. 4-38 Table 36. AC Output Amplitude and Waveform Test (L1-L2)......................................................... 4-39 Table 37. AC Output Amplitude and Waveform Test (L2-L3)......................................................... 4-41 Table 38. AC Output Amplitude and Waveform Test (L1-L3)......................................................... 4-42 Table 39. AC Output Amplitude and Waveform Test (L1-N) .......................................................... 4-42 Table 40. AC Output Amplitude and Waveform Test (L2-N) .......................................................... 4-43 Table 41. AC Output Amplitude and Waveform Test (L3-N) .......................................................... 4-43 Table 42. Checking Actual Value of the Output Voltage.................................................................. 4-44 Table 43. Checking the Output Voltage with the Oscilloscope......................................................... 4-46 Table 44. Measuring Output Frequency............................................................................................ 4-48 Table 45. Checking Phase Sequence ................................................................................................. 4-48 Table 46. Checking the Warning Lights (A08.1; A08.2) .................................................................. 4-49 Table 47. Checking the Output Under/Over Voltage Protection....................................................... 4-49 Table 48. Test Procedure for HV Relay ............................................................................................ 4-51 Table 49. Test Procedure for High-Low Input Voltage..................................................................... 4-52 Table 50. Checking the Capacitor Discharge Time........................................................................... 4-53 Table 51. Preparing for the Power Load Tests .................................................................................. 4-54 Table 52. Checking the Nominal Load.............................................................................................. 4-54

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Tables Table 53. Testing for Overload ......................................................................................................... 4-56 Table 54. Testing Maximum and Minimum Voltage ........................................................................ 4-58 Table 55. Testing for Short Circuit on Nominal Output Load........................................................... 4-59 Table 56. Regulation Characteristic .................................................................................................. 4-61 Table 57. Load Switching ................................................................................................................. 4-62 Table 58. Checking BC Under-Voltage Control ............................................................................... 4-63 Table 59. Checking BC Over-Voltage Control ................................................................................. 4-64 Table 60. Checking the A700-Chopper Dead Time .......................................................................... 4-64 Table 61. Checking Input-Output Voltage ........................................................................................ 4-67 Table 62. Checking A700-Chopper Waveforms ............................................................................... 4-68 Table 63. Checking A700- Current Limitation ................................................................................. 4-71 Table 64. Battery Switchover Test .................................................................................................... 4-72 Table 65. TTDiag Tests..................................................................................................................... 4-75 Table 66. External Load Contactor Sequence ................................................................................... 4-77 Table 67. Warm-up Switch Test........................................................................................................ 4-79 Table 68. Simulating Over Temperature ........................................................................................... 4-83 Table 69. Simulating Open Voltage Sense Line to Battery............................................................... 4-84 Table 70. Checking External Enable Switch ..................................................................................... 4-85 Table 71. Checking Inverter Voltage Limitation and Imbalance Detection ...................................... 4-86 Table 72. Checking BC Operation in Final Configuration................................................................ 4-88 Table 73. Checking the “Dead Battery Start”.................................................................................... 4-89 Table 74. External Connection Torque Requirments .......................................................................... 5-6 Table 75. Breakdown of LRUs and Their Locations......................................................................... 5-10 Table 76. To Remove the Control Board Assembly (A09) ............................................................... 5-19 Table 77. To Install the Control Board Assembly (A09) .................................................................. 5-20 Table 78. To Remove the Diode Snubber Circuit Boards (A14.1 – A14.5)...................................... 5-21 Table 79. To Install the Diode Snubber Circuit Boards (A14.1 – A14.5) ......................................... 5-21 Table 80. To Remove the Diode Resistor Boards (A16 & A17) ....................................................... 5-22 Table 81. To Install the Diode Resistor Boards (A16 & A17) .......................................................... 5-22 Table 82. To Remove the Inverter Control Board (A38) .................................................................. 5-24 Table 83. To Install the Inverter Control Board (A38)...................................................................... 5-24 Table 84. To Remove the Voltage Divider Boards (A74, A76 & A79) ............................................ 5-25 Table 85. To Install the Voltage Divider Boards (A74, A76 & A79) ............................................... 5-26 Table 86. To Remove the Regulator Control Board (A78) ............................................................... 5-27 Table 87. To Install the Regulator Control Board (A78)................................................................... 5-28 Table 88. To Remove the Diode Snubber (A15)............................................................................... 5-29 Table 89. To Install the Diode Snubber (A15) .................................................................................. 5-29 Table 90. To Remove the 15V Power Supply Board (A07).............................................................. 5-30 Table 91. To Install the 15V Power Supply Board (A07) ................................................................. 5-31 Table 92. To Remove the Phase Control Board (A34)...................................................................... 5-32 Table 93. To Install the Phase Control Board (A34) ......................................................................... 5-32 Table 94. To Remove the Temperature Compensation Board (A75)................................................ 5-33 Table 95. To Install the Temperature Compensation Board (A75) ................................................... 5-34 Table 96. To Remove the 5V DC Supply Board (A77) .................................................................... 5-35 Table 97. To Install the 5V DC Supply Board (A77)........................................................................ 5-35 Table 98. To Remove the C03 Capacitor .......................................................................................... 5-36 Table 99. To Install the C03 Capacitor.............................................................................................. 5-36 Table 100. To Remove the R03 Resistor........................................................................................... 5-37 Table 101. To Install the R03 Resistor .............................................................................................. 5-37 Table 102. To Remove the Control Trigger Board (A02) ................................................................. 5-39 Table 103. To Install the Control Trigger Board (A02) .................................................................... 5-39 Table 104. To Remove the Dead Battery Start Board (A04)............................................................. 5-40 Table 105. To Replace the Dead Battery Start Board (A04) ............................................................. 5-40 Table 106. To Remove the High Voltage Relay Board (A05) .......................................................... 5-41

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Tables Table 107. To Install the High Voltage Relay Board (A05).............................................................. 5-41 Table 108. To Remove the Capacitor Monitoring Board (A06)........................................................ 5-43 Table 109. To Install the Capacitor Monitoring Board (A06)........................................................... 5-43 Table 110. To Remove the Crowbar Assembly (L02) ...................................................................... 5-44 Table 111. To Install the L02 Crowbar Assembly (L02) .................................................................. 5-45 Table 112. To Remove the Capacitor Discharging Resistors (R01).................................................. 5-47 Table 113. To Install the Capacitor Discharging Resistors (R01) ..................................................... 5-47 Table 114. To Remove the Inverter Heat Sink Module (A300) ........................................................ 5-51 Table 115. To Install the Inverter Heat Sink Module (A300) ........................................................... 5-52 Table 116. To Remove the Inverter Heat Sink Module (A400) ........................................................ 5-55 Table 117. To Install the Inverter Heat Sink Module (A400) ........................................................... 5-56 Table 118. To Remove the IGBT Driver Board (A31) ..................................................................... 5-57 Table 119. To Install the IGBT Driver Board (A31)......................................................................... 5-58 Table 120. To Remove the Actual Value Transformer Boards (A32, A33)...................................... 5-61 Table 121. To Install the Actual Value Transformer Boards (A32, A33) ......................................... 5-61 Table 122. To Remove the High Voltage Warning Light Board (A08.1) ......................................... 5-62 Table 123. To Install the High Voltage Warning Light Board (A08.1) ............................................ 5-62 Table 124. To Remove the Fault Light Board (A12) ........................................................................ 5-64 Table 125. To Install the Fault Light Board (A12)............................................................................ 5-64 Table 126. To Remove the Re-Start Switch (S01) ............................................................................ 5-65 Table 127. To Install the Re-Start Switch (S01)................................................................................ 5-66 Table 128. To Remove the Dynamic Voltage Resistor Assembly (R02) .......................................... 5-68 Table 129. To Install the Dynamic Voltage Resistor Assembly (R02) ............................................. 5-68 Table 130. To Remove the Dynamic Voltage Limiter Assembly (A100)......................................... 5-70 Table 131. To Install the Dynamic Voltage Limiter Assembly (A100) ............................................ 5-70 Table 132. To Remove the Dynamic Voltage Limitation Board (A01) ............................................ 5-71 Table 133. To Install the Dynamic Voltage Limitation Board (A01)................................................ 5-71 Table 134. To Remove the LVPS Chopper Assembly (A700).......................................................... 5-73 Table 135. To Install the LVPS Chopper Assembly (A700)............................................................. 5-74 Table 136. To Remove the A71 PC Board........................................................................................ 5-76 Table 137. To Install the A71 PC Board ........................................................................................... 5-77 Table 138. To Remove the Fan Assembly (M30) ............................................................................. 5-79 Table 139. To Install the Fan Assembly (M30)................................................................................. 5-80 Table 140. To Remove the Capacitor Assembly (C31-C36)............................................................. 5-83 Table 141. To Install the Capacitor Assembly (C31-C36) ................................................................ 5-84 Table 142. To Remove the Input Fuse (F01)..................................................................................... 5-85 Table 143. To Install the Input Fuse (F01)........................................................................................ 5-85 Table 144. To Remove the High Voltage Warning Light Board (A08.2) ......................................... 5-86 Table 145. To Install the High Voltage Warning Light Board (A08.2) ............................................ 5-86 Table 146. To Remove the AC EMI Filter Board (A35)................................................................... 5-87 Table 147. To Install the AC EMI Filter Board (A35) ...................................................................... 5-88 Table 148. To Remove DC EMI Filter Board (A80)......................................................................... 5-88 Table 149. To Install DC EMI Filter Board (A80)............................................................................ 5-88 Table 150. Maintenance – Every 3 months ......................................................................................... 6-1 Table 151. Maintenance – Each year .................................................................................................. 6-1 Table 152. Recommended Spare Parts ................................................................................................ 6-2 Table 153. Hardware Torque Values.................................................................................................. B-1 Table 154. Location of Jumpers & Test Points on the A38 Board ..................................................... C-2 Table 155. Location of Jumpers & Test Points on the A78 Board ..................................................... C-3

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Chapter 1— Introduction

Service Access

Internal Access:

The Inverter can be opened easily and quickly even when the unit is in place. The Side Access Cover allows access to most of the electronic controls and most of the modules that are likely to be replaced during servicing. Bottom Access Covers allow access to the other compartments and improve access to the inverter electronic assemblies. The service covers are held by large thread captive fasteners and can be opened using a Torx head (T30) driver.

Connections: All electrical connections are easily accessible from the exterior of the Inverter.

• DC Input connections (L+ & L-) are located within the Input Junction Box on the South side of the unit.

• AC and Battery Output connections (L1,L2,L3,N,B+,B-,BN+) are located within the Output Junction Box located on the west side of the unit.

• Ground connections are located on the exterior of the unit on the east and west sides of the unit

• The X100 and X200 connectors for control and diagnostics are located on the north side of the unit, adjacent to the Side Access Panel.

Simple Unit Removal:

All routine maintenance work and the most repair service chores can be carried out without dismounting the unit from the rail car. If removal is necessary, the unit can be removed relatively easily at the LIRR maintenance facility.

Figure 2. Orientation and mounting of Inverter/BC

Bottom Panels

Hinged at CenterBottom Access Panels

Side Access Panel

Side Panel Hinged at Top

EAST

WEST

SOUTH

NORTH

Input Terminal

BoxOuputTerminalBox

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Chapter 2— Theory of Operation

Figure 11. LED array of the AC control board A38

A300 A400

V31/32

V33/34

V35/36

T 100

UIMAX

IDYN

IMAX

UACMAX

COUTP

CACTIV

TTRANS

UIMIN

ENABLE

RUN

STDBY

ERROR

RESET

T 80

UISYS

YELLOW

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

RED

YELLOW

YELLOW

YELLOW

YELLOW

YELLOW

GREEN

GREEN

Table 3. A38 Control Board Status Indicators

Indicator LED Color

Description Unit Shutdown

Field in TTDiag

WR Panel

ENABLE Green Enable signal from car is applied (inverter enable)

No Enable

RUN Green Inverter Unit Running with Input Power No Run

STDBY Yellow Standby: Inverter ready for operation but input voltage below minimum

No Ready

ERROR Red Serious AC fault. For details see adjacent LEDs

Yes Error

A300 A400

Red Identification of defective inverter module: A300 or/and A400

NA NA

V31/32 Red IGBT driver A31 defective or current overload of IGBTs V31/V32

Yes IGBT 31/32



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Chapter 2— Theory of Operation

AC to DC Rectification The Battery Charger uses the AC output of the Inverter as its source of input power. This 3-phase AC output is converted to DC through a 3-phase Full Bridge Rectifier as shown in Figure 12. The rectifier combines the 3 phases of the 230VAC input, converting it into a single 700VDC current. The output (shown in Figure 12) has a relatively high ripple (variation in voltage).

Figure 12. Three Phase Full Bridge Rectifier and Output

3 Phase ACInput

+ DC Output

- DC Output

Rectifier OutputDC with Ripple

Combined 3 Phase AC

L1

L2L3

Generating the DC output voltage Figure 13 outlines the steps taken in the Battery Charger (BC) to control the DC output voltage. Note the reference number (1-5) on the right side. These are referred to in the discussion below.

The BC must produce a constant low voltage output (5) from the varying higher input voltage. The BC uses a Pulse Width Modulation (PWM) technique to control the overall output voltage. By rapidly switching on and off the current flow, it is possible to regulate the overall voltage. The timing of the pulses is affected by the input voltage. To highlight the difference, Figure 13 is divided into two columns:

– Input voltage at the upper limit of tolerance (left column) – Input voltage at the lower limit of tolerance (right column).



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Chapter 3 -Diagnostics

Table 8. Troubleshooting based upon WR/AUX Status Indicators

Problem Code

TTDiag Panel Status Indicator

Meaning of Indication Possible Cause Possible Remedy/Further Action

If VI<min (WR) is on. This is a normal operational state. The Inverter is ready to run but there is insufficient input voltage.

303 Ready(WR)

No error present, but input voltage VI of the inverter is below specified minimum. Inverter is on standby.

If VI<min (WR) is off. A38 Board is possibly defective

Replace A38.

304 Error(WR)

Serious error (shut down of inverter).

Inverter shutdown by the A09 Control Board

Investigate specific errors on the TTDiag indicator panels. If no other errors, replace A09 board.

305 Enable(WR)

No error present

Error in electronics voltage supply of AC board A38

The 15V board power supply is out of range. This will cause other faults because the board is not working properly.

Replace A07 board (15 V Power Supply) after verification of out of range voltages on both the A38 and A78 boards. Perform Test 2A (Control Boards Power Check) and Test 2B (Control Board Power Supply Voltages) to check operation.

306 VH err(WR)

A leaky capacitor C03 could impact the 37.5 V input to the A07.

Replace C03



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Chapter 3 — Diagnostics

Table 11. Troubleshooting based upon Functional Test Results

Test Code Functional Test Observed Failure Probable Cause Further Action/Possible Remedy

Fan is not rotating or turning in the wrong direction.

Fan may be mis-wired. Check the connections at X2. Follow the Fan installation instructions.

Measurements at high input voltages are out of range. Measurements at lower input voltages are OK.

Possible loose connections Inspect for loose connections on cables connected to the A300/A400 modules and the transformers.

Measurements are out of range across all phase pairs.

Possible faulty A38 board Replace the A38 board.

FT21 Test 10A Nominal Load.

Measurements related to only one phase is out of range.

Possibly a faulty T31-T33 current transformer

Replace both A300 and A400 modules.

Possible faulty A38 board. This board controls output current of the Inverter.

Replace the A38 board.

Possible faulty A09 board Replace the A09 board.

The IMAX indicator fails to turn on at the correct voltage. The maximum current exceeds 490A.

Possible faulty T31-T33 current transformers. The A38 board uses these to measure output current.

Replace both the A300 and A400 modules

FT22 Test 10B Overload.

Indications of TTDiag are incorrect. Possible faulty A09 board Replace the A09 board.

Possible faulty A38 board. Replace the A38 board. FT23 Test 11 Maximum and Minimum Voltage Tests.

Measured voltages are out of range. Possible faulty A32 board. Measures voltage at the inverter output.


FT24 Test 12A Short Circuit on Nominal Output Load.

Unit fails to respond to a changes in load within a specified period of time. This is indicated by the oscilloscope traces.

Possible faulty A38 board. The A38 controls the reaction to load changes and hence is defective.


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Chapter 4 — Functional Test


Warning

Do not run the inverter at moderate to high loads (>100A) for extended periods (>1 minute) with the bottom access panels open and/or the fan disconnected. The transformers could over heat and be damaged.

Do not touch or handle printed circuit boards without proper grounding. Static discharges can damage components.

Use a diode to protect the power supply.

Recommendations Do not use conductive tools near boards while powered. Place jumpers by hand or use non-conductive tools.

Keep a trusted voltmeter attached to BusBar+ and BusBar- at all times to verify capacitor charge levels. See Figure 21.

Only low voltage DC power is present on the Hinged Electronics Panel. All other areas should be considered as potentially containing high voltages. This includes the Left and Right portions of the Electronics Bay behind the Hinged Electronics Panel.

STANDARD FUNCTIONAL TEST SETUP

The tests listed in this section are intended to be performed in order as they are presented in this section. Each test is written to allow individual test to be performed out of sequence, however all sub test should be performed in order ( In Test 1, perform tests 1A, 1B & 1C). All test will assume that the unit has been setup for testing as outlined in Table 15..

Table 15. Stardard Functional Test Setup

Step Action

1 Open and remove the Side Access Cover . Follow the instructions in Section 5.

2 Release the hinged panel behind the Side Access Panel Follow the instructions in Section 5.

3 Open and remove the both Bottom Access Covers . Follow the instructions in Section 5.

Connect Inputs 4 Connect the HVPS (defined in Table 13) on L+ and L-

They should not be applied at this time, Switch should be open 5 Connect Ground to the ground terminals on the exterior of the Inverter/BC.

Connect Voltmeters These voltmeters are used throughout testing, leave them in position


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Table 15. Stardard Functional Test Setup

Step Action

6 Connect a voltmeter to “BusBar +” and “BusBar –“ in electronics bay on plates near A300/A400. as shown in Figure 21.

Figure 21. Bus Bar Connection Points

Recommendation This voltmeter measures the voltage across the input capacitor. Leave it in position throughout testing as a safety precaution. It will provide confirmation that voltage in the capacitor has dissipated.

7 Connect a voltmeter to terminals B+ and B- 8 Connect a voltmeter to the output terminals at L1 and L2 9 Connect loads on L1, L2, L3

They should not be applied at this time, Switch should be open. Connect the X100 Test Interface (Figure 22) to the X100 connector at the exterior of the Inverter/BC.

Turn the Enable switch on. Set S1 to the OK position (Up) to simulate an normally closed Battery Temperature Switch Set the Load Shed (Warm-up) switch to the on position (middle position on X100 Interface). The K3 and K4 contacts will be energized during operation. Set Pot 1 switch to UP position connected to the actual Battery Sensor on X100 Test Interface

10

Connect the battery sensor wires from the X100 Test Interface to: Red B+ Black B-

11 Connect a PC to connector X200. Note: Requires a serial cable NOT a null modem specified in the TTDiag User Manual and Table 13. Start the program TTDiag at the PC with “TTDiag.”. Type O to set the TTDiag into online-mode.


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Checking A700-Chopper Waveforms (Test No. 13E) This test checks the trigger signals from the A78 board to the A700 module. Shown on CH1 and CH2 in Figure 45. Their rising edges should occur at the same time. The falling edge of CH2 should occur before the falling edge of CH1. The duration of the CH1 pulse should be noticeably longer than the CH2 pulse. The output from the IGBTs near T1 on the schematic is displayed on CH3. The signal frequency should be 19 – 21 KHz and should produce a relatively constant output voltage to the Battery, with some ripple, as shown in Figure 46 on CH4.

Follow the steps in Table 62 to check A700-Chopper waveforms.

Table 62. Checking A700-Chopper Waveforms

Step Action

1 Continue from Table 61. 2 Turn off the PSB ( to turn of power to the electronics) 3 Connect the Battery load bank to the B+ and B- terminals. Keep existing

connections at B+ and B-. 4 To Simulate BC operation:

Place a jumper on the J8 “Freigabe” jumper location on A78 Place a jumper on the J15 “Ena” jumper location on A78

5 Connect a 10:1 probes from CH1 to test point P9 (A2) on A78. Connect a 10:1 probes from CH2 to test point P18 (D2) on A78.

6 Connect the Rogofsky current probe in the cables through current sense on A700.

Figure 44. Rogofsky Probe on A700 Current Sense Line


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Table 62. Checking A700-Chopper Waveforms

Step Action

7 Connect the Differential Voltage Probe Positive (Red) to B+ Minus (Black) to B- Attach the probe to CH4

8 Turn on the PSB and set the voltage to 24VDC ( to power to the electronics) 9 Switch on a Nominal Battery load on B+.

10 Raise the input voltage from the HVPS to about 500V. 11 With output at 37.6V, compare your results with

Figure 45. Figure 45.

Stopped 2001/07/26 20:01:06 20us/div

(20us/div)NORM:50MS/s

CH1=10V DC 10:1

CH2=10V DC 10:1

CH3=200mV DC 1:1

=Filter=Smoothing : OFFBW : FULL

=Offset=CH1 : 0.0VCH2 : 0.0VCH3 : 0.000VCH4 : 0.0V

=Record Length=Main : 10KZoom : 10K

=Trigger=Mode : AUTOType : EDGE CH1 Delay : 0.0nsHoldoff : MINIMUM

CH1 A2(P9) CH2 D2(P18) CH3 I prim 20A/div GND (P7) Time base: 20µs/div Oscilloscope-Trigger: Type: Normal Source: CH1 Rising Edge

Compare results with Figure 45. YES = OK NO

Shape of waveforms on CH1 & CH2 are similar

Rising edges of CH1 & CH2 waveforms are coincident

12

Shape of the CH3 waveform same as Figure 45.


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Chapter 5 — Removing & Replacing LRUs

Crowbar Assembly (L02) This assembly contains L02, A03, and VTH01 and is located just above the A400 inverter module as shown in Figure 79. The crowbar assembly is considered an LRU and is accessible from the side access panel (see section Side Panel Access) and the East (left) bottom access panel (see section Bottom Panel Access).

Figure 79. Crowbar Assembly (L02)

The procedure for removing the crowbar assembly is described in Table 110. The procedure for installing the crowbar assembly is described in Table 111.

Table 110. To Remove the Crowbar Assembly (L02)

Step Action

Cut the 2 cable ties (Item 1) from the tie mounts near the A02 board leading to the A02/X10 connector. Move the cables out of the way It may be necessary to remove cable ties (Item 2) on the wire leading to A02/X11, X12, and X13. Remove two hex head bolts (Item 3), each securing a cable marked VTH01-AL, from the base plate, next to L02 . Move the two cables aside.

1

2

3

4 One of the L02 wires goes to A100 in the Right (West) Section (Item 4). Six harness Ties will have to be cut in order to free this wire from the cable going to the Right Section.



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Chapter 5 — Removing & Replacing LRUs

Table 110. To Remove the Crowbar Assembly (L02)

Step Action

5 Remove a hex bolt from the –VD01A terminal on the A100 heat sink (in the Right Section) This terminal is just to the left of VD01. (See Figure 92, Item 4). As an alternative to cutting the six harness Ties, cut back the L02 wire from A100 at its entrance to the wire bundle. Do the same at its exit point to L02. Add additional Ties for the replacement L02 wire.

Remove four socket head screws at the corners of the L02 Assembly base plate (Item 7).

6 The other L02 wire is internal to the assembly. 7 Remove the yellow and red wires with push-on connectors from the A02 board

at the X1 and X2 (Item 5) connectors. A02 is on the Mounting Platform above C01.

8 Remove the socket-head screw holding 2 gray wires with a yellow strip marked VTH01-AL on base of the L02 assembly near the side access panel (Item 6). Cut the first cable tie holding those two wires together.

9

Table 111. To Install the L02 Crowbar Assembly (L02)

Step Action

Mount the assembly on the plastic mounting stand-offs with L02 closest to the A400 module. Secure the base with four socket-head screws (Item 7 – ¼-inch steel) with split-locks and flat washers and tighten to 48 in.-lbs.

Use a cable tie to secure these two wires together between the tie mount and the socket head screw. Connect the push-on connectors with red and yellow wires from X1 and X2 (Item 5) to A02. A02 is on the Mounting Platform above C01. Make sure all connectors are securely in place. Use a cable tie to secure these wires to the cable mount between the L02 assembly and the A02 board.

Replace the six cable ties securing the L02 wire (Item 4) attached to the left section of the A100 heat sink. Connect the two cables marked VTH01-AL (Item 3) attached to the base plate at the terminal locations next to L02. Secure with hex bolts, split-locks, and flat washers and tighten until snug, and then add another ¼ turn. Secure the cables with cables ties (Items 1 & 2). Inspection: Make sure that all screws and nuts are properly torqued and that they are marked by Glyptol.

1

2 Connect the two gray wires with a yellow stripe (marked VTH01-AL) directly to the base near the side access panel (Item 6). One wire comes from the A02/X8 connector and the other from the circuit board in the circuit board on the L02 assembly. Secure with a socket-head screw with a split-lock and washer.

3

4 Replace the hex bolt on the –A terminal on the A100 heat sink (in the Right, West section). This terminal is just to the right of VD01. (See Figure 92, Item 4).Tighten the hex bolt until snug, and then add another ¼ turn.

5

6

7 8



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