2016

SINGLE LINE DIAGRAM OF POWER CIRCUIT OF LHB COACH

Guided By:
Mr.KESHAV KUMAR
Sr.instrutor
TL/AC
CETI, Thakurli

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 PROJECT REPORT ON
NEUTRAL SECTION

:PRINCIPAL:
MR. YASHWANT URHEKAR
CETI , Thakurli

:Guided By:

Mr. VED PRAKASH SAHU

Sr.instrutor
OHE

:COURCE CO-ORDINATOR:

Mr. KESHAV KUMAR Mr. J.L.GENDLE

Sr.instructor Sr.instructor
TL/AC TRS(EMU)

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 TABLE OF CONTENTS

Sr. No. Topic Page No.

01 Acknowledgement 04

02 Project team 05

03 Certificate 06

04 Introduction of LHB 07

05 Advantages of LHB Coaches 08

06 Power Supply Arrangement 10

07 Single Line Diagram of Power Circuit of LHB 12

Coaches
08 Equipment use in LHB Coaches 13

09 LHB AC Coaches Contactors & Relay 27

10 LHB AC Coaches Fuses 29

11 Power Car(LHB) 30

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ACKNOWLEDGEMENT

It is indeed a matter of great pleasure and proud to present this project

of NEUTRAL SECTION. we are highly indebted to Mr. Ved Prakash
Sahu(OHE) Sr. instructor of CETI Thakurli for his invaluable guidance
and wish to record our deep sense of gratitude and appreciation for his
support.
We would like to render our sincere thanks to Mr.Yaswant
Urhekar, principal CETI Thakurli, Mr.Ved Prakash Sahu Sr. instructor
(OHE) of CETI Thakurli, Mr.J.S.Gendle Sr. Instructor (EMU),course
coordinator of CETI Thakurli and Mr.Keshav Kumar Sr. instructor
(TL/AC), course coordinator of CETI, Thakurli for their continuous
support, guidance and inspiration in all the phases of our project work
and encouragement that we have received.

Project Team

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Project Team

Sr. No. Name Designation Div/Rly.

1 Mr. DALIP SINGH MEENA Tr. SSE LJN/ NER

2 Mr.KRISHNA NAND YADAV Tr. SSE ALD/NCR

3 Mr. SANDEEP KUMAR MAURYA Tr. JE LJN/NER

4 Mr.DEVENDRA SINGH Tr. JE LJN/NER

5 Mr.SANDEEP KUMAR JAREDA Tr. JE LJN/NER

6 Mr.RAJU KUMAR GOND Tr. JE LJN/NER

7 Mr. RAJU Tr.JE

8 Mr.ROHIT PATIL Tr.JE

9 Mr. PREMCHANDRA PRAJAPTI Tr. JE

10 Mr. JITENDRA PRASAD Tr.JE

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 CERTIFICATE

This is certify that project work entiteld NEYTRAL SECTION is a

bona-fide work carried out by.......an
induction trainee of CETI batch from 03 OCTOBER 2016 to 18 MARCH
2017 under my guidance and direction.

Signature of guide: Signature of course coordinator:

Mr.VED PRAKASH SAHU Mr.KESHAV KUMAR Mr.J.L GENDLE

Sr.instructor Sr.instrutor Sr.instructor
OHE TL/AC TRS(EMU)

Signature of principal:

Mr. YASHWANT URHEKAR

Principal
CETI Thakurli

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 LHB TYPE COACH

(M/s LINKE HAFFMAN BUSH, GERMANY)

In order to make quantum jump in passenger coach technology and to bring it to

contemporary world standards, Indian Railway entered into supply and
technology Transfer contact with ALSTOM-LHB, Germany, As part of supply
contract M/s ALSTOM-LHB , Germany supplied 24 coach consisting of 19 second
AC Chair cars and 3 Generator cum brake Vans.

Rail coach factory, Kapurthala has been entrusted

with the task of developing and manufacture of modern, high speed state of art
coaches under transfer of contract.RCF took the challenge, achieved the target
and rolled out first rake of LHB coaches on 13-12-2003 for Rajdhani Express
between New Delhi to Mumbai Central.

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Advantages of LHB Coaches

Passenger Related Areas

Improved ride comfort ride index of 2.5/2.75 at 160 Kmph As compared
to 3.25/3.5 for ICF coaches at 130 Kmph.
Higher speed potential of 160 kmph.
Windows of big size allowing good visibility with functional roller blinds.
Luggage rakes of modern designs with integrated lamps for all seats.

Mechanical Advantages
Modern designs of vestibule for inter car connection.
Anti climbing feature to prevent climbing off during collision.
Four emergency window are provided per coach.
Coach length is increase by about 1.7 m to provide extra carrying capacity.
Length of ICF coach is 21337 mm (21.3 meter)where as LHB coach is
23040 mm (23.04 meter) . This extra length means two additional rows of
chairs in chair cars or one additional bay in sleeper coaches.

1 AC 18 to 24
2 AC 46 to 54
3 AC 64 to 72

Electrical Advantages
Low noise, microprocessor controlled AC unit.
Light weight epoxy molded 60 KVA Transformer.
Integrated modular single switchboard with controls of AC lighting.
Provision of FRLS cables.
Uniformity of illumination.
IGBT based battery charger used.
Humidity control sensor provided.
Temp control in seven step.

Disconnecting and earthing device provided.

Exhaust fan provided in toilet
Flap motor to adjust volume of fresh air automatically.
NTC type sensor provided.

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 POWER SUPPLY ARRANGEMENT
The power system for the coach has been designed to feed the
various electrical loads in the system operating at different voltage. There will be
following voltage system for feeding the various electrical loads.

750 V 3 Phase AC supply system

415 V 3 Phase AC supply system
240 V AC single Phase
110 V AC single Phase
110 V DC

The coach will select the input supply from either of the two feeders
available on the coach at 750 V Three phase supply through disconnecting and
earthing device provided in which board cabinet.

The 750 V 3 phase supply is stepped down to 415 V ,3- phase supply
with the help of one 60 KVA epoxy cast and encapsulated transformer, which is
provided on the under-frame of the coach.

The electrical equipment of roof mounted package units, exhaust fans and
pump equipment are supplied with 415 V, 3-phase supply received from 60
KVA transformer.

Loads of electrical appliances provided in sub pantry such as hot case,

bottle cooler, and refrigerator shall be fed with single phase at 240 V, 50 Hz
by using one out of three phases and neutral connection of 3-phase 415V
AC supply.

The lights, electric razors socket etc. shall be supplied at 110 V, single
phase AC received from regulated battery charger.

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 The 110 V DC is used for supplying control for roof mounted package unit ,
anti-skid device, light control, emergency lights, telephone, night lights,
berth reading lights, power contactors control etc.

A DC-DC converter shall be used to obtain 24 V DC for control systems for

pump, sanitary and public address system, return air flap unit i.e. servo
motor of air conditioning system etc.

The power and control supply arrangement to various electrical loads in

the coaches shall generally be similar to originally imported LHB AC
coaches. The 415/240 V AC network is designed as unearthed IT-4
conductor system.

Roof coach wiring shall be routed in PVC rigid conduit/trenches conduits.

Under frame wiring shall be with IP68 protection and shall be covered with
perforated cable trays as a primary safe guard against ballasts hitting.

All the equipment above 250 V shall be earthed at two places and below
250 V at one place. Voltage segregation shall be ensured during wiring.

As per rule 64-A of IE rules, over current protection shall be provided to

disconnect the supply automatically, if the rated current of the equipment,
cable or supply line is not designed to with stand.

The system will have earth fault/earth leakage protection to disconnect the
supply automatically, if the earth fault current exceeds the limit of current
for keeping the contact potential within reasonable limits.

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 FEEDER JUNCTION BOX

3 phases,750 volts AC supply.

A Feeder is a conductor which coonects the local generating station

to to the area where the power is distributed.

The main consideration in the design of a feeder is the current

carrying capacity.

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 Disconnecting and Earthing Device

Disconnecting and earthing device is provided in switch board cabinet and is fed 750
V from power car through ZS couplings. It has two positions ON & EARTH. It
disconnects coach feed at 750V in case of emergency like contactor jamming and
earths the coach for maintenance even during running of coaches.

Capacity : 120Amp.

Purpose : It is an off load switch to ensure earthing before

maintenance.

Locations : In bottom right side of switch Gear rack.

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Summary of technical specification of LHB Coaches Electrical
Equipments
INTER VEHICULAR COUPLER ASSEMBLY

Rated Current Capacity : Phase & Neutral wires-400Amp

: Earth wire-260 amp

: control wires-25Amp

Cable Size : Phase wire-120/150Sq mm

: Neutral wires-95 Sq mm

: Earth wires-70 Sq mm

Insulation Resistance Value : More than 500 mega ohms

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MAIN FEEDER FUSE

Fuses : HRC 750V,63 Amp, 25KA

: Total 3 number in each feeder

MEASURING & MONITORING RELAY (MMR)

Purpose : To check for phase sequence matching between iv

coupler wires & coach 3-phase wires.

: Additionally it gives over voltage & under voltage

protection also.

Setting : +/- 10% of 750 V for O.V & U.V

MINIMAL VOLTAGE RELAY

Purpose : To protect battery from over discharging

: It works in three steps. At 106 V it arrange to switch off reading

light.

: At 104 V it arrange to switch off DC to DC converter load

: At 96 V it arrange to switch off emergency lights also.

Setting : As above

LIGHTING TRANSFORMER

Rating (KVA/Volt/Amp) : 3KVA 230/110 Volt AC

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COACH LIGHTING

Type

Fluorescent tubes :18 watts

Incandescent lamps :10 watts(for night light & pantry)
Halogen lamps :10 watts (reading lights)

Fluorescent tubes are used as general lighting, vestibule, toilet,

Pantry and emergency working at 110 volts AC/DC with inverter

And with polycarbonate diffusers.

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The inverter for fluorescent lamp
Normal input voltage :110v AC/50Hz (88-138 v Range )

The inverter for Reading Lights

Normal input/output voltage : 110v DC/12 v DC

: 0-60 w/12v

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60 KVA TRANSMORMER

Rating (KVA/Volt/Amp) : 60KVA,750/415Volt

: 3 Phase (46.2/83.4 Amp)

Type of Transformer : Cast Resin Dry type

Type of Mounting : Underslung,4bolt

Location : Underframe

Cooling : Natural air cooled

Class of Insulation : H

Connections : Star-Star

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PUMP

Rated speed : 2800 RPM

Rating (HP?KW/AMP) : 0.5 H.P/0.37KW/1.2 Amp

Motor insulation Class : F

Total head : 8Metre

Discharge : 38 LPM

Power supply of controller : 24 volt

MAIN BATTERY CHARGER

Purpose : To give battery the regulated voltage

Rated output voltage (float) : 121 v at 4 amp

Boost Charging setting : 127 V at maximum 6 amp.

Boost current limit : Above 6 amp

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BATTERY

Type pure lead tin VRLA monoblock battries

Operating temp. range -40 to +50 deg. C

Terminals high conductivity copper alloy terminals

Separator high quality absorbent glass mat separator

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Pressure valve self releasing pressure regulating valve

Container impact resistant ABS container &lid

Plates plates with superior grids and active materials

Charging for pure float float 13.5 v for 12 v battery

Application boost- 13.8 v for 12 v battery

Charging for semicyclic float -13.7 v for 12 v battery

Application Boost 14.0 v for 12 v battery

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EXHAUST FAN
Purpose to exhaust the coach air to atmosphere in order to dilute the carbon
dioxide concentration & to make toilet & corridor portion indirectly air
conditioned. Location for exhaust toilet, control panel & mini pantry equipment
area.

RMPU UNIT
Nos. of RMPU unit in each coach 2 units (2 X 5 Ton ) capacity each in power car
only one unit.

BLOWER MOTOR

Rated speed 1420 RPM

Rating (HP/KW/Amp.) 1.0 HP/.75 KW/1.85 Amp.

Fan blade material Plastic

Motor insulation class H class

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CONDENSER MOTOR

Rated speed 1380 RPM

Rating(HP/KW/Amp.) 1.0 HP/.75 KW/1.85 Amp

COMPRESSOR

Type of compressor hermetically sealed

Rating 415 v 3ph AC 50 Hz
LP cut out (for scroll) 20.0 BARS (max.)
HP cut out (for scroll) 27.5 BARS (max.)

FILTERS

Fresh air size 48 cm x 26 cm

Return air size 83 cm x 43 cm

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MINI PANTRY EQUIPMENT

HOT CASE

Heater rating 500 W for one unit

Blower rating 45 W
Air flow qty 230/250 cubic meter per hour

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BOTTLE COOLER

Capacity 2nd AC 280 LTR 3rd AC 170 LTR

Comp Rating KCE 444

Refrigerant used R-134
Cond. Motor Rating 1/36 HP
Capacitor size 10 micro farad

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DEEP FREEZER

Capacity 2nd AC 37 LTR 3rd AC 22 LTR

Comp. rating KCE 345LAG

LHB AC COACHES CONTACTORS & RELAY

K01,K02 Main contactor feeders

K03,K04 MMR(measuring monitoring relay) 750 v

K05 Anti stand drive

K06 brake application

K07 brake release

K08 MVR(minimal voltage relay step 1)

K09 MVR (minimal voltage relay step 2)

K10 MVR (minimal voltage relay step 3)

K11 Light control relay (AC light)

K12 Light control relay (Reading light)

K13 Light control relay (night light)

K14 Light control relay (AC light)

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K15 Light control relay (DC light)

K16 Light control relay (DC light)

K17, K18 Light control relay

K19, K20 UIC light remote control relay

K21, K22 Aux cont. return air flap motor

K23 415 v OK relay

K24, K25 Contactor pump control

K26, K28 Blower motor cont.

K27 Controller OK

K29 Exhaust fan cont.

K31,K32,K36,K37 Condensor motor cont.

K33,K34,K38,K39 comp. motor cont.

K35,K40 Air heater cont.

K41,K42 Local main supply cont.

K43 common cont. for LMS

K44 main cont. transformer output

K45 MMR 415 v for LMS

K48 Emergency light relay

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LHB AC COACHES FUSES

F42/43=25 Amp Main 110V DC

F10/11/12=100 Amp Main transformer output 440 V

F47/48/49=80 Amp LMS incoming 440V

F50/51/52=63 Amp Net 1 feeder incoming 750 V for coach

F53/54/55=63 Amp Net 2 feeder incoming 750V for coach

F56/57=2 Amp UIC light remote control 24V DC

F58/59/60/61/62=2 Amp insulation control 110V AC/440V AC

F67=1 Amp LMS 230V (K41)

F68=1 Amp LMS 230V (K42)

F69/70/71=1 Amp MMR-LMS (K43)

F72=1 Amp main contractor transformer output (K44)

F73=1 Amp 415V Ok (K23)

F74/75=10 Amp 1 Amp MMR net 1-750V

F90/91/92=1 Amp MMR net 1-750V

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F94/95/96=1 Amp MMR net 2-750V

POWER CAR (LHB)

ALTERNATOR

KVA-500/400KW

750Volts , 3 Phase,1500RPM

Amps-385

Extitation=45V

ALTERNATOR PROTECTION

1) Over loading-280 Amp

2) Under voltage
3) Earth leakage
4) Short circuit

ENGINE

BHP-490

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 SAFETY DEVICE FOR ENGINE

1) Over speed cut out=1800 RPM CFR On

2) High water temp.=70F-90C cut supply to FSS & FSRD
3) Low lubrication oil pressure
4) 3 to 7 Kg

STATRER MOTOR

Volts-24 DC series motor

Compound motor-4 pole

Starting current-260 Amp

Rotation-clockwise

STARTER BATTERIES

24 Volts

390 AH for starting engine

Starting current-260 Amp

THROTTLE MOTOR

Use to very speed of engine=24V DC

OVR RELAY

Input-750

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RADIATOR MOTOR

415 Volts

40 H.P

54 Amps

Radiator Starter-Star/Delta

VENTILATION FAN

415 Volts

5 KW

Duty-51

ACB

3 Pole circuit breaker

Making capacity=25KA

Breaking capacity=50KA

Provided with UVR & ELR

UVR-Coli activated by 415V & pick up voltage is 380V

TRANSFORMER (Delta)

Input-750V

Output-415V

Current

Primary-42.2A

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Secoundary-83.4A

POWER CAR GENRAL INSTRUCTION

Take a round in every 60 minutes in the engine room to check whether all
equipments are working normally & enter the reading in the log book in
every one hour.

Record the quantity of fuel while taking/handing over the charge.

Inform your in charge before energizing the feeder.

Record tripping. If any in the log book.

Always keep your tool box ready with you. Check expiry date of fire
extinguisher.

As & when you get a chance e.g at halt station. Check the under frame.

Keep the power car clean & tidy. Do not keep inflammable articles & ensure
that there is no oil spilled in power car. Always use tin containers for
storing oil etc.

Maximum load permissible on a CUMMINS engine is 360 amp. (feeder load

should no exceed 300 amp.)

Do record the reason in the log book if standby engine has to be started
enroute.

Ensure that all the HRC fuses are of proper rating and all the indicator
lamps are in working condition.

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Equipments Details

ZS Coupling (Male) 02 Nos.

ZS Coupling (Female) 02 Nos.

Switch Board Cabinet 01 No

Disconnecting & Earthing Device (DED) 01 No.

MMR 03 Nos

Feeder Contactors(750V) 02 Nos.

60 kVA Transformer 02 Nos.

Contactor for Transformer Output (415 V) 02 Nos.

Blower Motors 02 Nos.

Compressors 04 Nos.

Condenser Motors 04 Nos.

Microprocessor 01 No.

Filters in RMPU 04 Nos.

Mono Block Pumps 02 Nos.

Pump Controller 01 No.

RBC (6.5 KW) 01 No

EBC (2.5 KW) 01 No.

Set of Batteries(12Vx09 Nos) 70 AH VRLA 01 Set.

1 KVA Transformer -- 01 No.

Wheel Skid Protection (WSP) -- 01 No.

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 Capacitor Bank 01 No.

Wheel Skid Protection (WSP) 01 Set.

Controlled Discharge Toilet System (CDTS) 02 Nos.

Fluorescent Tubes 24 Nos

CFL for Toilet light 02 Nos.

Exhaust Fan for Toilet 02 Nos.

Night light LEDs 09 Nos.

Emergency light LEDs 04 Nos.

Water Boiler 03 Nos.

Deep Freezer 02 Nos.

Refrigerator 01 No.

Bottle Cooler 02 Nos.

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