Technical

Description
50kVA/400Hz
Issue A
Converter

Technical Description

50kVA Converter
3x440V/60Hz >> 3x200V+N/400Hz

Date: 16-Jun -2016 Page 1 of 13

 Technical
Description
50kVA/400Hz
Issue A
Converter

Table of contents

1 INTRODUCTION .......................................................................................................................................................... 3

2 DESCRIPTION OF CONVERTERS .................................................................................................................................. 3

2.1 GENERAL ................................................................................................................................................................ 3

2.2 EMI SUPPRESSOR .................................................................................................................................................... 3
2.3 POWER STAGE & FILTER ............................................................................................................................................ 5
2.4 FREQUENCY GENERATION .......................................................................................................................................... 5
2.5 CONTROL ELECTRONIC .............................................................................................................................................. 7
2.5.1 Frequency Generation & reference voltage generation. ............................................................................. 8
2.5.2 PWM generation ......................................................................................................................................... 8
2.5.3 Output voltage control and output current control .................................................................................... 8
2.5.4 Fault detection ............................................................................................................................................ 9

3 MECHANICAL ARRANGEMENT ................................................................................................................................. 10

4 TECHNICAL DATA ...................................................................................................................................................... 11

4.1 INPUT VOLTAGE ..................................................................................................................................................... 11

4.2 OUTPUT VOLTAGE 400HZ ....................................................................................................................................... 11
4.3 GENERAL .............................................................................................................................................................. 11
4.4 DESIGN ................................................................................................................................................................ 11
4.5 LOCAL CONTROL & MONITORING ............................................................................................................................. 12
4.6 COOLING REQUIREMENTS ........................................................................................................................................ 12
4.7 ANTI CONDENSATION HEATING ................................................................................................................................. 12
4.8 RELIABILITY ........................................................................................................................................................... 13

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 Technical
Description
50kVA/400Hz
Issue A
Converter

1 INTRODUCTION

EUROATLAS introduces hereby state-of-the-art static power conversion equipment designed

under the measures of the latest available technology and providing typically environmental
features as shock resistance, wide operating temperature range, humidity and low structure
borne noise. Furthermore EMI measures are provided in order to operate the equipment together
with sensitive equipment.
The proposed static power conversion equipment fulfils the main requirements stated in
customers specification. There are several performance data which are even better than required.

2 DESCRIPTION OF CONVERTERS

2.1 General

(see block diagram next page)

Basically the converter is designed to convert an ac voltage of 440V/60Hz into a high quality 3ph
sine voltage with 200Vac and a frequency of 400Hz. The output power is to be used for helicopter
supply.
The technology is based on pulse width modulation (PWM) technique and uses a 3ph IGBT
(insulated gate bipolar transistor) power stage. The output voltage control is designed for single
phase regulation providing excellent line voltage regulation even at 100% unbalanced load.
State-of-the-art control electronic is integrated utilising programmable logic devices and micro
controllers and featuring on-board fault detection.
Overload and short circuit situations are managed by accordant derating of the power stage.
The input stage is formed by a galvanic separated transformer providing a delta and a star voltage
on secondary side to build a 12 pulse rectifier for generating the DC link voltage.
The output is designed with a transformer in star connection used for providing the neutral phase.

2.2 EMI Suppressor

The EMI suppression circuitry is used to fulfil the limits of the MIL-STD-461. Measures are provided
to reduce differential mode and common mode interferences on input and output leads.

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 Technical
Description
50kVA/400Hz
Issue A
Converter

Block Diagram

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 Technical
Description
50kVA/400Hz
Issue A
Converter

2.3 Power Stage & Filter

The power stage consists of three transistorized half-bridges with IGBT-technology (IGBT =
Insulated Gate Bipolar Transistor), a gate drive circuit and an output low-pass filter. Each half-
bridge is built of two power IGBTs (upper and lower).

The power transistors are driven by galvanically insulated gate drives. The transmission of PWM-
driver signals from the control circuit to the power stages are isolated by optical couplers. The
actual output power sine wave is obtained from the output power PWM signal using a second
order LC low-pass reducing the harmonics and forming the fundamental wave.

2.4 Frequency Generation

The technology is based on the pulse width modulation (PWM) technique (see Functional Block
diagram : PWM-Signal Generation). The centre of the control system is a crystal controlled digital
frequency generation providing

 the sine wave references,

 the minimum power transistor dead time
 the necessary chopper signals to generate a multi pulse PWM sine wave.

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 Technical
Description
50kVA/400Hz
Issue A
Converter

PWM Power Generation

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 Technical
Description
50kVA/400Hz
Issue A
Converter

2.5 Control Electronic

The control electronic is designed to adopt all electronic functions that are required to build a
complete converter system except power stage and power driver. Following functions are
provided:

 frequency generation
 PWM generation
 3 phase voltage sense with active rectifier and averager
 3 phase output voltage regulation
 common output current regulation
 over current detection
 short circuit detection
 soft start circuit
 output voltage reference circuit
 power stage fault management
 drive circuits for start contactor,
input contactor and output contactors
 converter on/off logic
 fault logic
 generation of all monitoring signals
 generation of signals for external use
 start/stop management
 input voltage supervision
 dc link voltage supervision
 aux supplies for 15V, 5V and 24V

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 Technical
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50kVA/400Hz
Issue A
Converter

2.5.1 Frequency Generation & reference voltage generation.

The master clock frequency of the system is about 10MHz. This frequency is divided into several
sub frequencies required for the individual applications inside the PLD.
The PWM signal required for the inverter power stage is build by a sine / triangle comparison. The
frequency of the triangle is equal to the switching frequency of the power stages and is generated
by an analogue triangle generator on this board. The sine wave frequency is equivalent to the
output sine wave of the inverter. There are three sine reference voltages generated digitally.

2.5.2 PWM generation

The three phase sine reference outputs are compared with a bipolar triangle.
Each comparator PWM signal is splitted to an upper and a lower power transistor drive signal
taking into consideration the power transistor dead time.

2.5.3 Output voltage control and output current control

The control electronic provides single phase output voltage control and is equipped with three
pathes each build of
 an averager
 an active rectifier
 an active low pass filter
 and a PI voltage controller

The voltage control is of type average amplitude control providing excellent static output voltage
control and a sufficient dynamic control. Due to single phase control the output voltage tolerance
is very low even at unbalanced loads of 100%. During start-up the output voltage rises with a
linear slope during approximately 160 ms. The output voltages can be adjusted by a
potentiometer.
The output voltage of the PI voltage controller sets the amplitude of sine reference by using a
multiplying D/A converter.
Turning down a service potentiometer will interrupt the voltage control loop and allows a
manually output voltage adjustment without control loop influence for service purpose.
The output current control is a common circuit for all three phases and allows current limiting and
constant current mode during short circuit conditions. The current sense simply consists of three
current transformers with full wave rectifiers and shunts.

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50kVA/400Hz
Issue A
Converter

The current sense signals are amplified and merged to a common signal as actual value of output
current. Several comparator circuits are provided to check the output current value for short
circuit conditions and for over load.
The introduction of a short circuit sequence is derived from an over current signal of the power
stage that indicates the maximum allowable current for the power transistors. Generally the short
circuit sequence is starting with a shut down of the power stages by switching them to high
impedance. The temporary shut down signal (10ms-20ms) prepares the voltage controller and the
current controller for a soft start. After the shut down signal is released the current controller sets
the constant current mode. When the short circuit is cleared the unit returns to the voltage mode
automatically. Constant current mode and over load are limited in time. After a certain time has
passed the inverter switches off to failure mode.

2.5.4 Fault detection

The control electronic provides a fault detection and fault analysing circuit. The fault logic is build
by a priority logic giving the most important failures the highest priority.
The priority logic consists of a register representing a binary fault number. All occurrences of
failures initiate a fault latch where the fault number is displayed on a 7-segment display located on
the control board. A summing fault will be displayed on the monitoring panel.

Following parameters are supervised (as a minimum)

 input voltage supervision for upper and lower limit*)
 input charge voltage detection for existence of a minimum voltage *)
 output voltage supervision for upper limit *)
 24V aux voltage supervision for lower limit *)
 fan supervision **)
 internal air temperature for upper limit **)
 power stage temperature for upper limit *)
 over load supervision for upper limit and time **) *)

*) Immediately converter switch off when fault occurs.

**) Warning only
Generally all converter switch-off by fault have to be cleared by pressing the stop push button on
the monitoring panel.

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 Technical
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50kVA/400Hz
Issue A
Converter

3 MECHANICAL ARRANGEMENT
The converter is housed in a steel frame cabinet containing fixed mounted units like transformers
and slide-in drawers for power electronics. All assemblies are accessible from the front by opening
the front door.
The cooling of the converters is achieved by fans. The air inlet is distributed on the front panel of
the converter. The air exhaust is located on the rear side of the cabinet.
Assemblies made of AlMg3. Cable entry from the bottom side. General construction according to
BV 3100.

Cabinet shown without shock mounts.

Weight (complete cabinet) 720kg ± 5% (without shock mounts)

Dimensions cabinet W=810mm H=1612 D=610mm (without shock mounts)
Service space in front 850mm
Cable inlet from bottom side

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 Technical
Description
50kVA/400Hz
Issue A
Converter

4 TECHNICAL DATA

4.1 Input Voltage

Voltage 440V, 3ph according to STANAG 1008 e8
Frequency 60Hz ±5%
Current, nominal approx. 75A at 440V and nominal load
Current, inrush less than nominal input current.
Power factor > 0.9

4.2 Output Voltage 400Hz

General MIL-STD 704 F
Power 50kVA , power factor 1.0…0.8ind
Voltage 3ph 200V/115V adjustable by  5%
Static tolerance < 1 % at any static and balanced load
Volt. unbalance < 5% at 100% unbalanced load
Volt. transient < 5% @ load step 50-100-50%, < 16% @ load step 0-100-0%, rec.20ms
Ampl. modulation 2 %
Distortion (THD)  3.0 %
Overload capacity 150% for 2min., 120% for 10min.
Short circuit current 200% of nom. current for 10 seconds
Frequency 400Hz with < ±0.1 % tolerance, crystal controlled
Efficiency >90%

4.3 General
Shock acc. to BV 0430/1.89
Vibration acc. to BV 0440/10.90
RFI / EMI acc. to MIL-STD 461F, CE102, RE102
Acoustic noise  65 db(A)20uPa in 1m distance
Insulation resistance Power leads > 10MΩ, signal leads > 100MΩ
Operating temperature 0°C…..45°C
Humidity nominal 85%, max 100% for 1h non condensing
Protection IP 43
Isolation acc. to VDE 0110, Part 1
Roll and Pitch arbitrary

4.4 Design
General design GL Germanischer Lloyd Electrical Installation GL III-1-3a, 15.12.2003

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 Technical
Description
50kVA/400Hz
Issue A
Converter

4.5 Local Control & Monitoring

Controls Local Extern

hard wired
Start and stop push buttons for converter X -
Start and stop push buttons for 400Hz output - X
Lamp test push button X -

Monitoring Local Extern

hard wired
Standby indication X -
On line indication 400Hz X X
Input voltage present lamp X -
Elapsed time counter X -
Output voltage, output current, output frequency and X -
output power by combined LCD meter

Warnings / Faults Local Extern

hard wired
Overload X -
High temperature X X
Fan failure X -
Internal fault X X

4.6 Cooling requirements

Following air flow rates have to be considered:

Equipment Condition Power losses Cooling requirement
One 400Hz converter Full load (50 kVA) 5500 W 1000 m³/h

Depending on the utilisation of the converter a sufficient air exchange (inlet / outlet) at the
cabinet location has to be provided.

4.7 Anti condensation heating

Power 100W
Voltage 440V/60Hz

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 Technical
Description
50kVA/400Hz
Issue A
Converter

4.8 Reliability

MTBF: EUROATLAS garantuees a system level Mean Time

Between Failure (MTBF) of 18.000 hrs, based upon the
following assumptions:

1) Normal operating conditions: Ambient Temperature = 25 C

 Effective cooling
 System output load = nominal value

2) Failure Rate Calculations based  MIL-HDBK-217F + Notice Feb.’95

upon:  Parts Stress Method
 Environment “Naval Sheltered” (Ns) at 25C
 CECC 00 801 document for CECC component data
 NPRD-91 document for non-electronic parts data

3) Reliability / MTBF modeling and  MIL-STD-756B

prediction based upon:  Mission reliability model
 Mission operating hours << Basic operating hours
 System parts subject to planned maintenance not
taken into account, assuming these parts are
maintained as recommended by EUROATLAS.

MTTR: EUROATLAS garantuees a system level Mean Time To

Repair of less than 1 hr. based upon the following
assumptions:

1) Calculation and prediction based upon:  MIL-HDBK-472, Procedure V, Method A.

 Intermediate Level Repair by “Remove & Replace”-
Method

2) Repair times of Line Replacable Units, using system fault detection & location < 20 Min.

3) Customer maintenance personnel participated in training course by EUROATLAS

4) Maintenance tasks and Fault-finding tasks are carried out according technical manual
instructions.

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