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STC-GS-1
General Services - Coaching deals with
Maintenance of Train
Lighting Coaches (Non AC)
Maintenance of AC coaches
Subsequent improvement by
Earth Fault
During 1900-1935
By providing Khus-Khus mats
By providing ice containers
II AC Cooling 24 C 26 C
Heating 19 C 21 C
AC (RMPU) - 25 kW,
AC (Under/Slung) - 25 kW
Salient Features
Provided on Rajdhani, Shatabdi, Duronto, Garibrath type
fully AC trains with large power requirements.
GENERATOR GENERATOR
CAR CAR
COACH SUPPLY
750 V, 3 AC
FEEDER LOAD
415 V, 3
50/60kVA TRANSFORMER 415 V, 3
LIGHTING TRANSFORMER
110 V, 3
LIGHTING LOAD
Advantages of EOG System
No restriction of Load due to high capacity power cars.
Standby DA sets.
ALT.
FIELD + TO COACH
WINDING - LOAD
RRU/ ERRU
BATTERY
BOX
Under slung type AC coaches
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Alternator 130 V DC, 25 kW 1 2
2 RRU/ERRU 130 V DC, 25 kW 1 2
12 WRA 1 motor 2
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Alternator 130V, 193A DC, 25kW 1 2
WRA/ Monoblock
11 3 , 415 V AC, 1 HP 2
Pump
RRU/
2 120 V, 37.5 A DC, 4.5 kW 1
ERRU
4 V-belt C-122 4
Description of Power Circuit
16A 16A
360 339 318
HEATER-1
359 338 317 &
358 337 316 HEATER-2
MCB-6 C6
32A 32A
360 357 336 315
359 356 335 314 COMP-2
358 355 334 313 MOTOR
63A 63A
415 V AC 3 Ph.
361 358
BO
362 359
YO
363 360
RO
32A 32A
360 354 333 312
R 359 353 332 311 COMP-1
358 352 331 310 MOTOR
Y
MCB-4 OL-4 C4
B
6A 6A
360 351 330 309
359 350 329 308 COND-2
BUS BAR
358 349 328 307 MOTOR
CABLE SPECIFICATION
MCB-3 OL-3 C3
S.No. SIZE (SQ.MM) SYMBOL USED
1. 1.5 6A 6A
2. 2.5 360 348 327 306
359 347 326 305 COND-1
3. 6.0 358 346 325 304 MOTOR
R Y B
6A 6A
360 345 324 303
1. IF SEPARATE FILTERED CONTROL SUPPLY OF
359 344 323 302 BLOWER
415V AC FROM INVERTER IS AVAILABLE THE 358 343 322 301 MOTOR
CONTROL CIRCUIT (MCB-8) WILL BE CONNECTED
TO TC1 & TC2 INSTEAD OF BUS BAR. MCB-1 OL-1 C1
2. MULTI STRAND ELASTOMERIC CABLES CONFIRMING
TO RDSO SPEC. NO. E-14/1 PART-1 (REV.II)
FEB. 1993 SHALL BE USED FOR POWER CIRCUIT.
10 11
FROM SHEET NO.2
415 V AC
110 V AC
12 12 12 44
VR-2 VR-1
21 22 23b 24b 25 HR
O/L-1 C-1
CR
POWER
46 45 SUPPLY
371 100
13 14 15 16 17
ELECTRONIC
TO ELECTRONIC THERMOSTAT
TIMEDELAY RELAY
(ETDR)
1 2 3 4 5 6 7 8
SENSOR TO BE LOCATED
A1 B1
AT RETURN AIR PATH IN RMPU
PCB
PCB
PCB
R R G R G G G G
C1 AC1 TO
100 100 100 100 100 100 SHEET No. 4
POWER ON
COOLING
AIR LOSS
AUTO
CONTACTOR
BLOWER MOTOR
O/L TRIP
HEATING
BLOWER
MANUAL
BLOWER ON
CONTACTOR
AUXILARY
NOTE:-
1. ALL CABLES FOR INDICATION LIGHTS SHALL BE PTFE OF 1.0 SQ. MM SIZE.
2. ALL CABLES FOR CONTROL CIRCUIT SHALL BE PTFE OF 1.5 SQ. MM SIZE.
1. BOTH COMPRESSOR ON.
2. COMPRESSOR-1 BYPASS
FROM SHEET NO. 3
24 C2 C3
3. COMPRESSOR-2 BYPASS
82 82
RSW-5
C3 82
2
23 C6 2
C2 48 48
1 3 1 3 70 T38 C6
40 40 40 40 48 48
T40
49 a b 84
61
OHP-1
O/L-2 O/L-3 C-2 C-3 T26
T28 60 T32 T34
59 71 C4 C5 T39
HP1
HP2 83 85
41 42 43 44 45 46
T27
T33 72 73 T41
51 62 T43
T29 T30
58
T35
T36 21 22 OHP-1
LP1 69
LP2 87
PCB
57 T42
T31 52 63
T37 68
86
9 10 11 12 O/L-4 13 14 15 16 O/L-5 17 18 19 20 23 24 25
G G
PCB
PCB
PCB
PCB
PCB
65
54 65
54
R G G R R R R 66 R R R R R R G
R
55 66
C2 N C3 N N1 Ph1 N C5 N1 Ph1 N N
C6
N
C4 FROM FROM
SHEET
NO.3
{ Ph
N ETDR SHEET
NO.3
{ ETDR
100 100 100 100
CONTACTOR
CONTACTOR
CONTACTOR
CONTACTOR
CONTACTOR
HEATER ON
COMP.1 O/L
COMP.2 O/L
COND.1 O/L
COND.2 O/L
OHP 1 TRIP
COMP.1 ON
COMP.2 ON
COND.1 ON
COND.2 ON
OHP 2 TRIP
HEATER
BYPASS
BYPASS
COMP.2
COMP.1
COMP.1
COMP.2
COND.1
COND.2
HP 1
HP 2
LP 1
LP 2
NOTE :
1. FIRST FERRULE No. 40 & LAST FERRULE No. 100.
2. FERRULE No. NOT USED - 47, 50, 53, 56, 64, 67, 74 TO 81, 85, 88 TO 99.
3. R-RED LED INDICATOR & G-GREEN LED INDICATOR
4. CABLE SIZE FOR ALL INDICATION LIGHTS SHALL BE PTFE OF 1 SQ.MM.
5. CABLE SIZE FOR CONTROL CIRCUIT SHALL BE PTFE OF SIZE 1.5 SQ.MM.
SCHEMATIC DIAGRAM FOR POWER PANEL
PUMP1 17
M U,V,W 2611
R TO 117 RSW-1 26 261 RSW-2 TO
P 4157,4158
C S TB 8 500A 300A 2612 OVR 6A MCB
4159 W7 PUMP2 19
B
R1, Y1, B1 4151, 4152 U1,V1,W1
300
330
FROM 4153
TB 7 R2, Y2, B2 RS W3 TB2
16
17
191,192
26 2614 2613 MCB
193,N 181 181 18
TO INV2 +(DP)
TO INV1 +(DP)
TO INV2 +(DP)
TO INV1 +(DP)
TO
TB4 TO MCB (+10A)
ALT-2
500
700
116
117
TO 40A MCB
FR1
MCB
RSW-6
FROM M R 17 117 19 (IC, L)
191,192 194,195 197,198 FY1
TB 1 C S MCB TO FROM TB6
193, N 196 199
B W4 TB 1
19 26
N FB1 N
MCB 17 16,17,116,117
- Ve FROM SHUNT
T
TO ALT-1
FROM U/F
TO ALT-2 TO
AMMETR TB 5
AMMETR
18 0 2.5A 1814 / VM
16
VOLT 2.5A 70
TO 201
METER TB 4
FROM U/F 16
FROM U/F 19
FROM U/F 116
1814 263 262 TO CL2 5A 1811
FROM FROM
706
707
701
702
TB 3 TB 4
TB 3
TO
5A 1182
10A 1803
RCL1
RCL2
BATT
1&3
2&4
FSL
FSL
AMMETER
10A 1804
700
201
19
18 40A 18
FROM
FROM 500A SHUNT TB 4 FROM TB 4
TO RSW 5
40A 26
FROM
RSW 6
IC1 10A 500
TO TB 4
L2 5A 330
FROM
RSW 5
L1 5A 300
SP 5A SP
PAIL 2.5A 7
Capacity : 25 kW
Voltage : 130 V +/- 5% on DC side (97V, 3phase AC)
193 A Max on DC side.
Cut in Speed : 380 RPM (30 Kmph )
MFO : 700 RPM (51 kmph approx for 135 A at 135V)
Max. Speed : 2500 RPM (156 Kmph approx)
Mounting : Transom mounting
Belts : V-belts (C-122)
Insulation : H- class
Resistance between field terminals : 7.3 ohms
Resistance between phase terminals : 0.08 ohms
Alternator Pulley : 200 mm PCD 6 groove
pulley
RRU/ERRU
Capacity : 25kW
Voltage : 130V+/-5 % V DC
Current : 25kW 193A DC Max
Battery
Voltage : 2V
Capacity : 1100 Ah
Type : VRLA
Battery charger
Input Voltage : 3-Ph 415 Volts, 50 Hz.
Input current : 45Amps
Output Voltage : 130V DC
Output current : 200 Amp.
AC WRA/ Monoblock
Voltage : 3-Ph, 415V, 50Hz.
Capacity : 0.5 HP
Inverter
Capacity : 25kVA
DC Input : 90V- 140V DC with 15% ripple
Rated input current : 250A
AC Output : 3- Ph. 3-wire, 415V+/- 5%
PWM sine wave
Output frequency : 50 Hz+/- 3%
Output power factor : 0.8
Rated Output current : 35A
Power Panel Equipment
Voltmeter : 0-200V DC
Center-Zero-Ammeter : 500-0-500 DC
Ammeter for Alternator-I & II : 0-300A DC
RSW1 (Alternator supply selector rotary switch) : 400/500Amps
RSW2 (Inverter supply selector rotary switch) : 300Amps
Capacity of HRC Fuse between RSW1 & RSW2 : 400Amps
Capacity of HRC Fuse for inverter supply (RMPU) : 250Amps
Capacity of HRC Fuse for inverter supply (RMPU) : 250Amps
Capacity of HRC Fuse for AC plant 1&2 supply (U/S): 160Amps
Transformer for fans, mobile/laptop charging : 2 kVA,
415V/ 110V
AC.
RSW3 for Inverter Selector : 16Amps
Input side MCCB for 440/110V transformer : 16Amps
Contactor cum MCCB for WRA : 16Amps
RSW4 for fans : 16Amps
RSW5 for Lights : 16Amps
RSW6 for night lights : 16Amps
RSW7 for WRA selector : 16Amps
MCBs for +ve, -ve circuits of FTLs/ CFL Night : 6Amps
Lamps, fans, Mobile charging inverter.
AC Control Panel Equipment (RMPU)
RSW1 : 63Amps
MCB TP : 63 Amps.
MCB TP for blower, condensers : 6 Amps
MCB TP for compressors : 32 Amps.
MCB TP for heaters : 16 Amps
MCB DP for Control T/F : 4Amps
Contactors for blower, condensers : 6 Amps
Contactors for compressors : 32Amps
Contactor for heater : 16Amps.
Control Transformer : 415/110V AC
Compressor
Condenser Fans
Diameter : 24 21
Motor capacity : 1 HP x 2 1 HP x 2
Refrigerant : R-22 less than 2.5 kg each R-22 less than 3.0 kg each
circuit circuit
The lights are arranged in two circuits (L-I, L-II) and fans in
one circuit-F, each controlled by a rotary switch.
B+
MAIN RECTIFIER
B-
BRIDGE
FIELD RECTIFIER
F-
BRIDGE FIELD
CONTROL
CIRCUIT F+
VOLTAGE &
CURRENT
SENSOR
A2 A3 REGULATOR
A1
FIELD
Minimum Short
Non-fusing/ 60 Sec.
size of cable time (60
Fuse Fuse size non Fusing/
Sr Circuit fuse protected sec)
location rating tripping tripping
for short rating of
Current circuit
circuit cable
Positive/ 6A
7/0.85
1. Negative DFB (0.20mm) 8A 13A 37A
(4mm)
Branch fuse (35 SWG)
LI, LII & Junctio 7/1.7
2. 16A HRC 148A
Fan n Box (16 mm)
SPM-I & 7/1.7
3. -do- 16A HRC 148A
SPM-II (16 mm)
Main 7/2.52 (35
4. -do- 35A HRC 325A
Negative mm)
Fuse + & - Fuse
5. 40A HRC
battery Box
The inductor type
Brushless alternator is an
axle driven, power-
generating machine with
V belt drive, mounted on
the bogies of the coaches.
These are designed as per
spec. no. RDSO/PE/SPEC/
TL/0054-2003 (Rev0) with
amndt.1 &2.
The standard ratings at the dc output terminals of the
rectifying and regulating equipment are 4.5 kW, 37.5A,
120 Volts.
It is driven by 4 Nos. V belt coupled between the axle
and the alternator pulley.
The Alternator with the help of static/electronic rectifier
cum regulator unit regulates and rectifies the voltage
which is used for:
i. Charging the coach batteries
ii. To meet electrical load i.e. fans, lights, mobile charging points
etc. in the coach.
The alternator is suspended on bogie on suspension boss fitted with
alternator pin.
The suspension boss fitted with a renewable bush having bore dia of
32.5 mm + 0.20 mm and alternator pin of diameter 31.75 mm + 0.0
mm / -0.10 mm.
The alternator is secured with safety chains (as per RDSO Drg.
SKEL 3934) to avoid dropping of it on track in case of any
breakage during run.
The alternator is secured with safety chains (as per RDSO Drg.
SKEL 3934) to avoid dropping of it on track in case of any
breakage during run.
Axle pulley - A pulley fitted
on the axle of the coach to
drive the alternator by V
belt. The pitch circle
diameter (PCD) is 572.6
0.4 mm.
Alternator pulley A pulley fitted on alternator and driven by
axle pulley through V belt. The pitch circle diameter
(PCD) is 200 0.3 mm.
Rating:
Voltage : 124 V
Full Load amps : 38 A
Speed Range : 550 RPM to 2500 RPM.
Setting:
Normal : 124V +/- 0.5 V at 19 Amp.
And at 1500 RPM
Facility available for setting : 120V,122V & 124V
Load Current : 42 Amp (Maximum)
Battery charging current : 24 Amp (Max.)
In 110V, train lighting system, 6V, 120 Ah capacity mono
block batteries are used in all types of conventional non air-
conditioned BG coaches.
Water :
The water used for topping up and preparing
electrolyte shall conform to IS 1069 1993.
Electrolyte:
It shall be prepared from battery grade sulphuric acid
conforming to IS 266-1993 with latest amendment.
The level of electrolyte shall be at least 50 mm above the top
of separator protector in fully topped up condition (up to the
green level of float indicator).
The specific gravity of electrolyte when the battery is in fully
charged condition at 27 degree centigrade shall be between
1.210 to 1.220 for 120Ah. The specific gravity shall be
corrected to 27 degree centigrade using the formula given
under C1.3.2.2 of IS 8320-1982.
Manufacturing & commissioning date of Battery:
The year and month of manufacturer shall be punched on
positive terminal lug base with letter size not less than 6 mm
height and on Negative terminal side commissioning of
cells/batteries, month/year shall be marked by Railways.
It is suspended on coach in the under-frame and is
provided with front opening doors for paying attention to
batteries.
Mild steel rods threaded at both ends are fixed to the battery
boxes after loading the cells.
Field Diode
Blocking Diodes
Magnetic Amplifier
Zener diode
Fuses
Shunt (KEL)
Voltage detector (KEL)
Filter Circuit
Terminal Block.
Brushless alternator is totally enclosed
construction capable of developing a constant
voltage and used for Charging the coach battery
Operation of light, fans, Air Conditioner in the
coach.
The alternator consists of two sets of windings
UVC
Coach Indication
Panel
D1 D3 D5
x DC+
Current 1
1 K/ 50 W Sensor
+
W
ALT V 4700F/450V
U -
Fuse 500 E/ 50W
D2 D4 D6
F+ F-
M1 M2 M3
DC-
3 x Power Modules 2
Control Ckt
FLD Diodes
65 D7
90
S1 7 8
U
0 9 7 7
8&5 F+
IG1 Fuse
V S2
6
IGBT Card
65 C1 +
NOTE:- D8 - T IG2
D9
OVP Card
- All given no.(1 to 9) are wire numbers
- S6 & S7- coming from OVP S6
S7
- Wire 5 & 6- coming from UVC
- C1- capacitor mounted in FLD card
9 F-
assembly.
For easy understand the ERRU circuit is divided into
five parts:
1. Power circuit
2. Field circuit
5. OVP circuit
1. Power circuit:
UVC
DISPLAY,
POWER WITH UVC
MODULES CARD
TRANSISTOR
IGBT DATA
ET
DOWNLOADING
UNIT
ISOPACK POWER DIODES
USB CONNECTOR
FOR DATA
DOWNLOADING
PRESS ENTER
PRESS ENTER
Current Sensors
6 2
( or Load Current)
Alternator Failure:
3 kW for MG TL coaches.
RDSO/PE/SPEC/AC/0056 -2014,
25 kW alternator
Rev 1
EL/TL-41/A 12 kW alternator
Quantity
TL coaches - 1 set/coach
All AC coaches except FAC - 2 sets/coach
FAC - 1 set/coach (being increased to 2 sets/coach)
Used for charging battery set of coach at nominal 110
V and catering AC and TL load of the coach.
SIL PD Steel
HMTD Kapsons
Presstech
IC Electrical
Alternator Part I Part II
25 kW KEL Kundra Best & Crompton
SIL PD Steels
HMTD
Presstech
BHEL
IC Electrical* * Not for RRU
Hetro polar, inductor and self exciting type having no
windings on rotor
Universal applicability
1 RRU/ERRU
Maintenance manual
Bearing cover
Shaft key
Castle nut
Split pin
Suspension pin
1. STATOR
2. NORTH POLE
3. SOUTH POLE
4. FIELD COIL
5. FIELD COIL
6. ARMATURE
WINDING SLOTS
7. ROTOR
Cut in Speed 350 50 r.p.m.
MFO (Min. speed for Full output) - 550 50 r.p.m.
Working Speed 2500 r.p.m.
Voltage setting at 1500 r.p.m at 19 Amps 128.5 0.5
Volt DC
Over Voltage Protection Setting 145 1 Volt DC
Current Setting 37.5 Amps
Current limiting 37.5 + 15% of rated load (amps)
Modified Nylon bush arrangement issued vide RDSO
letter no EL/1.6.9.15 Dt. 28.12.2012
Principle of working
Field winding concentrated in two slots and each coil spans, half
the total no. of slots.
DE- NU-311
25 kW
Make : SKF/FAG
NDE 6309
Feature 4.5 kW 25 kW
Rating 120 V, 37.5 Amp 130 V, 193 Amp
Factory set at (1500 RPM) 128.5V at 1/2 load 128 V at 1/2 load
Efficiency 70% at full load 80 % at full load
and 1800 RPM and 1800 RPM
Min. RPM for 2V ac r.m.s. 300 NM
Field winding resistance 4.5+/- 0.5 8.5+/-1.5
Stator winding resistance 0.4+/- 0.05 0.045+/-0.01
(phase to phase)
Suspension pin dia 31.75+0/-0.10 mm 35.0 +0.2/-0.3 mm
Feature 4.5 kW 25 kW
Insulation class F H
RDSO/PE/SMI/
SMI for checking shaft of TL
11 TL/026 2003 Oct. 2003
alternator
(REV.`0)
Sr SMI/MS N0 Description Reference
RDSO/PE/SMI/AC/ Protection of Lead wire EL/1.6.9.15 dt.
12
0033-2006 (Rev. 0) of TL & AC Alternator 20.06.2006
For 4.5/25 kW
RDSO/PE/SMI/TL/0 RRU/ERRU voltage
13 June-2012
045-12(Rev-0) setting on TL and AC
Coaches
RDSO/PE/SPEC/TL Guideline to use standby
14 Aug-2012
/0175-2012 (Rev-0) circuit in ERRU
Provision of modified
RDSO/PE/MS/TL/0 terminal box cover for EL/1.6.9.15
15
020-2003 (Rev. '0') 4.5 kW 110 V TL 20.02.2003
Alternator
Sr SMI/MS N0 Description Reference
Provision of OV protection
RDSO/PE/MS/TL/0 EL/1.6.9.15
16 in RRU of alternator used in
021-2004 (Rev. '1') 19.08.2004
SG AC coaches.
Provision of modified
RDSO/PE/MS/TL/0 EL/1.6.9.15
17 terminal board assembly in
024-2003 (Rev. '0') 31.07.2003
4.5/18/25 kW alternators.
Provision of filter circuit in
RDSO/PE/MS/TL/0 EL/1.6.9.15
18 RRU of 4.5 kW alternators
033-2004 (Rev. '0') 18.08.2004
used in TL coaches.
Modification to cable layout
from 18 kW alternator EL/7.1.21/K
19 RDSO/AC/MS/22
terminals to junction box of dt. 4.7.91
AC coaches.
Sr. SMI/MS N0 Description Reference
Procedure for brazing
EL/7.1.21/K
20 RDSO/AC/MS/24 winding wire with flexible
17.12.91
lead wire on alternators.
RDSO/PE/MS/A
For protection of lead wire EL/7.1.38/1
23 C/ 0034-2005
in 4.5 /25 kW Alternator 23.08.2005
(Rev. 0)
Measurement of winding resistances
By suitable resistance measuring device at ambient temp.
R20 averaged for 5 m/cs. Not to vary by more than 7% of
declared value.
HV Test
Load test
Current vs voltage
Done at 1800 rpm. I varied from 10 to 193 A, keeping
speed constant. V not to vary 4%.
Current limiting characteristic test
Done just after temp rise or load test. Alternator run for 2
minutes in each direction with Open Circuit stator
winding and separate excitation at cut-in speed level at
speed of 3035 rpm.
Short circuit test
Done on cold m/c. O/P terminals short circuited with an
ammeter and excitation adjusted to achieve 25, 50, 75 and
100% full load. Curves plotted for various speeds.
Parallel operation
Done at 800,1800 and 2500 at 25,50 and 100% load.
Difference not to exceed 30 A.
OV protection:
Time delay of 3 seconds. Set at specified voltage for
different make.
Surge protection test:
At 1800 rpm, full thrown off and O/P voltage rise recorded.
Again full load leaving 10 A resistive load thrown off and V
not to rise > 400 V and should drop to normal in 5 seconds.
Efficiency test:
Efficiency at 1800 rpm to be >80%. Speed vs efficiency curves
at rated load.
Environmental tests:
Done on RRU only. Temp rise (dry and damp heat), in
corrosive atmosphere, combined dust humidity and heat and
vibration and shock test.
Hose proof test:
For RRU, IP 55S of IS 4691-85
Special tests
MHO measurement
It is of two types:
1)series type
2) shunt type
OVP
OVP
It stops the generation incase of any fault in the voltage
control ckt of RRU/ERRU
As and when the fault is removed from the circuit the OVP
automatically isolates it self or the latching can be
removed through a reset switch provided in the circuit.
It is used to know the working condition of OVP on train.
OVP Tripping
DC+ DC- F+ F- U V Remarks
MAKE Voltage
Connect loop
KEL 7 8 19 20 - - 150V DC wire between 8
& 13 of OVP
Connect loop
SIL,STS& 116/119V
DC+ DC- F+ F- - - between
ICECPL AC
DC +ve to U
Best& 1401V
B+ B- F+ F- AC1 AC2 -
Crompton DC
143-144V
KAPSON DC+ DC- F+ F- U V -
DC
Connect loop
150V
HMTD B+ B- 2 F2 - - between
DC
DC + ve to 10
PRESSTE 146 V
DC+ DC- F+ F- U V -
CH DC
OVP Tripping
DC+ DC- F+ F- U V Remarks
MAKE Voltage
Connect loop wire
KEL 7 8 15B 15R 13 14 150V DC between 8 & 13 of
OVP
Connect loop
SIL DC+ DC- F+ F- - - 150V DC between
DC +ve to V+
Connect loop
STESALIT DC+ DC- F+ F- - - 123V AC between
DC +ve to U
Connect loop
116-
ICECPL DC+ DC- F+ F- - - between
119V AC
DC +ve to U
OVP Tripping
DC+ DC- F+ F- U V Remarks
MAKE Voltage
Best&
B+ B- F+ F- AC1 AC2 1451V DC -
Crompton
HMTD B+ B- 2 2 - - 150V DC -
Primary Secondary
(Use and throw) (Rechargeable)
Alkaline Acid
Battery Components in Lead Acid Battery
Negative electrode - Spongy lead (Pb)
Positive electrode - Lead dioxide (PbO2)
Electrolyte - Dilute Sulphuric acid (H2SO4)
Separator - Glass or plastic
Jar/container - Hard Rubber or Plastic
Battery Connections
1. Series Connection
Positive terminal of one cell is connected to the negative
terminal of another cell
Increasing the overall voltage but the overall capacity remains
the same.
2 . Parallel Connections
Like terminals of all cells connected together
The overall voltage remains same but capacity will be increased
Battery Capacity
Amount of charge available when battery is discharged at a
specific rate specified in Ampere-hours (Ah).
Measurement
Battery terminal voltage under discharge under standard
conditions of 27C
Example:
A 2.0V Lead-acid battery rated for 200 Ah (for a 10-
hour rate) will deliver 20 amperes of current for 10 hours
under standard temperature before its terminal voltage
reaches specified value (for example 1.75V for VRLA or
1.85Vfor LMLA)
Battery capacity varies with the discharge rate.
Specific gravity of acid is the measure of its concentration
Indicates the state of charge of flooded cell but not the capacity
No free electrolyte
H2 O 2H+ + O2 + 2e-
At Negative Plate
O2 + Pb PbO
Advantages:
No water Topping
Office Friendly (No separate battery room required)
Small Size
Disadvantage:
Sensitive to Operating temperature
ELECTROCHEMISTRY OF LEAD-ACID BATTERIES
e- e-
Loading Charging
+ - + -
-- Pb PbO2 H2 0 Pb
PbSO4 SO4
-- H+
SO4 H+
H+ PbSO4
H2SO4 PbSO4
PbO2 PbSO4 H2SO4
H2 O
Discharge Charging
LEAD - ACID BATTERY DISCHARGE
Load Load
_ - SULPHURIC ACID + _
+
- WATER
MAX. H 2SO4
-LEAD DIOXIDE ON + MIN. H 2SO4
-LEAD SULPHATE ON + MAX. H2O
MIN. H2O
-SPONGE LEAD ON -
-LEAD SULPHATE ON-
MIN. PbO2 MIN. Pb
MAX. PbO2 MAX. Pb
MAX. PbSO4 MAX. PbSO4
MIN. PbSO4 MIN. PbSO4
_ - SULPHURIC ACID _
+ +
- WATER
-SPONGE LEAD ON -
-LEAD SULPHATE ON -
MIN. PbO2 MIN. Pb MAX. PbO2 MAX. Pb
Freshening charge:-
If cells are not commissioned after initial charging, the battery has to be
charged for 6 hours at 5% of rated Ah capacity charging current.
If it is constant voltage charger, battery has to be charged @ 2.4V per cell for 24
hours with 10% of rated Ah capacity charging current.
LMLA Battery Charging
Regular charging
Equalizing charging
Charge with 5% current till all cell voltages reach 2.6 to 2.7v.
correct sp.Gr. To 1.24 in all cells by adding di water
LMLA Battery Charging
Equalizing Charging (contd)
Recommendation
Improper terminal tightening X
Proper Terminal Tightening
Lid Damages Not Allowed
ADDING ACID DURING CHARGING
DAMAGED VENT PLUGS
OPERATING WITH LOW ACID LEVEL
OPERATING WITH CORRECT ACID LEVEL
Varying Acid Levels in Same Battery
OVERTIGHTENING OF TERMINALS
CAMTECH, Gwalior has prepared a video film on
Maintenance of LMLA batteries used in TL
Coaches
https://www.youtube.com/watch?v=leUkuod-v0s
Endless V-belts (multiple drive) are used for transmission of
mechanical power from the coach axle to the alternator which
supplies power to the train-lighting and air conditioning loads
in Railway coaches.
The width of the belt at its pitch zone. The width remains
unchanged when the belt is bent perpendicularly to its
base. This is a basic dimension of standardization for the
belt and for the corresponding pulley groove, considered
as a whole.
k. Matched Set
A set of selected number of belts, the lengths of which are
within the specified limits enabling them to be used
together on a multiple V-belt drive.
The C-122/3155 Lp endless V-belts of isosceles trapezoidal
cross section consist of a combination of elastomeric
compound(s) with polyster cord reinforcement and outside
polycot fabric coated with polychloroprene, the whole is
moulded together in a uniform manner and shaped in accordance
with the belt manufacturing practice.
Parameters Requirement
Hardness, IRHD 82 4
Tensile strenth, Kg/sq cm 100 min.
Elongation at break, % 150.min.
100 kgs.
Maximum permissible tension during
running operating
29.5 Kg for 25 kW
Maximum static tension per belt (Kg)
26.5 Kg for 4.5 kW
Angle = 40 degrees
The pitch lengths of belts corresponding to given pulley pitch
diameters and centre distances may be obtained by the
following formula :
1. 25 KW Axle pulley
Dia (pcd) 572.6 0.4 mm
Width 200 1 mm
2. 25 KW Alternator pulley
Dia(pcd) 200 0.3 mm
Width 210 1 mm
3. 12 KW Axle pulley
Dia (pcd) 415 0.4 mm
Width 200 1 mm
S.No. Description Particulars
4. 12 KW Alternator pulley
Dia (pcd) 160 0.3 mm
Width 200 1 mm
It should be ensured
that in case of 25 kW
alternator all the 12
belts and in case of 4.5
kW alternator all the 4
belts shall be of same
pitch length/Grade.
Re-tension of newly fitted belts shall be done after 1st trip or 500
km run, whichever is convenient.
Checking of length is
important to judge whether
set is matched or not and all
belts are of same grading.
Checking of gap
between two halves
of Axle pulley
Spring testing
4. No. of coils 14 12
5. Tensioning 780mm 780 mm
rod length
Following shall be checked in belt tensioning device:
F 76.5 kgf
34 0.25
+ 0.03
22.53 - 0.00
Gadget to check the Pitch length of V belt
19.0
20
Normal pitch dia 222.8
SAMPLE BELT
Nominal circumference of pulley SLIDING
FIXED PULLEY
at pitchPULLEY
dia is 700 mm
Nominal pitch length of the belt = 2E + 700 mm
F 76.5 kgf
Method of checking Angle of V Belt
38
42
The flanks of the belt shall not touch the sides of the V-
grooves.
Clean regulator externally.
20 W 20 W
GREEN
BLUE/ BLACK
RED
-VE
+VE
To check the earth with double lamp method made the
connection as per sketch (shown in previous slide) and
ensure both lamps should be of same wattage.
Connect +ve wire to +ve terminal and ve wire to
ve terminal.
Check the fuse for fans and ensure that it is of correct size (35
SWG) tinned copper.
In swiveling and bracket fans ensure that the fan dust cover is
promptly replaced after attention and also that the nylon cord
provided to prevent loss of fan dust cover, is available in
position.
Check FDBs cover for any gap and entry for waste/
rubbish material.
In addition to the instructions contained under "Trip
examination" the following works shall be carried out:
In case there are more than 1/3 of total cells with low specific
gravity, the entire set should be replaced.
Charge the cells for 12 hrs with 2.30 VPC and then carry
out the discharge test as per item no. i to iii of (a) above.
In addition to the instructions contained under "Quarterly
Examination following activities should be done:
Fit tension rod fixing pin of alternator with new washer and
split pin. Replace spring, if belts loose upon coach arrival.
Check distance between wheel hub and axle pulley with gauge
plate.
Ensure gap between the two halves of the axle pulley is 3.0
0.5mm.
Examine the indicating white mark on the axle pulley and ensure
that the pulley has not shifted. If pulley found shifted, remove the
pulley and re-tighten it after replacing rubber pads and provide
indicating white mark.
Replace all existing V belts with new V belts having
same grade/make.
Clean all dust with soft brush and vacuum cleaner from
inside, particularly from heat sink of electronic
components and terminal board.
Ensure that they have not been disturbed and are in locked
position.
Following tests shall be done to ensure proper working of
RRU/ ERRU with alternator:
Check field and phase HRC fuses for their proper rating
and fitment.
(i) Lead Acid Batteries
Clean the battery box externally and remove all dust
with dry compressed air.
Open battery box covers. Remove inter-cell
connections and take out the cells.
Clean the cells, inter-cell and end cell connectors
thoroughly. Replace spring washers, if each are
overlapping.
Check for crack in cell containers leading to leakage.
If needed, replace the defective cell with healthy cell
of similar capacity, make and lug date.
Check for heating signs on the positive and negative
terminals and discolouring of the cells container/ top
lid. Clean the sulphation of terminals.
Check the level of electrolyte in all the cells and top up with
distilled water, if necessary.
Check the specific gravity and voltage of all cells with cell
tester.
Check all vent plugs and float guides conditions and replace
defective ones.
Never use a fuse wire for field fuse. Always use HRC
fuse of specified value.
i. Dos
Use belt of the same lengths for a set.
S.No. 9 months
Frequency of Examination + 30 days
0 days
TL & AC EQUIPMENT
1.0 Alternators
Carry out visual inspection of terminal box for signs
1.1 of overheating, fumes and presence of water etc.,
clean it.
Check field and phase HRC fuses for their proper rating
4.5
and fitment.
Charge the battery bank at the rate I = 0.1 x C10 fully till
6.1.16 3 constant hourly readings of voltage found, indicating
the condition of a fully charged cell.
6.1.17 Fit the battery box covers and secure them properly.
S.No. 9 months
Frequency of Examination + 30 days
0 days
8.5 Check and ensure that the protection plates and grills are
provided on the three sides of the frame.
16.0 Fans
Check and clean plastic fan blade and ensure that there
16.1
is no crack on the blade or hub.
19.3 Check that all legend plates inside the control are intact.
20.0 RMPU
20.1 Replace all fresh air and return air filters
20.2 Clean all air bellows and ducts.
20.3 Check the condition of cables and conduits.
Pour water into drip tray and ensure that the poured
22.2
water is drained through the outlet pipe.
Power cars at both ends take entire load of whole rake, which
includes air conditioning (if AC coaches in rake), light and fan
circuit, and regulated battery charger circuit and mini pantry
equipment (if chair cars in rake).
Each power car has two DG sets (normally out of which one
DG set is standby).
Phase II Module No. STC-GS-1
FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II
GENERATOR GENERATOR
CAR CAR
End ON Generation System
Under slung panel for 750 volt and 415/ 190 volt supply.
RCF EDTS-
1. Set of panel
355,REV-1,AM-2
RDSO/PE/SPEC/
Transformer,9KV
TL/0158-
2. A/15kva,750/415
2010,REV-0, (9 kVA) (9 kVA) (15 kVA)
/ 190V AC
Type-Ist
RCF EDTS-
Zs coupling, 400
105,REV-E,AM-
10. Amp, 750v,3-ph,
1,2 & 3, CORE-
50hz
1,TYPE-Ist
Wheel set
RCF EDTS-
12. earthing
101,REV-C,AM-1
equipment
RDSO/PE/SPEC/T
L/ 0021-2005,
14. BLDC Fan
REV-2,COR-1,
BLDC
Fluorescent
16. RCF CC76213 --
lamp(FL)
Distribution panel
28. for pantry RCF CC72172 -- --
equipments
A disconnecting and
earthing device along-with
high voltage fuses is
mounted inside the panel.
Contactor K01
Fuses net1
Contactor K 02
Pump Controller
Type II 15 kVA for chair cars (pantry load and train lighting
load 12.5 kVA- 415V+ 2.5 kVA 190V AC).
These boxes are properly earthed by earth cable. These are totally
covered and locked by hinged bolts.
Ratchet Assembly
ZS Coupling
Phase II Module No. STC-GS-1
Two types of feeder junction boxes are provided on the
LHB coaches as given under:
Feeder junction box-
plug side 2 nos.
5
6
7
8
1. Test push button for ELU
2. RSW for feeder selection
3. RSW for charging socket
1
4. HRC fuse for charging socket
5. Rotary switch for L1
2 4
6. Rotary switch for LII
7. Rotary switch for fan 3
8. Rotary switch for SPM I, II
The lights are arranged in two circuits (L-I, L-II) and fans
in one circuit-F, each controlled by a rotary switch. Each
circuit of lights and fans is protected by HRC fuse which
acts as back up protection in case of any short circuit fault,
isolating the faulty circuit only.
Colour Code:
Qty Per
Item Code Description Wattage Load In
Coach
Passenger,Alarm,Cum,Re
PARCIL servation Chart 21 2 42
Illumination Light
F Fan 38 30 1140
MCS Charging Socket 15 20 300
Total Load 2206
GL Gangway Light 26 2 52
LL Lavat0ry Light 13 4 52
Passenger,Alarm,Cum,Reserva
PARCIL 21 2 42
tion Chart Illumination Light
F Fan 38 36 1368
17. Hammer kg 1
29. Hydrometer
70 Angular grinder
73 Knife set
74 Wire brush
75 Nylon brush
76 Paint brush
STEEL.
STEEL.
STEEL.
Steel
Technical Specifications :
Test voltage 500 V to 5000 V DC
IR Range 0 5 T
Display Digital
Short circuit current < 2mA
This LED glows after the HT is switch OFF, till the voltage
on test object/ HV terminal is below 50 V approximate.
Technical Details:
(For more details refer RDSO Spec. No. TI/SPC/OHE/TIPS/1031, December, 2013)
Saw in steel 20 MM
SPINDLE COLLER
43 MM
DIA
Length 600mm
Battery 9V DC6 LR 61
1/8" to 7/8"
1/4"
10,11,12,13,14,15,16,17,18,19,21,22,23,24,2
22 Sockets
6,27,28,29,30,32,33,34
105
205
Dusting work,panel,
window glass etc
cleaning work.
Alloy steel duly hardened jaw, nylon 6 moulded upon steel strip &
insulated up to -1000 volts and stainless steel rivet.
Alternator pulley
adjusting guage
Bearing puller -
12. IS 9193 1979
specification
Y : (prefix) Suburban
E : 4-wheeled stock
S : Second Class
M : Military
CN : 3-tier sleeper coach
CZ : Chair car
CD : Dining Car
CL : Kitchen car
CR : State saloon
CT : Tourist car (first class) (includes
bathrooms, kitchen, and sitting and
sleeping compartments)
D: Double-decker
Y: (not as prefix) With Ladies'
compartment (usually 6-berth
compartment with locking door)
AC : Air-conditioned
GS - Second class self-generating.
ER : Inspection Carriage.
RA : Officer Saloon.
Railway track,