Modernisation of suburban railcars of the 560 series

The aim of the project is to replace the aging parts of the electrical equipment of the suburban pantograph units of the 560 series. The parts that remained there are the original main transformer, traction motors and pneumatic switches changing direction and the modes of drive and brake. The following parts were completely replaced: traction inverters, regulators of traction drives, and inverters of the auxiliary drives.

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Basic features of POLL share in the project:

  • Design of the power scheme of traction converters.

  • Design and manufacture of regulators of traction converters. Complete software development.

  • Design and production of AC/DC converters of 230V AC/ 560V DC to supply inverters of auxiliary drives.

Each traction converter serves to supply one traction motor. Each motor drives one underframe of the electric unit. There are altogether four traction converters on one multiple unit usually consisting of two electric carriages and four carriages loaded. The traction converters are based on the IGCT thyristors from the production of ABB (formerly Polovodice). In the drive mode, the traction motor is supplied with the maximum voltage of 800V and the maximum current of 1100A. The input H-bridge of the traction inverter optimises the shape of the current drawn from the trolley wire. In the brake mode, the involvement of the traction converters ensures the EDB braking almost until the complete stoppage. The motor field-weakening happens in the drive as well as the brake modes continuously.

Each traction converter is controlled by its own regulator. There are always two controllers placed in one common chassis, but they function independently. The regulators regulate currents and voltages of the traction converters according to engineer’s input, they control the pneumatic switches of the drive and brake modes, they control the intensity of cooling of the traction converters, and they prevent wheel slips and skids. The algorithms of the software are optimised to ensure the least possible amount of ripples in the current from the trolley wire and they ensure the elimination of interfering reverse currents at frequencies that use rail circuits of the train protection system.

The first electric unit of 560 007-7 was reconstructed in Pars Sumperk. The revitalisation and testing took place in DKV Brno. In 2004, design tests were conducted in ZZO Cerhenice. By 2010, six multiple units (12 electric railcars) of the 560 series were reconstructed this way.

POLL, s.r.o.

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