Newag’s Dragon Locomotives Powered By ABBCombining their international experience with know-how gained during fiftyyears of modernisation and repair works of the rolling stock as well as with theirown market research, designers from Newag Gliwice have created the firstmodern Polish-built electric locomotive for hauling heavy freight trains adaptedto the needs of the Polish market.

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On 29 January 2014 both Dragonvariants met at Newag Gliwiceworks, positioned outside the test-ing hall. On the left is E6ACT-005,the first for LOTOS Kolej, and on theright E6ACT-002, destined for STKof Wrocław. At that time, LOTOSKolej’s E6ACT-006 and 007 loco-motives were in the final assemblystages.

Photo: Maciej Duczyński,Newag Gliwice

The design phase on Dragon proj-ect started in 2006 with the goal to build a powerful, safe, attractivelypriced, economical, well equippedlocomotive, using state-of-the-art tech-nologies. Its prototype, E6ACT-001,was presented on the TRAKO fair in2009 and started homologation testsin March 2010. Then the prototypemade its wider international debut atInnoTrans 2010.

The single voltage Dragon is thefirst vehicle of a Newag Gliwice six-axlelocomotive platform. Its main advantageis a high tractive force of 375 kN whichin connection with the locomotiveweight of 118 t and individual drive ofeach axle allows to haul trains weigh-ing up to 5,000 t. The 3 kV DC powersupply, maximum axle load below 20 tand high durability makes the Dragonperfectly adapted to difficult opera-

tional conditions and low permitted axleload. During the design process, focuswas set on safety and driver’s highcomfort, providing ergonomically de-signed cab and control panel, the safetycage and anti-climbing structure pro-tecting the driver in case of collision,the air conditioning unit and CCTV.

The Dragons are powered by asyn-chronous traction motors, fed by IGBTbased traction inverters. The locomo-

tive has a modular construction allowing,through a mere adaptation of the exist-ing platform, to offer solutions custo-mised to the specific needs of opera-tors - such as multiple voltage locomo-tives (3 kV DC/25 kV AC/15 kV AC),or electric locomotives equipped withan additional diesel engine.

Dragon is equipped with micro-processor control systems that allowsto adapt the operating mode to the

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Main Subsuppliers Of E6ACT Locomotives:

- pantographs - Stemmann-Tech-nik,

- line filter cubicle, traction con-verters, auxiliary converters,battery chargers, auxiliary filtercubicle and traction motors -ABB,

- braking system - Knorr Bremse, - braking resistor - Microelettrica

Scientifica (Knorr BremseGroup),

- TCMS - Inteco, - gearboxes - ZF, - cooling towers - Voith Turbo, - traction motor blowers - Comet

(Knorr Bremse Group), - HVAC - OE Industry, - train radio - Radionika, - event recorder - Hasler.

E6ACT-001, the Dragon prototype, at Źmigród test circuit on 7 April 2010.This locomotive is now owned by STK, Wrocław.

Photo: Newag A design comparison of the driver’s consoles on prototype (above) andbatch Dragon locomotive, E6ACT-002 (below).

greatly increased by adapting the samedriver desks as those already usedand tested on Griffin, the NewagGliwice’s first four-axle locomotive.This resulted into very simple and similarcontrol of both types, bringing advan-tages for future operators using simul-taneously these six- and four-axlelocomotives.

Traction System

The ABB traction system for Dragonincludes the following main subsystems(see diagram on the opposite pageright below): the line filter cubicle, theBORDLINE® CC1500 DC traction con-verters, the auxiliary filter cubicle andthe traction motors.

The two traction converters aredirectly fed from the 3 kV catenary viaautonomous DC-line filters in the linefilter cubicle. Each traction motor is sup-plied by its individual motor inverter.The single-axle drive ensures highestadhesion performance and a beneficialsystem redundancy. In addition, eachtraction converter includes an auxiliaryconverter and a battery charger for a redundant on-board supply system.

Track Gauge 1,435 mmLoading Gauge UIC 505-1Axle Arrangement Co’Co’Operating Voltage 3 kV DCMaximum Speed 120 km/hContinuous Rating Output 5,000 kW (at wheel rim) Starting Tractive Force 374 kNMax. Train Weight (at 6 ‰ gradient) 5,000 t Electrodynamic Brake Output - During Recuperation 5,000 kW- During Braking Into Resistors (max. loading) 2,400 kWMaximum EDB Force 150 kNLength Over Buffers 20,330 mmWheel Diameters (new/worn) 1,250/1,170 mmMinimum Curve Radius 120 mWeight 118 ±2 tBrake Systems pneumatical, electrodynamicParking Brake spring parking brake at each axleTraction Converter IGBT, BORDLINE® CC1500 DCTraction Motors AsynchronousAuxiliary Voltages 3 x 400 V AC 50 Hz

and 230 V AC 50 Hz110 V DC

Train Supply 3,000 V DCWork shop power supply 3 x 400 V AC 50 HzATP systems SHP, CA (vigilance unit),

RS (radio stop system)

Principal Technical Data Of Batch Dragons

A type AMXL450 ABB traction motor.

Photo: Newag

Photo: Newag

changing conditions, and on-boarddiagnostics system with full visual in-formation and data registration modulethat facilitate finding the location orprediction of possible failures. NewagGliwice high production standards, con-firmed by such certificates as IRIS andPN-EN ISO 9001: 2009, guaranteethe highest quality of the locomotives.

After more than a year of intensivecommercial operation of the E6ACT-001 locomotive with STK freight trains,all the return of experience has beentaken into account before launchingthe batch production. So far two con-tracts were signed for the delivery ofeight locomotives for the Polish freightoperators STK (E6ACT-002 to 004)and LOTOS Kolej (E6ACT-005 to 009).

In particular, the serial locomotivehas been seriously improved by in-cluding a traction system newly deve-loped by ABB to fulfil very high clientexpectations. ABB traction equipmentis known for their high reliability andeasy maintenance. The converters arebuilt on a modular platform design withstandardised, easy to handle PowerElectronic Building Blocks.

Another important improvementbrought on the serial Dragons is thedriver’s cab modernisation. All the driverswho have driven both the prototypeand the batch locomotives agree, thatthe latter are much more ergonomicand better insulated, and the air con-ditioning is more efficient. In addition,the standardisation level has been

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BORDLINE® CC1500 DC traction converter with open control swingframe. On the left side are power terminals, input switches, etc. On the rightside the PEBBs.

Input 3 kV DCTraction Output 3 x 833 kW (at the wheel) Braking Chopper 1,200 kWAuxiliary Output 175 kVA Battery Charger 15 kW/110 V DCVehicle Control Interface CanOpenDimensions (l x w x h) 1,800 x 875 x 2,030 mm Cooling Water/GlycolProtection Type IP54Weight 1,380 kg

Main Data Of BORDLINE® CC1500 DC Traction Converter

Power Electronic Building Block (PEBB).

Filter Packages For Line Input And Auxiliaries

The line filter cubicle includesredundant air-core DC-line chokes.The chokes are environmentally friendlyforced air cooled. For a safe and effi-cient cooling the temperatures of eachchoke are monitored and the air ventila-tion is adjusted depending on the load.

The air-cooled auxiliary filter cubicleincludes a LC sine filter and a three-phase transformer to feed the on-boardloads at 3 x 400 V AC and 1 x 230 V AC.A change-over switch is included toselect one of the redundant auxiliaryoutputs of the traction converters. Foruser-friendly maintenance, the compo-nents of both filter cubicles are easyaccessible directly from the machineroom aisle of the locomotive.

BORDLINE® CC1500 DC Traction Converter

The BORDLINE® CC1500 DC is a very compact and highly integratedIGBT traction converter. The ruggedIP54 converter housing contains on theright side the Power Electronic BuildingBlocks (PEBB) and the DC-link capa-citors. The environmentally friendly watercooled PEBBs are configured as motorconverter (3x), braking chopper, auxi-liary converter and as a battery chargermodule. The lightweight PEBBs areoptimised for service aspects: easy tohandle and to exchange.

The motor converters, braking chop-per and the auxiliary converter are basedon two-level technology with standard6.5 kV IGBT modules. The batterycharger is realised with low voltageIGBT’s. The converter control and powersupply units are placed on a swing framein front of the PEBBs providing excel-lent access to all key components.

The AC800 PEC control platformis probably the most powerful modularcontroller on the market also used inABB wind converters, high powerindustrial drives and many other appli-cations. This unit covers all control andprotection functions, sensor inputs,diagnostics, and provides a simple inter-face to the vehicle control. In cooper-ation with the train control manage-ment system, standard ABB softwaremodules control for example the slip-slide functionality, pantograph bounceor enhanced electrical braking modeof the locomotive.

For diagnostics, an Ethernet in-terface is available. In-depth data canbe obtained using BORDLINE® - View,a diagnostic tool including an advancedself-diagnosis function, which gives ad-vice and instruction for smooth serviceand repair. It runs on standard PCs.

On the left side of the traction con-verter the internal fan/heat exchangerunit, the pre-charge module, currenttransducers and the power terminalsare located.

The BORDLINE® traction convert-ers for Dragons are produced at ABBPoland in Łódź. Furthermore ABB pro-vides local service and a logistic con-cept for spare parts, close and dedi-cated to customer’s needs.

Traction Motors

The Class E6CAT locomotives arefitted with ABB’s AMXL450 traction

Auxiliary filter cubicle.

Line filter cubicle.

A diagram of the traction system, which was designed in very close cooperation between ABB Switzerland and Newag Gliwice designers.

BORDLINE® CC1500 DC traction converter with closedcontrol swing frame (right side).

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ABB’s Real Time Simulator at ABB Switzerland in Turgi.

BORDLINE® CC1500 DC converters production at ABB Poland in Łódź.

motors. They are axle hung three-phaseasynchronous motors with a Class 200vacuum pressure insulation. The motorwith its grease lubricated bearings de-signed for robustness and reliability ishighly integrated into the vehicle struc-ture, and it includes sensors for tem-perature and speed measurements.

Commissioning And Homologation

Before commissioning, ABB’s trac-tion system underwent comprehensiveverification and validation tests. Theprotection functions, normal operationbut also special operating conditionssuch as line voltage variations (over-volt-age, under-voltage), operating throughneutral sections, pantograph bounceand weak line supply (rotating convert-ers) have been verified on the real timesimulator. This is a „Hard Ware in theLoop Simulation“ with original convertercontrol HW and SW.

Besides type tests of all compo-nents, ABB also performed a combinedtest on traction converter, traction motorand auxiliary filter cubicle in order tooptimise the system already beforecommissioning on the locomotive. Both,the real time simulator tests and thecombined test have reduced signifi-cantly the time and effort for commis-sioning and homologation.

The static commissioning was per-formed at Newag in Gliwice. After testson Źmigród test circuit performed byInstytut Kolejnictwa (a Polish NotifiedBody) in last quarter of 2013 all changeshas been approved by Notified Body,and serial Dragon received type license.All the results were positive, not a singletest needed to be repeated.

Additionally the Dragon passed anintensive test program with loads of upto 3,905 t on gradients up to 10.7 ‰and the first batch locomotive, E6ACT-002, was finally handed over to STKWrocław in December 2013.

Market Outlook And Further Dragon Versions

There is a big interest for Dragonson the market of freight operators. Fromone side, operators need a heavy dutylocomotive to allow them to haul as

many full-loaded wagons, as possible.On the other side, on a big part of therailway network, the maximal permittedaxle load is quite low (e. g. up to 20 tper axle), especially in coal mine areas.In such a situation, a six-axle locomo-tive is an ideal solution to haul heavytrains, of up to 5,000 t.

As an answer to various customerrequests, Newag Gliwice has started thedesign of following Dragon variants:- a single voltage 25 kV AC version,- a multi voltage AC/DC version, - a dual power version with additional

350 kW diesel engine,- a heavy version with 450 kN starting

tractive effort.This makes Dragon platform even

more attractive for potential customers.Together with Griffin platform this givesthe possibilities to fulfill all customerneeds in terms of locomotives.

Majid Belkhayat,Newag Gliwice S. A., Poland

Thomas Lüttin, ABB Switzerland Ltd.

Photos and diagrams, unless cited, by ABB

Combined test of a traction converter and an auxiliary filter cubicle.

Traction motor with load machine on the test bench at ABB.

Photo on the right:The flagships of Newag Gliwice:Griffin and Dragon. This photowas taken at Gliwice works on 29 January 2014.

Photo: Maciej Duczyński,Newag Gliwice

AC 800PEC control.