EM2000 Electrical Systems Guide

ELECTRO-MOTIVE DIESEL, INC. CONFIDENTIAL AND PROPRIETARY INFORMATION
Copyright © 2008 ELECTRO-MOTIVE DIESEL, INC
SD70ACe Electrical Systems

Electro-Motive Diesel is owned by
Progress Rail Services, A Caterpillar Company
CONFIDENTIAL and PROPRIETARY Information
© 2012 Electro-Motive Diesel
Describe the functions of the EM2000 modules.
Identify the main electrical components of the
SD70ACe.
Describe the operation of the various electrical
systems.
Effectively use the schematic as a
troubleshooting tool.
OBJECTIVES
At the end of this course, participants will be
able to:

Safety
Locomotive Computers
High Voltage System
Companion Alternator System
AGENDA

Safety
Discharging the high voltage (DC Link)
AGENDA

Locomotive Computers
EM2000 (“the brain”)
EM2000 module functions
Communication Network (CAN)
FIRE Computer (display)
EMDEC Computer (diesel motor control)
FastBrake Computer (air brake control)
AGENDA

High Voltage System
Main Generator
DC Link Switchgear (DCL)
IGBT Inverters
Traction Motors
Directional Control
Dynamic Braking (DB)
Ground Relay System
AGENDA

Companion Alternator System
Companion Alternator (CA9)
Main Generator Field Control (Chopper)
Blower Motors
Auxiliary Power Converter (APC)
AGENDA

SD70ACe Locomotive

Safety: Discharging the High Voltage
DCL 123
DCL 123
BOGIE #1
MAIN
GENERATOR
(TA17)
#1
3Φ
DC LINK +
DC LINK -
3Φ
IGBT
INVERTER #1
B1
B2
DB
GRIDS
DC LINK SWITCHGEAR

BOGIE #2
3Φ
DC LINK +
DC LINK -
3Φ
DCL 456
DCL 456B3
B4
DB GRIDS
+ BLOWER
IGBT
INVERTER 2
MAIN
GENERATOR
(TA17)
#2
DC LINK SWITCHGEAR

“B” Contactors
These contactors
connect the DB
grids to the high
voltage system.
Safety

DC Link
Switchgear
(DCL)
This switchgear makes the connections between the main
generator (TA17) and the IGBT inverters. This path is
called “DC Link”.
Safety

Short circuit bus bars DC Link
Switchgear
Motor

DCL 123
DCL 123
DC LINK SWITCHGEAR
BOGIE #1
MAIN
GENERATOR
(TA17)
#1
3Φ
DC LINK +
DC LINK -
3Φ
IGBT
INVERTER #1
B1
B2
DB
GRIDS Capacitors

ISOLATION SWITCH:
“RUN”
3000 VDCTA17
DCL
DCL
+
_
B
B
+
_
INVERTER
DB GRIDS

The capacitors are discharged through the DB grids.
TA17
DCL
DCL
+
_
DB GRIDS
B
B
+
_
0 VDC
INVERTER
ISOLATION SWITCH:
“ISOLATE”

After the high voltage is discharged:
DCL moves to position 2 to keep 0 VDC on the capacitors.
TA17
DCL
DCL
+
_
DB GRIDS
B
B
+
_
0 VDC
INVERTER

ISOLATION
SWITCH
Safety

Power Supply Chassis
EM2000 Module Chassis
Panel Mounted Modules

3 MAIN FUNCTIONS:
POWER
LOGIC
DISPLAY
EM2000 FUNCTIONS

POWER:
EM2000 controls the main generator field
EM2000 controls the IGBT inverters
EM2000 controls the tractive effort and the dynamic
braking effort
EM2000 FUNCTIONS

LOGIC:
EM2000 receives commands from the
operator (throttle, switches)
EM2000 sends and receives commands
on the 27 pin trainline connector
EM2000 controls and monitors most
relays, contactors, and magnet valves
EM2000 commands the diesel engine
speed (via EMDEC)
EM2000 FUNCTIONS

DISPLAY:
EM2000 receives commands from the FIRE display
EM2000 records data in memory archive (Fault
Archive, Running Totals)
EM2000 displays information on the FIRE screen
(Data Meters)
EM2000 performs diagnostic functions via the FIRE
screen (self tests)
EM2000 FUNCTIONS

EM2000 Chopper
Inverters
Traction
Motors
Diesel
Engine
Speed
EMDEC
Companion
Alternator
TA17
Field
Throttle
Selection
Locomotive
System
Data
(DC)
(AC)
FIRE

POWER SUPPLY MODULES (PSM)
STATUS LEDs
TEST POINTS
PRG301: REGULATE & BOOST
PSM305: + 5 VDC EM2000
PSM312: ±12 VDC EM2000
PSM315: ±15 VDC SENSORS
RADAR
CHOPPER

CENTRAL PROCESSING / MEMORY (CPM) MODULE
CPU: TA Excitation, Inverter PWM
Flash PROM: Operational Programming
RAM: Data Storage (Running Totals,
Fault Archive, Unit Info), Lithium Batteries (3 years)
Plug connection on front of module for laptop
Download Faults and Operational Data
Reprogram

SERIAL COMMUNICATION (SCM) MODULE
EM2000 – FIRE Data for Intellitrain, Event Recorder, etc.
To be eliminated

CONTROLLER AREA NETWORK
(CAN or CAN Bus)
EM2000
EBV EMDEC
CAN Bus
FC1
FC2
Ethernet

EMDEC CAN Connection
CAN Cable
CONTROLLER AREA
NETWORK
(CAN or CAN Bus)

CAN Cables
EM2000 Module Chassis
(Rear)
CONTROLLER AREA
NETWORK
(CAN or CAN Bus)

MAIN PROCESSING UNIT (MPU)
Inverter Control
One MPU Module per Inverter
VVVF Controller
Protection Sequence
Fault Recorder

ANALOG – DIGITAL - ANALOG (ADA) MODULE
Analog Signal

MRPT ANALOG SIGNAL
ADA MODULE
POWER DISTRIBUTION PANEL
(PDP)
± 15 VDC
FROM PSM315
MR PRES 130

MRPT
PDP4
GBLWA

POWER DISTRIBUTION PANEL (PDP)

DCL1V / DCL2V TCC1A
VOLTAGE CURRENT
ADA MODULE

TEMPERATURE & PRESSURE
BAR PRES
RADAR
SPEED
ADA MODULE

Slide 40
DIGITAL INPUT - OUTPUT (DIO) MODULE
Digital Signal
ON
OFF
FIRE Display
OUTPUT: FCS2 > ON
INPUT: FCS2 < ON
Digital Input: 74 Volts 5 Volts 24 Input Channels
Digital Output: 5 Volts 74 Volts 26 Output Channels
Opto-Isolated (LEDs)

DIGITAL INPUT
FIRE Display
ALTRST < ON
SHARED
+74V
- 74V
ALTRST < OFF
DIO MODULE
EM2000
CHASSIS
5 V

DIGITAL OUTPUT
SHARED
FIRE Display
FPR > ON
FPR > OFF
DIO MODULE
+74 VDC
-74 VDC
EM2000
CHASSIS
5 V

Slide 43
MULTIPLEXING (MUX)
Each DIO has 24 input channels
First 8 input channels are MULTIPLEXED
DIO Output Channel Operates 10 times/sec
Interlock / Switch
(B1 Contactor, for example)
DIO Input Channel
B1 < OFF
B1 < ON
FIRE Display

START
GNBW
CB
GNBWCB < OFF
SPARE
START < OFF
DCCL < OFF
DCOP < OFF
MUXON < ON
MUXOFF < OFF
MUX1 MUX2 MUX3 MUX4 MUX5 MUX6
MUX1
MUX2
MUX3
MUX4
MUX5
MUX6
(SELF TEST)
MULTIPLEXING (MUX)
FIRE Display
3
Up to 5 devices monitored by
1 input channel
DCCL DCOPSPARE

MUX1 MUX2 MUX3 MUX4 MUX5 MUX6
MUX1
MUX2
MUX3
MUX4
MUX5
MUX6
GNBWCB < OFF
SPARE
START < ON
DCCL < OFF
DCOP < OFF
MUXON < ON
MUXOFF < OFF
(AUTO TEST)
3
FIRE Display
DCOPDCCL
GNBW
CB
MULTIPLEXAGE (MUX)
STARTSPARE
Up to 5 devices monitored by
1 input channel

Pins 1 - 8Pins 9 - 16
Pins 17 - 24
Pins 25 - 32
CMU CONNECTORMULTIPLEXING (MUX)

MUX 1 Output (1st Device)
To DIO input channel
MUX 2 Output (2nd Device)
MUX 3 Output (3rd Device)
MUX 4 Output (4th Device)
MUX 5 Output (5th Device)
MUX 6 Output
(MUX ON/OFF
Self Test)
Not used
CMU CONNECTORMULTIPLEXING (MUX)

MUXSEL1 < ON
MUX1
(SELF TEST)

MUXSEL2 < ON
MUX2
(SELF TEST)

MUXSEL3 < ON
MUX3
(SELF TEST)

MUXSEL4 < ON
MUX4
(SELF TEST)

MUXSEL5 < ON
MUX5
(SELF TEST)

MUX6
(SELF TEST)
MUXON< ON (ALL)

MUXOFF<OFF (ALL)
“MUX7”
(SELF TEST)

EM2000 MULTIPLEXER SCREEN
MUXON Tests all MUX input channels – should always be ON
MUXOFF Tests all MUX input channels – should always be OFF
MUXSEL Tests the 5 MUX output channels – should always be ON

MUX1
DIODE INPUT PANEL
(DIP)

MULTIPLEXAGE (MUX)
The diode panels provide isolation between devices

Without Diode Panel

WRONG!!
Without Diode Panel

With Diode Panel

MULTIPLEXING (MUX)
Possible problems:
• Poor connection on DIP board
• Poor CMU connection
• Failed DIO module
• Failed diodes on DIP board
• Low voltage ground

VOLTAGE AMPLIFICATION MODULE (VAM)

ANALOG SIGNAL CONDITIONER (ASC)
MGCTA1/2 (Main Generator Current)
TL24T (DB/Slow Speed Reference Signal)
BATTV (Battery Voltage)
ASC300

TRAIN LINE FILTER (TLF)

FIRE
(FUNCTIONALLY INTEGRATED RAILROAD ELECTRONICS)
Integration
Operator Interface
Manages communications
between subsystems

CAN
FC
(FIRE Computer)
Display
Fire Power
Supply (FPS)
SCM
(EM2000)
PC Card
Reader
Download
Port
Crash Hardened
Memory (CHM)
Speakers
GPS
+/- 15 Vcc
EM2000EMDEC Fuel Gauge
Speed
Indicator
IPM
FIRE
EBV

FIRE

DISPLAY
Alerter Operation
ALERT
25
ALERT
25
Alerter countdown varies with locomotive speed
Alerter icon flashes when countdown reaches T-25 seconds
At T-20 seconds, alerter icon on steady and audio warning begins
At T-10 seconds, audio warning reaches maximum volume
At T-0 seconds, FIRE initiates a penalty brake application
ALERT
24
ALERT
23
ALERT
22
ALERT
21
ALERT
20
ALERT
19
ALERT
18
ALERT
17
ALERT
16
ALERT
15
ALERT
14
ALERT
13
ALERT
12
ALERT
11
ALERT
10
ALERT
9
ALERT
8
ALERT
7
ALERT
6
ALERT
5
ALERT
4
ALERT
3
ALERT
2
ALERT
1
ALERT
0

DISPLAY
Event Recorder
• Real time clock (Greenwich Mean Time)
• Locomotive speed
• Brake Pipe pressure
• End of Train BP pressure and status
• Independent Brake Cylinder pressure
• Throttle position
• Dynamic Brake position (Set up and 0-74VDC)
• Bell status
• Horn status
• Direction (Reverse/Forward)
• Distance
• Locomotive ID number
• Safety Signals.
The Event Recorder is an integral part of the FIRE computer.
Collects and records locomotive and operator data.
Data can be downloaded by PCMCIA Card or serial connection.
Typical recorded events:

DISPLAY
Maintenance Mode
MAINTENANCE AUTHORIZATION
DATE = March 15, 2010 = 03 15 10
A = 0 + 3 + 1 + 5 + 1 + 0 = 10 (use last digit)
B = 0 (last digit of year)
C = 5 (last digit of day)
D = 1 (first digit of day)
Authorization Code for March 15, 2010
0 0 5 1
A B C D
March 15, 2010

GPS
Antenna
Speedo
Fuel Gauge
PC Card Reader
Speakers
Power
Ground
Connection
(CAN)
FIRE Screen Rear Connections

Fuel Gauge Control Box
J1 To Left & Right Side Display
J3 To FIRE Computer
J2 Laptop Connection
J1 J2 J3
Electronic Fuel Gauge

PC Card Reader
Green light flashes during
download
Do not remove card until
download is finished

Mobile Communications
Package (MCP)
The mobile communications package function provides a
RF communication link between the locomotive and a
railroad’s data network. The FIRE system must collect and
disseminate MCP data that can not be communicated
directly to a functional subsystem.
MCP ADD-ON TO
BACK OF FIRE SCREEN

EMDEC Electronic Control Modules (ECMs)
Each ECM controls 8
cylinders
Sender:
Injectors 9 - 16
Sensors
Receiver:
Injectors 1 - 8

Status Lights
24 Volt Power Supply

Interface Board

Electronic Unit Injector (EUI)
EMDEC

Needle valve begins to open:
2,000 – 2,400 psi
Final pressure: 16,000 – 18,000 psi
Coil
Poppet Valve
Needle Valve &
Spray Tip
PLUNGER
EMDEC Electronic Unit Injector (EUI)

EMDEC
SENSORS
SRS:
1 Pulse / 360°
#1 Cylinder at TDC
TRS:
36 Pulses / 360°
These sensors give engine
position and speed

EMDEC
TEMPERATURE
SENSOR

EMDEC

PRESSURE
SENSOR
EMDEC

EMDEC Sensors in a
Box
EMDEC

FastBrake
Pneumatic Operating Unit (POU)

Main Generator / Companion Alternator
TA17 Output CA9 Output

Main Generator Stator & Rotor
TA17 Field
CA9 Field
Stator Rotor

Alternator Configuration
To Blowers
APC
Battery
Charging
(AC)
CHOPPER
To Inverters
Main Generator
(TA17)
Companion
Alternator
(CA9)
Rotating
Field
Coils
Stator
(AC)
(DC)
(DC)

B1/B2
B3/B4
DC LINK 1
DC LINK 2
DCL SWITCHGEAR
IGBT
INVERTER 1
IGBT
INVERTER 2
BOGIE #2 BOGIE #1
DB GRID 1
DB GRID 2
+ BLOWER
APC
APC DIODE
ASSEMBLY
CAB HEATER / AC
BATTERY
CHARGING
CA9 - 1
CA9 - 2
CA9
FIELD
CHOPPER
3-PHASE
BLOWERS
3Φ
AC
DC
DC
3Φ3Φ
220VAC
400VAC
200VAC
72 – 78VDC
72 – 78VDC
MAIN
GENERATOR
(TA17)
MG
FIELD
Power System

Traction Rectifiers
Diodes
3 PH
3 PH

Main Generator
DC Link Switchgear
Diodes
3 PH
3 PH
+ -+ -

DCL Switchgear Motor

RUN: DC Link charged
High Voltage Circuit
B2
B1
TM 1
DB GRIDMAIN
GENERATOR
(TA17)
+
_
+
_
TM 2 TM 3
DCL
A CB
3Φ
AC
DC
DC
3Φ
AC
+
_
3,000
VDC
IGBT
INVERTER
#1

Tension de “DC Link”
ISOLATE: DC Link discharged via DB grids
0
VDC
TM 1
+
_
+
_
TM 2 TM 3
A CB
3Φ
AC
DC
DC
3Φ
AC
+
_
B2
B1
IGBT
INVERTER
#1
DCL
DB GRIDMAIN
GENERATOR
(TA17)

Tension de “DC Link”
DCL short circuit bus bar maintains 0 VDC
0
VDC
B2
B1
TM 1
+
_
+
_
TM 2 TM 3
A CB
3Φ
AC
DC
DC
3Φ
AC
+
_
DB GRID
DCL
IGBT
INVERTER
#1MAIN
GENERATOR
(TA17)

3 PH
3 PH
+ -+ -
+
-
+
-
Phase Modules

• Supplied with rectified MG
output (« DC Link »)
• Inverter output is controlled by
the commutation of the IGBTs
• IGBTs are controlled by
EM2000
• Air cooled
Each group of
phase modules
produces 3-phase
power for one truck
Inverters

Electrical and
fiber optic
connections
NEG POSAC
Phase Module

EM2000 INTERFACE MODULE
Fiber Optic
Electrical
INVERTER
Fiber Optic
Fiber Optic

MPU Module
Interface Module

Interface Module
Fiber Optic Connections

Fiber Optic
Connections
INTERFACE MODULE

U V W
IGBT = Insulated Gate Bipolar Transistor

+
_
AC

FULL BLOCK @ ~ 70 KM/H

Traction Motors

IGBT Power Supply
(GDPS)
Supplies operating power
for the IGBTs
The output is self-monitored
and a fault signal is sent to
the interface module if a
problem is detected.

(GDPS)

OVCRf
Protection Panel
Inverter Protection

Inverter Protection

Resistance « Crowbar »

A CB B CA
ABC-ABC-ABC BAC-BAC-BAC
Directional Control

TM 1
+
_
B1
B2
+
_
TM 2 TM 3
A CB
3Φ
AC
DC
DC
3Φ
AC
+
_
DC LINK
VOLTAGE
Dynamic Brake
DB GRID
DCL
IGBT
INVERTER
#1MAIN
GENERATOR
(TA17)
The DB grids are connected
to DC Link by the “B” contactors

“B” Contactors
Dynamic Brake

Dynamic Brake

AC Traction Motors DC Traction Motors
Dynamic Brake

Ground Relay System

750 – 825 mA
Ground detection
Ground Relay System

Ground Relay Transductor
(GRT)
Imbalance Detection

Ground Relay Transductor (GRT)
Ground Relay System
Imbalance Detection

Imbalance Detection

TRANSDUCTOR (GRT)
TGR TRANSFORMER
Imbalance Detection

Companion Alternator( CA9) :
Power to the CHOPPER for MG
field excitation
Power for all 3-phase blower
motors
Power to the APC for battery
charging

72 - 220 VAC
(APC)
60 - 200 VAC
120 - 400 VAC

MG Excitation
60 - 200 VAC
Blowers
120 - 400 VAC
CA9 voltage depends on engine speed
CA9 Test Points
APC
72 - 220 VAC

CHOPPER
EM2000
CONTROL
AC
DC
TA17 Field
Main Generator ExcitationCA9

Chopper
Main Generator Excitation

Brushes & Slip Rings
TA17 Field

BLOWER MOTORS
CA9 provides power for the
blower motors
Generator Blower
Locker / Dust Bin Blower
Traction Motor Blower
Cooling Fans
#2 Traction Motor Blower

Always functions when the
engine is running
Generator Blower

Dust Bin Blower
Locker
Blower
Motor:
2 - speed
Controlled by EM2000
via contactors

Traction Motor Blowers
2 - speed
via contactors

Cooling Fans
2 - speed
via contactors
Rotation is clockwise
when viewed from top

APC
31 kW

72 – 220 VAC from CA9:
Battery Charging
Low Voltage System
CA9 Field
APC
72 – 78 VDC

CA9 Field
APC
72 – 78 VDC

APC

END

EM2000 Electrical Systems Guide

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