www.bombardier.com
Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
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services – crO component re-engineering and Overhaul
every PArTcOunTs
*Trademark(s) of Bombardier Inc. or its subsidiaries.
POrTfOliO
Building on experience
In 2000 CRO was set up as part of our Services Division
at Bombardier’s largest site in Hennigsdorf, just outside
Berlin. Our highly specialized test facility and the expertise
of our specialists – pooling the knowledge resources of
the companies acquired by Bombardier Transportation –
provided a solid foundation for this new venture.
Working together closely with our clients our team
was able to acquire a deep understanding of your
requirements and to cooperatively develop innovative
solutions to meet the challenges and specifications of your
everyday needs. As a result we are able to offer products
and services which meet the ever-increasing demands of
railway operators especially in matters of fleet availability.
We have committed staff offering comprehensive support,
from error diagnostics to repair works/overhauls right
the way through to the final testing of the components
(including documentation with reports and certificates).
Our portfolio covers a range of services, from the overhaul
and modernization of components to maintenance/
revisions, inspections/reports, testing and repairs of all
kinds, to complete rebuilding/redesign of components
which have gone out of production.
We currently carry 1100 different standard products, a
clear indicator not just of the variety we offer, but also
of our flexibility. Our customers benefit from our broad
experience and the proven competence gained in many
successful national and international projects.
space and equipment
Covering an area of 2,700 m2 our production hall is
equipped with complete infrastructure and overhead
crane lifts for up to 5 t, as well as facilities for handling
various liquids.
In addition we have a 1000 m2 power electronic test
facility incl. equipment room with voltage supply sources,
loads, data processing technology, safety engineering and
ventilation technology.
sophisticated test facility
On our numerous individual test stations we test your
products under operational conditions. To this end we
also use freely programmable control systems and set
up automatic testing procedures. Tests can be carried
out using all supply voltages commonly used for railway
applications (AC, DC, 16 2/3 Hz) and the necessary freely
configurable loads.
main competencies
• Overhaul (also preventiv)
• Repair / troubleshooting / commissioning (also on site)
• Maintenance (revisions)
• Modernization
• New/Rebuilt
• Obsolescence management
• Replacement of DOS services software by up-to-date Windows
applications (BOMBARDIER* DAVIS*)
• Testing contracts
• Special cleaning of components
main products
• Traction converters / inverters (type DASI, DASU)
• Auxiliary converters (type HBU, DBU, BUR)
• Converter modules
- Locomotive modules (oil-cooled valve sets)
- Choppers
- Rectifiers, Inverters
- Battery chargers
• Control units
- Printed circuit boards
- Diagnosis software and diagnosis units
• Electromechanic components
- High-speed circuit breakers
some of our customers are
• Deutsche Bahn (Germany)
• S-Bahn Berlin/ S-Bahn Hamburg/ S-Bahn München (Germany)
• BVG Berlin (Germany)
• Dresdner Verkehrsbetriebe (Germany)
• Magdeburger Verkehrsbetriebe (Germany)
• Erfurter Verkehrsbetriebe (Germany)
• Essener Verkehrs AG (Germany)
• Verkehrsbetriebe Zwickau (Germany)
• SBB (Switzerland)
• NSB (Norway)
• Linzer Lokalbahn ÖBB (Austria)
• Wiener Linien (Austria)
• ESL Eurotunnel (France/ United Kingdom)
• RENFE (Spain)
• CFL Luxemburg
• MTR Hong Kong (China)
• New Jersey Transit (USA)
• MTAB Kiruna (Schweden)
• RZD (Ru)
• Ampang Line – Kuala Lumpur/ Malaysia
services – crO Component Re-engineering and Overhaul
S-Bahn Berlin Series 481
U-Bahn Berlin Series H
EMU ICE3
RIC Passenger Coach WLAB
tramway Dresden NGT6DD
POrTfOliO
Building on experience
In 2000 CRO was set up as part of our Services Division
at Bombardier’s largest site in Hennigsdorf, just outside
Berlin. Our highly specialized test facility and the expertise
of our specialists – pooling the knowledge resources of
the companies acquired by Bombardier Transportation –
provided a solid foundation for this new venture.
Working together closely with our clients our team
was able to acquire a deep understanding of your
requirements and to cooperatively develop innovative
solutions to meet the challenges and specifications of your
everyday needs. As a result we are able to offer products
and services which meet the ever-increasing demands of
railway operators especially in matters of fleet availability.
We have committed staff offering comprehensive support,
from error diagnostics to repair works/overhauls right
the way through to the final testing of the components
(including documentation with reports and certificates).
Our portfolio covers a range of services, from the overhaul
and modernization of components to maintenance/
revisions, inspections/reports, testing and repairs of all
kinds, to complete rebuilding/redesign of components
which have gone out of production.
We currently carry 1100 different standard products, a
clear indicator not just of the variety we offer, but also
of our flexibility. Our customers benefit from our broad
experience and the proven competence gained in many
successful national and international projects.
space and equipment
Covering an area of 2,700 m2 our production hall is
equipped with complete infrastructure and overhead
crane lifts for up to 5 t, as well as facilities for handling
various liquids.
In addition we have a 1000 m2 power electronic test
facility incl. equipment room with voltage supply sources,
loads, data processing technology, safety engineering and
ventilation technology.
sophisticated test facility
On our numerous individual test stations we test your
products under operational conditions. To this end we
also use freely programmable control systems and set
up automatic testing procedures. Tests can be carried
out using all supply voltages commonly used for railway
applications (AC, DC, 16 2/3 Hz) and the necessary freely
configurable loads.
main competencies
• Overhaul (also preventiv)
• Repair / troubleshooting / commissioning (also on site)
• Maintenance (revisions)
• Modernization
• New/Rebuilt
• Obsolescence management
• Replacement of DOS services software by up-to-date Windows
applications (BOMBARDIER* DAVIS*)
• Testing contracts
• Special cleaning of components
main products
• Traction converters / inverters (type DASI, DASU)
• Auxiliary converters (type HBU, DBU, BUR)
• Converter modules
- Locomotive modules (oil-cooled valve sets)
- Choppers
- Rectifiers, Inverters
- Battery chargers
• Control units
- Printed circuit boards
- Diagnosis software and diagnosis units
• Electromechanic components
- High-speed circuit breakers
some of our customers are
• Deutsche Bahn (Germany)
• S-Bahn Berlin/ S-Bahn Hamburg/ S-Bahn München (Germany)
• BVG Berlin (Germany)
• Dresdner Verkehrsbetriebe (Germany)
• Magdeburger Verkehrsbetriebe (Germany)
• Erfurter Verkehrsbetriebe (Germany)
• Essener Verkehrs AG (Germany)
• Verkehrsbetriebe Zwickau (Germany)
• SBB (Switzerland)
• NSB (Norway)
• Linzer Lokalbahn ÖBB (Austria)
• Wiener Linien (Austria)
• ESL Eurotunnel (France/ United Kingdom)
• RENFE (Spain)
• CFL Luxemburg
• MTR Hong Kong (China)
• New Jersey Transit (USA)
• MTAB Kiruna (Schweden)
• RZD (Ru)
• Ampang Line – Kuala Lumpur/ Malaysia
services – crO Component Re-engineering and Overhaul
S-Bahn Berlin Series 481
U-Bahn Berlin Series H
EMU ICE3
RIC Passenger Coach WLAB
tramway Dresden NGT6DD
SERVICES
MAINTENANCETraction Converter DASU 7.1
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The S-Bahn Berlin is operating 500 2-car trains
of the 481 series. The traction converters type
DASU 7.1 are used as a GTO traction inverter,
which consists of one inverter container and
one resistance container per 2-car unit. A full
train set consists of four 2-car units.
Since 2001, Bombardier has been contracted to provide
the maintenance of the traction converter, type DASU 7.1.
To date, more than 600 maintenance cycles have been
performed. The maintenance work on the inverter
container and the resistance container can be completed
within five days. Finally, the electrical functionality of the
traction converter is tested.
Technical data – DASU 7.1
Feed-in via conductor rail Polarity negative
• Nominal voltage UNom
= 750 V DC ± 33 1/3 %,
• Maximum line current (driving) Ilinemax
= 900 A
• Maximum line current (braking) Ireversemax
= 1800 A
Output Pulse inverter for supplying
six traction motors
• Output current (operational cycle) IA = 795 A
eff
• Max. output current Imax
= 2000 A eff
• Max. cut-off current in operation Imax
= 3600 A
• Output voltage UA = 0 ... 530 V
• Output frequency fA = 0 ... 125 Hz
• Max. pulse frequency phase module fP = 450 Hz
Brake controller
• Pulse frequency of the brake fB = 250 Hz
controller module
Cooling forced-air cooling
Air speed at the heat sink vL = 8 m / s
Technical data – S-Bahn series 481
Quantity 500 2-car units
Manufacturer AEG/ Adtranz/ Bombardier
Hennigsdorf, DWA/ Bombardier
Halle
Years of manufacture 1996 -2004
Traction output 594 kW
Max. starting acceleration 1,0 m/s2
Braking rate 1,3 m/s2
Motor type Three-phase current
Power system 750 V
Current transmission conductor rail, on the side,
contacted from below
Number of traction motors 6
Gauge 1435 mm (-5 mm / + 30 mm)
Tare weight 59.0 t
Maximum permitted speed 100 km/h
www.bombardier.com
MAINTENANCE
DASU 7.1
Scope of services
• Incoming inspection
• Special cleaning of the entire traction converter
DASU 7.1
• Disassembly
• Maintenance work
- Repair or refurbishment of phase modules, brake
controller and drain circuit module
- Inspection of main contactor
- Inspection and, if necessary, replacement of cables
and plug connections
- Fan replacement
- Performing necessary repairs to all container
components (electrical/mechanical)
• Assembly and automatic function test by modelling a
complete operational cycle
• Issue appropriate certificate
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
OVERHAULPower supply converter systems for passenger coaches for RZD
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
In 1994, Bombardier produced the WLAB200
coaches for RZD according to RIC standards in
Görlitz. The overhaul significantly improved
the reliability of the customers’ fleet
consisting of 85 coaches. As a result, the
coaches will be able to travel through Western
Europe for another 15 years.
In December 2010, Bombardier was contracted to
provide the overhaul of 85 converter sets which are
supplying energy to the WLAB200 coaches.
Every two days, a complete converter set consisting
of a five-system converter, an auxiliary converter and
two equipment boxes was completed. 55 coaches were
ready by December 2011, when the Moscow – Berlin –
Paris line was re-opened. By May 2012, all 85 coaches
had been modernized. As part of the modernization of
the auxiliary converter, the GTO inverter was replaced
by an IGBT inverter. The five-system converter is able
to handle the different voltages (conforming to UIC) of
the train power supply line as required. The auxiliary
converter supplies the air conditioning system and
other consumers with energy.
Technical data – Five-system converter FSU 1.1
Input voltage 1,500 V DC
(in accordance with UIC Standard) 3,000 V DC
1,000 V; 16 2/3 Hz
1,500 V; 50 Hz
3,000 V; 50 Hz
Output voltage 520 – 600 V
(Sinus or square-wave voltage) 220 – 240 V
Output voltage battery charging unit 110V DC; 8kW
Output power 45 kVA
Dimensions (WxHxL) 2.80 x 0,60 x 1.80 m
Weight 1,860 kg
Technical data – Auxiliary converter DWR 8.1
Input voltage 520 – 600 V
Output voltage 3 x 169 – 264 V; 27 – 60 Hz
Output power 23 kVA
Dimensions (WxHxL) 2.20 x 0,60 x 0.90 m
Weight 625 kg
Technical data – RIC Coaches WLAB200
Manufacturer Bombardier (formerly
Waggonbau Görlitz)
Initial commissioning 1993 - 1994
Design speed 200km/h on the UIC grid
160 km/h RZD
Fleet size 85 cars, of those
• 46 cars with 33 seats
• 18 cars with shower with 30 seats
• 21 VIP cars with 8 seats
Length 26.40 m
Width 2.87 m
Height 4.25 m
Tare weight 56 t
www.bombardier.com
Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
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OVERHAUL
POWER SUPPLY CONVERTER
SYSTEM
Scope of services
• Incoming inspection
• Disassembly and special cleaning of the converter sets
• Refurbishment and repair of the containers
• Replacement of all cables
• Modernization of the control unit and the high-voltage
dial device
• Replacement of defective, obsolete and unusable
components (transformers, capacitors, fuses,
fans, etc.)
• Replacement of GTO inverter by an IGBT inverter
• Assembly, commissioning and testing
• Issue appropriate certificate
FSU 1.1 in the testfield
DWR 8.1
Detail from FSU 1.1
SERVICES
OVERHAULTraction converter modules ALP 46
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
In the USA, the Bombardier ALP series has
been successfully used for passenger transport
for many years. The first ALP 46 series were
delivered from 2001 to 2002. They usually run
in combination with double-deck coaches.
The transport company New Jersey Transit is
operating 29 of these locomotives.
In 2011, the operator decided to overhaul 58 traction
modules in order to improve the vehicles’ availability.
From 2011 to 2012, the modules were overhauled by
Bombardier. The ALP46 has two traction converters
with four inverters operating as a group drive. The
two traction motors of each bogie are supplied by one
inverter. As a result, the two remaining inverters can be
used to supply the train bus bar as well as the auxiliaries
of the locomotive. Since the overhaul, the modules have
achieved 100% availability. The modules that have not
been retrofitted yet are planned to be overhauled.
Technical data – Traction module (inverter)
Technology GTO thyristors
Nominal DC link voltage 2800 VDC
Commutable current 2300 A
Max. average switching frequency 300 Hz
Max. line voltage 2184 V
(fundamental oscillation effective value)
Max. output current 1050 A
Coolant Polyolester
Installation position vertical
Height 1108 mm
Depth 727 mm
Width 472 mm
Weight (incl. coolant) 360 kg
Technical data – Locomotive ALP 46
Number of locomotives 29
Output 5.3 MW
Voltage systems 25 kV 60 Hz
12.5 kV; 60 Hz
12 kV; 25 Hz
Tractive force at starting 316 kN
Length 19,498 mm
Width 2,950 mm
Height 4,490 mm
Max. speed 161 km/h
www.bombardier.com
OVERHAUL
ALP 46
Scope of services
• Cleaning and disassembly
• Removal of passive and active power electronics
• Replacement of switchable power semi-conductor
components
• Modification of the gate driver
• Repair of damaged components
• Assembly
• Functional testing with full load test
• Issue appropriate certificate
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
OVERHAULTraction converter UW 2423-2803
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The Eurotunnel Group (ET) provides a fast and
efficient rail service between Cheriton
(England) and Coquelles (France) on a 50 km
stretch beneath the English Channel. The ET
5.6 MW locomotives are equipped with
sophisticated electrical components.
In August 2006, Bombardier was contracted to
provide the overhaul of 51 traction converters of these
locomotives. The overhaul was completed in February
2009. In the first stage, the traction converters were
removed from each locomotive, subjected to a special
cleaning process and completely disassembled.
Then, the wires were replaced and the individual
components were overhauled. After reassembly, a
final leak test on the cooling circuits (oil) and the
electrical functionality test of the traction converter
were performed. Every eight weeks, the service team
completed the overhaul of three converters.
Technical data – UW 2423-2803
Maximum output power 2000 kW
Maximum power dissipation 90 kW
Cooling method Mineral oil circuit
Maximum output current 862 A
Output voltage
• Effective value 0 … 2200 V
• Output frequency 0 … 139.3 Hz
Input voltage of the H-bridge
• Nominal value 1200 x 2 V
• Peak value 1600 V
Pulse frequency 250 Hz
Input frequency, Nominal value 50 Hz
Voltage in the DC link current 2200 … 2800 V
Resonance frequency 100 Hz
DC link circuit
• Maximum input current 920 A
• Inverter frequency 0 … 200 Hz
Weight including oil 2600 kg
Technical data – Locomotive
Gauge 1435 mm
Maximum slope in tunnel 11°
Stretch length 55 km
Nominal weight of the train 2100 t (plus 2 locomotives
weighing 136 t)
Train length 800 m
Power supply alternating current single-phase
Line frequency 50 Hz
Catenary nominal voltage 25 kV
Wheel arrangement Bo’Bo’Bo’
Maximum speed 160 km/h
Design speed 175 km/h
Number of traction motors 6
Continuous traction force 310 kN
Based on a speed of 65 km/h
Tractive force maximum 400 kN
www.bombardier.com
OVERHAUL
UW 2423-2803
Scope of services
• Disassembly of the traction converter
• Special cleaning of the entire traction converter
• Valve set overhaul incl. leak test
• Coupling overhaul
• Contactor overhaul
• Inspection of the DC link capacitors
• Replacement of the entire wiring
• Leak test for the entire traction converter
• Function and light load test
• Issue appropriate certificate
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
REPAIRSTraction Converter ET474
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The S-Bahn Hamburg is operating 103
vehicles of the ET474 series. The vehicles were
delivered between 1996 and 2001. Traction
converters type 13SG36 are used to supply the
traction motors.
Since 2006, the converters of the S-Bahn Hamburg have
been repaired by Bombardier. These repair services
also include the complete overhaul of the converters.
Obsolete or defective components are being exchanged
and the complicated cooling circuit thoroughly cleaned.
Before delivery, all traction converters undergo a
complete testing, i.e. the functionality as well as the
thermal stability of the system are tested by modelling a
complete operational cycle.
Technical data – traction converter
Type 3-phase inverter with brake
controller
Technology GTO thyristors
Nominal input voltage 1200 VDC
Input voltage tolerance -30% + 20% (temporarily +30%)
Output voltage 936V (max. line voltage, base
oscillation effective value at UN)
Output current approx. 1000A (base oscillation
effective value)
Dimensions (W x D x H) 1190 x 595 x 540
Weight without coolant 328 kg ± 3%
Cooling system Liquid cooled
Technical data – S-Bahn Hamburg
ET474
Quantity 224 rail cars (ET); 70 inter-
mediate cars (EM) (474.1+2);
42 intermediate cars (EM) (474.3)
Manufacturer Traction equipment: Adtranz,
now Bombardier
Mechanical parts: LHB, now
Alstom Transport Germany
Year(s) of manufacture 1996 - 2001 / 2006
Power system 1200 V DC (474.3 plus
15 kV 16.7 Hz AC)
Current transmission Conductor rail on the side,
contacted from the side (474.3
additionally from the catenary)
Number of traction motors 8
Track width 1435 mm (Normal track)
Length over the coupling 66,000 mm
Height 3,720 mm
Width 3,008 mm
Tare weight 100 t (474.1); 94 t (474.2);
106 t (474.3)
Maximum speed 100 km/h
Hourly output 920 kW
Acceleration 1.0 m/s2
Brake delay 0.7 m/s2 (electrical brake);
1.2 m/s2 (rapid braking)
www.bombardier.com
REPAIRS
13SG36
Scope of services
•Incoming inspection
•Dismounting of main components
•Special cleaning of all components
•Cleaningandflushingthecoolingcircuitofthetraction
converter
•Removal of defective components or modules
•Replacement of all sealings, especially in the cooling
circuit
•Installation of all components
•Testing of cooling circuit
•Complete electrical test under nominal conditions
•Test/repairreportandissueappropriatecertificates
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
MODERNIZATIONTraction Converter 13SG31
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
From 2013 until 2014, 52 inverter modules
type 13BH15 of the 13SG31 were upgraded to
IGBT technology for the Dresden transport
authority (DVB). In addition to a higher
availability rate, the lifetime of the modules
was increased and the maintenance
intervals extended.
Numerous vehicles of different operators are equipped
with converters type 13SG31, which include two inverter
modules type 13BH15 manufactured by Bombardier.
Due to the obsolescence of the semi-conductors,
a retrofit solution was implemented. In the scope
of this technical solution, patented by Bombardier,
the obsolete transistor modules were replaced by
mechanically compatible IGBT modules. The gate
drive units were replaced by a corresponding IGBT
drive unit. A special adaptation of the power sections
ensures the operation of the existing traction motors
without additional switching equipment. This plug and
play solution ensures that all mechanical, electrical
and optical-electrical interfaces are fully compatible
with the old inverter module, using bipolar technology.
Due to 100% identical functionality, a combined
operation of the inverter modules can be guaranteed.
Technical data – Traction Converter 13SG31
Input voltage 600 / 750 VDC
Input current 2 x 83 A
Auxiliary voltage 24 VDC (+20% - 30%)
Output voltage 0 … 560 V
Nominal output current 2 x 200 A
max. output current (t < 20 s) 2 x 420 A
Output frequency 0 … 200 Hz
max. switching frequency of the 500 Hz
IGBT modules
Brake chopper nominal current 200 A
Max. permitted brake 600 A
chopper current
Permitted continuous power 2 x 14 kW
of brake resistor
Coolant 1 56% Water, 44% anti-freeze N
Coolant flow rate 16 l (8 l per WR module)
Max. coolant temp. at heat 55 °C
exchanger output
Coolant 2 Air
Flow rate 0.8 – 1 m3/s
Max. air intake temp. 40 °C
Technical data – NGT 6 DD
Quantity 47 Unidirectional car
13 Bidirectional car
Manufacturer DWA Bautzen
Year(s) of manufacture 1995 - 1998
Tare weight 33.4 t / 34.5 t
Maximum speed 70 km/h
Traction output 4 x 95 kW = 380 kW
Number of traction-motors 4
Power supply system 750 VDC
www.bombardier.com
MODERNIZATION
13BH15
Scope of services
• Incoming inspection
• Disassembly of the converter module
• Installation of new IGBT modules
• Mounting of new copper bars
• Installation of new IGBT Gate Unit
• Complete functional test
• Issue appropriate certificate
Traction converter 13SG31
Inverter module 13BH15
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
MODERNIZATIONAuxiliary Converter DBU 02.03.1
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The DBU 02.03.1 supplies the auxiliaries of the
Vienna subway vehicles on the U1/U11 line.
By modernizing the auxiliary converter and
replacing obsolete components, the life cycle
and the availability of the components were
significantly increased.
After the successful testing of a modernized DBU
prototype in 2013, Bombardier was contracted with
the modernization of 20 DBU02.03.1. Currently, several
devices are in daily operation. This solution offers the key
advantage that all electrical and mechanical interfaces
can be retained. The power supply unit with IGBT semi-
conductors is equipped with the latest technology.
In addition, the existing control unit only requires
slight adjustments to the new power device. By using
a new switching technology, a considerable number of
components have become redundant which leads to a
significant weight reduction of the entire device. The
low-inductive design of the power device and the newly
adapted wiring also prevents negative impacts on the
interference current of the unit. The special adaptation
of the power device ensures unrestricted operation of
all DBU consumers. In addition, there is an option of
equipping all modernized devices with a diagnostic unit
to store failures.
Technical data – DBU
Input voltage 750 VDC +30 % / -30 %
Output voltage UA1
3 x 380V / 220V 60Hz
Output power 43 kVA
Output voltage UA2
110 VDC
Output power 8 kW
Output voltage UA3
24 VDC
Output power 4 kW
DC link voltage UZK
490 VDC
Switching frequency WR-IGBT 60 Hz, block control
Switching frequency Chopper IGBT 500 Hz
Cooling method forced air cooling
Dimensions (L x W x H) 1300 mm x 800 mm x 650 mm
Weight 435 kg
Technical data – U1/U11
Drive 8 x 125 kW alternating current
asynchronous motors
v/max 80 km/h
Current infeed 750V 3. Rail
Motor output 1000kW / 1360 PS
Track width 1435mm
Weight 56000 kg
Seats 98
Standing space 182
www.bombardier.com
MODERNIZATION
DBU
Scope of services
• Cleaning and disassembly
• Setting up a new power section using IGBT technology
• Removing redundant components (e.g. commutation
inductor)
• Rewiring and modifying the wiring layout
• Adapting existing control unit to the new power device
• Preparing the control unit for an additional diagnostic
unit
• Repair of damaged components
• Assembly
• Performing a full load test
• Issue appropriate certificate
New Power Section
DBU
Replaced Power Section
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
MODERNIZATIONAuxiliary converter HBU
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The ICE1 has been in operation since 1991.
A comprehensive modernization project of
various systems and components was initiated
in order to align the components and vehicle
lifetime by replacing obsolete elements, addi-
tionally resulting in an increased availability.
In August 2006, Bombardier was contracted to
provide the modernization of 60 HBUs types 9.1, 9.2
and 10. After a completion period of only one year,
the project was finalized in 2008. In the scope of
the modernization project, the ventilation system
was optimized and equipped with heat pipes which
prevent the contamination of the interior. In addition,
the power unit was equipped with IGBT technology
and the diagnostic unit was renewed. This plug and
play solution guarantees unrestricted operation of
all consumer units. Within 15 days, three HBUs have
been cleaned in a special procedure and modernized
afterwards. The operator benefits from a significantly
lower maintenance effort and an increased reliability of
the HBUs. Safe and efficient operation of the ICE1 fleet
is guaranteed for years to come.
Technical data – HBU
Input Voltage 885 V +27% / -20%, 16,7 Hz
Output voltage 440 V max. square-wave
Output frequency 60 Hz max.
Output Power 65 kVA
Dynamic Overload
• DC link voltage 700 V
• Inverter input current 300 A
• Cooling AF
• Main Blower of HBU 440 V / 60 Hz, 1,4 kW
• Blower of Control Unit 220 V / 50 Hz, 3 x 20 W
• Auxiliary voltage 110 V +25% / 30%
Diagnosis Unit
• Digital inputs level 0V / +24 V
• Number max. 16
• Analog inputs level 0V … +10 V
• Number max. 8
Sampling cycle
• Digital 20 ms
• Analog 160 ms
Max. error memory (ring buffer) 100
Serial interface RS 232
Connection piece Spring-loaded terminals
Technical data – ICE 1
Quantity 59 sets (60 built)
Manufacturer AEG, ABB, Henschel, Krauss-
Maffei, Krupp, Siemens etc.
Year(s) of manufacture 1989 to 1993
Tare weight 849 t (12-car train after retrofit)
Maximum speed 280 km/h
Traction output 2 x 4800 kW
Tractive force on starting 400 kN
Number of traction motors 8
Power supply system 15 kV / 16.7 Hz
www.bombardier.com
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MODERNIZATION
HBU
Scope of the services
• Disassembly and special cleaning of the HBU
• Installing an improved cooling system (heat pipe)
• Replacing the thyristor inverter with an IGBT inverter
• Installing a new diagnostic unit
• Replacing the DC-link circuit for the electrolyte
capacitors
• Replacing the control unit fan
• Assembly and complete functional test
• Issue appropriate certificate
Module before/ module after (from left)
Auxiliary converter
Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
NEW CONSTRUCTIONAuxiliary Converter H-BUR 3x04A-110-B
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The IORE locomotives have been in service by
the Swedish operator MTAB since 2000. They
are the most powerful electrical locomotives in
the world (2 x 5400 kW) and are operating in
double traction to transport iron ore from the
world’s largest iron ore.
As part of the construction project for the new “Kiruna”
locomotives, Bombardier produced 16 auxiliary conver-
ters type H-BUR 3x0,4A-110-B based on documentation
from the original manufacturer. Since the entire fleet of
17 double locomotives were equipped with the same
type of auxiliary converter, the availability, quality and
reliability of the system can be guaranteed. In addition,
the identical stock of spare parts and maintenance work
lead to significant savings.
There is an option for six more locomotives in 2014.
Technical data – H-BUR-3x04A-110-B
Input
• Input voltage 400 VAC (280 … 500 V)
• Input frequency: 16 2/3 Hz
• Nominal power 100 kW
• Power factor > 0.98
• Max. input current 360 A
• Auxiliary voltage 110 VDC (+20% - 30%)
3 three-phase current outputs
• Max. output power 110 kVA (3 channels)
• Output voltage 400 V (± 5 %)
• Nominal output current 160 A
Output frequency
• 2 variable-frequency channels 5 … 50 Hz (± 1 Hz)
• 1 fixed-frequency channel 50 Hz (± 1 Hz)
Battery charging
• Max. output power 16,3 kW
• Nominal voltage 110 VDC
Temp.-dependent charging voltage 100 VDC … 136 VDC
Nominal charging current 120 A
Temperature measurement 2 x PT100
Cooling system
• Coolant 56% Water, 44% Antifrogen N
• Coolant temperature -40 °C … +60 °C
• Coolant flow rate 2 x 35 l/min
Weight 2.4t
Technical data – IORE
Quantity 17 dual-locomotives
Manufacturer ADtranz, Bombardier
Year(s) of manufacture 2000 - 2004, 2009 - 2010,
2013 - 2014
Tare weight 2 x 180 t
Maximum speed 80 km/h
Traction output 2 x 5400 kW
Tractive force on starting 2 x 700 kN
Number of traction-motors 2 x 6
Power supply system 15 kV / 16.7 Hz
www.bombardier.com
Scope of services
• Assembly of subassemblies
• Setting up the entire cabinet system
• Assembly and wiring of the overall device
• Complete functional test, i.e. max. load test under real
conditions
• Test reports of the individual modules and the entire
device
• Issue appropriate certificate
Auxiliary Converter
NEW CONSTRUCTION
H-BUR 3X04A-110-B
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
NEW CONSTRUCTIONAuxiliary converter 240-75
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The EL 2 electric locomotive, weighing 100t,
was constructed by LEW (Lokomotivbau-
Elektrotechnische Werke) in 1953.
It usually pulls 16 coal waggons with a total
weight of 1600t on the LAUBAG AG rail
network. In 2010, the EL2 of LAUBAG AG
was modernized.
Between February 2009 and May 2010, seven
auxiliary converters type 240-75 were produced
according to the contract with LAUBAG.
Since the entire fleet was equipped with the
same type of auxiliary converter, the consistent
stock of spare parts and identical maintenance
efforts resulted in cost savings, guaranteed
quality and increased system reliability.
Technical data – H-BUR 240-75
Type auxilliary power supply with
battery charging and external
supply
Line voltage range DC -1,600 V to -3,000 V
Output voltages
• DC 24 V for battery-charging and onboard supply, 12 kW
• 3 AC 400 V without neutral, 75 kW
• 3 AC 400 V with neutral, 11kVA
Excitation for the DC machine 48 V / 240 A
Cooling liquid-cooled
Technical data – EL2
Manufacturer LEW
Years of manufacture 1952 - 1988
Gauge 1435 mm
Starting tractive effort 294 kN
Total weight 100 t
Maximum speed 65 km/h
One-hour rating 1400 kW
Traction DC DC converter 2
Number of traction motors: 4
Electric-Brake Line regenerative and
rheostatic type
www.bombardier.com
NEW CONSTRUCTION
H-BUR 240-75
Scope of services
• Assembly of the subcomponents
• Assembling and wiring the overall device
• Complete functional test: full load test under real
conditions.
• Test reports of the individual modules and the entire
device
• Issue appropriate certificateH-BUR 240-75
Module H-WRE261.1
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +49 3302 89 2088
SERVICES
SERVICE SOFTWAREBOMBARDIER DAVIS
COMPONENT RE-ENGINEERING AND OVERHAUL (CRO)
The BOMBARDIER* DAVIS* software allows
the data memory on rail vehicles to be quickly
and easily read out. The service software is of
central importance for the diagnosis and
maintenance of control units and
converters on rail vehicles.
Bombardier DAVIS is a user friendly service software
that enables the operator to read out error logs. It
replaces and integrates various older DOS applications
such as PDA-Info, Bedien, HSP_DIAG and GARREG,
allowing data to be transmitted to computers with later
versions of Windows. In addition, with the help of the
DAVIS software, the process data of the control unit can
be parameterized. Bombardier supports its customers
with implementing the software and provides technical
support for the evaluation.
www.bombardier.com
SERVICE SOFTWARE
BOMBARDIER DAVIS
References
•City rail Ampang Line in Kuala Lumpur
•City rail BR 481 in Berlin
•Subway T2000 in Oslo
•City rail GT6 in Zwickau
•City rail GT6 in Mainz
BOMBARDIER DAVIS
•supports Windows XP, Windows Vista, Windows 7,
Windows 8 / 8.1
•replaces the DOS programs PDA-Info, Bedien,
HSP_DIAG and GARREG
•supports RS232 adapter for USB, PCMCIA, Bluetooth
and WLAN
•allows parallel processing of several control units and
devices
•is easy to operate using the mouse or touchpad with a
parallel, active keyboard
•allows control of the access rights via 3 user levels incl.
password protection
•accelerates reading out the process data memory
•allows automatic generation of years for control units
without year recording
•displays the process data in separate histories and
statuswindowsincludingapplication-specifichelptext
for the diagnosis
•supportsblackboxfunctionincludinggraphical
evaluation
•includesanexportfunctionfortheprocessdata,
e.g.intoMicrosoftExcel
•provides graphical presentation and adjustment of
process variables
•can be started multiple times and thus allows the
process data for several control units to be read out
and evaluated simultaneously
*Trademark(s) of Bombardier Inc. or its subsidiaries.
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Bombardier Transportation
Am Rathenaupark
16761 Hennigsdorf
Germany
Phone +49 3302 89 0
Fax +493302892088