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ST155
STATIC CONVERTER SYSTEM
440V 60Hz / 440V 400Hz
2 x 90kVA

TECHNICAL SPECIFICATION

Function Name

Elaborated RD-US E. Terrasi

Checked QA V. Burgalassi

Approved RD-US G. Franzò

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REVISIONS

Rev.n° Description Date

R00 First issue 15/11/2018

R01 Added par. 6.6.4 18/12/2018

R02 Modified §4, §5.1, §6.1, §6.4, §6.6.1, §6.6.3, §7 18/01/2019

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DEFINITIONS AND ABBREVIATIONS

AC Alternating Current

BITE Built In Test

DC Direct Current

EC Eurocontrol

EMC Electromagnetic Compatibility

EMI Electromagnetic Interference

FAT Factory Acceptance Test

g Acceleration Of Gravity

HAT Harbour Acceptance Test

IEC International Electro-Technical Committee

I/O Input/Output

MNPC Multilevel Neutral Point Clamped

MTBF Mean-Time-Between-Failures

MTTR Mean-Time-To-Repair

NPC Neutral Point Clamped

PCB Printed Circuit Board

rms Root-Mean-Square

UPS Uninterruptable Power Supply

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INDEX
1 Scope ............................................................................................................ 5
2 Premises ....................................................................................................... 5
3 Quality Assurance ....................................................................................... 5
4 Design, Development and Qualification .................................................... 6
4.1 Standard References ................................................................................... 6
4.2 CE marking .................................................................................................. 7
4.3 Qualification ................................................................................................. 7
5 System description ...................................................................................... 8
5.1 Parallel operation ......................................................................................... 8
6 Panel description ......................................................................................... 9
6.1 Power Stage ................................................................................................ 9
6.2 Auxiliary power supply ............................................................................... 10
6.3 Control system ........................................................................................... 10
6.4 Local Interface ........................................................................................... 10
6.4.1 Local HMI ...........................................................................................................11
6.4.2 BITE ...................................................................................................................11
6.5 Remote Control (option - to be specified) .................................................. 12
6.6 Converters in parallel ................................................................................. 12
6.6.1 Multi parallel operation (option - to be requested)...............................................12
6.6.2 Automatic load management (option - to be requested) .....................................12
6.6.3 Load Transfer (option - to be requested) ............................................................12
6.6.4 External source enable.......................................................................................13
7 Electrical Data ............................................................................................ 14
8 Mechanical Data ......................................................................................... 15
9 Environmental Data ................................................................................... 16

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1 Scope
This specification establishes the composition, the performances, the functional and the
operational requirements of the ST155 system, composed by two identical static converters
identified as Eurocontrol part number Q953-ST155.

2 Premises
The present specification is the result of the merge of similar projects already delivered for
different naval applications. Most of them have been installed on submarines of various
Navies all over the world in the last ten years, other on board of mine hunters.

As an example, we are proud to be on board of the Walrus Class Submarines with our
equipment (3 x 60Hz converters 75kVA each + 2 x 400Hz 10kVA each) working in parallel
24hours per day since ten years ago without any failure and a few hours per year of
preventive maintenance.

3 Quality Assurance
Eurocontrol S.p.A. has implemented and maintains a Quality Management System which
fulfils the requirements of the standard ISO 9001:2015, certified by RINA accredited
ACCREDIA.
RINA CERTIFICATE N° 1226/98/S IQNet CERTIFICATE N° IT-5225

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4 Design, Development and Qualification

The design of the panel aims to satisfy the customer requirements in accordance to
international standards; as a result of the design phase a compliance matrix associated to a
design justification file could be provided to the customer together with a drawing pack
(installation drawing, main assembly drawing, electrical diagram, three dimension model of
the panel) and documentation related to the SW if required.
Particular attention is given to the selection of materials and components for flammability,
toxicity, strength in order to guarantee the maximum design life of the equipment and the
minimum maintenance time.
Most of the solutions, both HW and SW, adopted in the design of the equipment here
described, come from previous similar projects:
- the power stage of the AFE and the INVERTER adopts well known power
semiconductors modules already use in different qualified projects
- the PCBs are derived from the same reference projects
- the design of the chassis is derived from another cabinet with the same dimensions
installed on board of minehunters (Q646 for reference)
- in addition most components have already been adopted in the above mentioned
power converter (Q646) and many other equipment already qualified

4.1 Standard References

The documents listed in the following table are for reference only. Some of them (MIL-HDBK-
2036, for instance) cannot be used as a requirement, they are for guidance only. The last
valid revision of the documents stated below is considered. Specific requirements are
described in the pertinent chapter.

STANAG 1008 ED9 Characteristics of Shipboard Electrical Power System in

Warship of the North Atlantic Treaty Navies
MIL-STD-108 Definition of and basic requirement for enclosure for electric
and electronic equipment
MIL-STD-167-1 Mechanical Vibrations
MIL-HDBK-454 General Guidelines for Electronic Equipment
MIL-STD-461 Requirements for the Control of Electromagnetic Interference
Emissions and Susceptibility.

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MIL-STD-740-1 Airborne Sound Measurement

MIL-STD-740-2 Structure borne Vibratory Acceleration Measurements and
Acceptance Criteria of Shipboard Equipment.
MIL-STD-810 Environmental Test Methods and Engineering Guidelines.
MIL-STD-1310 Standard Practice for Shipboard Bonding, Grounding and
Other Techniques for Electromagnetic Compatibility and Safety
MIL-S-901 Shock Tests, H.I. (High-Impact) Shipboard Machinery,
Equipment, and Systems, Requirements for
MIL-STD-1399, Interface Standard for Shipboard Systems, Electric Power,
Section 300 Alternating Current. (Metric)
DOD-STD-1399, Interface Standard for Shipboard Systems, Ship Motion and
Section 301 Attitude. (Metric)
MIL-HDBK-2036 Preparation of Electronic Equipment Specifications
MIL-C-5015 Connectors, Electrical, Circular Threaded, AN Type

4.2 CE marking
In addition to the above mentioned rules, the design of the equipment is CE markable,
however because CE mark requires additional EMC and environmental testing it is not
expected to be CE marked if not requested from customer.

4.3 Qualification
Several Eurocontrol systems have been qualified in certified laboratories. Most of the
solutions (both HW and SW) adopted in the design of the system here described, comes
from previous similar projects, for this reason some qualification can be achieved by the
extension of previous testing, otherwise by demonstration or physical tests.
Due to the weight of the panel, shock requirement could be demonstrated by analysis, via
FEM analysis starting from the complete three dimensions model of the panel elaborated in
our premises, bolted connection verification and components certifications.
Eurocontrol has the necessary equipment to make pre-compliance EMC tests on its
premises and a full test for airborne noise.

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5 System description
The part number ST155 defines the system for the Hellenic Navy, composed by two identical
power converters identified as Q953-ST155.

Level Part Number Description

1 ST155 CONVERTER SYSTEM

2 Q953-ST155 CONVERTER 90KVA 440V 60HZ/400HZ 3PH

2 Q953-ST155 CONVERTER 90KVA 440V 60HZ/400HZ 3PH

5.1 Parallel operation

The two converters could operate
in parallel, sharing the load.

The two panels exchange data in

order to share the load and to know
the mutual status.

As per our experience it is strongly recommended to let the converters always run in
parallel, in fact:
- the product lifetime increases due to the fact that each converter works with a load
lower than nominal with a great benefit in terms of thermal management;
(please note that the design of the panel does not foresee any mechanical rotating
parts except the fans that are normally off; a thermal management based on different
thermal sensors and/or switches has been implemented in order to reduce airborne
noise and to increase fan lifetime);
- the continuity of service increases due to the fact that the total power is always
available and the probability of an overload is strongly reduced.

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6 Panel description

6.1 Power Stage

The architecture consists of an input stage provided with EMI filtering for decoupling the
converter from the ship supply and reducing the high frequency voltage components
generated by the carrier of the inverter.
The power contactor is commanded to be closed only after the end of the dc bus
precharge stage: on the front panel of the cabinet a three positions (OFF-ON-START) rotary
switch (here identified as S101) has been foreseen:
in the “OFF” position the contactor (K101) cannot be
closed; the third “START” is a momentary position;
the operator should hold, for less than 2 seconds,
the selector in this position to charge the dc bus.
Once the dc bus voltage is higher than the minimum
voltage of the “internal 24V power supplier” this last
will automatically starts; then the control system is
supplied and enables the input contactor to be closed; the operator then should release the
handle and the switch automatically goes to the intermediate and stable “ON” position. The
input contactor short-circuits the power contacts of the switch. One of the advantages of this
configuration is the absence of inrush current.
The AFE rectifier, responsible of the generation of a DC BUS, consists in a sinusoidal LC
filter and a configuration of six IGBT; the inverter stage adopts the same components of the
rectifier and an LC sinusoidal filter in output to prevent EMI pollution and reduce du/dt
transients on the trafo windings, that could affect the reliability of the trafo itself. The power
transformer has the double task to create the necessary input – output galvanic insulation
and to provide adequate output voltage. The transformer has an electrostatic shield between
primary and secondary winding.

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6.2 Auxiliary power supply

In case auxiliary power supply is not available it will be internally generated by means of an
auxiliary transformer placed inside of the cabinet, fed from the input line and protected by
means of a three poles fused switch (or automatic breaker if preferred). The auxiliary line
supplies internal fans and contactor coil.

6.3 Control system

The IGBT control comes from a DSP developed for this kind of applications.
The organization of the PCBs consists of the following main electronic cards:
- Power supply (DC/DC converter – 300W),
- MCU control board (The adopted DSP is a Texas TMS320F28335)
- I/O board,
- IGBT drivers
- Current and voltage sensors PCBs
The MCU control board is directly installed over the I/O Interface PCB and connected only to
that. The MCU control board is responsible for both power and logic management as
described in the next chapters.

6.4 Local Interface

By means of a three positions rotary switch (off/on/start) the operator can switch on the
converter, while to command the closing of the output contactor, if available, he should press
a virtual pushbutton on the touch panel1 (7 inches, TFT 65k colours equipped with a super
capacitor).
Automatically the display shows input and output data (voltage, current, frequency, power)
and even internal temperature measurements. A dedicated page shows the available active
alarms; another page could show the alarm history with the last BITE messages. Each
warning is numbered to avoid misunderstanding in communication between crew operator
and base assistance.
Different lamps are available to give the indication of mains line present and about the
general status of the cabinet and output.

1
In case of extreme environmental requirements the touch panel could be substituted by a mimic
associated to an LCD display.

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Next pictures shows an example of local interface of one of our power converter, in this case
an UPS provided with three rotary switches: for mains line, for battery line and for control
mode selection.

6.4.1 Local HMI

The local HMI is organized on different pages: on main page it is possible to monitor the
electrical data in input and in output, to know the general status by means of a virtual “SYS
OK/ALARM” lamp and to scroll on the other available pages.
A dedicated page shows the available ACTIVE ALARMS; another page could show the
ALARM HISTORY with the last 100 BITE messages. Each warning is numbered to avoid
misunderstanding in communication between crew operator and base assistance.
Another page is used for maintenance purposes and settings (i.e.: lamp test, language
selection, SW version info, I/O status).
In addition to English, multi-language support can be available on request.

6.4.2 BITE
The system Is provided with a Built In Test system that monitors all relevant data: a certain
number of messages are related to the input line (i.e.: phase sequence, phase presence,
voltage level, frequency range), to the output line (i.e.: overload, overvoltage, under voltage,
short circuit protection), to the internal devices (i.e.: thermal sensors, breaker status, igbt
check, dc bus voltage…..).
Messages are classified as warnings that do not cause any service interruption, or failures.
Both kind of alarm can be easily reset by means of the local interface, only if the cause is no
more active.
The complete list of BITE messages with associated corrective actions is provided in the
technical manual provided with the equipment.

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6.5 Remote Control (option - to be specified)

In order to be remote controlled the cabinet will be equipped with a dedicated rotary switch,
I/O card and related interface connectors. Different kind of communication protocols could be
provided in order to let the converter communicates with the ship communication system.

6.6 Converters in parallel

The converter is ready to operate in parallel with another one with same part number; by
means of a wired connection between them (it could also be an Ethernet cable), they
exchange control data and other general information in order to guarantee and maintain the
output waveform synchronized, in phase and an equal load repartition.
Please refer also to par. 5.1.

6.6.1 Multi parallel operation (option - to be requested)

The converter should operate in parallel with two similar converters; in order to work together
in parallel and to perform load repartition a wired connection is required but the system could
be upgraded via SW, without HW modifications.

6.6.2 Automatic load management (option - to be requested)

As a function of the power request the master converter should automatically “call” a second
converter to work in parallel and share the load in order to reduce its internal temperature,
guarantee a bigger available power to the load for transient requests, reduce airborne noise.
In the same way the master converter could command the slave converter to switch off. This
function is more effective in case of multi-parallel operation.
Another essential advantage of this function is the increased availability of the system, in
fact in case of failure of one converter the second could be automatically switched on with a
very short dead time (less than 100ms) and for those predictable failures, like over
temperature, the second converter will be connected in parallel in advance without
interruption on load side. The operator should also decide to “force” the status of each
converter.

6.6.3 Load Transfer (option - to be requested)

It is part of our experience (on board of Gaeta minehunters between our UPSs and the
bypass power line, on board of Walrus submarines between our static converters and the

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shore line) the load transfer functionality on both directions, ship to shore and vice versa,
with a transient parallel operation between our converters and an external source.
The converter should be temporary paralleled to an external source in order to transfer the
load to this last or to receive the load from the other equipment. This option requires the
adoption of a power contactor in the output stage of the converter and external sensors in
order to measure the external source voltage phase and level.

6.6.4 External source enable

Each converter power output contactor will be provided with one or two auxiliary normally
closed contacts.
By means of on board wiring it is possible to connect these contacts in the control circuit of
an external power contactor (K1 in the picture): only if both power converters are
disconnected from the 400Hz Ship Net it is possible to close K1.

Figure 1: simplified diagram for external power converter control

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7 Electrical Data

NOMINAL INPUT DATA

Voltage 440V 60Hz 3ph Stanag 1008 ED9

Power 95 kVA

Power Factor Cos phi 1

THD I < 3%

Current 125 Arms

Efficiency >92% @ > 50% load

OUTPUT DATA

Voltage 450V 400Hz 3ph Stanag 1008 ED9

Power 90 kVA

Power Factor Cos phi 0.8 … 1

Current

 Nominal 115 Arms

 Overload …..30 sec 128 Arms (100kVA)

 Overload ……5 sec 160 Arms (125kVA)

 Overload ……2 sec 200 Arms (155kVA)

 Max Peak Current 355 Apeak Crest Factor > 3

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8 Mechanical Data

Dimensions

Wide 1000 mm

Depth 600 mm

Height 1800 mm

Other Data

Weight Max 850 kg

Shock Mounts TBD 4 on the basement

TBD 2 stabilizer on upper rear side

IP Grade IP54 EN 60529

Cooling Air Forced by internal fans

5 kW max @ 90 kVA load

Mounting Hardware In accordance with MIL-STD-1225

Size and Weight In accordance with DOD-STD-1399 - Section 071

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9 Environmental Data

Environmental

Airborne Noise Grade A3 or B MIL-STD-740-1

Fungus In accordance with MIL-STD-810 - Method 508

Humidity 85% non-condensing MIL-STD-810 - Method 507

Ship Motion and Attitude Up to sea state 7 DOD-STD-1399 - Section 301

Shock Grade A MIL-S-901

Temperature 0…..+45°C @ nominal load

Max +60°C 15 minutes

Vibration Type 1 vibration MIL-STD-167-1

Materials

Parts LFH and Halogen free Cables and wiring accessories

PCB RoHs compliant

generally compliant to MIL-STD-454

Painting In accordance with MIL-STD-171

Processes In accordance with MIL-STD-454

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