FS450R12KE3/AGDR-71C S is a high-performance IGBT module kit launched by ABB, with product number 68569354. This kit integrates Infineon’s advanced IGBT chips with ABB customized driver boards, designed specifically for medium power and high voltage application scenarios. It has high reliability, high efficiency, and ease of maintenance, and is widely used in industrial automation, new energy, transportation, and other fields.
Core components:
IGBT module (FS450R12KE3): using Infineon E3 technology platform, supporting 1200 V voltage and 450 A rated current, with low saturation voltage drop and high switching frequency characteristics, suitable for high-frequency power conversion.
Drive board (AGDR-71C): A specialized drive board designed by ABB, integrating multiple protection functions such as overcurrent, overheating, and undervoltage, supporting optocoupler isolation signal input, strong anti electromagnetic interference ability, and ensuring precise switching of IGBT modules.
2、 Product specifications
Power parameters:
IGBT module:
Rated voltage (Vces): 1200 V
Rated current (Ic, RMS): 450 A
Pulse current (Icm): 900 A (10 ms pulse width, duty cycle ≤ 1%)
Saturation voltage drop (Vce (sat)): Typical value 1.7 V (@ Ic=450 A, Tj=25 ° C)
Driver board:
Power supply voltage:+15 V DC (on)/-7 V DC (off)
Drive signal: Optocoupler isolation, compatible with TTL/CMOS levels, input impedance ≥ 10 k Ω
Protection response time: Overcurrent protection<1 μ s, overheat protection threshold can be configured through parameters.
Physical characteristics:
Weight: The net weight of the kit is approximately 1.8 kg (including modules and driver boards).
Size:
Module size: 140 mm x 50 mm x 16 mm (length x width x height)
Driver board size: compatible with module design, supports parallel installation to save space.
Heat dissipation design:
Thermal resistance (Rth (j-c)): 0.045 K/W (from junction to shell), requires efficient aluminum profile radiator or water cooling system, recommended wind speed ≥ 6 m/s.
3、 Application Fields
Industrial automation:
Inverter: Suitable for ABB ACS800 and ACS580 series, driving 160-200 kW motors, used in heavy load scenarios such as mining machinery and rolling mills, supporting direct torque control (DTC) and multi motor linkage control.
Servo system: The servo drive of high-precision injection molding machines and printing machinery achieves fast start stop and position control, improving production efficiency.
Industrial heating equipment: induction heating power supply, electric arc furnace, etc., supporting high-frequency switching (up to 20 kHz), optimizing heating efficiency.
In the field of new energy:
Photovoltaic inverter: Large centralized inverter (above 500 kW), compatible with 1000 V DC bus, achieving efficient MPPT tracking and grid harmonic suppression.
Energy Storage System (ESS): A large-scale battery energy storage converter (PCS) that supports bidirectional power flow and meets the high reliability requirements of grid level energy storage.
Hydrogen energy equipment: The power module of the electrolytic cell power supply supports high voltage and high current output, suitable for alkaline electrolysis or PEM electrolysis scenarios.
Transportation:
Electric vehicle charging: The core power module of the ultra fast charging pile (over 300 kW) supports an 800 V high-voltage platform, reducing charging time to less than 10 minutes.
Rail transit traction: The auxiliary inverter module of light rail and subway provides stable power supply for onboard equipment (such as air conditioning and lighting), adapting to vibration and wide temperature (-40~70 ° C) environments.
4、 Product advantages
High reliability and long lifespan:
The module has passed ABB’s rigorous reliability tests (such as high temperature and humidity tests, vibration tests), with an average time between failures (MTBF) of ≥ 100000 hours.
The driver board adopts a redundant design with built-in dual overcurrent detection (DESAT and current sensor) to reduce the probability of false triggering and extend the system life.
Efficient and energy-saving:
Infineon E3 technology significantly reduces conduction and switching losses, with an efficiency improvement of 6% compared to similar products, making it suitable for long-term full load operation scenarios.
Support soft switching technology (such as zero voltage switching ZVS) to further reduce electromagnetic interference (EMI) and energy loss.
Flexible adaptation and easy maintenance:
The plug and play design is compatible with ABB’s entire range of frequency converters, supporting quick replacement and reducing downtime.
The driver board provides standardized interfaces and can monitor module status (such as junction temperature and switch frequency) in real-time through ABB DriveWindow software, providing early warning of potential faults.
Compliance and Security:
Certified by CE, UL, and RoHS, it complies with the EN 61800-5-1 industrial drive safety standard.
Equipped with safety grounding (PE) and anti electric shock protection (IP20), the fault signal of the drive board can be directly connected to the safety PLC, meeting the requirements of SIL2 level safety system.
FS300R12KE3/AGDR-72C S is a high-performance IGBT module kit launched by ABB, with product number 68569541. This kit integrates advanced IGBT chips from Infineon with ABB’s self-developed driver board, designed specifically for medium to high voltage power conversion scenarios. It has high reliability, high efficiency, and flexible adaptability, and is widely used in industrial automation, new energy, and transportation fields.
Core components:
IGBT module (FS300R12KE3): using Infineon E3 technology platform, supporting 1200 V high voltage and 300 A high current, with low saturation voltage drop and high switching frequency characteristics, suitable for high-frequency power conversion.
Drive board (AGDR-72C): ABB customized drive solution, integrating multiple protection functions such as overcurrent, overheating, undervoltage, etc., ensuring reliable switching of IGBT modules, supporting optocoupler isolation signal input, and strong anti electromagnetic interference capability.
Product specifications
Power parameters:
IGBT module:
Rated voltage (Vces): 1200 V
Rated current (Ic, RMS): 300 A
Pulse current (Icm): 600 A (10 ms pulse width, duty cycle ≤ 1%)
Saturation voltage drop (Vce (sat)): typical value 1.8 V (@ Ic=300 A, Tj=25 ° C)
Driver board:
Power supply voltage:+15 V DC (on)/-7 V DC (off)
Drive signal: Optocoupler isolation, compatible with TTL/CMOS levels, input impedance ≥ 10 k Ω
Protection response time: Overcurrent protection<1 μ s, overheat protection threshold can be configured.
Physical characteristics:
Weight: The net weight of the kit is approximately 1.5 kg (including modules and driver boards).
Size:
Module size: 122 mm x 44 mm x 14 mm (length x width x height)
Driver board size: Suitable for module installation, supports compact layout.
Heat dissipation design:
Thermal resistance (Rth (j-c)): 0.06 K/W (junction to shell), needs to be matched with aluminum radiator, recommended wind speed ≥ 5 m/s.
Application area
Industrial automation:
Inverter: Suitable for ABB ACS800 and ACS580 series, driving 110-160 kW motors, used for loads such as fans, pumps, and conveyors, supporting direct torque control (DTC) and vector control.
Servo system: high-precision machine tools, robot servo drives, achieve fast response and precise positioning, and adapt to high dynamic performance requirements.
Industrial power supply: Inverter modules for UPS power supply and switch mode power supply, ensuring uninterrupted power supply for critical equipment.
In the field of new energy:
Photovoltaic inverter: centralized or string inverter, supporting DC voltage of 600-1000 V, realizing MPPT tracking and grid connection, suitable for large photovoltaic power plants and distributed generation systems.
Energy Storage Converter (PCS): Bidirectional power conversion for battery energy storage systems, supporting seamless switching between charging and discharging modes, meeting the needs of grid frequency regulation and peak valley arbitrage.
Wind power converter: The converter module of a doubly fed wind turbine is suitable for wide voltage inputs (400-690 V), with high reliability and resistance to grid disturbances.
Transportation:
Electric vehicle charging: The core power module of the DC fast charging pile (DC pile) supports high-power charging (such as over 120 kW) and shortens charging time.
Rail transit auxiliary system: auxiliary power modules for train air conditioning and traction converters, adapted to harsh onboard environments such as vibration and shock.
Product advantages
High reliability and long lifespan:
Adopting ABB’s rigorous quality control process, the module undergoes long-term durability testing (such as 1 million switch cycles) to adapt to harsh industrial environments (temperature -40~85 ° C, humidity ≤ 95%).
The driver board integrates redundant protection circuits to reduce the probability of faults caused by overcurrent and overheating, and extend the system life.
Efficient and energy-saving:
Infineon E3 technology optimizes switch losses, increasing efficiency by 5% compared to previous generation products, reducing system heating and energy consumption, and complying with the EU ErP energy efficiency standard.
Supports high-frequency switching (up to 25 kHz), which can reduce the size of passive components and improve system power density.
Flexible adaptation and easy maintenance:
Compatible with ABB multiple series frequency converters, supports plug and play, reduces debugging time.
Modular design facilitates replacement, and maintenance only requires replacing the kit without the need to disassemble the system as a whole, reducing downtime costs.
Provide supporting heat dissipation solutions (such as ABB original heat sinks) to ensure installation compatibility and heat dissipation efficiency.
Compliance and Security:
Passed CE, UL, RoHS certifications, compliant with EN 60664-1 insulation standards and EMC requirements.
The driver board supports safe grounding design and meets industrial grade electric shock protection (IP20). During operation, faults can be quickly located through LED indicator lights.
Ordering and Technical Support
Material Number: 68569541
Packaging contents: IGBT module x 1, driver board x 1, installation screws x 4, thermal grease x 1, quick installation guide x 1
technical support:
The official website provides datasheet, driver board circuit diagram, and firmware upgrade tool.
ABB’s global service network provides on-site debugging, fault diagnosis, and training services, with free replacement of faulty kits during the warranty period.
Brand/Series: Infineon E3 series, which belongs to industrial grade medium power IGBT modules.
Function: Achieve power conversion from DC to AC, support high-frequency switching, suitable for medium voltage and current converter scenarios.
Driver board:
Model: AGDR-71C
Function: Provide gate drive signals for IGBT modules, integrate protection functions such as overcurrent, overheating, and undervoltage, and ensure reliable switch control.
Product Code: 68569303 (ABB internal material code, used to uniquely identify kit configuration).
Miller clamp: suppresses gate oscillation and improves electromagnetic compatibility (EMC)
Application scenarios
1. Industrial transmission system
Inverter: Suitable for ABB ACS580, ACS880 and other series inverters, used to control 75-110 kW motors, commonly used in loads such as fans, pumps, compressors, etc., supporting vector control and direct torque control (DTC).
Servo system: high-precision servo drives, such as machine tool spindle drive and robot joint control, achieve fast response and precise positioning.
Industrial power supply: The inverter module of uninterruptible power supply (UPS) and switch mode power supply (SMPS) ensures the stability of power supply.
2. New and renewable energy
Photovoltaic inverter: the core power module of string inverters, supporting a DC voltage range of 400-800 V, achieving MPPT tracking and grid connection.
Energy Storage System (ESS): The bidirectional energy conversion of Battery Storage Converter (PCS) supports switching between charging and discharging modes to meet the frequency regulation needs of the power grid.
Low power wind power: Converter module for small wind turbines, adapted to permanent magnet synchronous generators, to achieve stable control of voltage and frequency.
3. Transportation and Special Equipment
Electric vehicle charging: The power module of the charging station (AC/DC station) supports fast charging technology to improve charging efficiency.
Rail transit auxiliary system: The motor drive of the train air conditioning and ventilation system meets the requirements of vibration resistance, wide temperature range (-40~70 ° C) and other onboard environmental requirements.
Welding equipment: IGBT type welding machine, supporting pulse welding process, improving welding quality and efficiency.
Key points for installation and maintenance
1. Installation Guide
Mechanical installation:
Heat sink selection: It is recommended to use ABB original heat sinks or equivalent aluminum profiles. The contact surface should be coated with thermal conductive silicone grease (thickness ≤ 0.1 mm) to minimize thermal resistance.
Fixed torque: Use M4 screws to tighten diagonally with a torque of 6-8 N · m to avoid module deformation or poor contact.
Electrical connection:
Main circuit: Low inductance copper bars or cables with a spacing of ≥ 10 mm are required for the DC bus (+/-) and output terminals (U/V/W) to reduce parasitic inductance.
Drive signal: A twisted pair shielded cable with a length of ≤ 0.5 meters is used, and the shielding layer is grounded at one end (near the drive board) to avoid electromagnetic interference (EMI) affecting the gate signal.
Grounding requirements: The IGBT module housing (E terminal) should be directly connected to the system ground with a grounding resistance of<0.5 Ω to ensure safe discharge of leakage current.
2. Maintenance and troubleshooting
Daily inspection:
Appearance: Check the surface of the module for cracks, erosion, or discoloration, and the status of the driver board indicator light (such as green normal, red fault).
Electrical testing: Measure the output voltage of the drive board (+15 V/-7 V), and observe the gate waveform with an oscilloscope (Vge should have no oscillation and a steep rising edge).
Cooling system: The fan speed is normal, and the radiator temperature is ≤ 75 ° C (when the ambient temperature is 25 ° C). Regularly clean the dust to ensure good ventilation.
Common troubleshooting:
Overcurrent fault: Check whether the motor load, cable insulation is damaged, or if the drive board is faulty (such as optocoupler damage).
Overheating alarm: Check if the fan stops running and if the thermal grease is aging. Replace the cooling components or clean the cooling channels.
Module failure: If a short circuit or open circuit is detected between C-E poles, the IGBT kit should be replaced as a whole and the driver board should be checked for synchronous faults (such as protection circuit not responding in a timely manner).
Alternative models and compatibility
Same series upgrade options:
FS300R12KE3:300 A current level, other parameters are the same, suitable for power boosting scenarios (such as 132 kW motor drive).
FS225R12KL4: Infineon E4 series, with lower saturation pressure drop (Vce (sat) ≈ 1.6 V) and an efficiency improvement of about 3%, can directly replace E3 series.
Driver board compatibility:
AGDR-71C is designed specifically for FS225R12KE3. If replacing it with another brand of IGBT (such as Mitsubishi CM200DY-12H), it is necessary to match the corresponding driver board and adjust the gate resistance and dead time parameters.
Safety and Compliance
authentication:
Compliant with RoHS 2.0 and REACH environmental standards, certified by UL 1557 and CE (compliant with EN 60664-1 insulation requirements).
Safe operation:
After a power outage, wait for at least 5 minutes and use a multimeter to confirm that the bus voltage is less than 30 V to avoid residual charge in the capacitor causing electric shock.
Wear an anti-static wristband during operation to avoid direct contact with the IGBT gate (G pole) and prevent electrostatic breakdown (ESD sensitivity level HBM 200 V).
The faulty module needs to be handled by professional personnel. Disassembly or random disposal is prohibited to avoid the leakage of harmful substances.
IGBT module, also known as insulated gate bipolar transistor module, is a core device in the field of power electronics. It combines the advantages of MOSFET (metal oxide field-effect transistor) and BJT (bipolar junction transistor), and has the characteristics of high voltage, high current, high switching speed, and low conduction loss. It is mainly used for power electronic conversion and control, such as inverters UPS、 Electric motor drive, solar power generation, electric vehicles and other scenarios are essential components for achieving efficient power conversion. The IGBT MODULE KIT FS450R17KE3/AGDR-61C S launched by ABB, with product number 64783831, has demonstrated excellent performance in numerous applications.
Product Overview
This IGBT kit combines advanced technology and design concepts. FS450R17KE3, as an IGBT module, has powerful power processing capabilities. It can operate stably under certain voltage and current conditions, providing reliable power conversion support for various types of power equipment. AGDR-61C S is a matching driver board, which precisely controls the opening and closing of IGBT modules to ensure the efficient operation of the entire system. The two work together to form a high-performance IGBT kit. The product number 64783831 can track its production batch, quality control, and other related information, making it convenient for users to query the source and quality assurance of the product during use.
Product specifications
Power parameters: FS450R17KE3 has a high rated voltage and can adapt to high voltage environments, providing guarantees for stable operation of power equipment at different voltage levels. Its rated current also reaches a certain value, which can meet the application scenarios with high power demand. It plays an important role in equipment such as motor drives and industrial inverters, ensuring that the equipment can efficiently output power.
Size and weight: The net weight of the entire IGBT KIT product is approximately 1.28kg. Among similar products, this weight design considers both product compactness and factors such as heat dissipation and structural strength. The dimensional data of the product, such as net depth/length, net height, net width, etc., indicate that it has a reasonable external design, which is easy to install inside various equipment and adapts to different spatial layout requirements.
Application Fields
Industrial automation: In industrial automation production lines, motor drive is a key link. This IGBT KIT can be used to control the speed and torque of motors, achieving precise motion control. For example, in machine tool processing, textile machinery and other equipment, it can ensure the stability and accuracy of motor operation, improve production efficiency and product quality.
In the field of new energy: In solar power generation systems, inverters are the core equipment that converts direct current into alternating current. This IGBT kit from ABB can be applied to inverters to efficiently convert power, stably converting the direct current generated by solar panels into alternating current that meets the requirements of the power grid, achieving effective utilization of solar energy. In the field of wind power generation, it can also be used for inverters and other equipment to ensure the stable operation of wind power systems.
Transportation: In the charging facilities of electric vehicles, this IGBT KIT can be used for the power conversion part of the charging station to achieve a fast and stable charging process. At the same time, there are also applications in the on-board inverters of electric vehicles, which convert the DC power of the battery into AC power to drive the motor and provide reliable support for the power system of electric vehicles.
Product advantages
High reliability: ABB, as a well-known brand, strictly follows quality standards in the product manufacturing process. This IGBT kit uses high-quality materials and advanced manufacturing processes, ensuring high reliability of the product during long-term use, reducing the probability of failures, and lowering equipment maintenance costs.
Efficient and energy-saving: The design of FS450R17KE3/AGDR-61C S optimizes power conversion efficiency and reduces energy loss. In various applications, efficient power conversion can be achieved with low energy consumption, which meets the demand for energy-saving products in modern society and helps enterprises reduce operating costs and achieve sustainable development.
Strong adaptability: This kit has good adaptability and can be integrated with various devices and systems. Whether it is the design and selection of new equipment or the upgrading and renovation of old equipment, this IGBT KIT can be easily applied, providing users with flexible solutions.
Brand/Technology Platform: Infineon E3 series, an industrial grade IGBT with low loss and high reliability.
Function: As a power switching device, it is used for energy conversion in inverters and supports high-frequency switching and four quadrant operation.
Driver board:
Model: AGDR-62C
Function: Provide IGBT gate drive signals, integrate protection circuits (overcurrent, overheating, undervoltage detection), and adapt to the driving requirements of FS300R12KE3.
Product Code: 64717812 (ABB internal material code, used to identify kit configuration).
62: Driver version compatible with 1200 V level IGBT
C: Coated board design to enhance corrosion resistance (suitable for humid or dusty environments)
Technical parameters
1. IGBT module (FS300R12KE3)
Electrical characteristics:
Rated voltage (Vces): 1200 V
Rated current (Ic, RMS): 300 A (@ Tc=80 ° C, sine wave load)
Peak current (Icm): 600 A (10ms pulse, duty cycle ≤ 1%)
Saturation voltage drop (Vce (sat)): typical value 1.8 V (@ Ic=300 A, Tj=25 ° C)
Switching frequency: up to 25 kHz (depending on heat dissipation conditions and load)
Mechanical and thermal characteristics:
Packaging: Press Fit press fit packaging, supports direct insertion into PCB or heat sink, reduces soldering stress
Dimensions: 122 mm x 44 mm x 14 mm (length x width x height)
Weight: Approximately 0.45 kg
Thermal resistance:R th(j−c)=0.06 K/W (shell to shell), requires aluminum or copper heat sink, recommended wind speed ≥ 5 m/s
Protection function: Built in freewheeling diode (FWD), supports short-circuit protection (detected by DESAT of the AGDR-62C driver board).
2. Drive board (AGDR-62C)
Power supply and interface:
Power supply voltage:+15 V DC (drive on)/-7 V DC (drive off), isolated power supply design
Signal input: Optocoupler isolation, compatible with 3.3 V/5 V TTL signals, input impedance ≥ 10 k Ω
Output current: Peak driving current ± 15 A (meets fast switching requirements)
Protection and monitoring:
Overcurrent protection (OC): triggered by detecting IGBT saturation voltage drop (DESAT), response time<1 μ s
Overheating protection (OT): Monitor module junction temperature, block drive signal when overheating occurs
Fault feedback: Provide fault output signals for optocoupler isolation (such as OC and OT status), which can be connected to the control system.
Application scenarios
1. Industrial transmission system
Inverter: Suitable for ABB ACS800, ACS580 and other series, used to drive 30-132 kW motors, commonly used in loads such as fans, pumps, conveyors, etc.
Servo system: high-precision servo drive, supporting vector control and position control, suitable for scenarios such as machine tools and robots.
Medium voltage application: By connecting multiple modules in series or parallel, it can be extended to medium voltage converters (such as 3.3 kV systems) for high-power equipment such as elevators and compressors.
2. Renewable energy
Photovoltaic inverter: a power module for string or centralized inverters, supporting MPPT tracking and grid connection.
Energy storage system: Battery Storage Converter (PCS), realizing bidirectional energy conversion between charging and discharging, supporting DC bus voltage range of 400-800 V.
Wind power converter: a converter module for doubly fed wind turbines, suitable for wide voltage inputs (400-690 V) and high reliability requirements.
3. Power electronic equipment
UPS power supply: The inverter module of the online UPS ensures uninterrupted power supply during power outages.
Welding power supply: IGBT type welding machine, supporting high-frequency pulse welding to improve welding quality and efficiency.
Industrial heating equipment: Induction heating power supply, used in metal heat treatment, melting and other scenarios, with a switching frequency of up to 20 kHz.
Installation and Maintenance Guide
1. Installation points
Mechanical installation:
Heat sink selection: It is recommended to use aluminum profile heat sinks (such as ABB original models) with a contact surface flatness of ≤ 5 μ m and coated with thermal conductive silicone grease (thickness 0.05-0.1mm).
Fixing method: Use M4 screws to tighten diagonally with a torque of 6-8 N · m to avoid uneven force on the module.
Electrical connection:
Main circuit: Low inductance copper bars with a spacing of ≥ 10mm are required for the DC bus (+/-) and motor output terminal (U/V/W) to avoid creepage.
Drive signal: Using twisted pair shielded cables with a length of ≤ 0.3 meters, the shielding layer is grounded at one end (near the drive board side).
Grounding requirements: The IGBT module housing (E terminal) should be directly connected to the system ground wire, with a grounding resistance of<0.1 Ω.
2. Maintenance and troubleshooting
Daily inspection:
Appearance: Check if there are cracks or burn marks on the module, and if the LED indicator light on the driver board is normal (green indicates normal, red indicates malfunction).
Electrical testing: Use a multimeter to measure the output voltage of the driver board (+15 V/-7 V), and observe the gate waveform with an oscilloscope (Vge rise/fall time should be ≤ 100 ns).
Cooling system: Fan speed ≥ 90% of rated value, radiator temperature ≤ 70 ° C (when ambient temperature is 25 ° C).
Common faults:
Overcurrent tripping: It may be caused by motor short circuit, drive board failure, or IGBT aging. It is necessary to investigate the main circuit and drive signal waveform.
Overheating alarm: Clean the dust on the radiator or replace the fan, and check whether the thermal grease is dry, cracked, or ineffective.
Module damage: manifested as a phase loss in the inverter output. Use a multimeter to check the resistance between C-E (normally unidirectional conduction, otherwise breakdown or open circuit).
Alternative models and compatibility
Same series upgrade options:
FS450R12KE3:450 A current level, other parameters are the same, suitable for power boosting scenarios.
FS300R12KL4: Infineon E4 series, with lower saturation pressure drop (Vce (sat) ≈ 1.6 V) and an efficiency improvement of about 5%.
Driver board replacement:
If it is necessary to adapt to other brands of IGBT (such as Mitsubishi, Fuji), the corresponding driver board needs to be replaced and the gate resistance and dead time parameters need to be re matched.
Safety and Compliance
authentication:
Compliant with RoHS 2.0 and REACH regulations, UL 1557 (power semiconductor) and CE certification (compliant with EN 60664-1 insulation requirements).
Safe operation:
After power failure, wait for at least 5 minutes and use a multimeter to confirm that the bus voltage is less than 30 V to avoid residual charges causing electric shock.
Wear an anti-static wristband during operation to avoid direct contact with the IGBT gate (G pole) and prevent damage from electrostatic discharge (ESD).
The faulty module must be marked as’ High Voltage Danger ‘and returned to ABB’s designated repair point. Disassembly by oneself is prohibited.
Ordering and Technical Support
Ordering information:
Material Number: 64717812
Packaging contents: IGBT module x 1, driver board x 1, installation screws x 4, thermal grease x 1 tube, quick guide x 1
Brand/Series: Infineon E3 series, which belongs to high-voltage and high-power IGBT modules.
Function: Used as a power switch for inverters, realizing the conversion of DC to AC electrical energy.
Driver board:
Model: AGDR-66C
Function: Provide gate drive signals for IGBT modules and integrate protection circuits (overcurrent, overheating, short circuit detection).
Product Code: 64717839 (ABB internal material code, used to uniquely identify the kit).
2. Meaning of Model Parameters
FS300R17KE3：
FS: Infineon Standard IGBT Module
300: Rated current 300 A (RMS, RMS)
17: Rated voltage 1700 V
KE3: E3 technology platform, low loss design
AGDR-66C：
AGDR: ABB Driver Board Series
66: Driver version compatible with high voltage level IGBT
C: Coated board (suitable for harsh environments, enhancing corrosion resistance)
Technical parameters
1. IGBT module (FS300R17KE3)
Electrical parameters:
Rated voltage (Vces): 1700 V
Rated current (Ic, RMS): 300 A
Pulse current (Icm): 600 A (10ms pulse width)
Saturation voltage drop (Vce (sat)): Typical value 2.1 V (@ Ic=300 A, Tj=25 ° C)
Switching frequency: up to 20 kHz (depending on heat dissipation conditions)
Mechanical characteristics:
Package: Press Fit, supports direct soldering or plug-in installation
Size: Approximately 121 mm x 44 mm x 14 mm
Weight: Approximately 0.5 kg
Heat dissipation requirements: thermal resistance R th(j−c)0.08 K/W (typical value), requires the use of an efficient radiator.
2. Drive board (AGDR-66C)
Supply voltage:
Main power supply:+15 V DC (driving IGBT on), -7 V DC (off bias)
Auxiliary power supply: isolated power supply, strong anti-interference ability
Interface features:
Optocoupler isolated input, compatible with TTL/CMOS levels
Fault feedback signal: Output overcurrent (OC) and overheat (OT) signals through LED or digital interface
Protection function:
Gate voltage monitoring (Vge undervoltage protection)
Active Miller clamp (suppresses oscillation)
Short circuit protection (DESAT detection, response time<1 μ s)
Application scenarios
1. Industrial sector
Medium and high voltage frequency converters: such as ABB ACS800 series models suitable for 1700 V level, used to drive high-power motors (such as mining machinery, steel rolling mills).
Renewable energy:
Wind power converter (doubly fed or full power converter), supporting high voltage ride through (HVRT) function.
Photovoltaic inverters (centralized or distributed) improve conversion efficiency and grid adaptability.
Power quality equipment:
Static Var Generator (SVG) and Active Power Filter (APF) are used for harmonic control and reactive power compensation.
2. Rail Transit and Ships
Traction inverter: a traction system for subways and high-speed trains that meets high reliability and vibration resistance requirements.
Ship electric propulsion: drives the propulsion motor, supports wide speed range and four quadrant operation.
3. Special power supply
High frequency heating power supply: The power module of induction heating equipment supports high switching frequency.
Pulse power supply: Pulse applications such as radar and particle accelerators that require fast switching.
Installation and maintenance
1. Installation points
Mechanical installation:
The module needs to be installed vertically on the heat sink, ensuring a flat contact surface, and using thermal conductive silicone grease (thickness ≤ 0.1mm).
Fixed torque: The screws need to be tightened in diagonal order, and the torque value should refer to the manual (usually 6-8 N · m).
Electrical connection:
Main circuit: Copper bars or low inductance cables are required for the DC bus (+/-) and output terminals (U/V/W) to reduce parasitic inductance.
Drive signal: using twisted pair shielded cables with a length of ≤ 0.5 meters to avoid electromagnetic interference (EMI).
Grounding: The driver board and module casing must be reliably grounded with a grounding resistance of<1 Ω.
2. Maintenance and troubleshooting
Daily inspection:
Visually inspect the surface of the module for cracks, erosion, or discoloration.
Measure the output voltage of the driver board: turn-on voltage+15 V ± 5%, turn off voltage -7 V ± 5%.
Cooling system: fan speed, radiator temperature (≤ 80 ° C is normal).
Common faults:
Overcurrent fault: It may be caused by motor short circuit, drive board failure, or IGBT aging, and an oscilloscope is needed to detect the gate waveform.
Overheating alarm: Failure of cooling fan, accumulation of dust in radiator, or failure of thermal grease, requiring cleaning or replacement.
Module damage: manifested as a phase loss in the inverter output, requiring a multimeter to detect module continuity (normally, unidirectional conduction between C-E).
Alternative models and compatibility
Upgraded models of the same series:
FS450R17KE4:450 A current level, E4 technology with lower losses, suitable for scenarios requiring higher power.
FS300R17KL4: 1200 V version, can be replaced if voltage requirements decrease (system voltage compatibility needs to be confirmed).
Driver board compatibility:
AGDR-66C is only compatible with IGBT at 1700 V level. If it is replaced with other voltage modules (such as 1200 V), the driver board (such as AGDR-61C) needs to be replaced synchronously.
Safety and Compliance
authentication:
Compliant with RoHS 2.0 environmental standards and certified by UL and CE safety regulations (please refer to specific documentation).
Compliant with IEC 60664-1 insulation standard, suitable for pollution level 2 environment.
Safe operation:
After power failure, wait for the capacitor to discharge (≥ 10 minutes) and use a multimeter to confirm that the bus voltage is less than 30 V.
Wear an anti-static wristband to avoid direct contact with IGBT pins (G is highly susceptible to electrostatic breakdown).
The faulty module needs to be professionally handled to avoid high-pressure residue or debris splashing during disassembly.
IGBT module: Model FS450R12KE3, belonging to Infineon’s high-power IGBT module, suitable for industrial grade inverter applications.
Driver board: Model AGDR-61C, a gate driver board designed for ABB to drive IGBT modules and ensure reliable switch control.
Product number: 64635875, is an internal ABB material number used to identify specific kit configurations.
Key parameters
IGBT module (FS450R12KE3):
Voltage/Current: 1200 V withstand voltage, 450 A rated current (RMS), suitable for medium power converters.
Technical features:
Adopting Infineon E3 series chips, with low saturation voltage drop (V CE (sat)) and efficient switching performance.
Compatible with short-circuit protection and temperature monitoring functions, with built-in freewheeling diode (FWD).
Packaging form: Press Fit technology, suitable for welding or crimping installation, to improve mechanical reliability.
Drive board (AGDR-61C):
Power supply voltage: usually ± 15 V DC, supports isolated driving, and has strong resistance to electromagnetic interference (EMI).
Interface: Suitable for IGBT module gate signal input, may include optocoupler isolation or digital signal interface.
Protection function: Integrated overcurrent, overvoltage, and overheating protection, supporting fault signal feedback to the control system.
Application scenarios
Industrial transmission system:
Suitable for ABB frequency converters (such as ACS800 series), servo drives, or medium to high voltage inverters, used for motor control (such as fans, pumps, rolling mills, etc.).
Renewable energy:
The power conversion process of photovoltaic inverters and wind power converters supports grid connected or off grid applications.
Power quality equipment:
Such as Static Var Compensators (SVC) and Active Power Filters (APF), used for harmonic suppression and reactive power regulation.
rail transit:
The converter module in subway and light rail traction inverters meets the requirements of high reliability and vibration resistance.
Kit composition and installation
Typical package contents:
IGBT module (FS450R12KE3) × 1
Drive board (AGDR-61C) x 1
Supporting hardware: Install screws, insulation gaskets, and thermal grease (used for heat dissipation between modules and heat sinks).
Mechanical installation: It needs to be fixed on the radiator to ensure reliable heat conduction path and torque compliance with specifications (usually 5-10 N · m).
Electrical connection:
Main circuit: Connect the DC bus (+/- DC) and motor output (U/V/W).
Control signal: The gate terminals (G/E) of the driver board and IGBT module are connected through shielded cables to avoid electromagnetic interference.
Safety precautions:
Wear an anti-static wristband during operation to prevent static electricity from damaging the IGBT chip.
Before supplying power to the driver board, it is necessary to confirm the voltage polarity to avoid module burnout caused by reverse connection.
Maintenance and troubleshooting
Daily maintenance:
Regularly inspect the surface of the module for cracks and burn marks.
Measure the output voltage of the driver board (normal ± 15 V) to ensure that the IGBT on/off voltage meets the requirements.
Check the cooling system (fan, radiator temperature) to ensure that the junction temperature (Tj) is below the maximum allowable value (usually 150 ° C).
Common faults:
Overcurrent fault: It may be caused by motor short circuit, load sudden change or drive board failure, and the main circuit and drive signal need to be checked.
Overheating alarm: Insufficient heat dissipation caused by blocked radiator or fan failure, requiring cleaning of the heat dissipation channel or replacement of the fan.
Module damage: manifested as unbalanced output of the inverter and triggering of short circuit protection. It is necessary to replace the IGBT module and check whether the drive board is synchronized with the fault.
Alternative models and compatibility
Compatibility module:
If FS450R12KE3 is out of stock, you can consider upgrading to the same series model (such as FS450R12KE4, higher efficiency) or other brand modules with the same parameters (driver board compatibility needs to be confirmed).
Driver board replacement:
AGDR-61C corresponds to a specific IGBT model, and when replacing it, it is necessary to ensure that the driving signal parameters (such as driving resistance and dead time) match.
Safety and Compliance
Certification: Compliant with RoHS environmental standards and may have obtained safety certifications such as UL and CE (please refer to specific documentation).
Safety regulations:
Follow ABB’s “High Voltage Safety Operation Manual” and wait for the capacitor to discharge (≥ 5 minutes) after power failure before performing maintenance.
The faulty module needs to be professionally handled to avoid contamination from high voltage residues or semiconductor fragments.
Applicable products: Suitable for ACS800-01/U1 and ACS800-02/U2 products.
Warning and Caution
Warning: Remind of situations that may cause serious injury or death and/or damage to equipment, such as dangerous voltage, electrostatic discharge, etc.
Attention: Remind users of special situations or events, or introduce relevant information on the topic, such as dangerous high voltage at motor cable terminals.
Installation and maintenance work
Only qualified electrical engineers are allowed to install and maintain transmission units.
It is prohibited to install or repair transmission units, motor cables or motors with electricity. After cutting off the input power, wait for at least 5 minutes until the intermediate circuit capacitor is discharged, and use a multimeter to measure and confirm the discharge before operation.
Do not operate control cables when the transmission unit or external control circuit is energized.
All insulation tests must be conducted with the cable disconnected, and ensure the correct phase sequence when reconnecting the cable.
grounding
Proper grounding is necessary to ensure the safety of personnel, reduce electromagnetic radiation and interference. The cross-sectional area of the grounding wire must meet safety regulations, and multiple equipment grounding terminals cannot be connected in series.
In scenarios that comply with European CE standards, cable entrances should maintain a 360 degree high-frequency grounding, and the cable shielding layer should be connected to the protective grounding wire (PE).
Do not install frequency converters with EMC filters in floating or high ground resistance power systems.
Mechanical Installation
The transmission unit is heavy and should not be carried by a single person. When carrying, do not let the front panel bear the weight and rely on lifting the back for transportation.
Ensure that drilling debris does not enter the transmission unit during installation, ensure sufficient cooling space, and do not fix the transmission unit by riveting or welding.
operate
Before debugging the transmission unit, ensure that the motor and driven equipment are suitable for operation within the speed range provided by the transmission unit.
Do not activate the automatic fault reset function of standard applications in situations where danger may occur.
Do not use the main power circuit breaker to control the start and stop of the motor. Instead, use control commands from the control panel keys or transmission unit I/O board.
Permanent magnet motor
When ACS800 is used to drive permanent magnet motors, only scalar control mode can be used.
When the permanent magnet motor is running, do not operate the transmission unit, as its operation transfers electrical energy back to the intermediate circuit. Even if the inverter is not working, the power supply will still charge the transmission system.
During installation and maintenance, use a fuse switch to disconnect the motor from the transmission unit. If possible, lock the motor shaft, connect the motor connection terminals together, and ground them.
Do not operate the permanent magnet motor at speeds higher than the rated speed to avoid overvoltage and capacitor bank rupture.
Product Overview
ACS800-01/U1: A wall mounted transmission unit used to control low-voltage AC asynchronous motors, with different external specifications (R2~R6), protection levels including IP21 (NEMA1) and IP55 (NEMA4, indoor only), etc. The control panel is CDP312R, including printed circuit boards such as main circuit board (RINT), motor control and I/O control board (RMIO), etc. The motor control mode can choose direct torque control (DTC) or scalar control.
ACS800-02/U2: There is relatively little mention in the document, and the external specifications are R7 and R8. Other information can refer to the relevant content of ACS800-01/U1. Some chapters of the two are common, such as safety instructions, electrical installation design, and braking resistors.
Installation
Mechanical Installation
Unpacking and inspection: After unpacking, check for any damage to the appearance, verify if the nameplate of the frequency converter matches the order, and check if the optional modules and equipment are complete.
Preparation before installation: Install vertically, place the radiator against the wall, check if the walls and floors of the installation site meet the requirements, ensure that there is enough space around the transmission unit for cooling air circulation, facilitate maintenance and repair, and pay attention to the space requirements when placing equipment of different protection levels up and down.
Installation method: including wall mounted installation and cabinet installation. Wall mounted installation requires marking the installation hole position with a punching template, fixing screws or bolts, installing the transmission unit and tightening it; Attention should be paid to the horizontal installation distance between the frequency converters when installing inside the cabinet, to prevent the recirculation of cooling air, and to set up air baffles.
Electrical installation design
Motor compatibility check: Ensure that the rated voltage and current of the motor meet the requirements, and avoid the rated voltage of the motor being less than 1/2 of the rated input voltage of the transmission unit or the rated current being less than 1/6 of the rated output current of the transmission unit.
Protecting motor windings and bearings: The output pulse voltage of the transmission unit may affect the motor insulation and bearings. ABB du/dt filters, common mode filters, etc. can be used to reduce the impact. Suitable filters and insulated bearings should be selected according to the motor type and power.
Power supply system connection: A manually operated circuit breaker can be installed between the AC power supply and the transmission unit, which must comply with relevant standards, such as using category AC-23B, etc; The input cable needs to be equipped with a fuse group, and the fuse model should be selected according to local safety regulations, input voltage, and rated current of the transmission unit.
Cable selection and wiring: The main power and motor cables need to be selected according to local regulations to meet the requirements of load current and temperature. The protection ground cables need to consider inductance and impedance limitations; It is best to use shielded cables for control cables, with separate routing for analog and digital signals to avoid long-distance parallel routing. When crossing, the angle should be 90 degrees.
electrical installation
Insulation performance inspection: Check the insulation performance of the motor and motor cables, disconnect the transmission unit from the main power supply, use a 1kV insulation meter to measure the insulation resistance of each relative protective ground, and the resistance value should be greater than 1 megohm.
Power cable wiring: Determine the length of wire stripping according to the external specifications, ground the cable shielding layer, connect the main power cable and motor cable to the corresponding terminals, and fix the junction box cover and front cover.
Control cable wiring: Thread the control cable through the entrance hole and connect it to the relevant detachable terminals on the RMIO board, ensuring a secure connection, grounding the shielding layer, and fixing the control cable and front cover.
Maintenance
Maintenance Cycle
Capacitor update: once a year when stored.
Temperature inspection and cleaning of radiator: Depending on the dust content in the environment, it should be done every 6-12 months.
Cooling fan replacement: Replace every five years, and replace spare fans for IP55 units and some IP21 units every three years.
Maintain content
Cleaning of radiator: Remove the cooling fan, use clean and dry compressed air to blow the radiator from bottom to top, while using a vacuum cleaner to absorb dust at the air outlet, and then install the cooling fan.
Cooling fan inspection: Pay attention to the noise of the fan bearings and the temperature of the radiator. Replace them in a timely manner when signs of damage appear, and use ABB designated spare parts.
Capacitor inspection: Electrolytic capacitors are used in the intermediate circuit, with a service life of about 100000 hours. Damage is often accompanied by the main power fuse melting or fault tripping. If there is suspicion of damage, contact the ABB representative office and use designated spare parts.
LED indication: The LED lights on the RMIO board and control panel installation components can indicate faults and normal power status.
Technical data
IEC level: lists the rated capacity, external specifications, air flow rate, heat loss, and other data of different models of ACS800-01 under 50Hz and 60Hz grid power supply.
Capacity reduction
Temperature induced capacity reduction: When the ambient temperature is between+40 ° C and 50 ° C, for every 1 ° C increase, the rated output current decreases by 1%. The rated current Icont.max is not allowed to be applied in environments exceeding 40 ° C.
Capacity reduction caused by altitude: When the altitude is between 1000-4000m, the rated current decreases by 1% for every 100m increase. If it exceeds 2000m, consult the local ABB dealer or office.
Main power cable fuse: provides cable specifications, fuse models, parameters, etc. corresponding to different models of ACS800-01.
Cable entry hole: information such as terminal size, cable diameter, and tightening torque for different external specifications.
Size, weight, and noise: The size, weight, and noise data of each external specification under different protection levels.
Motor wiring: parameters such as voltage, frequency, current, power limit, and recommended maximum motor cable length.
Efficiency and cooling: The efficiency is approximately 98% of the rated power, and the cooling method is an internal fan with a flow direction from the bottom to the top.
Protection level and environmental conditions: Protection levels include IP21 and IP55, as well as operating conditions such as environmental temperature, relative humidity, and pollution level.
Materials and applicable standards: Information on materials such as transmission unit casing and packaging boxes, following international standards such as EN50178, EN60204-1, etc.
Braking resistor
Configuration and selection: Transmission units with external specifications of R2 and R3 include built-in brake choppers, R4 and larger brake choppers are optional (model+D150), and resistors are additional components; When selecting the transmission unit/chopper/resistor, it is necessary to calculate the braking power to ensure that the resistor resistance and heat loss capacity meet the requirements.
Installation and wiring: All resistors must be installed outside the transmission unit module, with flame-retardant materials nearby. They should be connected using cables of the same model as the input cables of the transmission unit, with a maximum allowable length of 10m. The shielding layer should be properly grounded.
Protection and debugging: It is recommended to configure the main circuit contactor for external specifications R2~R5, and whether R6, R7, and R8 are needed depends on the selection situation; A thermal switch should be installed inside the braking resistor and connected to the digital input port as an external fault interlock signal; Activate the brake chopper function during debugging, turn off the overvoltage control function, and check the resistance value setting.
As a globally renowned giant enterprise in the fields of power and rail transportation, ALSTOM has a profound technical foundation and rich industry experience. Since its establishment, we have been committed to providing advanced technological solutions and high-quality products to global customers. In the field of industrial automation control, ALSTOM has established an excellent brand image through continuous innovation and research and development investment. Its products are widely used in various complex industrial scenarios and are known for their reliability and high performance. The ALSTOM LE109A-1 Controller Module is a typical product in the field of industrial control modules.
Core functions
Logical control: capable of executing complex logical operations, processing input signals according to preset control logic, and outputting corresponding control instructions to achieve precise control of industrial equipment. For example, in the automatic production line, according to the input signals of different sensors, control the start and stop of motors, the opening and closing of valves and other equipment actions.
Data collection and processing: It can collect real-time data from various on-site sensors, such as analog data such as temperature, pressure, flow rate, as well as digital data such as equipment status. After preprocessing operations such as filtering and converting the collected data, it is stored in internal memory for subsequent analysis and decision-making.
Communication function: Through the built-in communication interface, data exchange is carried out with the upper computer, other controllers, and on-site intelligent devices. On the one hand, uploading equipment operation data and status information to the upper computer for real-time monitoring by operators; On the other hand, it receives control instructions issued by the upper computer to achieve remote control functions.
Event recording and alarm: With event recording function, it can record key events during equipment operation, such as equipment start stop time, fault occurrence time and type, etc. When an abnormal situation is detected, an alarm signal can be triggered in a timely manner to notify the operator through indicator lights, buzzers, or communication networks, so as to quickly respond and handle the fault.
Working principle
The operation of ALSTOM LE109A-1 Controller Module is based on microprocessor technology. When external sensor signals are input to the input interface of the module, they first pass through the signal conditioning circuit to convert signals of different types and amplitudes into standard signals suitable for microprocessor processing. The microprocessor performs logical operations, data processing, and other operations on input signals according to pre written and stored control programs in internal memory. The calculation results are converted into control signals that can drive external actuators (such as relays, contactors, etc.) through the output interface circuit, thereby achieving control of industrial equipment. Throughout the entire work process, the communication module is responsible for exchanging data with external devices, sending out internal operational data, and receiving control instructions from external devices. At the same time, the event recording and alarm module monitors the real-time operation status of the system. Once any abnormalities are detected, relevant event information is immediately recorded and an alarm signal is issued.
Key advantages
High reliability: Using industrial grade electronic components and advanced manufacturing processes, rigorous quality testing and reliability testing ensure long-term stable operation in harsh industrial environments. For example, in environments such as high temperature, high humidity, and strong electromagnetic interference, normal working performance can still be maintained, reducing equipment downtime and improving production efficiency.
Powerful processing capability: equipped with high-performance microprocessors and large capacity memory, capable of quickly processing complex control logic and large amounts of data. When facing high-speed automated production lines or large-scale industrial control systems, being able to respond promptly and accurately execute control tasks ensures the efficient operation of the system.
Flexible Scalability: Provides rich input/output interfaces and communication interfaces, making it convenient for users to expand the system according to their actual needs. It can easily connect more sensors, actuators, and other intelligent devices to upgrade and optimize system functions, meeting the constantly changing needs of different industrial application scenarios.
Easy to maintain: The module has self diagnostic function, which can monitor its own working status in real time, quickly locate the fault point after discovering the fault, and facilitate quick repair by maintenance personnel. At the same time, adopting modular design, each functional module is relatively independent, and can be easily replaced in case of failure, reducing maintenance costs and time.
precautions
Installation environment: It should be installed in a dry, well ventilated, non corrosive gas and strong electromagnetic interference environment, avoiding direct sunlight. The installation location should be far away from heat sources and water sources to ensure the normal working temperature and humidity conditions of the module.
Electrical connection: When making electrical connections, be sure to disconnect the power supply and strictly follow the wiring diagram for correct wiring. Pay attention to distinguishing between input and output interfaces to avoid module damage or equipment failure caused by incorrect wiring. After the wiring is completed, it is necessary to carefully check the firmness of the wiring to prevent problems such as loose connections and poor contact.
Software programming: When writing and downloading control programs, the programming software and tools provided by ALSTOM should be used, and relevant programming specifications should be followed. Ensure the correctness and stability of the program, and avoid device malfunctions or system failures caused by program errors. At the same time, regularly backup the program to prevent data loss.
Daily maintenance: Regularly clean the module to prevent dust accumulation from affecting heat dissipation and electrical performance. Check the working status indicator lights of the module and observe for any abnormal flashing or extinguishing. Regularly conduct functional testing on modules to ensure that all functions are functioning properly. If any abnormalities are found, the machine should be stopped for inspection and maintenance in a timely manner.
Application scenarios
Industrial automation production line: widely used in various automated production lines such as automobile manufacturing, electronic equipment manufacturing, food and beverage processing, etc. Responsible for logical control and data collection of various equipment on the production line, such as robots, conveyors, processing equipment, etc., to ensure efficient and stable operation of the production line, improve production efficiency and product quality.
Power system: Used in power plants, substations, and other electrical facilities to monitor and control the operational status of electrical equipment. For example, the start stop control, parameter monitoring, and fault alarm of equipment such as generators, transformers, and circuit breakers ensure the safe and reliable power supply of the power system.
Intelligent building: In the intelligent building control system, it is used to achieve automated control of lighting, air conditioning, elevators, water supply and drainage equipment inside the building. By collecting various sensor data such as indoor temperature, humidity, and light intensity, the device’s operating status is automatically adjusted according to preset control strategies, achieving energy conservation, consumption reduction, and improving the intelligent management level of buildings.
Transportation: In the field of rail transit, it can be used for the operation control and monitoring system of trains such as subways and light rails. Accurately control the traction, braking, door control and other functions of the train, while collecting real-time train operation data to ensure the safe and on-time operation of the train. Used in transportation hubs such as ports and airports to control the operation of cargo loading and unloading equipment, transport vehicles, etc., and improve transportation efficiency and management level.
ALSTOM’s UT150-1 is a device with significant application value in the industrial field. From the model perspective, UT150-1 has clear markings, making it easy to identify and configure in various industrial systems.
In terms of application, UT150-1 is mainly used in DCS/PLC industrial control systems. In these systems, it plays a crucial role in facilitating the stable operation of the entire industrial control process. In order to ensure performance, the device adopts a series of advanced measures, such as digital filtering and power frequency shaping sampling. This technology can effectively eliminate periodic interference, ensure the accuracy of data acquisition, avoid signal deviation caused by interference, and thus ensure the stable operation of the control system. At the same time, UT150-1 also uses measures such as timed calibration of reference point potentials to prevent potential drift. Potential drift may affect the normal working state of equipment, and this measure can adjust the potential in a timely manner to maintain stable operation of the equipment.
NOTE
To install the controller, select a location where:
1. No-one may accidentally touch the terminals;
2. Mechanical vibrations are minimal;
3. Corrosive gas is minimal;
4. The temperature can be maintained at about 23°C with minimal fluctuation;
5. There is no direct heat radiation;
6. There are no resulting magnetic disturbances;
7. The terminal board (reference junction compen sation element, etc.) is protected from wind;
8. There is no splashing of water; and
9. There are no flammable materials
Never place the controller directly on flammable items.
If the controller has to be installed close to flammable items or equipment, be sure to enclose the controller in shielding panels positioned at least 150mm away from each side.
These panels should be made of either 1.43mm thick metal plated steel plates or 1.6mm thick uncoated steel plates.
Mount the controller at an angle within 30° from horizontal with the screen facing upward. Do not mount it facing downward.
CAUTION
1) Before you start wiring, turn off the power source and use a tester to check that the controller and cables are not receiving any power in order to prevent electric shock.
2) For safety, be sure to install a circuit breaker switch (of 5A and 100V AC or 220V AC, and that
conforms to IEC60947) near the instrument so as to be operated easily, and clearly indicate that the
device is used to de-energize the instrument.
3) Wiring should be carried out by personnel with appropriate electrical knowledge and experience
IMPORTANT
1) Use a single-phase power source. If the source has a lot of noise, use an isolation transformer for the primary side and a line filter (we recommend TDK’s ZAC2205-00U product) for the secondary side.
When this noise-prevention measure is taken, keep the primary and secondary power cables well apart.
Since the controller has no fuse, be sure to install a circuit breaker switch (of 5A and 100V AC or 220V AC, and that conforms to IEC standards) and clearly indicate that the device is used to de-energize the controller.
2) For thermocouple input, use shielded compensating lead wires. For RTD input, use shielded wires which have low resistance and no resistance difference between the 3 wires. See the table given later for the specifications of the cables and terminals and the recommended products.
3) The control output relay cannot be replaced even though it has a limited service life (100,000 relay
contacts for the resistance load). Thus, an auxiliary relay should be used so that the load can be turned on and off.
4) When using an inductive load (L) such as an auxiliary relay and solenoid valve, be sure to insert a CR filter (for AC) or diode (for DC) in parallel as a spark-rejecting surge suppressor to prevent malfunctions or damage to the relay.
5) When there is the possibility of being struck by external lightening surge, use the arrester to protect the instrument.
NOTE
• Always fix a terminal cover bracket to the UT150 controller before wiring if an optional anti-electric
shock terminal cover (part number: L4000FB) is used.
• Two types of optional anti-electric-shock terminal covers (part numbers T9115YE and T9115YD) are
available for the UT152 and UT155 controllers, respectively.
Field and purpose
As a globally renowned enterprise in the fields of rail transit, electricity, etc., Alstom’s UT150-1 control board is commonly used in the control systems of rail transit vehicles, such as subways, light rails, trains, etc., to achieve various control functions of the vehicles, ensuring the safe operation and efficient performance of the trains. For example, it may be responsible for controlling important functions such as traction, braking, speed regulation, and door opening and closing of the train.
Working principle
Signal processing and transmission: The control board receives signals from various sensors and operating devices of the train, such as speed sensors, position sensors, driver operation handles, etc., processes and analyzes these signals, and then sends control signals to the corresponding actuators according to preset logic and algorithms to achieve precise control of the train’s operating status.
Communication and network connection: Through specific communication protocols and network interfaces, the UT150-1 control board interacts and communicates with other systems and devices on the train, such as the central control system, traction system, braking system, etc., to share information and work together to ensure the coordinated operation of the overall train system.
FEATURES
High reliability: Adopting redundant design, fault-tolerant technology, and highly reliable electronic components to ensure stable operation in complex operating environments, reduce the probability of failures, and ensure the safety and reliability of train operation.
High real-time requirements: Real time response is required for train control, which can react to various signals and events in a very short time to achieve precise control of train operation and meet the safety and efficiency requirements of train operation.
Strong anti-interference ability: With good electromagnetic compatibility, it can work normally in the complex electromagnetic environment on the train, without being affected by electromagnetic interference from other devices, and without causing interference to other devices.
Maintenance
Regular inspection: It is necessary to regularly inspect the UT150-1 control board, including visual inspection, connection component inspection, circuit board status inspection, etc., to discover possible physical damage, looseness, corrosion and other issues.
Cleaning and dust removal: Keep the control board clean, regularly remove dust and debris, and prevent dust accumulation from affecting heat dissipation and circuit performance.
Software updates and upgrades: With the development of technology and changes in train operation requirements, it is necessary to timely update and upgrade the software of the control board to fix vulnerabilities, optimize performance, add new features, etc.
