VW Golf Citystromer, tipo 1HX0E, Hatchback, Electric-Motor, 0 ccm, 20 KW, 27 HP, 100 kmph, 1994 to  1997

SIEMENS SIMOVERT model 6SV1 LONG INVERTER
regenerative braking capable, liquid cooled Max DC power - 100 kW,
FROM VOLKSWAGEN GOLF A3 City Stromer.

COMPARE PETROL ENGINE and ELECTRIC ENGINE IN GOLF A3

POSITION OF PETROL ENGINE IN GOLF A3   POSITION OF ELECTRIC ENGINE IN GOLF A3

INVERTER POSITION IS BEHIND FRONT MASK OF GOLF 3 ATTACHED TO BATTERY BOX.

 

On below image black arow is fuse Bussman fuse 300A data here http://www.partsprocurement.com/Fuses/BUSSMANN-FWH-300A.asp

DSCF0799.jpg (245735 bytes)

On above image green arow is fuse ........data here...

300 A fuse web link http://www.siba-fuses.com/front_content.php?idart=117&nummer=5005406.300

 

POSITION OF SIEMENS INVERTER

INVERTER POSITION WHEN FRONT MASK  OF GOLF 3  AND INVERTER COVER ARE REMOVED.

DEAR FRIENDS and BUSINESS PARTNERS WORLDWIDE,

MANY OF YOU HELP ME WITH DETAILS TO COMPLETE PARTS NEEDED TO TEST INVERTER.

I FINALLY FIX AND REPAIR SIEMENS SIMOVERT 6SV1 LONG INVERTER AFTER ALL HARD WORK INVERTER WORKING WITHOUT ANY PROBLEM.

IT WAS GREAT TROUBLE FINDING PROPER FEMALE X1 CONNECTOR FOR THIS X1 MALE CONNECTOR  VISIBLE FROM OUTSIDE OF INVERTER AND  MAKE PROPER CABLE AND MAKE SWITCHES FOR CONTROL AND CONNECTING ALL THIS AS IS ON THIS IMAGE FROM INSTRUCTION MANUAL IMAGE FROM METRIC MIND AND BEGGING MANY PEOPLE WORLDWIDE TO HELP FOR INFORMATION TO COMPLETE AND TEST AND REPAIR THIS UNIT.

HERE IS ORIGINAL GOLF A3 CONNECTION DRAWING FROM X1 CONNECTOR

I TRY TO GET INFORMATION FROM DIFFERENT SIEMENS companies and THEY REFUSE TO HELP ME ON ALL LEVELS. Answer was: SIEMENS can not give these documents to me due to legal reasons.

Regards
Rudolf Bosnjak  CONTACT DATA WITH ME IS HERE

 


AC drives, inverters, and adjustable frequency drives are all terms that are used to refer to equipment designed to control the speed of an AC motor. The term SIMOVERT is used by SIEMENS to identify a SIMOVERT = SIemens MOtor inVERTer  (AC drive).

Due to the special requirements in a vehicle a high power to weight ratio, a good degree of efficiency and a low price are extremely important for the electric drive.

In 1995 Volkswagen launched the Golf CityStromer as a pure electric vehicle developed and manufactured under real serial conditions. Nevertheless, sales volume did not exceed 150 vehicles due to lacking customer acceptance related to higher costs and lower performance compared to conventional cars.

For Siemens systems it is for instance motor-inverter matching parameters, i.e. motor's stator winding parameters and magnetic characteristics are stored in inverter's EEPROM to maximize performance and efficiency working with that particular motor.

The  inverter is able to control permanent magnet synchronous electric motor, 20 KW, 27 HP used in VW Golf A3 and asynchronous motor drives with the same hardware. See image of this motor. model 1FV5104-6WS09-Z

See here label data for permanent magnet synchronous electric motor, 20 KW, 27 HP  

See here rotor speed sensors inside permanent magnet synchronous electric motor.

Low weight and volume of inverter  is reached by water-cooling of the power semiconductors and capacitors.

A good efficiency is obtained with low saturation IGBTs.

It is possible to connect a PC to a serial interface for commissioning, monitoring and diagnostics via interface PCB.

In addition a DC/DC power converter for the 12 V system is integrated in the inverter housing.

SIEMENS SIMOVERT 6SV1 LONG INVERTER

SIEMENS SIMOVERT 6SV1 LONG INVERTER

SIEMENS SIMOVERT 6SV1 LONG INVERTER INSTALLATION  MANUAL AS PDF FILE FROM   METRICMIND

X1 CONNECTOR CABLE DSCF0992
X1 CONNECTOR OPPOSITE SIDE DSCF1050
X1 CONNECTOR BOARD DSCF1040
X1 BOARD NUMBER  DSCF1051
X1 CONNECTOR PCB SIDE DSCF1052

SERIAL INTERFACE ADAPTER CONNECTOR AND COMMUNICATIONS IS KIND OF CAN RS 232 PROTOCOL, WORKING UNDER DOS-DOS OPERATING SYSTEM!

ORIGINAL X5 CONNECTOR DSCF0846 AND SIMILAR X5 CONNECTOR AND SIMILAR  SERIAL CABLE AND web site data is HERE

WHAT IS THIS X5 CONNECTOR PART NUMBER IS AND WHO IS MANUFACTURER ON BELOW IMAGES, CAN YOU HELP IN INFORMATION DETAILS AND DATA SHEET?

SIMOVERT PC CONNECTOR AND CABLE DATA

X5 CONNECTOR WIRES DSCF1046

PC COM1 PORT connector IS DB 9 MALE.

RS232 CABLE EACH END IS DB 9 FEMALE TO DB 9 FEMALE. THIS SERIAL INTERFACE AND SOFTWARE PROTOCOL ALLOWING OPERATION ON SIMPLE TWO WIRE BUS.

I MAKE MY TEMPORARY ADAPTER CABLE FOR X5 CONNECTOR WITH WIRES SEE HERE DSCF1036 NUMBERED TO PIN NUMBERS  IN X5 CONNECTOR AND SOLDERED TO PIN NUMBERS IN DB9 MALE CONNECTOR.

X5 CONNECTOR WIRES ARE CONNECTED TO X2 CONNECTOR ON PCB NUMBER 485000.5016.03 TO X2 BOARD CONNECTOR VIA CABLE A2/X2 ON THIS IMAGE FRONT_SIDE, SEE THIS BOARD FROM BACK SIDE  BACK_SIDE

THIS BOARD IS 3-THREE LAYER PCB AND HAS EMBEDDED FOLLOWING LISTED PARTS INSIDE METAL CASE ON THIS IMAGE DSCF100

On this board are following IC.

  • LM 2925 Low drop regulator with delay reset.

Inside metal case is visible:

  • XILINX XC3042PC841 FPGA - field-programmable gate array
  • SAF-C167-LM 16-Bit CMOS Single-Chip Microcontroller with 4 Kbyte RAM, with CAN, with PLL FROM Siemens.
  • 2 x AM29F002B-70PI, 2 Megabit (256 K x 8-Bit) CMOS 5.0 Volt-only Boot Sector Flash Memory.
  • X24C16P, is a CMOS 16,384 bit serial E2PROM, internally organized 2048 X 8. The X24C16 features a serial interface and software protocol allowing operation on a simple two wire bus.
  • 2 x SOMETHING, still searching what is this 2 IC...

3 HAL SENSORS HKZ 121 BIPOLAR IC ARE CONNECTED TO  X4 MOTOR ENCODER CONNECTOR AND SEE HERE INSIDE MOTOR HAL SENSORS

IGBT DRIVER BOARD WITH HP OPTO COUPLER DSCF1053 MODEL CNW 4503. Single Channel, High Speed Optocouplers. Meets VDE 0884, UL and other regulatory standards. Integrated Gate/Base Drive Optocouplers for Isolated Power.

IGBT = Insulated Gate Bipolar Transistor, power semiconductor modules are today's state-of-the-art power electronics for the traction system of electric vehicles.

IGBT BOARD FACTORY NUMBER DSCF1053
IGBT DRIVER BOARD PCB NUMBER DSCF1056

IGBT DRIVER BOARD and DC BUS DSCF1054

IGBT DRIVER BOARD FRONT DSCF1055
IGBT DRIVER BOARD BACK DSCF1057

IGBT TRANSISTORS DSCF1058
IGBT TRANSISTORS V4 V5 AND TEMPERATURE SENSOR B2 DSCF1059


IGBT TRANSISTORS V1 V2, WITH STILL UNKNOWN ELEMENTS RJ AND R3 DSCF1060

IGBT TRANSISTOR V6 AND TEMPERATURE SENSOR B2 DSCF1062

THIS PART ON BELOW IMAGES WHERE IS WRITTEN EBG   HXP/1/C  5RJ 51808
DSCF1063
DSCF1064

HOW TO BUILD IGBT TESTER SEE SCHEMATIC

HOW TO TEST AN IGBT BRICK

HEAT SINK TEMPERATURE SENSOR DSCF1065

INVERTER OPENED DSCF0799

INVERTER LABEL DSCF0786

SCHALTBAU MAIN BREAKING SWITCH K1 AND K2 DSCF0800

SCHALTBAU Cam Contactors for Battery Voltages SEE WEB SITE

 


Diagnostic software SIADIS for Siemens Simovert inverter - VW Golf A3 CityStromer

SEE AND READ HERE MORE.

 

Java Calculators

A number of on-line design calculators using Java Applets are offered to designers and engineers.  The design templates were derived from authentic references and based on practical and real life experiences.   We would welcome any comments from our guests.

IGBT Based Voltage Source Inverter (VSI) Loss Calculator

Inductor Design Calculator

4 JUNE 2007 YEAR, FIRST SETUP FOR TESTING INVERTER- MOTOR -  SOFTWARE...

ALL PARTS DESCRIBED ABOVE ARE DONATION FROM DIFFERENT PEOPLE.

ONCE AGAIN THANK YOU TO ALL FOR HELPING ME TO TEST THIS INVERTER.

DONORS and SPONSORS IN ORDER HOW THEY OFFER HELP AND SUPPORT

BATTERIES:  VESPROM

OLD PARTS FROM GOLF A3: INVERTER, MOTOR, CHARGER AND LOT OF OTHER PARTS:  MIRSAD KAJEVIC

INVERTER INSTALLATION SETUP MANUAL:  VICTOR TIKHONOV

RS 232 SERIAL INTERFACE CABLE PIN NUMBERS DATA:  MEELIS MERILO

SIADIS SOFTWARE and SETUP MANUAL FOR VOLKSWAGEN GOLF A3:  EDDY HUSTINX

X1 CONNECTOR:  IVICA KUBAT

PERSONAL COMPUTER 386DX, TO RUN SIADIS SOFTWARE FOR GOLF A3:  SALKO BJELOPOLJAK

FULL DOCUMENTATION ABOUT GOLF A3 CITY STROMER CONFIGURATION I GET FROM: ROLAND GABER

 

Best regards

Rudolf Bosnjak

May 2007 year.

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Copyright,  All rights reserved.  Rudolf Bosnjak.