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Phase II - Module No.

STC-GS-1
General Services - Coaching deals with

Maintenance of Train
Lighting Coaches (Non AC)

Maintenance of AC coaches

Carriage Repair Works


(Electrical side) in POH shops
Types of Broad Gauge Coaching Stock on Indian
Railways are primarily classified according to power
supply systems for Train Lighting and Air
Conditioning.

Self Generating Coaches (SG),

Mid on Generation Coaches (MOG) Not in Service

End On Generation Coaches (EOG) and

Head On Generation Coaches (HOG).


Head On Generation
(HOG) Coaches (LHB)

LHB Non LHB SG LHB

Hybrid Full LHB


Non AC coach AC coaches (both SG & EOG)
SLR (guard van) Power car
General Second (GS) Ist AC
Sleeper (SCN) 2nd AC
Chair car 3rd AC
Pantry Chair car
Double decker (chair car) Composite coach (any of two
accommodations in one coach)
Double decker (chair car)
Garibrath coaches
Pantry car
Train Lighting (NON AC) ICF Design Coach
Air Conditioned ICF Design Coach
Air Conditioned LHB Design Coach
Train Lighting (Non AC) LHB Design Coach
High Capacity Double Decker LHB AC Chair
Car (EOG)
(from day 1 as per Cheap Trains Act 1844)

On IR train services commenced in 1853.

Side wall bracket (general coaches) and ceiling (saloon


& Ist class) mounted Oil (vegetable or mineral) lamps.

One lamp per coach

To be fixed before sun set and removed after sun rise.


Used by East Indian Railway in last decade of 19th
Century in 400 carriages.

Improved quality of lighting

Gas storage at high pressure.

High initial cost but reduced maintenance cost.

Subsequent improvement by

o Using lamps with more than one burner

o Use of acetylene mixed gas


Experimented in France in 1893.

TL system invented by Mr A.B. Gill employee of


M/S J stone

Installed in MG saloon of manager Jodhpur-


Bikaner Rly in 1897. Dynamo of J stone co. (25
Amp, 16 V)

Dynamo and battery in front brake van & One


lamp per coach
South Indian Railways also installed a set of
equipment in 1897.

In 1901 by Rajputana-Malwa Railway 16 V


Battery adopted. Charging done with dynamo
installed in Ajmer W/S.
Both brake vans provided with battery and
dynamo.

Belts were being tightened by Guard on run.

Auto (centrifugal type ) cut out for dynamo (to


battery ) at 5 kmph
Locomotive, C&W Superintendents committee
was set up in 1889 in 9th meeting in 1907
reviewed progress of trials and adopted this
system.

In 1913 Railway Board issued orders for


adoption of electric lighting.

Initially up to 1907 no fans.


Started provision of fans especially in Ist class
coaches. Fans provided in Ist & 2nd class from
1907, in inter class from 1937 and in Third class
from 1950.

From 1955, 1 fan for each sleeping berth.

Double Battery Parallel Block (DBPB) system


Rake introduced in 1930 and Upper class coaches
also fitted with dynamo and battery (9th CWSC
meeting decision)
ESC recommended for double battery system in
1949 but not approved by Board due to
circulating currents.

Uncontrolled theft of copper from electrical


equipment.
RDSO report on evaluation and performance of
DBPB 24 V DC TL system in 1967
recommended;

o Silicon blockers in place of auto cut switches.

o Manually operated switch in place of magnetic switch.

o Aluminum wiring in place of Copper wiring.

o Bogie mounted Dynamo/Alternator with V belts.

22nd ESC discussed the need to go for 110 V DC


system.
RB accepted RDSO recommendation for 110 V
DC in 1968.

Used Ist time during 1950 with first lot of fully


AC coaches. (axle driven 18 kW, 130 V dc
generator provided with carbon pile voltage
regulator).

ICF built 6 rakes with 110 V dc system in


1976.
In 1987 M/S Best & Crompton developed brush
less alternator.

These coaches used 3 & 4.5 kW Alternator and


regulator.

Battery 90 Ah , 11V, 5 cells monoblocks.

Light and Fan circuits controlled by MCBs.


During 1988, Railway Board appointed special
committee of CEEs to work out modalities of
extending this system to all coaches.

After acceptance of this committees report in


early nineties, all newly built SG coaches now
work on 110 V dc system.

All 24 V dc coaches have also been converted in


110 V dc system.
V dc trial rakes were fitted with FL fittings. AC
coaches had FL fittings since beginning.

From 90s onward, all coaches are provided with


FL fittings.

In 1992, CFLs introduced in ACCN coaches.

LED lights are being provided in new coaches.


Insulated dc system offers following advantages:

i. System in healthy condition will not offer any


dangerous shock by touching any of the 2 dc
wires.

ii. Short circuit level will be adequate for proper


discrimination.
iii. In an emergency, train lighting can be continued with
an earth fault on one of the 2 wires as the battery is on
floating circuit and there will be zero current with
single earth fault.
ISC = 0

Earth Fault
During 1900-1935
By providing Khus-Khus mats
By providing ice containers

First air-conditioned coach

Manufactured in the year 1936 at Matunga Workshop,


Mumbai

Introduction of AC coach in regular service


Manufactured by ICF, Chennai in 1965
Low Medium High
I AC Cooling 22 C 24 C 26 C
Heating 17 C 19 C 21 C

II AC Cooling 24 C 26 C
Heating 19 C 21 C

RMPU type AC coaches with Electronic


thermostats have fixed settings of 23 C -25 C
Gas leakage

Accumulated Dust reduces heat transfer.

Under slung Eqpt. gets hit by ballast, Cattle


run over etc.

Coach weight increase.


RMPU of 5.2 TR each was introduced in the year
1992 with 25 KW alternator.

Now a days two high capacity packaged air-conditioning


units of 7.0 TR for AC II tier & AC III tier coaches and
10.0 TR for LHB Double Decker coaches are being
used.

For first AC - one unit of 7 TR is being used

Mounted above the toilets on both ends supplying


conditioned air in the tapered duct to serve the coach end
to end.
Condensor Fans Air Intake For
The Condensor
Fans
RMPU Under Slung AC
Weight 900 Kgs (2 units) 2700 kgs
Installation time 4 hrs 4 days
Refrigerant R 22, 134a/407 R 134a
Refrigerant charge 2.85 Kgs 15 Kgs
Danger due to cattle
Nil Heavy
run over / flood
Down time for
4 hrs. Very long time
repairs
Generation is AC which after AC-DC
rectification becomes 110 V DC.

Volt DC (with battery back up) for lights &


fans. For AC (RMPU)

It gets converted into 415 V, 3 ph through


Inverters.
750 Volt Generation from DG sets placed in
power cars at the ends.

Power Supply from OHE through LOCO


Transformer.
Salient features
Axle driven under slung Alternator with V belts.

110 V dc regulated at different speeds through


RRU/ERRU.

Battery back up during standing/slow movement of


train.

2X25 kVA, 110 V dc/415 V inverters for AC load.

110 V DC supply for lights and fans.


Advantages of SG System
It gives better flexibility in rake formation; majority of
SG type coach is more.

The system is independent of mode of traction.

As each coach has battery, so no additional source is


required. No separate power car required

The problem / defect in any particular coach do not


affect the others.

Feed extension is possible in emergency from adjacent


coach
Disadvantages of SG System
Load restricted to 2X25 kW per coach at present.

Bulky 1100 Ah (AC)/ 120 Ah (Non-AC) coach battery


required as power is not generated during standby /
slow movement .

No standby alternator /battery in non-AC coaches so


system became poor reliability.

Extensive maintenance due to under-slung alternator, v-


belt, axle pulleys, tensioning device, inverter, battery
etc.

Poor system efficiency around 57%.


Batteries for TL & AC
Non-AC Coaches

110 V dc (nominal), 120 Ah, 6 volt, 18 Mono blocks


of LMLA or 2 Volt, 57 cells of VRLA or 6 Volt, 19
mono blocks of VRLA

Air Conditioned coaches

1100/ 800 Ah (VRLA/low maintenance)- 110 V dc:


56 cells of 2 Volt each.
Alternator for TL & AC

Non AC - 4.5 kW,

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.

Two power cars each with 2X320 kW (high Capacity)


Diesel alternator sets.

Power fed by two feeders 750 V 3- ph through IV


couplers, stepped down to 415 V 3 ph for AC by 50/60
kVA transformer

110 V ac lighting and fans by 415/110 ac transformer.


FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II

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.

Does not require bulky batteries, alternators.

Standby DA sets.

Independent of mode of traction.

Less maintenance required due to elimination of under


slung alternator, battery, axle pulley, V-belts etc.

Higher system efficiency than SG system.


Disadvantages of EOG System

Flexibility in rake formation not possible.

High cost of energy due to high fuel cost.

Noise and smoke pollution from power cars.

Passenger capacity reduced due to provision of


power car.
Salient Features

Single phase power supply received from OHE


through loco or tapped from OHE in power
car through separate pantograph.

Cost effective, reliable and energy efficient.


Elimination of heavy under slung equipment viz
alternator, battery, Inverter etc. in SG coaches
and DA sets in EOG power car avoiding noise
and smoke pollution.

Inverter (single phase to 3 phase) can be


mounted on/ under loco or power car or
individual coach.
Operating Formation of rakes, Placement of rakes, planning of
new coaching depots, Planning of new trains,
Timetabling, Rake rationalization, planning of POH
of coaches, Co-ordination for sick marking.

Commercial Introduction of new trains, Extra coaches and trains


for seasonal rush, Special trains, Refund in case of
Non AC, passenger complaints

Co-ordination for coach maintenance, placement of


Mechanical
rakes, integrated coach maintenance, Sick line
maintenance.
Publications issued by CAMTECH, Gwalior
on various topics of Coaching available on
internet. (Search Camtech publications)
Volumes published by IRIEEN on various
topics of Train lighting and Air-conditioning

Volumes on Coaching maintenance

Manual of coaching maintenance and design

Technical instructions issued by RDSO from


time to time for reliability.
Phase II - Module No. STC-GS-1
Based on the type of generation, there are three systems
adopted over IR. These are -

Self Generating System (SG),

End On Generation System (EOG) and

Head On Generation System (HOG) - trials are under


progress
In this system, power supply is generated in individual
coach through alternators propelled by axles.

Power generated during run supplies coach supply and


also charges the battery bank provided in each coach,
which in turn supplies power to the coach while the coach
is stationary.

The alternators are fitted in the under frame driven by the


axle through V-belts.

These alternators generate 110V, AC, 3, which is


rectified and regulated by Rectifier cum Regulator Units
(RRU/ERRU).
The RRU further passes 110V DC for coach supply and
battery charging.

This system is used for Air Conditioned coaches and Non


AC coaches of Mail/Express/Passenger trains.

ALT.

FIELD + TO COACH
WINDING - LOAD

RRU/ ERRU
BATTERY
BOX
Under slung type AC coaches

Roof Mounted Package Unit


(RMPU) type AC coaches

Non AC coaches (TL Coaches)


Under slung type SG AC coaches
These coaches are also called conventional type SG AC
coaches.
These coaches are equipped with following equipment:

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

800 Ah Low maintenance


3 Battery 56 cells #
Lead Acid

4 V-belt C-122 1x (6+6) 2x (6+6)


5 Compressor ACCEL/ Carrier 1 2
Qty/ Coach
SN Equipment Rating
1st AC Others

6 Compressor Motor 8.5/10 HP, 110 VDC 1 2

7 Condenser Motor 1.5 HP, 110V DC 2 4

8 Blower Motor 1 HP, 110V DC 1 2

9 Condenser Coil Under slung 1 2

10 Cooling Coil Over the corridor 1 2

11 Heater Unit 110V DC, 6 kW 1 2

12 WRA 1 motor 2

# Now for better reliability 1100 Ah VRLA batteries are being


retrofitted.
Roof Mounted Package Unit (RMPU) type SGAC coaches

These coaches are also called RMPU type SGAC coaches.


These coaches are equipped with following equipment:

Qty/ Coach
SN Equipment Rating
1st AC Others
1 Alternator 130V, 193A DC, 25kW 1 2

2 RRU/ERRU 130V,193A DC, 25 kW 1 2

3 Battery 1100 Ah, VRLA 56 cells

4 V-belt C-122 1 x (6+6) 2 x (6+6)

5 Sealed Compressor 3 , 415 V AC 2 4


Qty/ Coach
SN Equipment Rating
1st AC Others

6 Condenser Motor 1 HP, 3 , 415 V AC 2 4


7 Blower Motor 1 HP, 3 , 415 V AC 1 2
8 Condenser Coil Roof Mounted 2 4
9 Cooling Coil Over the corridor 2 4
10 Heater Unit 3 , 415 V AC, 3 kW 2 4

WRA/ Monoblock
11 3 , 415 V AC, 1 HP 2
Pump

Input: 110V DC, 25 kW


12 Inverter 1 2
Output: 3 , 415 V AC
Non AC coaches
These coaches are equipped with following equipment:

SN Equipment Rating Qty/ Coach


1 Alternator 120 V, 37.5A DC, 4.5 kW 1

RRU/
2 120 V, 37.5 A DC, 4.5 kW 1
ERRU

120 Ah, 6V VRLA or 120 2 V, 57 cells or 19 Mono


3 Battery Ah, 6 V Monoblock blocks VRLA/ 54 cells or
LMLA 18 mono-block LMLA

4 V-belt C-122 4
Description of Power Circuit

The 3- phase, 415 VAC, 50Hz power supply is used to


operate two hermetically sealed compressors, one double
shaft blower motor, two condenser motors and one set of
heaters through six contactors.

All the equipment are protected by over load relays and


MCBs.
FIRST FERRULE No. 301
LAST FERRULE No. 371 2A
359 371
FERRULE Nos. NOT USED TO CONTROL
358 370 TRANSFORMER
340,341,342,364 TO 369.
MCB-8
R Y B
2A
360 321 CC-HTR 1
359 320
TC2 358 319
TO CONTROL CIRCUIT CC-HTR 2
MCB-8 MCB-7
TC1

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

RSW-1 MCB MCB-5 OL-5 C5


50 Hz IN COMING

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

4. 16.0 MCB-2 OL-2 C2

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.

POWER WIRING DIAGRAM


FLC-RLY-000101/CP/DATED: 04/08/98 (REV 1)
Description of Control Circuit

A step down transformer of 415V/110V is used to provide


110V AC, single phase to control circuit.

The thermostats, PCBs, OLPs, HP cut out, LP cut out,


timers, etc. operate at this control voltage.
RSW - 3
24
2 3 TO
1. VENT
2. AUTO 1 4 SHEET No. 4
23
3. MANUAL COOLING
4. MANUAL HEATING 2 3 2 3
1 4 1 4
MCB 4 23a 24a
370 36 20 RSW-2 C-1 18 AC-1 19

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

FIRST FERRULE No. ...10


LAST FERRULE No. .....100
FERRULE No. 11, 20, 37 TO 99
NOT USED

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

262, 1814 3,4,4a,5


RSW-6
ALT-1 (FL)
221,222
223
M 4154,4155 X TO
C R 400A 250A 250A 26
4156 TB 1 FROM 40A
B 250A 250A 250A

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 201


5A SP

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

IC2 10A 700

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

VM 262 2.5A FROM TB 4


TO TB 4
Alternator

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

Make : Maneurop/ Compelend Maneurop/ Compelend


scroll scroll

Power : 5250 W +/- 20 % 5250 W +/- 20 %


consumption depending on ambient depending on ambient
temperature temperature

Current : 8.5A+/- 25% at 8.5A+/- 25% at


415VAC 3-phase 50Hz 415VAC 3-phase 50Hz
depending on Ambient depending on Ambient
temperature temperature
Power factor : 0.85 0.85
C.F.M.(Displacement) : 12.033 C.F.M, R- 12.033 C.F.M, R-
22 Vapour 22 Vapour

Volume : 117.65 117.65


CC/Revolution CC/Revolution
Evaporator Motor
Type : Centrifugal type Centrifugal type

Diameter : 10 (250mm) 11 (280mm)

Air flow (CFM) : 4200 Cu.Mtr/Hr+/- 4000 Cu.Mtr/Hr at 20


10% at 20 mm water mm water guage
guage

Pressure (External Static) : 25 mm Minimum 25 mm Minimum


water guage water guage
Speed : 1415+/- 10% RPM 1400+/- 10% RPM
Capacity : 1.5 HP 1.5 HP
Current : 2.6A +/-10% at 415 VAC 3- 2.6A +/-10% at 415
Ph, 50Hz. VAC 3-Ph, 50Hz.

Condenser Fans
Diameter : 24 21

Air flow : 4000 x 2 (6800 Cu.Mtr/Hr x 2) 3825 x 2 (13000


at 7mm static. Cu.Mtr/Hr minimum)

Speed : 910 +/- 10% RPM. 1400 +/- 10% RPM

Motor capacity : 1 HP x 2 1 HP x 2

Current : 2.1A+/- 10% x2 at 415V.AC 3 2.2A+/- 10% x2 at


Ph 50Hz. 415V.AC 3 phase 50Hz
Evaporator Coil

Face area : 0.254 sq.mtr x 2 0.265 sq.mtr x 2

Material of Tube : Copper Copper

Tube O.D. : 9.525 mm(3/8) 9.62 mm(3/8)

Fin material : Copper Copper

Fin thickness : 0.127 mm 0.14 mm

No. of fins/25mm : 15 12+/-1


Condenser Coil
Face area : 0.7376 sq.mtr x 2 0.67 sq.mtr x 2

Material of Tube : Copper Copper

Tube O.D. : 9.525 mm(3/8) 9.62 mm(3/8)

Fin material : Copper Copper

Fin thickness : 0.127mm 0.14 mm

No. of fins/25mm : 15 12+/-1

Refrigerant : R-22 less than 2.5 kg each R-22 less than 3.0 kg each
circuit circuit

LP : 35+/- 2 PSI 35+/- 2 PSI

HP : 415+/- 2 PSI 415+/- 2 PSI


(Self Generating TL Coaches)

Phase II - Module No. STC-GS-1


Most of the conventional non-air conditioned BG
coaches (ie. TL coaches) running on Indian
Railways are Self Generation (SG) type coaches
fitted with 4.5 kW alternators.

These coaches have 110 V DC systems for fan &


lights.

Each coach is provided with bogie mounted axle


driven one brush less alternator of 4.5 kW with
static rectifier-cum-regulator unit (RRU)/ Electronic
rectifier-cum-regulator unit (ERRU), giving an
output at 124 volts D.C.
(Ref: Specification No. EL/TL/48 (Rev.1) 2005)

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.

The circuit L-1 have essential/ emergency lighting circuit


which also include all Lavatory lights, 50% of compartment
lights, doorway lights, Night lights in all types of IInd Class
coaches.
Contd.......

The L-II light circuit feeds all the balance lights in


the coach.

The size of HRC fuse will be as per the type of


coach and the coach load, which will be governed
by the particular specification of the coach.

Re-wirable tinned copper fuses protect the branch


circuits for lights and fans.
4.5 K.W. BRUSHLESS
ALTERNATOR

110 V DC Train Lighting (TL) systems


Contd.......

These re-wirable fuses are located on a distribution fuse


board.

All branch circuits are protected by the fuses, both on


negative and positive sides.

Ordinarily one fuse protects upto a maximum of 3 light


points or 2 fans points.

The grouping of negative wires is done in such a manner


that the group load is within the capacity of the distribution
fuse board and arrangements are identical on positive and
negative sides.
Alternator Regulator block diagram

B+
MAIN RECTIFIER
B-
BRIDGE

FIELD RECTIFIER
F-
BRIDGE FIELD
CONTROL
CIRCUIT F+
VOLTAGE &
CURRENT
SENSOR

OVER VOLTAGE PROTECTION

A2 A3 REGULATOR
A1

FIELD

The general schematic wiring diagram is illustrated in RDSO


Drawing No. SKEL-3928 Alt. 2 which is to be followed.
Colour Code:
For easy identification of the cables, the various circuits have
colour code as indicated below:

Paralleling main and fan positive cables . Red

Light positive cables. .. Yellow

Fan negative cables ...Black

All other negative cables except fan negatives .Blue

The positive & negative cable is segregated by running them


in two separate conduits. The phase & field cables from
alternator to terminal box and from terminal box to rectifier
cum regulator should be run in flexible PVC conduits.
The size of fuses at various locations is as given below:

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.

Belts are kept under tension by a spring-loaded belt-


tensioning device.

V belts used are of C section size C-122 conforming to


RDSO Specification No. RDSO/PE/SPEC/0059-2004
(Rev.0)/ latest.
The rectifier cum regulator unit has mainly following functions:
i To rectify the 3 phase AC output of the alternator to DC output.
ii Regulating the voltage generated by the alternator at the set
value.
iii Regulating the output current.
The static Rectifier cum Regulator (RRU) consists
components
Power rectifier,
Magnetic Amplifier (MA),
Excitation transformer (ET),
Voltage detector (DT) and
Over volt protection relay (OVPR)

The Electronic Rectifier regulator unit (ERRU) employs


IGBT with driver circuit for the control of field excitation.

It employs Micro controller for the control of output DC


voltage, out put current, Battery charging current and field
current.

Electronic Rectifier cum Regulator (ERRU) is as per RDSO


specification No. RDSO/ PE/ SPEC/ D/AC/0013 (Rev.0).
Main features of ERRU with UVC (Universal Voltage
Controller):
Fast and reliable switching devices.

Alternator identifying facilities

Auto setting of parameters are such as output DC


voltage, battery current, load current which in turn
increase the life of battery and the alternator itself.

Monitoring real time value of alternator voltage, load


current, battery AH (IN), AH (OUT) etc., through
interface fitted inside the coach.
Main advantages of ERRU:

Control circuit is Modular type design.

Auto identification of alternator is ratings and


indications.

Auto setting of parameters are of voltage, load


current, Battery current, over voltage, over current
and current limiting for all the regulator of 4.5 kW,
18 kW and 25 kW.

UVC is interchangeable with all types of Electronic


Regulators from 4.5 kW to 25 kW.
Close regulation of voltage +/- 2 V over the entire range
of load and speed to have uniform charging of batteries.

Less voltage and current ripple are on Battery Charging


current.

Controlled Battery charging current to have longer life of


batteries.

Moulded Hall sensors for current sensing and setting


current limit.

Static over voltage protection and latching without


battery.

Isopack Power diodes directly mounted on the heat sinks


to have better heat dissipation.
Moulded PCBs to avoid dust and vibration problems.

Separate interface unit for monitoring the parameters like


DC Voltage, DC current, Battery charging and discharging
currents, Amp, Hours etc. and it can be downloaded.

This interface has facilities to store AH.IN and AH.OUT,


generation and non-generation time, total distance traveled
by coach and faults occurred in the regulators.

This interface also has Emergency unit. In case of failure of


one control unit, the other control unit will take care of both
regulators.
Rating and Setting for 4.5 kW Regulator:

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.

There are two types of batteries ie. Low maintenance lead


acid (LMLA) and valve regulated lead acid (VRLA).
Eighteen (18) Nos. mono-blocks (each consisting of 3 cell
used in series) of battery constituting one set, are arranged in
two battery boxes. In each battery box the mono-blocks are
arranged in one row of 9 mono-blocks and each mono-block
is kept perpendicular to the track.

These are used in conjunction with brushless alternators with


suitable rectifier cum regulator of 4.5 kW capacity with a
nominal setting of 126 V, 37.5 Amp at full load and 1500
rev./ min.

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.

FRP trays are provided at the bottom to avoid corrosion of


battery box from spillage of acid.
The interior of the battery box is painted with anti-corrosive
paint. The box is provided with ventilating grills to permit
flow of outside air over the cells.

A drain pipe is provided at the bottom of the box to allow


spilled acid or water to drain out.

Mild steel rods threaded at both ends are fixed to the battery
boxes after loading the cells.

While mounting the battery box in under-frame of the


coaches, special care is taken to provide locking nuts and split
pins to avoid any accidental falling of batteries while running.
BCT is provided centrally at the both sides of the
under-frame of the coaches for external charging
of the batteries at stations or maintenance lines.
All the cables coming from under-frame equipment
like regulator-rectifier, batteries and battery charging
sockets are terminated at the terminal board
mounted inside this box. Supply to the junction box
inside the coach is taken from this box.
Rotary Junction Box is
provided inside the coach. It
is used to arrange and
control the power supply to
various circuits of the coach
(e.g. light, fan etc.) with the
help of rotary switches and
HRC fuses.
Each coach is provided with four emergency feed
terminal boards on end panels, one each at the four
corners of the coach at lower level to enable emergency
connection to be made between adjacent coaches. On
these terminal boards, the outer terminal shall be
connected to the positive and the inner terminal shall be
connected to negative.
The coaches are fitted with
FTL, CFL or incandescent
light fittings.

The fluorescent light fittings


2 feet long, 20 watt, CFL of
11w x 2, incandescent lamps
25w/40w are working on
110 V DC supply.
Level of illumination (Ref:
RDSO spec. no.EL/TL/48
(Rev1) 2005).
The level of illumination to be attained in various types
of coaches shall be as given below
Class of coach Min. illumination level

Ist class compartments 30 lux

2nd class compartments 30 lux

Postal compartments 40 lux

Pantry compartments 30 lux

Lavatories and corridor 16 lux

Luggage compartment of SLR coaches 20 lux


On non AC BG coaches 400 mm
sweep carriage fans are used where
system voltage is 110 DC. These fans
are fixed type with voltage range is
90- 140V DC.

These fans are being replaced with


Brushless DC (BLDC) fans for 110
Volt dc, 400 mm and 450 mm sweep
fixed type.

The blades are made of fire retardant


plastic material.
Fuse distribution boards are
provided for each compartment/
bay of the coach.

The covers of Fuse distribution


boards are modified to restrict
the entry of waste/rubbish
material inside the FDB through
its cover and thus reduce the
possibility of fires incidences in
the cables in the vicinity of
FDB.
Phase II Module No. STC-GS-1
Power Rectifier

Field Diode

Blocking Diodes

Free wheeling diode

Magnetic Amplifier

Excitation Transformer/Field Transformer


Printed Circuit Board with diode and Potentiometer

Zener diode

Current transformer with burden resistance

Fuses

Over Voltage Relay

Bridge Rectifier for Voltage detector (KEL)

Shunt (KEL)
Voltage detector (KEL)

Capacitor assembly (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

A.C. Winding and field winding, both accommodated


in the stator.

The A.C. winding is distributed in the small slots &


field winding is concentrated in two slots .

Each field coil spans half the total number of slots.

The Rotor, consists of stacked stamping, resembles a


cogged wheel having teeth and slots, uniformly
distributed on rotor surface skewing the rotor axis.
The core of the stator which is completely embraced
by the field coils & retain a residual magnetism.

If excited by a battery once, the flux produced by the


field coils find its path through rotor, when the rotor is
rotated, passage of rotor teeth & slots alternatively
under the field and varying reluctance path for the flux
produced by the field coils.

Flux which vary periodically link with AC coil &


induced an alternating voltage in AC coil.
The frequency of induced voltage depends on the
speed of rotor.

The field is controlled through regulator to attain


desired output voltage.

The 3 phase output from the alternator is rectified by


the bridge connected silicon diodes.

The DC excitation to the field is obtained by full wave


rectification of alternating current provided through
the field transformer and the load winding of the
magnetic amplifier.
The voltage induced in the alternator winding is
dependent on the speed of revolution of rotor and on the
excitation current.

In the absence of voltage detector and magnetic


amplifier, the generated voltage of the alternator is
controlled by only saturation of stator, which is not
regulated.

The necessity of magnetic amplifier is come into


picture.
As soon as, the pre-set value of voltage reached, the
Zener diode in voltage detector starts conducting and
sends a control current through magnetic amplifier
winding.

The flux produced by the control current is in such a


way that it opposes the flux produced by the load
winding, thereby increasing the impedance of the field
circuit.

The increase in field impedance value reduces the field


current and brings down the voltage output to the
normal value.
The current limiting is also achieved in similar manner.

When the alternate current increases by pre-determined


load current, the voltage of the CT after rectification by
bridge will provide the necessary error signal for
magnetic amplifier.

In this case, voltage drop across the resistance R-1 will


cause the Zener diode to conduct.

The control current also passes through same control


winding.
The effect of this control current is to retain the current
at the limited value and to reduce the voltage and hence
the output current

Static over voltage protection (OVP) circuit is provided


to stop the generation is case of any fault of the
components and cause over generation.

As the voltage goes beyond the setting limit for more


than 3 seconds the OVP circuit immediately reduces the
field current and latches the output voltage at less than
90 volts, the latching remains even without battery.
Semiconductors having studs (main diodes, field
diodes) should not be over tightened. Recommended
torques for these are given below:-

a) Main diodes- 4.5 N-m.

b) Field diodes- 2 N-m.

As per RDSO/PE/SMI/TC/0003-99 (Rev. 0)

Solder (60/40,18 SWG) with 35 W soldering iron


Use silicon grease/ heat sinking compound between
mating surface of semiconductors with heat sink.

Use fuse link as per manufacture recommendations.


Phase II Module No. STC-GS-1
Electricity is required in a coach for operating lights
and fans as part of the minimum amenities to be
provided to the passengers traveling in a train.
One of the conventional methods is to generate the
requisite energy through the use of alternators driven by
the axle of the coaches.

The obvious problem with such arrangement was frequent


interruption and variation of frequency and voltage
generated with varying speed from stationary condition to
its maximum.

A battery of sufficient Ampere-Hour capacity was thus put


in parallel to feed the power to the coach during such low
voltage conditions. The battery was getting charged when
the generation was good.
Magnetic Amplifier based control was successfully
introduced at this stage to regulate and control the
DC voltage generated through the regulation of the
field current of the alternator.

This DC power is used to operate the various


electrical equipment and accessories inside the
coach.
This design of RRU is having its inherent limitations.

Poor voltage regulation.

No battery-charging feature of charging the coach


battery with current limit at constant voltage.
The voltage and current ripple in the 110V DC output
are varying substantially depending upon the type of
load and speed which may affect life of batteries.

Hence, it is felt necessary to go for an alternative


better design having fast response, better regulation
(within 2%) using fast switching devices with its
control circuitry to achieve higher reliability and fail
safe feature of the equipment.
The objective of the project ERRU is primarily to regulate
the alternator generation at the desired setting considering
the load condition and to maintain a constant charging
current for the battery and to reduce voltage as well as
current ripple.

In addition the system is intended to have fast response and


fail safe protection.

The Electronic Rectifying cum Regulator Unit also have


some additional feature, viz., over voltage protection,
overload protection with fast corrective response together
with various annunciations for indicating the system status.
High performance 16 bit microcontroller used to ensure
real time response.

Use of intelligent control algorithm for improved


performance.

Total CMOS (complementary metaloxide


semiconductor) design for low power consumption and
reliability.

Excellent DC voltage regulation of 1% against typically 7-


10% with conventional system.
Reduction of the ripple content in the controlled DC
output (less than 1% ripple content as compared to the
15% in conventional system).

Better Current Regulation and current ripple (less than


10% compared to typically 25% in conventional system).
Intelligent Battery Management algorithm with over current
control to charge the battery at a constant voltage for
additional life and health of the coach battery.

Reduction of Cut-in and MFO speed for better power


management.
RDSO specification No. RDSO/PE/SPEC/
AC/0013-2011 (REV-2) For Electronic
Rectifier cum Regulator Unit (ERRU) FOR 25
kW & 4.5 kW Alternator fitted on AC & TL
Coaches issued in December, 2011.
No load DC Output voltage : 135 V (Maximum)

DC Output Voltage setting : 129 0.5 V, 97 A at 1500 rpm

Voltage regulation : 2% of set voltage

Efficiency at full load at 1800 rpm : 95% (minimum)

Voltage ripple : within 2%

Current ripple : within 10%


Load variation : 10 A to 193 A

Speed variation : 800 rpm to 2500 rpm

Voltage at 15% over load : 120 V (minimum) at 222 A

Current limiting : 230 A (maximum)

Battery charging current limits (max) : 220A


No load DC Output voltage : 130 V (Maximum)

DC output voltage setting : 128.5 0.5 V at 19 A at 1500 rpm

Voltage regulation : 2% of set voltage

Efficiency at full load at 1800 rpm : 95% (minimum)

Voltage ripple : within 2%

Current ripple : within 10%

Load variation : 1 A to 37.5 A


Speed variation : 600 rpm to 2500 rpm

Voltage at over load of 40 A : 115 V (minimum)

Current limiting : 43 A (maximum)

Battery charging current limits(max.) : 24 A


HALL Sensor
L
Alternator O
A
D
Field

UVC

IGBT Based Field


Micro Controller Analog Signal
Power Switching
Conditioning
Module

DC/DC Switching Keyboard/Display


Power Supply

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

FLD Card Ckt.

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

3. Voltage control circuit

4. Current sensing circuit

5. OVP circuit
1. Power circuit:

Alternator 3 phase bridge Filter circuit Hall sensors(2)


rectifier

Coach load Battery


3 phase supply from alternator is converted into DC by
power rectifier consists of Isopack power diodes.

Filtered dc output current is sensed by load hall sensor and


battery current is sensed by battery all sensor.

DC output voltage is available at DC+ and DC- terminals


for roof load and B+ and DC-for battery charging
2. Field circuit
DC supply required for field excitation is drawn
from alternator is rectified

Field supply is controlled by IGBT and UVC

UVC is control the field current to maintain the


set output voltage of alternator

The gate of the IGBT is controlled by


microcontroller , which is programmed with all
date as per the requirements of the specification
3. Voltage Control Circuit

The circuit consists of SMPS unit, micro


controller.

If the voltage exceeds preset value the micro


controller gives signal to gate of IGBT

IGBT is fast switching device controls output


voltage and maintain with in limits
4. Current sensing circuit:

When ever current exceeds preset value the


microcontroller gives signal to gate of IGBT

IGBT controls output current and maintain with in


limits

Hall sensor used to sense the current flowing in the


alternator is fed into main circuit to limit the output
current and protect the equipment from over current
5. Over voltage protection circuit:

It is provided to stop the generation incase of


any fault of the components and cause over
voltage.

When over voltage exceeds 145V OVP


equipment disconnects the field circuit
BLEEDER
RESISTOR CAPACITOR
FIELD
CARD

UVC
DISPLAY,
POWER WITH UVC
MODULES CARD

TRANSISTOR

IGBT DATA
ET
DOWNLOADING
UNIT
ISOPACK POWER DIODES

These diode modules contain two diodes in a single


pack and have a base plate.

They can be mounted directly on the heat sinks


needed no insulation in between. This results in
effective heat transfer to the heat sink and thereby
reducing temperature of the device.

These isopack power diode used as 3 phase bridge


rectifier.
Rating of diode modules are as:-
D1-D6 (25 kW) Power Diode 350A/ 1200V
D1-D6 (4.5kW) Power Diode:- 50A/1200V
UVC CARD AND UVC DISPLAY UNIT

Universal application with a common design to


achieve inter changeability among the same make.

Electronic controller unit having microcontroller


can identify the rating of alternator and
automatically adjust parameters.

It can control the field current.

Ensures load sharing between two alternators.


UVC CARD & UVC DISPLAY UNIT
IGBT (INSULATED GATE BIPOLAR
TRANSISTOR)

Switching device to control DC input signal to the


field for regulating DC output.

It provide faster speed, better drive than power BJTs.

It is a semiconductor device combines high voltage


and high current BJT with low power and fast
switching MOSFET.
OVER VOLTAGE PROTECTGION(OVP)

Static over voltage protection circuit is provided to


stop the generation is case of any fault of the
components and causing over generation.

As the voltage goes beyond the setting limit for more


than 3 seconds the OVP circuit immediately reduces
the field current and Latches the output voltage at
less than 90 volts the Latching remains even without
battery.
It is tripping under no load or over load conditions
and reset by itself automatically within 2 sec.

The tripping voltage of the relay is set at 138+/- 1 V


for 4.5KW and 141+/- 1V for 25KW ERRUs.
OVER VOLTAGE PROTECTGION(OVP)
The Hall Sensor is a transformer operating with a
balanced magnetic flux principle to measure DC -
AC pulsating current with galvanic insulation
between primary and secondary circuit.

Hall Effect Sensors are used for sensing the output


load current and battery charging current. The
battery charging current is set to limit the charging
current as per the battery capacity.

These sensors are able to measure currents from 250


mA to approximately 1000A.
BLEEDER RESISTORS
ET (EXCITATION TRANSFORMER)
Excitation (Field) transformer
is used for step down the
alternator output voltage for
field circuit.
Field transformer output
voltage rectified by 1-phase
Bridge Rectifier & Rectified
voltage controlled by
switching device as per speed
& load to maintain the D.C.
output constant.
DATA DOWNLOADING UNIT

USB CONNECTOR
FOR DATA
DOWNLOADING

DATA DOWNLOADING UNIT


DATA DOWNLOADING PROCESS
FIRST CONNECT DATA LOGER TO UVC
BOX

PRESS SET PERA

PRESS ENTER

PRESS ENTER

DATA DOWNLOADING START WAIT FOR


SEVERAL MINUTES (5-8)
DATA UPLOADING PROCESS

CONNECT DATA LOGER TO


COMPUTER USB PORT

OPEN ERRU S/W


FOR UPLODING

PRESS UPLODING DATA

S/W WANT MODE OF


COMMUNICATION GIVEN
IT(USB, 1) AFTER THIS PRESS OK

AFTER PRESS OK DATA


UPLODING START
COMPUTER INTERFACE
Data can be logged through USB port by using a
commercially available pen drive.

Step 1: Insert the pen drive in the USB port


provided on CIP and wait for
approximately 40 seconds after which
the display on the LCD screen changes
to DOWNLOADING ERRU NPP
DATA.

Thereafter the display changes to


DOWNLOADING ERRU PP DATA.
Step2: After the downloading is over the display comes
back to show the default screen. Plug out the Pen
drive from the USB port. The entire operation
does not require any command from the user in
the form of key pressing to download the Data.

Step3: Insert the pen drive in the USB slot of the


Laptop/Desktop. Run the Software provided for
the analysis of data.
Step4: The name of the file present on pen drive will be
in the form of serialnumber.EFD where serial
number specifies the serial number of the ERRU
for which the data has been logged from CIP.
Select the respective file through the open file
command on the software. After the selection of
the file the data can be analyzed in Minute
Format, Hourly Format, Overall Cumulative data
analysis and Fault Analysis.
DATA CHECKING PROCESS

AFTER DATA UPLODING PRESS


LIVE DATA/ FAULT

PRESS LIVE DATA FOR DATA


CHECKING

PRESS FAULT FOR FAULT


FINDING
Power & Control Connectivity Of
Alternator With ERRU
DC- V
CIP
Connector
DC+ U
B+ W
F- F+

Battery +ve From the Alternator,


Terminal connect U, V, W and Field
Coach Load connections as F+ & F-
DC+ & DC-
Terminals
KEYBOARD
The Keyboard consists of four function keys and three
other keys for parameter setting.
Live Data:
Pressing this key displays the information of on line non-
cumulative data.
Cumulative:
Pressing this key displays the information of on line
cumulative data.
Fault:
Pressing this key displays the information of the faults
which have occurred in the system.
Set Data:

Pressing this key displays the information of the setting


parameters for the Electronic Regulator.

The other three keys are UP, DN & ENTER are


used for incrementing, decrementing of different
parameter set limits and to store them in a
nonvolatile memory.
LED NOMENCLATURE
There are 8 LED annunciations to alert the user about
the system status on line

Health: This green LED gives the health of Universal


Voltage Controller of the Electronic Regulator cum
Rectifier Unit. It is off whenever there is any problem in
the UVC.
LED NOMENCLATURE
Health:

This green LED gives the health of Universal Voltage


Controller of the Electronic Regulator cum Rectifier
Unit. It is off whenever there is any problem in the
UVC.
OV Volt:
As soon as the terminal voltage goes beyond 142 Volts
by anyhow, this RED led gives an indication that over
voltage occurred. Once this LED glows it will remain
latched unless and until the system is reset.
Alt Fail:
When the Alternator is moving above 600 RPM, but
the Alternator generated voltage is less than 110 Volts,
in such a condition it is assumed that the Alternator has
some problems, as it is not able to generate the
sufficient voltage.

This condition is considered to be the Failure of the


alternator and the RED LED glows to indicate
Alternator failure.
Bat Dis:
This red LED glows when the Battery is in the
discharging mode. Alternatively, it remains OFF during
the charge condition of the battery. In addition the normal
display gets automatically changes in accordance of
battery charging or discharging mode.
BAT CHG:
This GREEN LED glows only when the Battery is in the
charging mode. Alternatively, it remains OFF during the
discharge condition of the battery. In addition the normal
display gets automatically changes in accordance of
battery charging or discharging mode.
OV LOAD:

Over Load or Short Circuit condition is indicated by the


OL / SC FAULT LED.
Fuse Fail:

If any one or both the main fuses in the U & V phase


line fails due to any abnormal condition or the Field
Fuse is blown off, the FUSE

Fail Red Led glows to indicate the fuse failure. This


though does not affect the performance of UVC; what
for UVC health remains unchanged.
Bat Low:

As soon as the terminal voltage goes below 102V this


RED Led glows to give an indication that battery
voltage has dropped below 102V.
MAINTAINENCE
The ERRU is maintenance free equipment. Visual check
for mounting and external damages.
Weekly Maintenance:

During maintenance, check the various fuses for two


phases from alternator and the field fuse.

Check the power cable connections with load, battery


as well as with the alternator on the control-wiring box
of ERRU box.

Check the 12-core 1:1 cable continuity between


ERRUs and CIP.
Quarterly Maintenance:

Check all the wirings inside the ERRU box once in


three months of work.

Check the tightness of the various modules attached


with the ERRU box.
S. Quantity
Item Description
NO / ERRU
1 UVC Box 1
2 CIP(Coach indication panel) 1
3 Control Card 1

Power Control Module


(Comes with IGBTs, Field Rectifiers, Snubbers &
4 1
Field Current Sensors in one Integrated Module
fully assembled)
S. Quantity
Item Description
NO / ERRU

5 Power Diode Module 3

Current Sensors
6 2
( or Load Current)

Communication Couplers with 17 meters for NPP


7
side & 14 Meters for PP side 12-core wire fully 2
assembled
Probable
S. Symptoms
defects in Remedy / Remarks
NO observed
the system
Check the continuity of
The system not Power cable
1 power cables and replace if
working faulty
necessary.

Power Connect the battery and


UVC not
2 supply check the faults on LCD
working.
failure input at UVC box.
Check the continuity of the
Alternator Control
control wiring from ERRU
3. unable to wiring faulty
box to alternator.
generate power.
S. Probable
Symptoms
NO defects in Remedy / Remarks
observed
the system
3 Alternator Main fuse Check and replace (if blown) the
unable to failure ac phase fuses.
generate Field fuse Check and replace (if blown) the
power. fail field fuse.
4 Reduced Voltage Check the actual set voltage using
alternator setting the keyboard in the SETTINGS
generation changed. menu.
System in Check the current limit settings
current (total & battery charging current
control limits) and the actual loads from
mode. the display to ensure whether the
system is in current limiting mode.
PROBLEMS INDICATED BY LEDs
Over Voltage:

The Over Voltage fault can be re-setted by pressing the


Over Voltage Reset Buttons on CIP for individual
ERRUs (PP & NPP).

Over Load / Short circuit:

It indicates that the system is getting overloaded. In such


case to return to normal working condition, the load
should be decreased otherwise the ERRU will continue
running in reduced voltage regulation mode than its
normal regulation voltage.
Fuse Fail:

In case of Main Fuse (any of two) or Field Fuse failure


the LCD of CIP and ERRU gives the message. Replace
the blown fuses.

Alternator Failure:

In some cases of alternator failure (other than


mechanical) the ERRU shows the fault message.
Recharge the alternator or replace.

UVC health: Replace UVC in case of this LED glows.


Connect all the terminals strictly as directed in the
OEMs manual.

Connect Battery before starting test and see the


healthiness of UVC on keyboard display and LED.

Check the setting parameters before starting the test.


Parameters are loaded by default. If required these
can be changed as desired within certain predefined
limits.
Avoid running the ERRU at zero load. Please
connect at least base load corresponding to ERRU
capacity if testing without battery.

Vary the RPM gradually from 0 RPM to 2500 RPM.


Do not test the 25 KW ERRU without connecting the
battery while installed in the coach.

Always switch on the battery first, verify the


communication with CIP. Ensure the proper parameter
settings through the display panel and the proper load
connections before starting the test.

Never apply the field fuse when alternator is running


at a speed more than 400 RPM.
Never change the Rotary Power Changeover of the
coach (ALT1, ALT2, BAT) when the alternators are
moving and the ERRUs are in function.

The Rotary Changeover switch can be changed only at


the time of fault or emergency and only when the
alternators are not moving (train is stationary).

Do not touch the live parts inside the ERRU while


running.

Do not touch the IGBTs with naked hands.


Do not start the alternator through prime mover if
ERRU is not connected with battery.

Do not charge the battery by any external source if its


voltage is more than 140 Volts. This will trip the
ERRU in over voltage latched condition.
Phase II Module No. STC-GS-1
The brushless alternator with the help of rectifier cum
regulator unit (RRU/ERRU) is capable of developing
voltage from minimum speed to maximum speed.

One unit of 4.5 kW brush less alternator is used in


non AC (train lighting coaches) self generating
coaches.

2 units of 25 kW brush less alternators in parallel


with RRU/ERRU, battery, are used on self
generating AC coaches.
Ratings in use (at dc output terminals)

3 kW for MG TL coaches.

4.5 kW, 110/120 V DC, 38 A for TL coaches.

12 kW, 110/130 V DC for MG AC coaches and Jan


shatabdi.

25 kW, 110/130 V, 193 A for under slung and


RMPU type AC coaches
Specification no. Equipment

RDSO/PE/SPEC/TL/0054-2003 3 & 4.5 kW, 110 V


Rev 0 Amdt 1&2 brushless alternator

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.

RRU/ERRU used for


Rectify ac output of alternator
Regulate output of alternator
Prevent reverse flow of current from battery
Alternator Part I Part II

4.5 kW KEL Kundra Star Electric Company

SIL PD Steel

HMTD Kapsons

Presstech

Best & Crompton

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

Suitable for bi-directional generation

Operating condition -5 to 55 0C and 100% RH

Bogie transom mounted

Universal applicability

Able to operate without battery


Rotor shaft made of EN 24 (hardened and tempered)

Coach wheel Dia: New/fully worn -915/813 mm

Rotor and Alternator pulleys dynamically balanced

Finished shafts to be 100% ultra sonic tested

I/P & O/P sockets terminated on separate terminal


posts.

RRU is magnetic amplifier type field excitation control.

Insulated cleat provided on frame to support cables


Dual coated enameled winding wires and VPI adopted

Winding star connected (formed in stator overhung)

RRU has un-controlled, 3 phase full wave rectifier

RRU regulate O/P voltage at all speeds 800-2500 RPM


and at all loads from 10 A-rated current

Universal RRU when used with other make Alternator


MFO permitted tolerance of +- 50 RPM

Sr .no of Alternator: Ist two digits-Yr of mfr, Next two


digits- month of mfr & No. of m/c manufactured in
month.
Each alternator set comprises of

1 TL/AC alternator with 1/2 V grooved pulleys

Safety chains 2 for 4.5 kW/ 3 for 25 kW

1 RRU/ERRU

Belt tensioning device complete

Axle pulley complete with rubber pad and


hardware
Suspension pin complete with hardware

Crimping type sockets for Alternator and


RRU/ERRU

Maintenance manual

Items procured separately

V belts 4 (TL), 6+6 (AC)

Nylon suspension bushes 2/set


Cut-in speed:
Alternator speed in RPM at which rectified output is
110 V at no load.
Min speed for full output (MFO):
Min Alternator speed in RPM at which it gives rated
O/P current at rated V.
Voltage and Current detector:
Device to limit voltage and current of alternator to pre-
set values.
4.5 kW TL Coach 25 kW AC coach
alternator alternator
Wound stator with field coil
Rotor shaft with lamination
End shield (Driving End)
End shield (Non Driving End)
Bearing (NU311,Driving End)
Bearing (6309, Non Driving End)
Safety Chains
Lock nut
Lock Washer

Alternator Pulley 4 V groove

Cast Nylon bush

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

Both windings (AC & Field) accommodated in Stator.

AC windings distributed in small slots.

Field winding concentrated in two slots and each coil spans, half
the total no. of slots.

Rotor consists of stacked stampings like cogged wheel having


teeth and slots uniformly distributed on surface skewing rotor
axis.
Core of stator (completely embraced by field coils) retain
residual magnetism, if excited once by battery.

Flux produced by field coils find its path through rotor.

On rotation, rotor offers varying reluctance path for the field


flux.

Varying field flux induces alternating voltage in AC coils.

Frequency depend on speed and magnitude on speed and level of


excitation.
Circuit diagram
Functions

Rectification of 3 phase AC output of alternator


using full wave rectifier bridge.

Regulation of voltage at set value.

Regulating output current at set value.


Components

3 ph full wave rectifier (Diode D1 to D6) with heat


sinks.

1 ph full wave rectifier (Diode D16 & D17) on heat


sink along with free wheeling diode D18.

Sensing diodes (D19 & D20) for current/voltage


setting with zener diode Z1.
Full wave rectifier
4.5 kW
Drive end: NU-311 (Cylindrical)
Non drive end: 6309 (Deep groove ball)

DE- NU-311
25 kW

Terminal end NU-312 (cylindrical)

Other end 7312 (angular contact ball)

L 10 life 16 million km at 1500 RPM

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

Ripple content (max) 5% 3%

Alt pulley width 110.5+/-1.5 mm 200+/- 1 mm

Axle pulley width 110.5+/-1.5 mm 210+/- 1 mm

Cut in speed (min)* 357 RPM 400 RPM

MFO (max)* 600 RPM 800 RPM

Alt pulley groove angle 34+/-0.5 0 36+/-0.5 0

Axle pulley groove angle 38+/-0.5 0 38 +/- 0.5 0

* With new wheel dia (915 mm)


Feature 4.5 kW 25 kW
Tensioning device working length 310 mm 295 mm
Distance of axle pulley from 140+-1 mm 228+/-0.5 mm
wheel hub
Weight (max) NM < 525 kg
Current limit set between 228 & 232 A
Voltage not to dip <120 V at 225 A
Mating of Alt pulley with shaft > 80 %
Free hanging clearance from RL 178 mm
O/P V tolerance (10 A to full load) +- 4%
Feature 4.5 kW 25 kW
I limiting by potentiometer 228-232 A
Voltage not to dip below 120 V at 225 A
Max V set through potentiometer 140 V at 800 rpm on
10 A load
Max I set through potentiometer 232 A
Bearing L10 life > 16 million km at
1500 RPM
Bearing re-greasing interval >30 M or 6 lac km
OVR set at 145+- 1 V
Size of rotor (D * L)
No of teeth (slot) on rotor 8 12
Sr SMI/MS N0 Description Reference

Instruction for re-assembly of


NH type bearing of 18 kW EL/7.1.21/K
1 AC/SMI/9
KEL make alternator during Dt. 03.7.1991
POH

RDSO/PE/SMI/ Fits and limits on bearings of


EL/7.1.38/1
2 AC/ALT/0002 alternators and motors used on
Dt. 20.01.99
98(Rev.0) AC coaches.

RDSO/PE/SMI/ Procedure for measuring


EL/7.1.38/1
3 AC/ALT/0003, bearing clearance of a free
Dt. 20.01.99
98(Rev.0) bearing.
Sr SMI/MS N0 Description Reference
4 RDSO/PE/SM/ Condition monitoring of EL/7.1.38/1
AC/ALT/0004 bearings. Dt. 20.01.99
98(Rev.0)
5 RDSO/PE/SMI/ Fitment of outer race of EL/7.1.38/1
AC/ALT/0005 bearings in the housing. Dt. 20.01.99
98(Rev.0)
6 RDSO/PE/SM/ Testing and checking of new EL/7.1.38/1
AC/ALT/0006 bearings for alternators and Dt. 20.01.99
98(Rev.0) motors of AC coaches.

7 RDSO/PE/SM/ Guidelines to identify genuine EL/7.1.38/1


AC/ALT/0007 and spurious/reconditioned Dt. 20.01.99
98(Rev.0) bearings.
Sr SMI/MS N0 Description Reference
RDSO/PE/SM/ Proper mounting ,maintenance
8 TL/ /0003-99 and handling of power and April 1999
(REV.`0) field diodes provided in RRU
RDSO/PE/SMI/
Proper load sharing in AC EL/7.1.38/1
9 AC/001899
coaches. 05.02.1999
(Rev.0)
RDSO/PE/SMI/ Testing procedure for proper
10 AC/0019 2002 working of OV protection EL/7.1.38/1
(Rev. '0') provided in 25 kW alternator.

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.

Arrangement for anchoring


RDSO/PE/MS/TL of outgoing cables from
EL/1.6.9.15
21 / 0002 99 alternator TB/box to RRU
dt.15.02.1999
(REV.0) TB and UF TB of TL
alternators

RDSO/PE/G/0002 Guideline for rewinding of EL/7.1.38/1


22
-2005 (Rev. 0) TL/AC Alternator Aug. 2005
Sr. SMI/MS N0 Description Reference

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.

Temperature rise test


Alternator run at Irated and 2500 rpm and repeated at MFO.
Forced air-cooling 6 & 4 m/sec for alternator and RRU
respectively. Temperature rise by resistance method above
ambient of 550 not to exceed specified value.
IR Test

Measured before and after HV test between all terminals


shorted together and body with 500 V dc megger. Value
to be > 20 M.

HV Test

Immediately after temp rise test 1500 ac rms 50 hz


(gradually increased from 500 V) applied all shorted
external terminals and frame for 1 min. For acceptance
duration 5 sec and without temp rise test. ILeakage < 30 mA.
Open Circuit Test

Alternator run at minimum 5 speeds


(500,900,1500,1800, 2500) with field separately excited.
O/P voltage vs field excitation curves are plotted.

Load test

Conducted with resistance load and or with battery.

All characteristic tests done at 129 V, 96.5 A at 1500


rpm. (for 25 kW) Test consists of , No load test,
speed vs O/P, and Current vs V test.
No load test
Conducted at base load of 10 A. DC O/P voltage recorded
at MFO,1500,1800 and 2500 rpm and variation not to
exceed 4% of pre set voltage.

Speed vs O/P voltage


Done at full rated and half rated current at speeds from
MFO to max speed. V not to vary 4% of pre set value.

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 after I vs V test. Point when , current doesn't


increase even with load increase. Not to exceed 230 A.

Mechanical over speed and induced voltage 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

Ripple content not to exceed 3%. (Vmax-


Vmin)/(Vmax-Vmin)*100 %

Mating of pulley with shaft: Done using plug and ring


gauges and prussian blue and media

Shorting of power diode: At 1800 rpm and full load


for 2.
OC power diode

Junction temp of semi conductors

Dynamic balancing of rotor and pulleys

MFO at cold and hot condition

MHO measurement

Fire retardant test for terminal board


Tightening of alternating pulley with 30 kg-m torque
by torque wrench.

Heat the bearing by the induction heater during


fitment.

Use proper grade of grease as per manufacture


recommendations.

Quantity of grease to be used:


Ball Bearing 6309 -13 gms (approx)
Roller Bearing NU 311-20 gms (approx)
Fuse wire instead of fuse link.

Over tightening of diodes.

Less size of lead wire.

Hammer on pulley during removal.

Over tight the alternator pulley.

Heat the bearing more than 100oC.


Put extra grease in bearing.

Use less than 80% mating surface alternator pulley.

Use alternator pulley if V groove shine/0.5mm wall


are worn out.
Locking of alternator suspension hanger pin.

Alignment of alternator pulley with axle pulley.

Use same grade of V belts.

Check belt tension as per RDSO recommendation-4


kg weight, sag-14 mm. (max)
Tightening axle pulley with 30 kg-m torque and gap
between hub 3mm.0.5mm.

Check any damage or worn out part.

Check fitment of safety chain with alternator & bogie.


OVP is a protective relay used to protect the
electrical equipment from over voltages in
coaches.
Over voltages are voltages that exceed the normal values.

These normal values determine the insulation, which is


designed and tested according to the appropriate
regulations.

The degree of insulation varies depending on the type of


electrical equipment.

Over voltage generation may cause failure of lights & fans


and may lead to smoke emission in some cases.
Control winding of Magnetic Amplifier(MA) in RRU
getting open ckt.

Failure of Zener Diode in voltage detector.

Opening of resistances/potentiometer in the control unit.

Failure of control rectifier diodes (D5,D6,D7).

Opening of field diode or free wheeling diode.


It is a safety device.

It protects the coach from over voltage generation if


control circuit failed in RRU/ERRU.

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

If the voltage goes beyond 142volts dc for more than 3


seconds the OVP circuit immediately reduces the field
current and latches the output voltage at less than 90
volts.(in shunt type OVP)

The latching remains even without battery


OVP sensing the output voltage, and fed to a comparator,
electronic relay and a delay circuit. When the voltage
exceeds the set value, the delay circuit switches ON and
the comparator gives a pulse to an electronic relay
connected in series with the field circuit.(in series type)

The opening o f the electronic relay stops the generation,


After a preset delay time the signal is latched and the field
current will not be allowed.

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

BHELEML 7 8 15R 15B 13 14 145V DC -

HMTD B+ B- 2 2 - - 150V DC -

PIPL DC+ DC- W W1 U V 150 V DC -


1. Disconnect all terminal
wires at OVP.

2. Connect the OVP Test Kit


wires to corresponding
OVP terminals as per
SMI-0047-2013 (Rev.0).
3. Connect 110V DC
supply to Testing Kit.

4. Switch ON the input


supply ( Keep the Variac
position at minimum).
5. Increase the Variac
gradually to trip the
OVP.

6. Note the AC and DC


voltage reading at the
time of OVP tripping.
7. Finally decrease the
voltage with Variac and
switch off the supply
of testing kit.

8. Reset the OVP by


pressing the Reset button.
9. Reconnect the wires of
OVP by disconnecting the
Test kit wires.
Reasons for not working of OVP:
o Terminal connection of OVP are not connected properly.

o Incoming supply AC/DC to the OVP may not be


available.

o Relay used in the OVP circuit may be faulty.

o Electronic circuit used in the OVP may be faulty.

o Reset push button may be defective.

o Free wheeling diode of RRU may be defective.


It leads to over generation/low generation (80-90volts).

Causing lights and fans may burnt/dim.

Cells may over charge causing cell burst/internal short


ckt/under charge due to low generation.

Insulation damage, joints may lead to earth leakage.

There is a chance to broke fire.

Note: Check the OVP once in every 3 months on train.


Battery consists of two or more
cells electrically connected.

Cell is a device that converts the


Chemical energy into electrical
energy by means of an
electrochemical reaction.
Battery Classification
Battery

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

Specific gravity is measured by Hydro Meter

Cell open circuit voltage = Specific gravity + 0.845

Specific gravity varies with temperature

Higher Specific Gravity More capacity but shorter life

Lower Specific Gravity - Less capacity but longer life


Where is this 2.0V coming from?
At the negative electrode
Discharge
Pb + H2SO4 PbSO4 +2H+ + 2e- E = 0.356V
Charge
At the positive electrode
Discharge
PbO2 + 2H+ + H2SO4 +2e- PbSO4 + 2 H2O E = 1.685V
Charge
Overall Reaction:
Discharge
PbO2 + Pb + 2 H2SO4 PbSO4 (+ve Plate) + PbSO4 (-ve Plate) + 2 H2O
Charge
E = 2.041V
Flooded Vs Sealed Batteries
Flooded Lead-Acid Batteries

Electrodes/plates are immersed in electrolyte


Vented for gas escape
Distilled water must be added occasionally

Sealed Lead-Acid Batteries

No free electrolyte

Oxygen recombination and hence water is retained

Regulated vent to allow gases to escape at particular pressure


Recombination Reaction
At Positive Plate

H2 O 2H+ + O2 + 2e-

At Negative Plate

O2 + Pb PbO

PbO + H2SO4 + 2e- + 2H+ 2PbSO4 + 2H2O + Heat


Different types of Plates

Plante Flat grid Tubular


AGM (Absorbent Glass Mat)
SEPARATOR in VRLA CELLS
Conceptual View - Oxygen Recombination Process

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

PbO2 + 2H2SO4 + Pb > 2PbSO4 + 2H2O >


2PbSO4 + 2H2O PbO2 + Pb + 2H2SO4

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

CHARGED DISCHARGING DISCHARGED


LEAD ACID BATTERY CHARGING
CHARGER CHARGER

_ - SULPHURIC ACID _
+ +
- WATER

MIN. H 2SO4 -LEAD DIOXIDE ON + MAX. H 2SO4

MAX. H2 O -LEAD SULPHATE ON + MIN. H2 O

-SPONGE LEAD ON -
-LEAD SULPHATE ON -
MIN. PbO2 MIN. Pb MAX. PbO2 MAX. Pb

MAX. PbSO4 MAX. PbSO MIN. PbSO4 MIN. PbSO4


4

DISCHARGED CHARGING CHARGED


SEALED 2V CELL
SEALED 12V BATTERY
INITIAL CHARGING
INITIAL FILLING AND CHARGING
CONNECTIONS
ACID FILLING AND LEVELLING
CHARGING
SPECIFIC GRAVITY CHECKING
LEVELLING DURING CHARGING
MIST DURING CHARGING
VOLTAGE BEFORE & AFTER

DRY CELL END OF AFTER REST


WITHOUT ACID
CHARGING PERIOD
LMLA Battery Charging
When Charging Current (Amps) ECV at the Specific Gravity
Initial % Final % end of Charging Full
100% Discharge
discharge
Initial Filling 10% of rated Ah 5% of rated Ah 1.85V Filling 1.17
and charging capacity till capacity from 2.4V 1.22 0.005 0.02
voltage reaches till end of charge Fully
2.4V (2.6 to 2.7V)
charged
1.24 0.005
Reading to be taken every 4 hours. Allow rest period during charging if
Electrolyte temperature exceeds 50C. Add electrolyte with initial filling
specific gravity for topping up during initial charging only. Total mandatory
minimum charge input in Ah is 550% of rated battery Ah for cells with unformed
plates (300% for partially formed plates)

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

2.4v per cell at a charging current of 5% of rated ah

110% of drained ah capacity should be put back after every


discharge to maintain battery healthiness

Equalizing charging

Whenever voltage variation among cells 0.1v on float or on load


or specific gravity variation among cells 0.02

Otherwise, once in three months

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)

Minimum charge input (ah) during equalizing should be 50% of the


rated ah capacity

If it is a constant voltage charger, increase the voltage to 2.55V per


cell, charge for 16 hours at a current setting of 10% of rated ah
capacity

Recommendation

If voltage variation or specific gravity variation beyond specified


limits persist even after equalizing, replace particular cells.

They need to be tested and revived separately.


MAINTENANCE
LMLA batteries are widely preferred as
maximum life can be obtained from the battery
with little maintenance.

At the same time, they can suffer from premature


death if not given proper attention for periodic
maintenance.
Recommendations
Proper initial charging, correct specific gravity and
correct quantity of acid are very important for little
maintenance later.

Records of initial load test is very important to verify the


performance of batteries later and will help in identifying
reasons for failure later, if any.
What can go wrong during Initial
Charging?
Contaminated acid
Wrong specific gravity of acid
Insufficient acid quantity
Reverse connections while charging
Incomplete charging
Loose terminal connections or over tightening.
Cells left with dummy vent plugs.
Damaged cells installed leading to electrolyte leak.
What can go wrong in operation?
Wrong cable size between charger and battery
Improper connector sizes between cells
Wrong charger voltage settings
Insufficient acid quantity
Adding acid instead of DI water
Leaving vent hole and level indicator hole open
Insufficient or overcharging
High room temperature
Wrong calibration of measuring instruments
Routine Maintenance - Monthly
Check for dust accumulation around all connections from input
cable till the last cell in the battery bank and clean the dust
Check for any corroded bolts / cable lugs / connectors Clean /
replace them apply petroleum jelly
Check and clean dusted vent plugs and refit properly
Check and replace any broken cell as any acid leak will damage the
battery stand
Identify one pilot cell for every six cells in the battery
Check and record Float Voltage of pilot cells and verify if it is as per
recommendations given in manual
Apply site load and measure on load voltages of pilot cells after 15
minutes on load
Routine Maintenance Half yearly
Verify monthly maintenance records and ensure all
mandatory checks are carried out and are in order

Check the level of electrolyte in each cell and top up with


distilled water to maintain level within the marks

Check for proper functioning of measuring instruments


multimeter / ammeter / voltmeter recalibrate if necessary

Check float voltage and electrolyte specific gravity of each


cell and verify the State of Charge(SOC) of each cell

Give equalizing charge as recommended in the manual

Replace any broken vent plug or float guide


Routine Maintenance - Annually
Clean all cells for dust and acid mist

Clean all vent plugs for removing accumulated dust

Clean / replace corroded connecting parts

Ensure full state of charge of battery

Conduct load test up to 80% depth of discharge of battery

Level the electrolyte and conduct equalizing charge as given


in the manual

Check charger settings for correctness of voltage and


current as recommended in the manual
&


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

This video is available on internet at RDSO


Directorates CAMTECH Publications for
download Electrical 2015-16

This video can also be viewed on Youtube CAMTECH


Gwalior videos or following link:

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 reliability of the V-belt is essential to ensure that there is


no breakdown in the passenger amenities, viz. lighting, air
conditioning and air circulation devices i.e. fans in the
railway coaches.

Railways are using C-122/3155 Lp V-belts.

RDSO has also issued specification no.


RDSO/PE/SPEC/AC/00160-2014 (Rev. 1) for long life V
belts with Aramid cord which are under trial.
a. V-belt Drive

A drive which consists of one or more V-belts


mounted on grooved pulleys.

The profiles of the belts and the pulley grooves are


such that the belts come into contact with the
sides of the pulley grooves only and not with the
base of the grooves.
b. V-Belt
A belt, the cross section of which is shaped roughly like
a trapezium.
The latter is usually isosceles.

On the cross-section the trapezium is outlined by the


base, sides and top of the belt.

Cross Section of V-Belt

W = Nominal top width of a V-belt


A = Angle of V-Belt
T = Nominal Height of a V-belt
Wp = Pitch width of a V-belt
c. Angle of V-Belt (A)
The included angle obtained by extending the sides of the
belt.

d. Nominal Inside Length


The approximate length along the inside of belt while is an
untensioned condition.

e. Nominal Height of a V-belt (T)


Height of the trapezium outlined on a cross section.

f. Nominal top width of a V-belt (W)


Top width of the trapezium outlined on a cross-section.
g. Pitch width of a V-belt (Wp)

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.

h. Effective belt length (under specified tension)

The sum of the effective circumference of one of the


measuring pulleys and twice the distance between pulley
centres.
i. Pulley groove pitch width (Wp)
That width of the pulley groove which is dimensionally
the same as the pitch width of the belt associated with
the pulley.

j. Pulley pitch diameter (dp)


The diameter of the pulley measured at the groove pitch
width and represents the effective diameter of the pulley.

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.

Constructional cross sectional view of C-122 V-Belt


V-belt base material has the following properties:

Parameters Requirement
Hardness, IRHD 82 4
Tensile strenth, Kg/sq cm 100 min.
Elongation at break, % 150.min.

The finished belting has the following physical properties:

Elongation on a length of 200 Maximum percentage elongation


mm between reference lines. at load of 300kgf shall be 3% and
upto break 15%

Breaking strength 1150 Kgs (Min.)


Tension during actual conditions:

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

Service correction factor 1.6

Length correction factor 0.97

Correction factor for arc of contact 0.94


Cross section of the endless V-belt in C section is as shown
below with the nominal top, width and thickness in mm for C-
122/3155 Lp as indicated.

Nominal top width W = 22 0.5mm


Nominal thickness T = 14 0.5 mm

Angle = 40 degrees
The pitch lengths of belts corresponding to given pulley pitch
diameters and centre distances may be obtained by the
following formula :

L = 2C + 1.57 (D+d) + (D-d)


4C
Where,
L = pitch length of the belt
C = centre distance of the drive
D = pitch diameter of larger pulley, and
d = pitch diameter of smaller pulley
If the actual pitch length of the belt is equal to
nominal pitch length 1.0 mm, the belt is given
the code number as 50.

A deviation of 2.0 mm in length is represented by


one unit and the code number increases or
decreases as the length is more or less.
In order to avoid unequal distribution of load, the
belts running on a multiple V-belt drive should be
matched sets.

The belts of the same nominal pitch length matched to


the same grading number only shall be used for a
particular set.

The belts are kept/supplied in the matched set tied


together consisting of 12 or 4 belts as per requirement
with grade between 48 to 52 only.
Belt shall be checked for any deformity, bulging,
waviness, cracks blemishes, unevenness etc..

The v-belts confirming are marked legibly and


durably on the top surface with the symbol indicating
the belt cross-section, the nominal pitch length in mm,
grading number (length-code), year of manufacture
and manufacturers name or trade mark.
The pitch length of the belts shall be checked as
mentioned earlier.

The angle of V-Belt shall be checked with Profile


projector.
Along a straight portion of the
belt in an un-tensioned state, the
cross-section of the belt shall be
such that when placed in a gauge
as shown in given figure, it shall
not touch the bottom of the
gauge, the edges of the top width
s and t shall not be higher
than the points u and v at the
top of the template and the
Note: The pitch width of the belt 19
guiding mark mn on the mm, is the width of the gauge
template shall cut the whole at the level of this guiding mark

width of the belt in its upper half. mn drawn on the gauge.


Unfavorable storage conditions can lead to reduced belt
life and to variations in belt length. Following are the
important criteria for good storage.
The V belts should be stored in a cool, dry and well
ventilated stock room away from direct sunlight, steam
pipes, oil & corrosive fumes, high voltage apparatus.

The ambient room temperature shall be preferably


below 30 degree C.

Belts should not be stored on the floor or near


windows, radiators or airflow from heaters.
Some fibres used in strength members of belts are
subject to shrinkage in storage, the amount depending
on the temperature, relative humidity, and storage time.

During storage avoid excess weight on and distortion


of belts.

The ideal means of storage is hanging on saddle type


pegs. When the longer belts hung on pegs should be
coiled so that the loops are not greater than
approximately 2500 mm in circumference.
Pegs should be crescent (semi-circular) shaped and
large enough to avoid compression set from corners or
from acute bends of the belt.

It should preferably, not be stored for more than one


year after the date of manufacture.

Ensure that issue of V belts is being done according to


FIFO (First in First out) policy.
S.No. Description Particulars

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

5. 4.5 KW Axle pulley


Dia (pcd) 572.6 0.4 mm
Width 136.5 1 mm

6. 4.5 KW Alternator pulley


Dia (pcd) 200 0.3 mm
Width 136.5 1 mm
i) 25 KW alternators are provided with double end
drive with six belts on either side.

ii) 12 KW alternators are provided with single end


drive with six belts.

iii) 4.5 KW alternators are provided with single ended


drive with four belts.
Phase II- Module No. STC-GS-1
Checking and testing of V- belts drive is essential to ensure
proper working of TL & AC alternators, reliable generation and
proper load sharing between two alternators in AC coaches.
(Ref: RDSO/PE/SMI/TL/0027-2004, Rev.0 and guidelines issued
vide RDSO letter no. EL/6.9.9 dated 23.05.2013 & EL/7.1.38/1
dated 20.01.2011)

In order to check the new V-belts for proper fitment, gadgets


should be available at each depot/workshop for checking the
following:
Pitch length of V belt
Angle of V belt
Section of V belt
Pitch length of all the belts shall be measured by pitch length
testing machine before providing the belts in the coaches.

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.

Two or more makes of belts should not be used in a set.

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.

Electronic grade testing (pitch length) machine

Gadget to check pitch length of V belt


Nominal circumference of the pulley at pitch dia is 700 mm
Nominal pitch length of the belt is = 2C+700 mm
Along a straight portion of the belt in an un-tensioned state, the
cross-section shall be such that the edges of the broader (top)
side of the belt shall touch the sides of V-groove having an
included angle of 38 degree and the edges of the narrower
(bottom) side of the belt shall touch the sides of V-groove
having an included angle of 42 degree. The flanks of the belt
shall not touch the sides of the V-grooves.

Gauge for checking angle of V belt


Along a straight portion of the belt in an un-tensioned state, the
cross-section of the belt shall be such that when placed in a
gauge as shown in above figure , it shall not touch the bottom
of the gauge, the edges of the top width s and t shall not be
higher than the points u and v at the top of the template and
the guiding mark mn on the template shall cut the whole
width of the belt in its upper half.

Note: The pitch width of the


belt 19 mm, is the
width of the gauge at
the level of this
guiding mark mn
drawn on the gauge.
For effective power transmission from axle to alternator, health
of pulleys should be good.

Following Instructions to be followed during POH/IOH, C


schedule and maintenance at Workshops and coaching depots.

If bottom of the groove is


observed shining throughout
uniformly, the pulley should be
replaced.
The pulley groove walls should be examined for ovality with
the help of a steel scale. If the walls are worn out by more than
0.5 mm the pulley should be replaced.
Surface matching between pulley bore and shaft should not be
less than 80%.
The key in shaft should be fitted properly.
Worn key must be replaced by spare EN8 key. If matching of
80% is ensured then the chances of key failure are very less.
The angle of grooves should be checked by gauges.

If angle has increased, the pulley should be replaced. There are


different gauges for axle pulley and alternator pulley.

Gauge for checking


groove angle of
Alternator and Axle
pulley
Replace rubber pads of axle
pulley 100%. Check rubber
quality in each lot from M&C lab.

Checking of gap
between two halves
of Axle pulley

Ensure gap between two halves


of axle pulley to 3.0 0.5 mm
and tightening torque should be
upto 30 kg - mtr (maximum)
Life of pulleys is approximately 4 years. Date of replacement
should be punched on it as well as the alternator number on
alternator pulley, as they are matched.
After removal of alternator for POH, gap between bogie
suspension brackets should be checked.

Excess gap between bogie bracket and alternator suspension


bracket will lead to misalignment of alternator.
After fitment of alternator in the bogie suspension bracket,
alignment of alternator and axle pulley should be checked.

It can be checked by cord which should touch 4 edges of both


pulleys simultaneously.
It can be checked by laser beam also. Beam from
alternator pulley groove center should fall in the
center of corresponding axle pulley groove.

Do not paint the pulleys after cleaning. It will affect


heat dissipation.
Do not use repaired pulleys.

Clean pulleys, they should not have any dirt/grime/oil


traces.

Replace pulleys if grooves are worn out by 0.8 mm


depression on sides or bottom of groove is uniformly
shining.

Ensure gap between two halves of axle pulley to 3.0


0.5 mm and tightening torque should be upto 30 kg -
mtr (maximum).
Before commissioning of new belt tensioning device during
production of coaches, POH/ IOH or whenever spring or belt
tensioning device are replaced during normal maintenance, the
following instructions shall be followed.

It should be ensured that proper belt tensioning device with


spring as given below is provided.
Alternator No. of turns Dia. of
Drawing No.
capacity of spring spring wire
ROSO/PE/SK/AC/
25 kW 11 16
0068- 2004 (Rev.0)
4.5 kW SKEL 3940 14 14
Indication plate of belt tensioning device is cut to 250mm
irrespective of the kW rating of the alternator.
It is only to indicate that spring has to be changed if proper
tension with 4 kg weight test is not achieved.
Belt should be tightened to the maximum extent possible and
measurement of proper tension is to be done as under:
A weight of 4 kg should be hanged from the centre of the belt
span and see that the top surface of this belt does not go below
bottom surface of remaining belts.

Checking of V belt tension with 4 kg weight


Belt to be tightened till it reaches red mark
which may be confirmed by a 30cm steel scale.

For this following may be followed:

a. Insert steel scale of size 30cm as


shown and check that it is
passing easily between the V-
belts.

b. In case desired V-belt tension is


not achieved up to 250mm of
spring length, then tension rod
should be replaced.
Checking of V belt tension with
4 kg weight and steel scale
c. Ensure 35/50 mm barrel bush gap in the bogie
bracket of TL/AC coaches respectively.
(Ref: RDSO/PE/SMI/AC/0042-2009, Rev0)

Spring testing

Ensure testing of springs before fitment by


conducting, compression test. Compression test shall
be conducted on compression testing machine or
fabricated system in depot/ workshop.

Spring compression in step of 10mm and weight


applied shall be recorded in the format given on next
slide and deflection in mm per kg of load shall be
calculated.
Sr. Spring Wt. in Spring rate Remarks
length in mm kg. derived
1. 345 0 (Zero) Value of kg/ Obtained value of spring
mm should be stiffness should be verified for
2. 335 Weight
calculated. 4.5kW as per RDSOs drg. No.
3. 325 should be
SKEL-3040 sheet 2 as well as
4. 315 recorded
modified springs for 25kW
5. 305 alternator as per RDSOs drg.
6. 295 no. RDSO/PE/SK/AC/0068-
2004 (Rev.0).

Average value of old spring as


per RDSOs drg. no. SKEL -
3040 sheet 2 should be within
2.8-3.2kg/mm for 4.5kW and
4.8-5.5kg/mm for modified
springs for 25 kW alternator as
per RDSO drg. No.RDSO/
PE/SK/ AC/ 0068-2004 (Rev.0)
Spring Dimensions

S. Parameter Old spring drg. No. Modified spring drg. No.


No. Checked SKEL 3940 sheet 2 RDSO/PE/SK/AC/ 0068-2004
(Rev.0)
1. Free length 3453 345 3
2. Wire dia 14 0.1 16 0.2
3. Outer dia 114 1 118 1
of spring

4. No. of coils 14 12
5. Tensioning 780mm 780 mm
rod length
Following shall be checked in belt tensioning device:

Tensioning rod thread for any damage

Deformity in spring sheet

Deformity in rotary spring sheet

Damage of threads in special nut

Cut/ rubbing mark in spring coil


Ensure the voltage setting of 4.5kW/25kW RRU/ERRU
of TL and AC coaches.

Ensure proper load sharing of both alternators equipped in


the AC coaches.

The latest instructions for the difference in current of both


alternators are 30 Amp & 10 Amp in case of RRU &
ERRU respectively.

Ensure that every RRU & ERRU have equipped with


healthy OVP (Over Voltage Protection) relay and its
correct voltage setting is to be tested.
Ensure proper battery charging / pre-cooling during
maintenance before train departure to avoid sudden
loading of alternators. This will reduce the cases of belt
dropping.

Ampere setting of RRU/ERRU shall be ensured as per


specified limits.
Phase II- Module No. STC-GS-1
1. Belt slippage

Probable Causes : Alternator/ axle pulley worn out


Improper tension of V belts

2. Belt turn over and face twisted


Probable Causes : Misalignment of alternator/ axle
pulley
Particular V belt loose
3. Excessive stretch
Probable Causes : Improper spring tension of belt
tensioning device
4. Rapid wear
Probable Causes : Excess tension on V belts
Improper spring tension of belt
tensioning device
Pulley groove pitted
Misalignment of alternator/ axle pulley
Poor material quality of V belts
5. Belt bottom cracks wear
Probable Causes : Alternator/ axle pulley groove worn out
Poor material quality of V belts

6. Belt top cracks


Probable Causes : Pulley groove angle small
Poor material quality of V belts
7. Belt dropping
Probable Causes : Sudden loading on alternators
Improper load sharing between alternators
Current controlling of RRU/ERRU not
proper
Shifting of axle pulley
Misalignment of alternator/ axle pulley
Lateral play in alternator
Shifting of alternator shaft resulting in
shifting of alternator pulley and
misalignment.
8. Smoking of belts
Probable Causes : Alternator/ axle pulley groove worn out
Sudden loading on alternators
Unequal tension among the V belts
During maintenance/after fitment of alternator in the bogie
suspension bracket, alignment of alternator and axle pulley
should be checked.
It can be checked by cotton cord which should touch all the
four edges of the both pulleys simultaneously.
It can be checked by laser
beam also.
Beam from alternator pulley
groove center should fall in
the center of corresponding
axle pulley groove.
If misalignment is found, locate the cause of misalignment and
rectify it.
The gap formed due to the wear of bogie bush must
be measured during maintenance.

If it is more than 1mm, it should be replaced with


proper nylon bush because it may lead to wear of
suspension bracket that further contribute to destroy
the alignment of suspension arrangement
permanently.
The clearance between suspension brackets found more due to
improper workmanship/ measurement during the manufacturing
process of bogies.
Gap between bogie suspension brackets should be checked.
Excess gap between bogie bracket and alternator suspension
bracket will lead to misalignment of alternator (400+4mm max.
for AC and 268+4mm max. for Non AC coaches)
if the distance is more than specified, there may be
lateral play of alternator which affects the life of V
belts and the parallelism of brackets due to the
hammering effect of the horizontal play of the
alternator.
This also damages the bogie bushes.

It is better to put a suitable


washer between the
alternator collar and one of
the suspension brackets duly
checking the alignment.
The alternator may get stuck up due to the seizure
of bearing that may in turn results the belt
dropping.

To avoid this type of failures, the following


practices shall be followed:
Bearings should be cleaned and greased properly
during POH.
End shield of alternator should be properly
tightened to avoid entry of abrasive particles.
Vibration checking and clearance checking for
bearing should be done during POH.
Groove of alternator pulley and axle pulley should be
checked during POH and at the time of replacement
of V belt for worn out and groove base shining and
ovality.
The pulley is to be replaced if pulley groove width is
increase by 0.5mm at workshop level and 0.8mm at
depot level or the groove base of the pulley is shining or
mechanically damaged.

The standard groove angle is 36 degree for alternator


pulley and it is 40 degree for axle pulley. If the groove
angle is more, excessive wear at the base section or belt
bottom crack may happen and if the groove angle is
small, crushing and wear of belt at top or belt top crack
may happen.
Both the alternator pulley and axle pulley shall be
replaced during alternate POH or when ever
mechanical damage of pulley occurs.

Replace the old axle pulley fixing rubber pads with


new rubber pads during POH and whenever
replacement of axle pulley is required.

The number embossed in both halves of the axle


pulleys must be same.
Ensure gap between two halves of axle pulley to 3.0
0.5 mm with the tightening torque of 30 kg-m
(maximum).

The gap between axle


pulley halves should be
checked with feeler gauge
during maintenance.

After fixing of axle pulley,


verticality of the pulley
should be checked with
plumb or spirit level.

It is to be ensured that diameters of the pulleys are same as


specified.
Special care should be given during the provision of V belts
since it is one of the root causes of premature failures:

The reinforcement cords are broken if the belts are


forced over pulleys during fitment.

Change the belt set and install them in grooves only


after loosening the tension spring of belt tensioning
device.

During replacement, do not ride the wheel over belts


that definitely damage the reinforcement cord of V belt.

If belts are replacing, replace all the belts as set with


same grade, same make and of same batch.
In absence of proper tension in V-belts, they may get
failed due to belt slippage that increases the screeching
noise and heat.

Thus smoking may start from the belts that result in V-


belt drop.

The following actions shall be ensured to maintain


proper tension.
Tensioning of the final recommended value after
every first trip or 500 kms immediately after
provision of V belts at workshop or depots &
thereafter as per standard maintenance practices
mentioned in schedules.
Tensioning of the final recommended value after every
first trip or 500 kms immediately after provision of V
belts at workshop or depots & thereafter as per standard
maintenance practices mentioned in schedules.

It shall also ensure that correct type of belt tensioning


device spring as prescribed by RDSO equipped in
coaches during POH as well as at depot level.

Check the tightness of belts by 4 kg weight.


Excessive stretch may arise due to overloading
and internal breaks.

Overloading may be due to bad design, failed


bearings of the alternator, failure of output control
of the regulator of the alternator, or internal breaks
during manufacture or due to forcing the belts
over top of the grooves.
The temperature of the axle pulley groove may
approach to 27 C above from the ambient
temperature.

However in hot summer, ambient temperature


reaches as above as 49 C.

This increases the belt temperature more than that


of the design temperature.

This is also one of the causes of smoke emission


from V belts and belt drop.
Anti-rotating lug welding shall be done precisely in-butt
with suspension pin.

Suspension pin head thickness and anti rotating U


thickness must match perfectly to avoid rotation of S/pin &
therefore damage to Trans-mounting bush.
Standard tool kit for AC Escorting staff
Feeler gauge sets (0.05 mm to 1.00 mm)
Measurement of belt tensioning device
Free length of spring 345 mm
Length of indicator 250 mm
GO/NOGO gauges for checking the grooves of alternator
pulley and axle pulley.
Gadget of 4 kg weight for checking the tension of V-belts
V- Belts pitch length testing machine
Test bench for checking of RRU/ERRU & alternator 4.5 kW

Test bench for checking of RRU/ERRU & alternator 25 kW

BTD spring testing machine

VVVF type machine for load sharing in AC coaches

In-Situ testing kit of OVP

Gauges for measurement of cross section of V-belt


(Conventional Self Generating
NON AC Coaches)

Phase II- Module No. STC-GS-1


(Primary & Secondary Maintenance)
Attention on Maintenance Lines
Check the plate-form attention report and concentrate first on
attending the defects in these coaches by adapting systematic
trouble shooting procedures.
Proceed as follows in respect of other equipment.

First attend alternators in coaches for generation, which


have arrived "cold" and coach dark condition as per
platform report. Proceed as follows:

Check field fuse, replace if found blown, with proper rating


and approved make.
Check the continuity of field and phase winding with the
help of test lamp/ multi-meter to ensure that windings
are not open circuited.

Check for loss of residual magnetism with the help of


voltmeter across the field terminals. In case of loss of
magnetism, give 12 V DC flashing to the field terminals
for few seconds to regain lost residual magnetism.

Check that the regulator feedback loop is O.K.

Check connections for tightness in alternator and


rectifier regulator. If this is all right, remove belt from
alternator.
Use testing machine for testing alternator in situation.
Couple the portable motor drive with Alternator.

Check the DC output voltage at the rectifier and


regulator terminals. Identify the defects if any and
rectify them. The battery should be isolated while
doing this test.

Provide new split pin for pulley castle nut after


completion of work.

Check up the condition of safety chain and availability


of split pins in safety chain bolts.
Check up alternator suspension bracket and tension
gear for any damage and replace, if necessary.

Check up and tighten loose bolts in terminals box


covers.

Check availability of split pin for alternator castle nut.

Never energize field from battery in case of failure of


field circuit diode in regulator. Apart from non
regulation, this may cause permanent damage to field
windings.

If there is no generation, ensure that there is no


breakage in the cable termination.
Examine the indicating white mark on the pulley
axle and ensure that the pulley has not slipped. If
pulley has slipped, take necessary corrective
action.

Tap the pulley with hammer and judge the


tightness or crack by sound. If it gives clean
metallic sound the pulley is tight. Dull sound
indicates that it is loose. Bolt should be tightened
with torque wrench to 30 kgm.

Check the lock nuts and split pins for availability


and tightness.
Check the belt tension after every round trip of the coach.

For new V-belt fitted, the belt should be re-tightened after


completing the first trip.

Check condition of belt for fraying of edges, etc.,

Check the belts for overturn and correct it, if necessary.

Check the number of belts which should be 4 nos. for 4.5


kW alternators.

Tension should be felt by hand by striking it slightly. Belt


in correct tension will respond `alive' and `spring-back'. If
required re-tensioning, the same shall be re-tensioned.

Check that all the sets of belts provided should be of same


make & grade.
Commissioning and checking of new V belts

Whenever belts are replaced, to get optimum performance


following precautions should be exercised:
a) The belts of same nominal length i.e. same grading should be
used as a set.
b) Two or more makes of belts should not be used in a set.
c) Check tension of V belt after fitment by tension gauge.
d) Re-tension newly fitted belts after 1st trip or 500 km run,
whichever is convenient.
e) Check alignment of pulleys whenever alternator is replaced.
f) Replace pulleys if grooves are worn out. Check by GO/NO-
GO gauges.
To check the new V belts for proper fitment,
following gadgets should be available at each depot:
Pitch length of V belt
Angle of V belt
SAMPLE BELT
FIXED PULLEY SLIDING PULLEY

F 76.5 kgf

(iii) Section of V belt


E

34 0.25

+ 0.03
22.53 - 0.00
Gadget to check the Pitch length of V belt

19.0

Outside dia 234.62 - 0.06


+ 0.00

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

Gauge for checking angle of v-belts

Along a straight portion of the belt in an un-tensioned state, the


cross-section shall be such that the edges of the broader (top)
side of the belt shall touch the sides of V-groove having an
included angle of 38 degree and the edges of the narrower
(bottom) side of the belt shall touch the sides of V-groove
having an included angle of 42 degree.

The flanks of the belt shall not touch the sides of the V-
grooves.
Clean regulator externally.

Open regulator terminal cover and check for


signs of overheating in all the terminals/bus
bars/etc.

Check up for loose connections and tighten the


same. If the terminal board is found affected due
to heat, replace terminal board with new one.

Check for any damage to the phase and field


wires /cables inter connecting regulator and
alternator and its anchoring arrangement.
Check and secure properly the terminal cover and
regulator cover.

Check the cable termination of the regulator


visually for any abnormality.

If the alternator arrived without generation, then


open the regulator and check for any abnormality
and ensure the fuses are intact.

Check the cable for any abnormality from the


alternator to the regulator by using test lamp, if
found open/short, attend the same.
If needed change the regulator and ensure the
generation by running the alternator with a portable
motor.

Ensure that the settings of the alternator cum


RRU/ERRU are as under.
Description Passenger/ Express/
Super fast
54 cells in Lead Acid & 57 cells battery 128.5 0.5 Volts
bank (TL coaches fitted with VRLA
batteries)

Alternator voltage settings as mentioned above shall be


made at half load i.e. 19A for TL coaches, at 1500 rpm.
i. Conventional Lead Acid Batteries
To know the condition of cells during `Trip
Examination' some cells in a battery are treated as
`pilot' cells.

On arrival of train in the maintenance line,


disconnect all inter vehicle connections.

Record the specific gravity of `pilot' cells in each


battery.

Different cells should be identified as pilot cells


every month. The idea of identifying different
cells as pilot cells every month is to ensure that
true condition of the battery is reflected.
Marking of these cells to indicate pilot cells shall be
done as follows and repeat cycle further
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18

Month Pilot Cells


1st Month 1, 12, 13
2nd Month 2, 11, 14
3rd Month 3, 10, 15
4th Month 4, 9, 16
5th Month 5, 8, 17
6th Month 6, 7, 18

Check the floats of each cell and check for correct


electrolyte level as indicated in the float stem.
Replace missing/defective floats.

In case of low level, replenish with distill water.

If any cell needs too much water for replenishing,


watch for crack in the cells and also check the voltage
on load which should not be less than 1.80V.

In case of any defect, remove the mono-block and


replace by a spare one preferably of the same make
and lug date or a lug date as close to the one already
in the coach.
Coaches with discharged batteries which shows less
than 100 V on load should be put on charge at double
the normal rate of charge and the charging reduced to
half the rate of charge as soon as the gassing starts
and continued till the specific gravity rises to the fully
charged value which should be between 1210 and
1220.

Use the battery charging terminals provided in


coaches for charging purpose.

Check up correct polarity and connect the charging


cables.
Use a clip on D.C. ammeter of 0-25 A range to check
up the battery charging current. Note down the rate
of charging and the number of hours of charge.

Check specific gravity of pilot cells and the total


voltage of battery on load at the end of charge and
record.

Keep micro porous vent plug tight.

Ensure that washer is available in micro porous vent


plugs.

Check all the battery box members for any cracks in


the fabricated battery box/cradle and take corrective
action.
Check for proper fitment of mono block in the battery
box ensuring wooden packing pieces.

The person in charge of battery maintenance should


record all the readings mentioned above in his diary
and this information should be transferred to the
register maintained for various trains.

Check anti-theft rods and provision of nuts both inside


and outside the battery box on either side. Secure
battery box cover finally after all works are
completed.

Ensure that the fitment of the battery box is in order


with all the bolts, nuts, lock nuts, split pins etc.
Ensure the bottom plate of the box is well secured.

Ensure the cells are properly cleaned.

Ensure all micro porous vent plugs and sealed floats


guide are properly closed.

Check the terminations in the fuse and the condition


of the fuse.

Check the termination of cable in the under frame link


box, for proper condition and attend if needed.
ii. VRLA Batteries
(Ref. RDSO/PE/ SMI / TL /0024-2012/Rev.2 dated
17.08.2012)

Check for by-passing of the failed cells. If the


cells are found by-passed, replace these failed
cells immediately with the healthy ones.

Dust accumulation, if observed, clean with dry


cotton cloth.

Cell cover/ container cracked or bursts, if noted,


replace the cell with a healthy cell immediately.
In case of battery terminal/ cable over heating sign,
check for loose connection at the cell terminal post/
cable end. If required, replace the cable immediately.

Protective lid on safety valve if missing provide new


one immediately.

Charge the batteries, preferably for 6-8 hrs. after


arrival as cells may be partially discharged.

Do not boost charge the cells for more than 12 hours.


Before checking the earth in the coach, it should
ensure that coach is not connected to the adjacent
coach through EFT (Emergency Feed Terminal).

After isolating the coach the earth shall be tested by


using a double test lamp method as under:

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.

Connect middle wire to earth point.

If there is no earth fault in the coach, both lamps


will glow with same brightness.

If there is earth fault on ve side in the coach, lamp


fitted on ve side will not glow or glow very dim
but other lamp will glow normal.
If there is earth fault on +ve side in the coach, lamp
fitted on +ve side will not glow or glow very dim
but other lamp will glow normal.

If any earth is noticed the required corrective


measures should be taken to remove the earth before
inducting the coach in the service.
Following scheme is prescribed for all trains during primary
or secondary maintenance at a depot:
Switch on each fan individually and check its working.
If the fan does not start, short the switch terminals with a
small piece of wire temporarily.
If the fan starts it will indicate that the controlling switch
is defective. Replace defective switch.
If the fan does not start when the switch terminals are
shorted, proceed as follows for fans:
Test for supply at the 2-way connector terminals near
the fan with the switch on. If there is no supply, the
wiring is defective and has to be attended.
If fan is defective, repair or replace.
If the fan is noisy, check for loose blades/fan guards and tighten
them.

If the noise is due to bearings, replace the fan.

Check the fuse for fans and ensure that it is of correct size (35
SWG) tinned copper.

Clean guard and body of fan externally.

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.

The MCB/fuse controlling the fan circuit shall be checked for


correct rating (16A), proper functioning and replace if found
defective.
Switch on each lamp/tube light/CFL. If the lamp/tube
light/CFL does not glow, check lamp/tube light /CFL and
replace, if fused.
If the lamp/tube light/CFL is all right, check control fuse
and replace, if found blown.
If the fuse is all right, check control switch and replace, if
necessary.
If the switch is all right, check up lamp holder for any
defect or loose connection and rectify.
If there is no defect in the lamp holder, check up for supply
at the holder terminals and if the wiring is found defective,
rectify.
Provide switch covers and fuse covers promptly, if they are
missing.
If any dome cover is open or not secured properly, rectify
defect, if any and secure.

Replace broken glass domes/acrylic covers of tube


lights/CFLs.

Check MCBs/fuses for light circuits in junction box for


proper operation and replace defective MCBs. Check for
loose connections between MCB and bus bars and rectify.

Ensure that MCBs/fuses are intact for protection of each


circuit.

Check tightness of terminal connections of HRC fuse for


negative circuit in junction box.

Never by-pass or use incorrect fuses as this may result in


serious failures.
Earthing of wiring in the coach shall be checked both on the
positive and negative wire separately in each coach by the earth
testing device.

A coach with negative earth fault in case of 110 V DC systems,


which could not be attended in time, can be given in service in
case of emergency. The coach shall be taken for attention by the
primary maintenance station during the next trip.

Testing shall be done only at cable terminations.

Poor crimping of cable lugs and loose connections in terminals


may result in excessive heating and discoloration of lugs, tapes
and cables. Check for this during inspection and take prompt
action to locate and rectify the defects.

Replace incorrect size of HRC fuses by correct rating.


Check all fuses and ensure that they are secured tightly to their
terminals. Replace defective MCBs/fuses in junction box by
MCBs/fuses of correct rating.
Remember that fuses are provided for protecting circuits in case of
faults. Try to find out the cause of fault.
Loose and exposed/hanging wires should be secured and properly
covered.
In case wiring is found mechanically damaged or tampered with or
needs replacement, the coach should be marked electrically sick.
If the work is of a minor nature, this may be done in maintenance
lines.
Coaches which are suspected to have wiring defect either in the
under-frame or roof shall be subjected to insulation test with 500 V
megger.
Record all the attention given in the under frame and roof, the
Specific Gravity, the condition of generation, lamps, fans and
fuses, availability of belts etc. with coach and other details.
Check and ensure supply and functioning of each
Mobile/ Laptop charging point, replace if found
defective.

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:

Clean the interior of battery box.


Clean the cell tops and deposit of sulphation, if any in inter
cell and end cell connections.
Remove sulphated inter cell connections, clean the
connecting surface with a piece of cloth.
Use fresh fasteners.
Sulphated internal connections and fasteners should be
soaked in kerosene oil, cleaned with warm water and kept
ready for use.
Inter cell connections should be provided with both small and
large strips and four fasteners each with one hexagonal nut, one
spring washer to IS:3063 and two steel punched washers to
IS:2016.
Remove end cell connectors, clean the connecting surface both in
cell and connector thoroughly and provide back.
Check for proper crimping of terminal.
In case strands of connecting cable are found cut at the crimping
end, cut wire at the crimping end and re-crimp with a new inter
cell connector.
End cell connector confirming to IS:6848 should only be
provided.
Tinned copper crimping sockets with a single hole, if any,
provided as a stop gap measure should be replaced by standard
end cell connector.
Provide end cell connectors with both the fasteners each with
one spring washer to IS: 3063 and one punched steel washer to
IS:2016.
Tap sealed float guides and check for free movement.
Look for elongated holes in sealed float guides and replace such
guides. Replace deficient floats promptly.
Check whether vent plugs are of the anti-splash type and replace
if required.
Check the make of cells and the lug date.
Different "makes" of cells mono block if found mixed together
should be replaced by a single "make" of cells.
If it is not possible to do this during one fortnightly examination
this should be noted down and attempts made to replace the
same during the next fortnightly examination.
Check whether cell/ mono block packing is tight and provide
additional packing, if necessary.
Use only hard wood coated with acid resistant paint for cell
packing.
Check for provision of anti-theft rods and provision of nuts,
both inside and outside the battery box on either side. Replace
deficient rod and nuts.
Apply petroleum jelly on inter cell connection and end cell
connections.
Check battery fuses and replace overheated/incorrect size fuses
by correct size.
Check battery box fixing nuts for tightness.
In addition to the works mentioned in Trip &
fortnightly examination, carry out the following:

Check for tightness of terminal connections of alternators


and rectifier regulators.
Thoroughly clean externally the alternator and regulator.
Open inspection cover of regulator. Blow dust with a
portable blower. Secure covers tightly after inspection.
Check locking of current setting of regulator, if disturbed it
should be reset/locked as prescribed.
Check the alternator pulley for proper fixture and the
availability of castle nut and split pin.
Reset the correct position of pulley, if found shifted and
tighten the loose nuts with torque wrench with
recommended torque.
Check tightness of nuts and also availability of chuck
nuts and split pins in all fixing bolts.

Conventional Lead Acid Batteries


Record specific gravity of individual cells/mono block.
"Switch on" full load of the coach and record individual
voltage of cells and total voltage.
"Switch off" load. If the specific gravity is less than that
painted on the battery box, charge the cells as specified under
"Trip Examination" after topping up with DM water, if
required.
Use battery charging terminals provided on coaches for
charging purposes.
Charging should be continued till the specific gravity rises to
the value of mentioned in battery box, on "Pilot" cells.
In case pilot cells show no appreciable improvement, check
specific gravity of adjacent cells.
If the specific gravity does not improve in spite of charging,
replace the battery by another set.
Cells should be handled with due care while unloading and in
transit to avoid breakage.
On completion of charging, record the specific gravity of
individual cells. If there is any wide variation in the specific
gravity/ voltage of cells, disconnect and replace those cells
showing low specific gravity/voltage by spare ones.

In case there are more than 1/3 of total cells with low specific
gravity, the entire set should be replaced.

Cells showing reverse voltage, zero volts should be withdrawn


and replaced by charged cells immediately.

Record individual voltage of cells and the total voltage on full


load of the coach.

Change the marking of the pilot cell as given in trip schedule.


Open front door. Check all connections in MCB-cum-fuse panel
for tightness any for heating sign, fuses etc.
Check availability of terminal lugs for all cables in junction box
and replace if necessary by terminal lugs of correct size.
Check rotary switches / MCBs provided for lights, fans circuits
for correct condition and rotary switch and EFTs for proper
operation.
Replace/ repair defective MCBs.
Check up negative fuse and replace, if necessary by correct
ratings of HRC fuse.
If rotary switches are provided instead of MCBs, Check for
proper operation.
Check up HRC fuses provided with rotary switches for correct
rating and replace, if necessary.
Close front door and secure properly by the locking key, If
found defective, the same may be attended/replaced.
Superstructure wiring and under-frame wiring shall be
tested separately for which the main negative fuse in shall
be opened and controlling MCBs for all circuits kept off.
All other fuses shall remain in circuit.
Insulation resistance shall be measured with all fittings and
equipment connected both on under-frame and
superstructure.
The under-frame wiring shall be tested with battery fuse
open.
The IR value should be minimum 2 Mega-Ohm in fair
weather condition and minimum 1 Mega-Ohm under
adverse weather condition.
Availability of inspection cover of DFBs should be ensured.
The fan body, guards and blade shall be thoroughly
cleaned with cloth.
All fans shall be opened and condition of commutator,
brushes and brush gear shall be thoroughly checked.
Studs used for fixing the fan to coach body, shall be
checked and tightened, wherever necessary.
Availability of all the three fixing studs should be
ensured.
All the switches controlling the fans shall be checked for
its smooth operation and correct working and replaced,
where necessary.
Fan blades shall be replaced if found bent, or if there is no
proper air discharge.
Open each fitting with the dome key and remove the dust
of the fitting both from inside and outside.
Ensure free operation of locking mechanism and replace
defective fitting.
Clean first glass domes with wet cloth and then with a
clean dry cloth.
Replace rusted fittings and fittings with damaged surface.
Check up wattage of lamps and replace with that of
correct wattage.
Check up whether toggle switches are marked to indicate
lighting control "L", night light control `NL', side lamps
in guards compartment as `SL', tail lamps as `TL-Rear',
`TL-Front', luggage room as `LRL'.If not, stencil legends
with fluorescent paint.
Check up all lighting circuit fuses in each coach for correct
size and replace if necessary.
Stencil the size of fuses near the locations, if not already
done.
Mark inspection covers of distribution fuse boards as `DFB'
if not done already.
Thoroughly clean metal guards for roof light fittings in
luggage rooms and paint, if necessary.

Check each switch of lights and fans for proper fixing


and operation. Replace defective switches.
Switches should be provided in the locations intended for
them and provided with covers with their knobs exposed
for operation by passengers.
Check distribution fuse boards and fuse cut outs of light
and fan circuits, for over heating and tightness of
connections and provisions of correct size of fuses in the
fuse terminals.

Check up supply and marking of polarity of EFTs.


Replace missing EFTs and those without wiring nuts.
In addition to the instructions contained under "Monthly
Examination" following activities should be done:

i. Conventional Lead Acid Batteries

`Switch off load. Charge the cells at 50% of normal rate


of charge, i.e., at 1/10th of the rated capacity of cells.

Record hourly cell voltage and specific gravity reading


of every cell.

Terminate charging when 3 successive readings are


constant.
Record specific gravity and no load voltage of each cell 10
minutes after terminating charge.

Specific gravity should be between 1.210 and 1.220 for cells


upto 120 Ah capacity. The voltage should not be less than 2.1
V.

If there is a wide variation in the specific gravity and voltage


readings, such cells should be replaced.

Check the cell voltage on full load.

Cells showing reverse and low voltage are to be replaced with


healthy cells of the same make/type.
ii. VRLA Batteries
(Ref. RDSO/PE/SMI/TL/0024-2012/Rev.2 dated 17.08.2012)

13 Nm tightening torque of terminal bolt with torque


wrench for four terminal design cell (all makes
except Exide).

22Nm tightening torque of terminal bolt with torque


wrench for four terminal design cell (Exide).

Do not over tight.

Terminal post corrosion, if observed remove the


cable and clean the terminal post and cable lug with
brass brush or fine emery paper and apply petroleum
jelly.
a. If the total battery bank open circuit voltage for TL
coaches is 117.0 Volts or above for 57 Cells.
The following steps shall be followed:
(i) Discharge the battery bank with full coach load for
15 minutes (based on coach arrival battery SOC).
(ii) Note down the individual cell readings after 15
minutes while the coach is still connected during the
discharge.
(iii) If all the cell voltages are 1.98 Volts and above then
the cells are in healthy condition. Charge the cells
same to be put back into service.
(iv) If some of the cell voltages are less than 1.98 Volts
then give boost charging with 2.30 VPC for 12 hrs.
by charging them separately with current limited to
20% of battery rated capacity
(v) The weak cells, which are charged separately, must be
checked through a discharge at C-10 rate for 30 minutes,
the end of discharge voltage should be above 2.0 V. If
such a re-charged cell fails to qualify the above test, it
should not be put back in the coach.

(vi) After performing the discharge test on the revived cells,


the cells need to be charged at least for 4 hours, prior to
fitment in the coach.

b. If the total battery bank, open circuit voltage for TL


coaches is less than 117.0 Volts for 57 Cells.

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:

Carry out visual inspection of terminal box for signs of


overheating, fumes and presence of water etc., clean it.

Check the connections for any defect, if required re-


crimping and taping should be done. Replace spring
washers, if overlapping.

Disconnect the regulator and measure the insulation by


500 V megger; if found less than 10 M-ohm, remove
alternator and heat its winding in the oven at 80 degree C
for 1 hour.
Check the condition of outgoing cables and its cleating
arrangement. Replace the grommet, if necessary. Ensure that
flexible pipe carrying the cables is connected properly to the
grommet to prevent damage to insulation.

Check the suspension pin, main suspension lugs of alternator


and bogie brackets for any signs of crack. Provide new nylon
bushes and secure nuts and bolts, with new split pins. Play
between alternator lugs and bogie bracket should not be more
than 4.0 mm.

Check profile of V groove for worn out pulley as per SMI


No. RDSO/PE/SMI/TL/0030-2005 (Rev.0) dtd. 12.08.2005.

Check the pulley fixing, concentrating on lock nut and locking


collar pin. If lock nut is damaged, replace it.
Check safety chains and chain fixing nuts, bolts and split pins.

Replace tension rod sleeve.

Fit tension rod fixing pin of alternator with new washer and
split pin. Replace spring, if belts loose upon coach arrival.

Lubricate the threads of the tension rod and adjusting nut.


Check the lock nuts and split pins for availability and tightness.

Appropriate open jaw type torque wrench to be used for uniform


tightness of all studs, value of torque depends on the gap required
between two pulley halves.

Check distance between wheel hub and axle pulley with gauge
plate.

Check the condition of pulleys and its V grooves profile. Replace


the pulley, if required.

Tap with hammer and judge the tightness by sound.

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.

Follow the instruction given in SMI No.


RDSO/PE/SMI/TL/0027-2004 (Rev.0) dtd. 05.03.2004 for
checking new V belts.

The old V belts removed from service to be destroyed.

Check tension of V belts.

For the exact measurement of tension, a weight of 4 kg.


shall be hanged from the centre of belt span and see that the
top surface of this belt does not go below bottom surface of
remaining belts.
Clean regulator box externally and remove all the dust
with dry compressed air.

Open cover and change sealing sponge rubber gasket.

Clean all dust with soft brush and vacuum cleaner from
inside, particularly from heat sink of electronic
components and terminal board.

Check voltage and current setting.

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:

Set specified voltage 128.5 +/- 0.5 at half load 19 A &


1500 rpm.

Check OVP set voltage and working. Check the proper


suspension of the unit and provide new split pin in its
suspension bolt.

Tighten all the electrical connections and check whether


power connections are provided with locking washers.

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.

Check the conditions of connecting strips/ leads and replace if


required.

Check all suspension bolts of battery box suspension/ cradle


for signs of any crack, corrosion, rusting and take corrective
action.

Clean and examine condition of battery boxes.

Examine condition of FRP tray and replace if necessary.


Paint all battery boxes. Battery box will be applied with
Grey colour high build epoxy paint to RDSO Spec. No.
M & C/ PCN/111 to a thickness of 100 120 micron.
Provide all cells in battery boxes with proper packing.
Connect all inter-cell connections and end cell
connectors. Provide petroleum jelly on all connections.
Charge the battery bank at the rate I = 0.1 x C10 fully till
3 constant hourly readings of voltage found, indicating
the condition of a fully charged cell.
Fit the battery box covers and secure them properly.
(ii) VRLA Batteries
Refer Quarterly Schedule for the maintenance of VRLA
batteries.
Open each fitting and clean properly from inside and
outside. Ensure free operation of locking mechanism and
replace defective fitting.
Replace rusted fittings and fittings with damaged
surface.
Check all the lights for proper working. Rectify or
replace if necessary.
Check up all lighting circuit fuses for correct rating and
replace if necessary.
Check and clean plastic fan blade and ensure that there is
no crack on the blade or hub.

Ensure proper fixing of fans and locking arrangement.

Check for abnormal sound, rectify or replace, if needed.


i. Dos
Ensure that the correct polarity of field winding i.e. positive
connected to F+ while measuring the continuity of the field
winding, otherwise the alternator will not self excite.
Check the proper compression force on the tensioning
spring with indicator plate by tightening the special nut.
Keep the terminal box tightly closed.
Use the cable grommets or cable gland of correct size for
reducing the vibration of terminal connections.
It is preferable to anchor the cables externally to avoid
shocks and vibrations on the terminals.
ii. Donts

Dont use improper tools to handle the alternator; it


may damage parts of the alternator.

Dont re-grease the bearing frequently. Re-greasing


should be done after thoroughly cleaning the bearing
with white spirit. It is preferable to re-grease the
bearing only during POH.

Dont keep the belts in over tension as this may


reduce life of the belt.
i. Dos

Short all seven terminals of the terminal box before


measuring the insulation resistance.

Ensure that DC + and DC - are connected to


battery positive and battery negative respectively.
Wrong connection will damage main diodes.
ii. Donts
Dont disturb the settings of the regulator shunt and
potentiometer.

In any circumstances the burden resistance setting should


not be disturbed.

Dont open the regulator box unless there is a defect.

Dont use a megger to test the components. Use


multimeter.

Dont reverse the field terminals on regulator and


alternator.

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.

Belts should be stocked in lots as per date of receipt


and use in the principle of first in first out basis. The
belts shall be stored in a well ventilated room free
from direct sunlight and moisture.

Re-tension newly fitted belts after first trip.

Maintain a gap of approx. 55 mm between


supporting plate and fixing nut on the free end of
tension rod or upto the split pin for the 4.5 kW
alternators.

Maintain proper alignment between axle pulley and


alternator pulley.
ii. Donts

Do not allow loose belts.

Do not disturb the nut and check-nut on free end of


tension rod if proper gap is available between supporting
plate and fixing nut i.e. 55 mm for TL alternator.

Do not use repaired pulleys.

Do not use old and new mixed belts in sets.

Belt should not have any oil or grease traces, if persist


clean it by soap and water.

The matched set should have belts of one manufacturer


only. Do not use belt of same grade of different
manufacturer in a set.
(9 Months)

Phase II - Module No. STC-GS-1


The schedule IOH shall be carried out on sick line
at nominated primary depot.

Different SMIs issued by RDSO time to time for the


maintenance of TL & AC equipment are to be
followed.

Phase II - Module No. STC-GS-1


Particulars IOH

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 the connections for any defect, if required re-


1.2 crimping and taping should be done. Replace spring
washers, if overlapping.

Phase II - Module No. STC-GS-1


Particulars IOH
9 months
S.No.
Frequency of Examination + 30 days
0 days
Disconnect the regulator and measure the insulation by
500 V megger; if found less than 10 M-ohm, remove
1.3
alternator and heat its winding in the oven at 80 degree
C for 1 hour.

Check the condition of outgoing cables and its cleating


arrangement. Replace the grommet, if necessary.
1.4 Ensure that flexible pipe carrying the cables is
connected properly to the grommet to prevent damage
to insulation.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

Check the suspension pin, main suspension lugs of


alternator and bogie brackets for any signs of crack.
1.5 Provide new nylon bushes and secure nuts and bolts,
with new split pins. Play between alternator lugs and
bogie bracket should not be more than 4.0 mm.

Check profile of V groove for worn out pulley as per


1.6 SMI No. RDSO/PE/SMI/TL/0030-2005 (Rev.0) dtd.
12.08.2005.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

Check the pulley fixing, concentrating on lock nut and


1.7
locking collar pin. If lock nut is damaged, replace it.

Check safety chains and chain fixing nuts, bolts and


1.8
split pins.

Replace tension rod sleeve. Fit tension rod fixing pin


1.9 of alternator with new washer and split pin. Replace
spring, if belts loose upon coach arrival.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days
Lubricate the threads of the tension rod and adjusting
1.10
nut.

Check the logbook for abnormal/ unequal load sharing


and ensure that the difference is within the range of 30
1.11 A with RRU and 10 A with ERRU. Follow the
instructions given in SMI No.
RDSO/PE/SMI/AC/0018-99 (Rev.0) dtd. 05.02.1999.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No 9 months
Frequency of Examination + 30 days
0 days
2.0 Axle Pulley & Alternator Pulley
Check the lock nuts and split pins for availability and
tightness. Appropriate open jaw type torque wrench to
2.1 be used for uniform tightness of all studs, value of
torque depends on the gap required between two pulley
halves.

Check distance between wheel hub and axle pulley with


2.2
gauge plate.

Phase II - Module No. STC-GS-1


Particulars IOH
9 months
S.No
Frequency of Examination + 30 days
0 days
Check the condition of pulleys and its V grooves
2.3 profile as per SMI No. RDSO/PE/SMI/TL/0030-2005
(Rev.0) dtd. 12.08.2005. Replace the pulley, if required.

Examine the indicating white mark on the axle pulley


and ensure that the pulley has not shifted. If pulley found
2.4 shifted, remove the pulley and re-tighten it after
replacing rubber pads and provide indicating white
mark.
2.5 Tap with hammer and judge the tightness by sound.
Ensure gap between the two halves of the axle pulley is
2.6
3.0 0.5mm.
Phase II - Module No. STC-GS-1
Particulars IOH
S.No 9 months
Frequency of Examination + 30 days
0 days
3.0 V Belts
Replace all existing V belts with new V belts having same
grade/make. Follow the instruction given in SMI No.
3.1 RDSO/PE/SMI/TL/0027-2004 (Rev.0) dtd. 05.03.2004 for
checking new V belts. The old V belts removed from
service to be destroyed.
Check tension of V belts. For the exact measurement of
static tension, apply force `P with a spring balance at the
3.2 centre of span in direction perpendicular to the span until the
belt is deflected from the normal to the extent of 16 mm per
meter of span. The force `P should be between 31.4 to 47.0 kg.
Phase II - Module No. STC-GS-1
Particulars IOH
S.No 9 months
Frequency of Examination + 30 days
0 days
4.0 Rectifier Cum Regulator Unit (RRU/ ERRU)
Clean regulator box externally and remove all the
4.1
dust with dry compressed air.

Open cover and change sealing sponge rubber


4.2
gasket.

Clean all dust with soft brush and vacuum cleaner


4.3 from inside, particularly from heat sink of electronic
components and terminal board.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No 9 months
Frequency of Examination + 30 days
0 days

Check voltage and current setting. Ensure that they have


not been disturbed and are in locked position. Following
tests shall be done to ensure proper working of RRU/
4.4
ERRU with alternator:
Set specified voltage at half load at 1500 rpm.
Check OVP set voltage and working.

Check field and phase HRC fuses for their proper rating
4.5
and fitment.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

Tighten all the electrical connections and check


4.6 whether power connections are provided with locking
washers.

Check the proper suspension of the unit and provide


4.7
new split pin in its suspension bolt.

Phase II - Module No. STC-GS-1


Particulars IOH
9 months
S.No.
Frequency of Examination + 30 days
0 days
5.0 Battery Charger
Clean battery charger externally and remove all the
5.1
dust.
5.2 Clean all dust with soft brush and vacuum cleaner from
inside, particularly from heat sink of electronic
components and terminal board.
5.3 Ensure that the coarse and fine control switch is in
position No.1.

5.4 Check and clean all connections and contacts and


tighten all electrical connections.

Phase II - Module No. STC-GS-1


Particulars IOH
9 months
S.No.
Frequency of Examination + 30 days
0 days
6.0 Battery & Battery Box
6.1 Lead Acid Batteries
Clean the battery box externally and remove all dust with
6.1.1
dry compressed air.
Open battery box covers. Remove inter-cell connections
6.1.2
and take out the cells.

Clean the cells, inter-cell and end cell connectors


6.1.3 thoroughly. Replace spring washers, if each are
overlapping.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

Check for crack in cell containers leading to leakage. If


6.1.4 needed, replace the defective cell with healthy cell of
similar capacity, make and lug date.

Check for heating signs on the positive and negative


6.1.5 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


6.1.6
with distilled water, if necessary.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days
Check the specific gravity and voltage of all cells with
6.1.7
cell tester.
Check all vent plugs and float guides conditions and
6.1.8
replace defective ones.

Check the conditions of connecting strips/ leads and


6.1.9
replace if required.

Check all suspension bolts of battery box suspension/


6.1.10 cradle for signs of any crack, corrosion, rusting and take
corrective action.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days
6.1.11 Clean and examine condition of battery boxes.
6.1.12 Examine condition of FRP tray and replace if necessary.

Paint all battery boxes. Battery box will be applied with


6.1.13 Grey colour high build epoxy paint to RDSO Spec. No.
M & C/ PCN/111 to a thickness of 100 120 micron.

6.1.14 Provide all cells in battery boxes with proper packing.

Connect all inter-cell connections and end cell


6.1.15
connectors. Provide petroleum jelly on all connections.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

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.

For the maintenance of VRLA batteries follow the


6.2. instructions given in SMI No. RDSO/PE/SMI/TL/
0024-2004 (Rev.2) dt. 17.08.2012

Phase II - Module No. STC-GS-1


Particulars IOH

S.No. 9 months
Frequency of Examination + 30 days
0 days

6.3 LMLA Batteries

For the maintenance of LMLA batteries follow


the instructions given in SMI No. RDSO/ PE/
6.3.1 SMI/ AC/ 0032-2006 (Rev.0) dt. 31.05.2006. For
TL batteries follow RDSO/ PE/ SMI/ TL/ 0025
and RDSO/ PE/ SMI/ TL/ 0028.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days
UNDERSLUNG AIR CONDITIONING EQUIPMENT

7.0 Compressor ACCEL


Clean the compressor externally with dry compressed
7.1
air.

Clean the oil strainer with petrol or CTC (Carbon


7.2
Tetrachloride).

7.3 Replace filter bag for BG 34 BR

Phase II - Module No. STC-GS-1


Particulars IOH
9 months
S.No.
Frequency of Examination + 30 days
0 days
Check oil level and observe any signs of leakage, which
7.4 will be indicated by presence of oil at the point of
leakage.

Check for signs of leakage at joints & shaft seal and


7.5
rectify.

Replace the compressor oil with new oil. Follow the


instructions given in SMI No. RDSO/ AC /SMI/ 6 dtd.
7.6
08.09.1981 and correction slip issued vide L.No. EL/
7.1.75 dtd. May 1982.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

Examine the reading of HP, LP and OP gauges recorded


7.7 in the log sheet for any abnormality and take necessary
action.

Check the tightness of fasteners of compressor head and


7.8
its cover.

Examine the fixing arrangement, check the condition of


the anti vibration mounting pads and check the tightness
7.9
of bolts with 30 kg-m torque wrench and tighten, if
necessary.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days

7.10 Replace shaft seal assembly.


7.11 Replace HP/ LP/ OP cutout switches, if defective.

7.12 Tighten the clamping of the refrigerant pipeline.


7.13 Check leakage from HP/ LP/ OP cutout switches.
8.0 Condenser
Clean the condenser fins and copper tubes thoroughly as
8.1 per the instructions given in SMI No. RDSO/ SMI/ AC/
16 dtd. 29.05.1998.

Phase II - Module No. STC-GS-1


Particulars IOH
S.No. 9 months
Frequency of Examination + 30 days
0 days
8.2 Examine the fins for external damage due to flying
ballast and take corrective action if necessary.

8.3 Replace catch all filter.


8.4 Check the condition of body frame and replace the
condenser, if necessary.

8.5 Check and ensure that the protection plates and grills are
provided on the three sides of the frame.

8.6 Ensure minimum airflow of 4 meters per second through


condenser.

8.7 Check the leakage and rectify, if required.


Phase II - Module No. STC-GS-1
Particulars IOH
9 months
S.No.
Frequency of Examination + 30 days
0 days
9.0 Evaporator, Drip Water Drain and Expansion
Valve
9.1 Clean the assembly of evaporator coil and surroundings.
9.2 Clean the drip tray and drainpipe thoroughly and check
for water leakages.

Pour water on evaporator coil and ensure that water


9.3
drains out easily.
9.4 Clean the strainer, provided before expansion valve.
9.5 Replace return and fresh air filters.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
9.7 Replace canvas duct, if required.
9.8 Check the condition of heater bank.
10.0 Compressor, Condenser & Evaporator Motors
10.1 Clean the motors externally with dry compressed air.
Check mounting of all motors for any signs of crack,
10.2
corrosion and rusting. Take remedial action if required.

Check the condition of the anti vibration mounting pads


10.3 and check the tightness of bolts with 30 kg-m torque
wrench and tighten, if necessary.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Disconnect the motors connections, measure the


10.4 insulation resistance by 500 V megger; if found less
than 2 Meg ohms, replace the same.

Open inspection covers and examine the condition of


commutator. Clean with sand paper or pumice stone, if
10.5 necessary. Do not remove the dark tan film
unnecessarily. Remove all carbon dust with dry
compressed air.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Examine the condition of brush holders replace, if


required and measure the spring tension. If less than
10.6
the value recommended by manufacturer, replace the
spring.

Replace the carbon brushes with approved grade and


10.7
make.
10.8 Check for the positive locking of rockers.
Examine the incoming leads for proper connections
10.9 and tightness. Check the flexible conduit for its
condition and proper anchoring at both ends.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Check the bearings for noise by shock pulse meter and


10.10 replace, if required. Lubricate bearings with
appropriate quantity of recommended grease.

Examine flexible tyre coupling of compressor and


10.11
replace, if found defective.

10.12 Check the alignment of the compressor and its motor.


10.13 Check the starting resistance connectors for tightness.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Connect the motor connection and tighten the terminal


10.14
connections in the terminal box.

Check the direction of rotation of motor for


10.15
correctness.
10.16 Clean the condenser fan blades and tighten, if loose.
Clean the blower drum and check its fixing for
10.17
tightness.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
11.0 Dehydrator and Liquid Receiver
11.1 Check the sight glass for leakage, rectify if necessary.
11.2 Clean the strainer in the dehydrator-cum-filter unit.

After 10 minutes of starting the compressor, check the


11.3 level of liquid refrigerant. It should be at the bottom of
the lower glass of the liquid receiver.

After 15 minutes of starting the plant, feel the outlet and


11.4 inlet to dehydrator by hand for temperature difference.
The outlet should not be colder than inlet.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
12.0 Thermostats
12.1 Clean thermostat bulb with cotton.
Check for any breakage in mercury column or body of the
12.2 thermostat and replace it with new one if required. Do not heat
the bulb to join the the broken pieces of mercury column.

Check the condition of thermostat holder and its fixing


12.3 arrangement. Replace it with new one if found broken or
contacts defective.
Ensure working of plants in auto mode for all temperature
12.4
setting.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
13.0 Panel board
13.1 Clean the panel and remove dust.

13.2 Check the working of indicator lamps.

Ensure availability of spare fuses in the place provided


13.3
for the same.

Clean copper contact tips of contactors by suitable


13.4 chemical agent and check proper operation of
contactors.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
13.5 Provide arc chutes properly.
13.6 Check and tighten all electrical connections.
13.7 Check the relays and their connections.
Check the PCB in the thermostat circuits for their
13.8
proper functioning
13.9 Check all diodes and their connections.
13.10 Check all rotary switches and their connections.
Check the operation of cooling pilot relay (by short
13.11 circuiting terminals of C.T.). Remove short after the
completion of check.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

14.0 Coach Wiring

Revised check the earth leakage in the wiring with a


double test lamp method as explained in the RDSO
14.1
code of practice and prevention of fire as per EL/ TL
56.

Revised check for loose connection in all the junction


14.2
box/ terminal boards & tighten if necessary

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
Carry out coach insulation test as per item no. 5.8 of
14.3 code of practice for prevention of fire. (RDSO/ PE/ O/
0008-205, Rev. 0 dt. Oct. 2006).
Clean the electrical control/ cubicle and terminal boxes/
14.4
terminal boards, remove dust.

Check the locking and securing arrangement for the


door and covers of control/ power cubicle and terminal
14.5
boxes/ terminal boards/ fuse distribution boards.
Rectify or replace if necessary.
14.6 Check supply to laptop/ mobile charging points.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
15.0 Lights
Open each fitting and clean properly from inside and outside.
15.1 Ensure free operation of locking mechanism and replace
defective fitting.

15.2 Replace rusted fittings and fittings with damaged surface.

Check all the lights for proper working. Rectify or replace if


15.3
necessary.
Check all light switches for their condition and proper
15.4
working. Replace defective switches.
Check up all lighting circuit fuses for correct rating and
15.5
replace if necessary.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

16.0 Fans
Check and clean plastic fan blade and ensure that there
16.1
is no crack on the blade or hub.

Check the leakage current, if greater than 300 micro


16.2
Amps. Then replace capacitor in AC fan.

16.3 Ensure proper fixing of fans and locking arrangement.


Check for abnormal sound, rectify or replace, if
16.4
needed.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

17.0 Pre-cooling Unit


17.1 Clean rectifier unit externally with dry compressed air.
17.2 Clean and check terminal box connections.

Load the pre-cooling unit to its maximum capacity and


17.3
check for any overheating.

Check the pre-cooling socket pins and its fixing


17.4
arrangement.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
18.0 General
Check log- sheet of last trip and attend all the faults
18.1
recorded in the log sheet.
Run the plant for half an hour. Check system
operation, specially the following :

1. Suction pressure gauge reading should be 2-3


18.2
Kg/cm2.

2. Discharge pressure gauge reading should be 10


14 Kg/cm2.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
3. Oil pressure should be minimum 3.0 kg/cm2 above
suction pressure.

4. Suction should be cold and sweaty. Delivery should


18.2 be very hot and liquid line should be warm.

5. Feel the expansion valve by hand. It should be cold.

6. Ensure setting of fresh air damper.


Record the battery voltage on LOAD and NO LOAD
18.3
conditions.
18.4 Adjust the air diffuser for air distribution.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

ROOF MOUNTED AC PACKAGE UNIT


19.0 Control Panel
Check the log sheet and attend the defects noticed
19.1
during run as reported by escorting staff.

Clean the panel with vacuum cleaner or compressed air


19.2 and check for any loose connections. All cable entry
holes to be provided with grommets.

19.3 Check that all legend plates inside the control are intact.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

19.4 Check that glass cover over indication PCB is intact.

Check and clean the power and control contractors and


19.5 clean copper contact tips of contactors by suitable
chemical agent.

Check the connection of switchgear terminal blocks for


19.6
overheating and tightness.

19.7 Check rotary switches for proper working.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

19.9 Check the working of gauges, voltmeters and ammeters.

Take IR of live terminals to body for power and control


19.10 supply with 500 V megger and it should be more than 2
M ohms.

Check panel doors for proper closing and locking.


19.11
Check the door locks and hinges.

Check all safety and protection devices for their proper


19.12
working.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Replace defective/ by passed components including


19.13
indicator LEDs and lamps, if any.

19.14 Check proper working of electronic thermostat.

Remove the out going wires from MCB 7, in case of


19.15 scroll compressor. (There is no provision of crank case
heater in scroll compressor)

Clean accumulated dust over sensor of electronic


19.16
thermostat.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
19.17 Electronic thermostat
a. Clean the dust on the temperature sensor.

b. Calibrate the temperature sensor by digital contact


type calibrated temperature meter having probe
sensor.

c. Ensure the functional working of Display unit.

d. Check the cut in the cable of sensor and replace


damaged/ cut cable by new cable.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
19.17 Electronic thermostat
e. Ensure the connector for sensor i.e. Amphenol make
no. MIL C 5015 type 4 pin connector with
model no. MS 3106 R 14S 2S 3202 & MS
3106 F 14S 2S 3202 series for controller box

and sensor both. If not matched, replace by
Amphenol make series connector. Ensure the
interchangeability of one make sensor with other
make sensor.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

f. Correct the by pass connection for manual operation


and ensure the auto mode operation of electronic
thermostat.

g. Ensure the single setting of temperature i.e. cut in 25


degree C cut off 23 degree C in summer and 19 cut
in 21 cut off in winter.

h. Ensure that the insulation resistance is more than 20


Mega ohms. If less, take corrective action.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

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.

Check the working of all motors and take their IR values


20.4 with 500V megger and record the same. IR should be
more than 2 M ohms. If found less, take corrective action.

Check all the motors for abnormal sound by shock pulse


20.5
meter and replace the bearings, if necessary.
Phase II - Module No. STC-GS-1
S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
20.6 Check all the earthing wires provided on the equipments.

Check and clean condenser fan blades and ensure that


20.7
there is no crack on the blades or the hubs.

Check anti-vibration mounting pads of compressor,


20.8
condenser and blower motors and replace if necessary.

Check the working of HP, LP and control pressure


20.9 cutouts. Check the working of internal heat protection of
motors, if any.

Phase II - Module No. STC-GS-1


S.No Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Check the condition of latch for securing the evaporator


20.10
compartment cover.

20.11 Ensure proper clamping of all the refrigerant pipelines.


20.12 Check the condition of drainpipes and clean it.

Check heater tripping when blower MCB is off. (Shall be


20.13 read as below)
Check heater tripping through VANE Relay, OHP 1 & 2.

20.14 Check the working of RMPU.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
Run the plant for half an hour and check the current
drawn by various equipments with the help of
clamp tester. Normal currents for various
equipment and mode of operation shall be as
under:-
20.15 Package in cooling mode : 20 23 Amp.
Package in heating mode : 11 13 Amp.
Compressor motors : 7 10 Amp.
Condenser motors : 1.5 2 Amp.
Blower Motor : 1.5 2.5 Amp.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
20.16 Check working of all over load relays.

Check for proper operation of time delay relays


provided in compressor circuit. As soon as power
20.17 supply is switched `ON first compressor should
come in circuit after 2 minutes and the second one
after 2.5 minutes.

Check working of both Roof Mounted Package


Units (RMPUs) with either of the inverter on the
20.18
Self Generating (SG) AC coaches provided with
two package units.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
21.0 Inverter

The maintenance of coach inverter should only be



done through respective OEMs.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
22.0 Drip Tray
22.1 Clean the sludge inside the pipe walls and tray.

Pour water into drip tray and ensure that the poured
22.2
water is drained through the outlet pipe.

Check the normal flow of water in drip tray by


22.3
running the AC plant continuously for 2 to 3 hours.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

23.0 WRA ( Mono Block Type)

Clean and check complete assembly for any


23.1 defect or abnormality. Take corrective action,
if required.

23.2 Replace drain plug rubber washer.

23.3 Check proper operation of pump.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
24.0 Microprocessor Controller for RMPU
Check the insulation resistance. If less, take corrective
24.1
action.

Check on/ off switch for proper working. Replace


24.2
defective switch.
Check LED for proper working. Rectify or replace, if
24.3
necessary.
Clean the dust on the temperature sensor and humidity
24.4
sensor.
Phase II - Module No. STC-GS-1
S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Calibrate the temperature sensor by digital contact


24.5
type calibrated temperature meter having probe sensor.

Calibrate the humidity sensor by digital contact type


24.6
calibrated humidity meter.

Check the cut in the cable of sensor and replace


24.7
damaged/ cut cable by new cable.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days

Correct the by-pass connection for manual operation


24.8 and ensure the auto mode operation of micro-processor
controller.

Ensure the set temperature and night start hours and


night end hours for sleep mode operation. The data
24.9
should be in memory after once switch off and switch
on again.

Phase II - Module No. STC-GS-1


S.No. Particulars IOH
9 months
Frequency of Examination + 30 days
0 days
25. Testing
Generation testing should be conducted on SGAC
25.1 coaches by running both alternators through dyna
drive on full coach load.

Load sharing testing of alternators in SGAC


26.0
coaches shall be done.
Generation testing in TL coaches shall be
27.0
done.
Phase II - Module No. STC-GS-1
SMI and MS issued time to time by RDSO will
be followed and maintenance schedule shall be
up dated accordingly.

Phase II - Module No. STC-GS-1


Every IOH
S.
Items (12 Remarks
No.
Months)
1. V Belt Y
2. Suspension Bush Y
RDSO letter No.
3. Air Filters of RMPU Y EL/7.2.1 dtd.
24.03.2014
Alternator tension
4. Y
rod sleeve

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II Module No. STC-GS-1
Phase II Module No. STC-GS-1
These LHB variant new generation non ac passenger
coaches are being manufactured with stainless steel shells
to increase the life span of coaches.

These coaches have better parameters of passenger


comfort, safety and reliability in comparison to
conventional ICF design coaches.

These coaches are fitted with FIAT bogies and supplied by


power cars as in EOG system.
Phase II Module No. STC-GS-1
The End on Generation (EOG), Linke Hoffmann Bosch (LHB)
variant Non AC (TL) coaches can be broadly classified into
following types:

LHB variant General Second = LS


Class EOG Non AC Coaches

LHB variant 3 Tier Sleeper EOG = LWSCN


Non AC Coaches

LHB variant EOG Non AC Chair = LWSCZ


Car

Phase II Module No. STC-GS-1


Exteriors and Interiors views of LHB EOG NON
AC GS Coaches
Phase II Module No. STC-GS-1
Exteriors and Interiors views of LHB EOG NON AC 3
Tier Sleeper Coaches
Phase II Module No. STC-GS-1
Exteriors and Interiors views of LHB EOG NON AC
Chair Car
Phase II Module No. STC-GS-1
LHB variant non AC EOG coaches are equipped with 9/15
kVA step down transformers for stepping down 750 V, 3 AC,
4 wire, 50 Hz supply to 415 V/ 190V, 3 AC, 4 wire, 50 Hz
supply.

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

The neutral point of the 3 phase winding of the generator is


solidly earthed in the power cars.

The neutral conductor of the 750 volts, 3 phase, 4 wire


system shall not be earthed at any other point in the rake
composition.

Phase II Module No. STC-GS-1


Constant voltage regulated battery charger.

Onboard Switch Board panel with controls of lighting and


fan and their fuses.

Under slung panel for 750 volt and 415/ 190 volt supply.

Onboard supply only 110 volt dc and 190/110 V ac for


mobile charging sockets.

Phase II Module No. STC-GS-1


Provision of Dry type Transformer without encapsulation.

Elegant interior light fittings.

Integrated modular mini pantry unit in Chair cars.

Provision of Measuring and Monitoring relays in Feeder


circuit.

Wheel set earthing equipment for high life of axle bearings.

Provision of under slung mounted earthing and


disconnecting device.

Phase II Module No. STC-GS-1


Provision of under slung mounted water raising mono
block pump with pump controller (in 3 tier sleeper
coaches only). As per Railway board L. no.
2010(M)(PU)/1/28 dtd. 06.03.2012, overhead water tanks
are to be provided and water raising mono block pump
are to be eliminated.

Cable protection system with IP-67 protection and UL-94


V0 fire retardancy.

Phase II Module No. STC-GS-1


Provision of Emergency Feed Terminal (EFT) in future
coaches and the same is to be implemented during POH in
existing coaches.

Provision of Battery Charging Terminal (BCT) in future


coaches and the same is to be implemented during POH in
existing coaches.

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No ITEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)

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

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No ITEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)
RDSO/PE/SPEC/
VRLA battery, AC/0009-
3.
110v, 70 Ah 2008,REV-1,AM-
1,ANNX-A

Constant voltage RDSO/PE/SPEC/


4. regulated battery AC/129-2009,
charger REV-1
RCF LW71001
5. fuse box (+ve)
Alt. f
RCF LW71002
6. fuse box (-ve)
Alt. f

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No ITEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)
RDSO/PE/SK/TL/
Charging
7. 0179-2014 Rev.
Terminal (BCT) 0
RDSO/PE/SK/TL/
Emergency feed
8. 0179-2014 Rev.
terminal (EFT) 0
100 VA
Transformer
9. 750/110 V for
Feeder contactor
control

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No TEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)

RCF EDTS-
Zs coupling, 400
105,REV-E,AM-
10. Amp, 750v,3-ph,
1,2 & 3, CORE-
50hz
1,TYPE-Ist

Feeder junction RCF EDML-


11.
box 020,REV-I

Wheel set
RCF EDTS-
12. earthing
101,REV-C,AM-1
equipment

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No TEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)
Self priming
mono- block
pump- (To be RCF EDTS-186,
13. ----
eliminated as per REV-A, AM-1 & 2 ---
Railway Board
Directives)

RDSO/PE/SPEC/T
L/ 0021-2005,
14. BLDC Fan
REV-2,COR-1,
BLDC

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.No TEM Specification/ class Sleeper Car
Drawing (LS) (LWSCN) (LWSCZ)

Exhaust Fan for


15.
Lavatory

Fluorescent
16. RCF CC76213 --
lamp(FL)

17. FL, CFL double RCF LW76055 -- --

Emergency RCF EDTS-


18. Lighting Unit 151,REV-C,AM-1
(ELU) &2

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.
ITEM Specification/ class Sleeper Car
No.
Drawing (LS) (LWSCN) (LWSCZ)
Passenger alarm
19. coach indication light RCF LW76005 --- ---
(PACIL)
Passenger alarm
reservation chart
20. RCF CC76238 ---
indication light
(PARCIL)

Door way light (DL)


21. RCF CC76216
/ gangway light (GL)

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.
ITEM Specification/ class Sleeper Car
No.
Drawing (LS) (LWSCN) (LWSCZ)
22. Lavatory light (LL) RCF LW76033

23. Night lamp (NL) RCF CC76289 -- --

Switch plate RCF EDML-


24. -- ---
assembly 127,REV-0,
Switch plate RCF EDML-
25. -- ---
assembly 086,REV-4,
Switch plate RCF EDML-
26. -- --
assembly 125,REV-0,

Phase II Module No. STC-GS-1


Reference Second 3 Tier Chair
S.
ITEM Specification/ class Sleeper Car
No.
Drawing (LS) (LWSCN) (LWSCZ)
RCF CC72069/
27. Set of cage clamp
CC72070

Distribution panel
28. for pantry RCF CC72172 -- --
equipments

Material list for RCF EDML-126,


29. -- --
compartment light REV-1

Mini pantry (LHB RCF EDTS-339,


30. -- --
EOG type) REV-B
Phase II Module No. STC-GS-1
The set of panels comprises of the various cubicles
consisting of power and control switchgear as mentioned
below:

i. High Voltage Cubicle (under-slung mounted)

ii. Battery Charger Box (under-slung mounted)

iii. Low voltage panel (onboard)


Phase II Module No. STC-GS-1
(i) High Voltage Cubicle (under-slung mounted)

UNDER SLUNG HV PANEL

This fabricated stainless steel cubicle is mounted


in under-slung in the coach.

Phase II Module No. STC-GS-1


This panel houses the disconnecting and earthing device,
switchgear and fuses for 750 V, 415 V, 190 V, 110 V,
Pump controller, Anti skid device, MMR, RCBO
(Residual Circuit Breaker with Overload), rotary switches
for feeder selection etc.

From the front of the panel all the equipment can be


access for.

For maintenance front covers are provided with hinges


and locking arrangement. The box is earthed with two
earthing terminals on top and bottom.
Phase II Module No. STC-GS-1
o Disconnecting and Earthing Device

A disconnecting and
earthing device along-with
high voltage fuses is
mounted inside the panel.

It is an OFF load device


rated for 63 amps at 750
volts fed from Generator
Car through ZS couplings.

It has two positions ON &


EARTH.

Phase II Module No. STC-GS-1


HV 750V Panel

Contactor K01
Fuses net1
Contactor K 02

Contactor K24, K25


Fuses net2

The main function of this device is to separate the two feeders


(input supply) and simultaneously earthing 750 volts ac network
of the coach in case of emergency like contactor jamming or
maintenance of coach even during running of coaches.
Phase II Module No. STC-GS-1
Low voltage fuses for transformer secondary and other
415/190 volt circuit fuses and RCBO (Residual Circuit
Breaker with Overload)

415/ 190 V Panel


Phase II Module No. STC-GS-1
Battery charging
fuses and
connections

Battery Charging connection


Phase II Module No. STC-GS-1
Rotary switch for selecting net-1, OFF, net-2.

Rotary switch for selecting remote and local control of


supply.

Rotary switch for local/ Rotary switch for


remote selection feeder selection

Rotary Switch Control with Remote


Phase II Module No. STC-GS-1
(mono block pump and pump controller to be discontinued in
future production by PUs)

Anti Skid Device

Pump Controller

Pump controller and Anti Skid Device


Phase II Module No. STC-GS-1
(ii) Regulated battery Charger
Constant Voltage Regulated Battery Charger is
provided for rectifying ac supply into dc for
providing power supply in the coach at 110 V dc
and at the same time to charge the VRLA batteries
provided in the coach.

The under-slung mounted totally enclosed, IP 53


ingress protection cubicle houses the regulated
battery charger along-with connectors.

Phase II Module No. STC-GS-1


The battery charger is forced air cooled, IGBT based and
DSP (digital signal processor) controlled working on a
nominal input supply of 415 V, 3 phase, 50 Hz fed from
750/415 V transformer.

Phase II Module No. STC-GS-1


This is a 3 phase dry type distribution transformer designed
for LHB type NON AC EOG coaches for providing power to
coaches from 750 V supply of power cars.

There are two types of transformer i.e. type I- 9 kVA for


general IInd class and 3 tier sleeper coaches (train lighting
load 6.5 kVA-415V + 2.5 kVA -190V AC) and

Type II 15 kVA for chair cars (pantry load and train lighting
load 12.5 kVA- 415V+ 2.5 kVA 190V AC).

Both types of the transformers are star- star-star connected,


dry type and air cooled.
Phase II Module No. STC-GS-1
The class of insulation of winding is
class H.

Transformer is fitted under slung


with 4 nos. anti vibration mountings.

Following protection fuses are


provided in transformer:
For 9 kVA transformer-
HT HRC fuse 3.3 kV, 20 Amps. 3 nos.
LT HRC fuse 500 V, 16 Amps 6 nos.
For 15 kVA transformer-
HT HRC fuse 3.3 kV, 32 Amps. 3 nos.
LT HRC fuse 500 V, 32 Amps 6 nos.
Phase II Module No. STC-GS-1
Transformer is housed in stainless steel housing with IP 67
protection and over all dimensions, construction and
mounting of the transformer is same as in 60 kVA
transformer of LHB AC coaches.

Phase II Module No. STC-GS-1


VRLA battery requires no topping up under normal
working conditions and minimal maintenance during
lifetime of battery.

It has self sealing safety valve, which normally does not


open out during service.

These coaches are provided with 9 modules of 12 volt


70Ah, VRLA battery in series in one battery box mounted
Battery Box & Batteries
in under-slung.
Phase II Module No. STC-GS-1
The auxiliary power required for charging is supplied by a
regulated battery charger at constant voltage based as
required by the battery.

Current limit for battery charging is 20 Amp at constant


voltage with the voltage setting at 122.0 1.0 volt.

Phase II Module No. STC-GS-1


Battery Module Salient Features
Capacity : 12 V, 70 Ah (at 27 C) battery module
Container : PP-CP (Poly Propylene Co-Polymer)
V2 grade/ ABS (Acrylonitrile
Butadiene Styerene) FR V2 grade
Rate of Discharge : 10 hr
Handle is provided on container instead of lid.
Phase II Module No. STC-GS-1
Battery fuse boxes (+ve and ve) are provided in under frame
supported on brackets by fixing bolts.

These boxes are properly earthed by earth cable. These are totally
covered and locked by hinged bolts.

Battery Fuse Box (+ve) Battery Fuse Box (-ve)


Fuse Rating +ve 40 Amp/ 660 V = 01 no. as
Fuse Rating -ve 40 Amp/ 660 V = 02 nos.
Phase II Module No. STC-GS-1
Under-frame mounted Inter-vehicular coupler unit are
used for transmission of 3 phase, 5 wire, 750 V, 50 Hz
power supply from power cars to rake/ coaches (LHB
type) working on End On Generation (EOG) system.

Various sub assemblies of IVC are given as under:

Jumper Plug Assembly 2 nos.

Coupling Socket Assembly 2 nos.

Phase II Module No. STC-GS-1


Coupling
Socket
Assembly

Jumper Plug Blind Socket


Assembly Assembly 2 nos.

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.

Feeder junction box-


socket side 2 nos.

Feeder Junction Box Socket Side

Phase II Module No. STC-GS-1


Wheel set earthing equipment for the wheel set is provided
to prevent return current flow through the axle bearings
and likely damage.

Thus the earthing contact system acts as a current bridge


that creates a connection by means of wiper contact
(brush) from the stationary bogie frame to the rotating
wheel set.

Phase II Module No. STC-GS-1


This set comprises following subassemblies per bogie:
i. Wheel set earthing equipment with stainless steel braided
earthing cable.

ii. Earthing resistor assembly 0.1 Ohm with mounting bracket


and grounding cable 3 sets

Wheel set and earthing equipment Earthing resistor assembly


Phase II Module No. STC-GS-1
Resistances are provided to restrict the return current from
certain bogie parts and providing return current path
through pre-determined low resistance path.

Phase II Module No. STC-GS-1


{To be discontinued in future production as per Railway
Board L. No. 2010/M (PU)/1/28 dtd. 06.03.2012}

Mono-block pump set are used on non AC 3 tier sleeper


coaches for lifting water from main tanks mounted on the
under-frame to auxiliary tanks.

The water raising 3 phase horizontal centrifugal self-


priming mono-block pump with thermal switch as
protection device embedded in the motor.

Phase II Module No. STC-GS-1


The pumps are mounted on the under-frame on a cradle
arrangement with interconnecting stainless steel piping
arrangement.

Microprocessor based pump controller is programmed for


alternate loading of pumps during operation, isolation of
faulty pump, overload protection, running time etc.

The pump controller is located in 750 V HV panel in under


frame.

The nominal input voltage to controller is 110 V AC/DC.


Phase II Module No. STC-GS-1
The controller is preset to run one of the pumps for a
period of 4 hrs. (adjustable) continuously and then
automatically switch over to the other pump for same
duration to enable equal loading of the pumps.

In the event of failure of any one of the pumps, the


controller automatically switches over to the other
pump.

It is also possible to run the pumps in manual mode by


selection through a rocker switch provided on the
controller.

Phase II Module No. STC-GS-1


Pump controller Mono-block pump set

Phase II Module No. STC-GS-1


The on-board panel houses the rotary switch panel as
used in conventional coaches for distribution of light and
fan.

This also houses rotary switch for feeder selection to


select the feeders as provided in the under-slung HV
cubicle and rotary switch for mobile charging socket
along-with connectors, push button for testing AEL is
also provided in this box.

Phase II Module No. STC-GS-1


Negative Fuse
40 amp.

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

On Board Rotary Switch Panel Phase II Module No. STC-GS-1


BLDC Fan

Brushless DC carriage fans of sweep 400 mm, working on


110 V DC supply are being provided in railway coaches
which requires minimum maintenance.
Phase II Module No. STC-GS-1
A band of colour of about 20 mm wide over the
periphery of the fan body approximately at its middle
portion is applied as a colour code for the following:

Dark Green : BLDC fan without hall sensor


Dark yellow : BLDC fan with hall sensor

Phase II Module No. STC-GS-1


Flotescent Light Fitting
Fluorescent light (FL) fitting works at 110V AC/DC
ballast and is provided with poly carbonate diffusers.

These fittings are provided in general IInd class coaches


and in 3 tier sleeper coaches.
Phase II Module No. STC-GS-1
In chair car ceiling light double FL fitting are provided.
These fittings comprise 2 nos. 14 watt T-5 lamps and
LED light for night lamp inbuilt in the fitting.

Phase II Module No. STC-GS-1


This unit has an inbuilt charger, adequately rated battery
and interlocks.

In General lighting inside the coach is provided by 110 V


AC or 110 V DC supply from battery.

During extreme emergencies


like derailments and
accidents, the supply system
fails causing total darkness
inside the coach.
Emergency Lighting Unit
Phase II Module No. STC-GS-1
To facilitate easy exit of passengers and their immediate
rescue during such emergencies, these emergency lights are
provided.

These lights are provided in doorways and inside the coach


(4 nos. in each coach) which will illuminate automatically
on failure of normal power supply or dropping of supply
voltage to a certain value inside the coach simulating
accident conditions.

These light fitting can work up to 6 hrs continuous


illumination.

Phase II Module No. STC-GS-1


Each emergency light unit consists VRLA battery of 6 AH
capacity fixed inside the unit and LED cluster type lamp unit.

Healthiness of battery voltage is indicated by one AMBER


colour LED and if battery is discharged, a RED colour LED
glows.

Phase II Module No. STC-GS-1


In each coach 2 nos. gangway/ doorway lights are
provided each consisting 2 nos. 11 watt CFL with
individual electronic ballast. Ballast is suitable for 110
V AC/DC supply.

Phase II Module No. STC-GS-1


Lavatory light fitting with 11 watt CFL and electronic
ballast for individual lamp is provided. Ballast is suitable
for 110 V AC/DC supply.

Phase II Module No. STC-GS-1


These lamps are provided in 3 tier Sleeper coaches. Night
light fitting (LED based) are provided with bright white
high intensity LEDs and acrylic milky diffuser.

Sticker indicating berth


number are pasted on
night light lamp.

Night Light LED Type


Phase II Module No. STC-GS-1
Passenger Alarm Coach Indication Light
Phase II Module No. STC-GS-1
For LS/GS coaches

In 2nd general coaches 2 nos. fan


switches and 1no. switch and 1 no. 5
pin mobile charging socket on each
switch boards are mounted and total
20 nos. (10 nos. cabin side + 10 nos.
corridor side) are provided in coaches.

1 no. 500 mA glass fuse is provided in


phase wire in mobile charging socket
with fuse holder.

Phase II Module No. STC-GS-1


For 3 tier sleeper coaches
In 3 tier sleeper coaches switch
plate assembly complete with
polycarbonate cover frame and
powder coated steel plate with 4
nos. ON-OFF switches (2 nos. fan
switches and 1no. light switch and
1 no. mobile charging switch) and
1 no. mobile charging socket with
2 nos. 500 mA glass fuses (one
each in phase & neutral wire)
with fuse holders are provided on
either side of each cabin.
Phase II Module No. STC-GS-1
For Chair Car
In chair car switch plate assembly
complete with polycarbonate cover frame
and powder coated steel plate with 3 nos.
ON-OFF switches (2 nos. fan switches
and 1 no. mobile charging switch) and 1
no. mobile charging socket are provided.
(16 nos. in a car)

1 no. 500 mA glass fuse is provided in


phase wire in mobile charging socket with
fuse holder.
Phase II Module No. STC-GS-1
No MCBs are provided.

High voltage panel with regulated battery charger are


provided under slung.

Only 190/110V AC and 110 V DC provided in On-


board panel.

These coaches are HOG compatible.

Phase II Module No. STC-GS-1


Provision of stainless steel cubicles for under slung
panels.

In the original design coaches, the feeder contactors


(K01, K02) are with 110 volts DC control, however it is
modified and these have been changed to 110 volts AC
control by providing 2 nos. 100 VA transformer
750/110V.

Provision of 500 mA glass fuse for individual mobile


charging socket.
Phase II Module No. STC-GS-1
(Ref: RDSO Specification No. EL/TL/48 (Rev.1) 2005)

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.

Phase II Module No. STC-GS-1


Rotary
Junction Box

The circuit L-1 have essential/emergency lighting circuit


which also include all Lavatory lights, 50% of
compartment lights, doorway lights, Night lights in all
types of IInd Class coaches. The L-II light circuit feeds all
the balance lights in the coach.
Phase II Module No. STC-GS-1
Glass fuses of proper rating protect
the branch circuits for lights and
fans. These glass fuses are located
on a distribution fuse board.

Fuse Distribution Boards

All branch circuits are protected by the fuses, both on


negative and positive sides. The grouping of negative wires
is done in such a manner that the group load is within the
capacity of the distribution fuse board and arrangements are
identical on positive and negative sides.
Phase II Module No. STC-GS-1
Positive and negative wires run in separate conduits on
opposite side wall of the coach.

Colour Code:

For easy identification of the cables, the various circuits


have colour code as indicated below:
Paralleling main and fan positive cables . Red
Light positive cables. .. Yellow
Fan negative cables .. Black
All other negative cables except fan negatives Blue
Phase II Module No. STC-GS-1
Mini pantry equipment for LHB EOG Non AC chair car
comprises following equipment made of stainless steel:

a. Hot case 01 no.


b. Refrigerating unit (Bottle cooler) 01 no.
c. Storage compartment with sink 01 no.
d. Water boiler 01 no.
e. Bottle cooler/ deep freezer 01 no.
f. Cup board 01 no.

Phase II Module No. STC-GS-1


The hot case is meant to keep
warm and warm up
respectively precooked
dishes in casseroles. Hot case
is divided into 2 separate
parts. The temperature of
these divisions is separately
controllable by thermostat
switches.
Phase II Module No. STC-GS-1
H = 1095 mm.
Overall dimensions
W = 850 mm
D = 515 (475 + 40) mm

Power supply 230V +/- 10%, 50Hz +/- 3%


Thermostat Range 30C to 110C
34 nos. x 3 mm dia stainless steel wire mesh
Trays
trays

Phase II Module No. STC-GS-1


The hot case is provided with a circulating air system
(blower) to maintain evenly warm up.

In order to maintain uniform temperature inside the


compartments, thermostatic control is provided and
initially set at 80C.

A safety thermostat at factory preset is provided to avoid


excessive heating of the cabinet in case of blower motor
failure.

Phase II Module No. STC-GS-1


Item Brief description Qty.
Cat. No. QLZ06/3000(LH)
01
Hot air fan/ Blower Cat. No. QLZ06/0030(RH)
01
Insulation class H
Tube air heating M/s Escorts/ Eichen make 300mm long
02
elements (maximum)
Rotary switch 16A,
SG 16/61079 02
2pole, 2 way with OFF
Indicators (LED type)
i. Red For blower & heater ON 04
ii. Green For power ON 01
Thermostat Model No. EWS 110 2
Safety thermostat Temperature setting shall be at 95C 2
Trays 3mm dia stainless steel wire mesh trays 34
Phase II Module No. STC-GS-1
To keep the 120 nos., 1 litre
bottles of drinking mineral water
bottles at a temperature level of
3C to 5C refrigeration unit is
provided.

A circulating fan is provided at


the top of the unit for air
circulation and uniform cooling.

Phase II Module No. STC-GS-1


H = 1750 mm
a. Overall dimensions W = 550 mm
D = 515 mm (including door)
b. Power supply 230V +/- 10%, 50Hz +/- 3%
Foamed polystyrene (Styrofoam) or
c. Thermal insulation
polyurethane foam
Danfoss KP-61/ALCO/Honeywell
d. Thermostat
make
e. Compressor R134a charged compressors
comprise of copper tubes and
f. Condenser and evaporator coils
aluminium fins
g. Condenser and evaporator fans impeller 230mm dia type-A
h. Shut off valve indfoss/ danfoss make.
Phase II Module No. STC-GS-1
To keep the food/ drinks in cold storage, a refrigeration
unit is provided for different cooling temperatures. The
refrigeration unit consists of the following compartments:

Deep freezer compartment

The deep freezer is to freeze and preserve ice cream. The


permanent temperature setting shall be at least -18C. The
temperature setting range is from -18C to -25C.

Phase II Module No. STC-GS-1


Cooling compartment

The cooling compartment is to simultaneously cool curd & other


cartons to a temperature level of 3C to 5C. The unit have
shelves/ trays for storing the cartons vertically pulled out for
easy handling.

Bottle cooler compartment

The bottle cooler is to


simultaneously cool 12 nos., of
1 litre bottles of drinking water
to a temperature level of 3C to
5C.

Phase II Module No. STC-GS-1


Height = 775mm
a. Overall dimensions Depth = 520 mm
Width = 850mm
b. Max. Power 400 Watts
c. Operating voltage 230V +/- 10%, 50Hz +/- 3%
Dan Foss KP-61/Alco/Honeywell make
i. Deep freezer:- 18C to -25C
d. Thermostat make/Range
ii. Bottle cooler: 0 to + 10C
iii.Cooling compartment : 0 to +10C
Foamed polystyrene (Styrofoam) or
e. Thermal insulation
polyurethane foam
Phase II Module No. STC-GS-1
f. Compressors R134a charged compressors
g. Condenser and evaporator fans Impeller 230mm dia type-A

Comprising of copper tubes and


h. Condenser and evaporator coils
aluminium fins

i. Shut OFF valve Indfoss/ Danfoss make

Phase II Module No. STC-GS-1


The water boiler is rectangular
type design. Indications are
provided on the terminal box
for power ON and heater
ON

Phase II Module No. STC-GS-1


a. Capacity of water boiler 25 liters (approx.)
b. Power supply 230V AC 10% 50Hz3%
2 x 1500 Watt tube type emersion heating
c. Heating element
element
d. Thermostat Range 40-110C to IS:3017 (latest)
Height = 675mm (max.) (600 + 75mm)
e. Overall dimensions Width = 275mm (max.)
Depth = 380mm (max.)
Rock wool plate/ bonded mineral wool
f. Thermal insulation
having bulk density of 40-50 Kg/Cu.m
g. Water Inlet 15mm bore stainless steel pipe
h. Water outlet 15mm bore stainless steel pipe
Phase II Module No. STC-GS-1
Below the water boiler an open
cupboard compartment is
provided. This comprises a
stainless steel work surface with
a surrounding raised edge (no
slanting drip surface) and drawn
type sink to dimensions 330 x
255 x 125 mm.
Phase II Module No. STC-GS-1
A wall mounted cupboard
without door (2 shelves) is
provided for storage of vacuum
flask and cups. It is provided
with aluminium bar to prevent
the vacuum flask and cups
falling out. Unit is fabricated
form 1.0mm thick high grade
stainless steel sheet.
Phase II Module No. STC-GS-1
SN Equipment Rating Qty/ Coach
1 Step down Transformer 750 V / 415V AC, 3 , 15 / 9 kVA 1
9 Mono
2 Battery 120 Ah, 12 V Mono-block, VRLA
blocks
Input: 415V, 3 , AC, 50 HZ
3 Regulated Charger 1
Output: 110 V DC
3 phase 415 volt, 0.5 HP, 1.1
Amp, 2800 rpm, connection - Y,
Self Priming Mono Block
4. pump size 25x25 mm, head 8 m., 02
Pump
discharge 2520 LPH, insulation
class F,
100 VA Transformer for
5. 100 VA, 750/110 V 02
Feeder contactor control
Phase II Module No. STC-GS-1
LHB EOG TYPE NON-AC GS (LS) COACHES

Qty Per
Item Code Description Wattage Load In
Coach

FL Fluorescent Light 20 20 400


DL Door Way Light 20 6 120
GL Gangway Light 26 2 52
LL Lavat0ry Light 13 4 52
AEL Accidental Emergency Light 10 4 40
PACIL Passenger,alarm, Light 10 2 20
F Fan 38 30 1140
Total Load 1824

Phase II Module No. STC-GS-1


Item Qty Per Load
Description Wattage
Code Coach In
FL Fluorescent Light 20 20 400
DL Door Way Light 20 4 80
GL Gangway Light 26 2 52
LL Lavat0ry Light 13 4 52
AEL Accidental Emergency 10 4 40
Light
Phase II Module No. STC-GS-1
Item Qty Per Load
Description Wattage
Code Coach In

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

Phase II Module No. STC-GS-1


Item Qty Per Load In
Description Wattage
Code Coach

Fluorescent Light (28w+Nl-


FL 30 10 300
2w)

DL Door Way Light 26 4 104

GL Gangway Light 26 2 52

LL Lavat0ry Light 13 4 52

AEL Accidental Emergency Light 10 2 20


Phase II Module No. STC-GS-1
Item Qty Per Load In
Description Wattage
Code Coach

Passenger,Alarm,Cum,Reserva
PARCIL 21 2 42
tion Chart Illumination Light

F Fan 38 36 1368

MCS Charging Socket 15 17 255

Total Load 2193

Phase II Module No. STC-GS-1


Phase II Module No. STC-GS-1
Phase II - Module No. STC-GS-1
One of the methods to reduce the down time of the
coaching stock is to provide the proper tools with
modern design.

Availability of proper tools with artisan staff is essential


to enhance the productivity and quality of work.

Performance record of tools is required to be kept to


review their performance.

Phase II - Module No. STC-GS-1


1. Always use the right size and type of tool for the job being
done.

2. Keep tools in proper working condition.

3. Never alter a tool from its original condition.

4. Always wear safety goggles when using punches, chiesels,


hammers and cutting tools.

5. Never use a tool as a hammer unless manufactured for that


purpose.
Phase II - Module No. STC-GS-1
6. Never use a pipe extension to increase the leverage of any
wrench.

7. Adjustable wrenches should be tightly adjusted to the nut


and pulled so that the force is on the side of the fixed jaw.

8. Never use a pipe wrench to bend, raise or lift a pipe.

9. Ratchet mechanisms should be cleaned and lubricated


periodically with light grade oil.

10. Keep hammer heads tight on the handle. Never use a


hammer with a loose or damaged handle.
Phase II - Module No. STC-GS-1
11. Metal cutting chisels are intended for cutting, shaping and
removing metal softer than the cutting edge itself.

12. Always strike the struck base of a chisel or punch. The


striking face of the hammer should have a dia.
approximately 10 mm larger than the struck face of the
punch or chisel.

13. Never use screw drivers with rounded tips.

14. Never use a screwdriver as a chisel, punch, scraper or pry


bar. Use screw driver for screw driving only.

Phase II - Module No. STC-GS-1


(In Proper Tool Bag)

S.No. Description Qty

Tool box of size 325x440x120 mm (Approx.) with fixing


1. arrangement for tools and locking arrangement with 2 1 set
no. keys

Neon bulb tester cum Screw driver set with 8 nos of


2. 1 set
blade.

Phase II - Module No. STC-GS-1


S.No Description Qty
Combination plier insulated with thick CA sleeve with
3. 1
joint cutter length 205 mm
4. Digital multi-meter 1
5. T spanner of sizes 10, 13, 15, 17 1
Panel key square type size suitable for opening of
6. 1
control panel of AC coaches
7. Key for opening fittings of AC coaches 1
Test lamp holder (brass) fitted with two mtrs. of 2 core
8. 1
flexible copper wire
9. Torch with cells (+2 cell spare) 1

Phase II - Module No. STC-GS-1


S.No Description Qty

DE spanner set 8 pcs of sizes 6/7, 8/9, 10/11, 12/13,


10. 1 set
14/15, 16/17, 18/19, 20/22

11. Allen key size 4 mm, 3/16, 7/32 1

Heavy duty cable cutting knife adjustable in aluminium


12. 1
casing over all size 140 mm

13. Adjustable spanner length 255 mm 1


14. Infrared Digital Thermometer (Temperature gun) 1
15. Insulated Nose plier 6 1
16. Tongue tester A.C. (0-100 A) 1

Phase II - Module No. STC-GS-1


S.No Description Qty

17. Hammer kg 1

18. Hacksaw frame with blade (+ 1 spare blade) 1

19. PVC Insulating tape 25 mm 1

20. Wire fuse 1

Phase II - Module No. STC-GS-1


(In proper tool bag)
S.No. Name of Tools Qty.

Combination plier insulated with thick CA sleeve with


1. 1 no.
joint cutter length 205 mm

2. Insulated Wire Stripper & Cutter 16 sq.mm 1 no.


3. Insulated Long Nose Pliers 6 1 no.

Neon bulb tester cum Screw driver set with 8 nos of


4. 1 no.
blade similar

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
5. Fitting Opening Key (FDB/CFL/Tube light/RRU) 1 no.
DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13,
6. 1 set
14/15, 16/17, 18/19, 20/22
7. Adjustable spanner length 255 mm 1 no.
Test lamp holder (brass) fitted with two mtrs. of 2
8. 1 no.
core flexible copper wire
9. Hacksaw frame with blade (12") + One extra blade 1 no.
10. Flat file 150 mm 1 no.
11. Ball pen Hammer 300 gms 1 no.
12. Torch with cell, LED 1 no.

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
13. Fuse puller 150mm 1 no.
14. Digital Multimeter with tongue tester 1 no.
15. PVC Insulating Tape 25mm 01 roll
Heavy duty cable cutting knife adjustable in
16. 01 no.
aluminium casing over all size 140 mm
17. Infrared Digital Thermometer (Temperature Gun) 01 no.
18. Chiesel 150 mm 01 no.
19. Fuse Wires 01 set
20. Spare lamp/CFL/FTL 01 set
21. Capacitor for AC fan 03 nos.

Phase II - Module No. STC-GS-1


Tools Kit for TL Fitter (In Proper Tool Bag)
S.No. Name of Tools Qty.
Combination plier insulated with thick CA sleeve with
1. 1 no.
joint cutter length 205 mm
2. Insulated Wire Stripper & Cutter 16 sqmm 1 no.
3. Insulated Long Nose Pliers 6 1 no.
Neon bulb tester cum Screw driver set with 8 nos of
4. 1 each
blade similar
5. Fitting Opening Key (FDB/CFL/Tube light/RRU) 1 no.

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13,
6. 1 set
14/15, 16/17, 18/19, 20/22
7. Ring Spanner Set 1 set
8. Adjustable spanner length 255 mm 1 no.
Test lamp holder (brass) fitted with two mtrs. of 2 core
9. 1 no.
flexible copper wire
10 Flat file 150mm 1 no.
11. Ball pen Hammer (300 gm) 1 no.
12. Torch, 4 cell (LED) 1 no.
13. Fuse puller 6 1 no.

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
14. Hydrometer 1 no.
15. Cell tester (Range 12V DC) 1 no.
16. Digital Multimeter with tongue tester 1 no.
17. PVC Insulating Tape 25mm 01 roll
Heavy duty cable cutting knife adjustable in
18. 01 no.
aluminium casing over all size 140 mm
19 Infrared Digital Thermometer (Temperature gun) 01 no.
20. Chiesel 150mm 01 no.
21. Cleaning Brush 01 no.
22. Fuse Wires 01 set

Phase II - Module No. STC-GS-1


S.No. Name of Tool

Combination plier insulated with thick CA sleeve with joint


1.
cutter length 205 mm

2 Insulated Wire Stripper & Cutter 16 sqmm


3 Insulated Long Nose Pliers 6

Phase II - Module No. STC-GS-1


S.No. Name of Tool
Neon bulb tester cum Screw driver set with 8 nos of blade
4.
similar to Jhalani P. No. 830 or equivalent
5. 4 way keys
6. Ring spanner set ( 8- 32)
Set of box spanner with 1/2" socket set containing 19
7.
socket (11 to 32) and 6 attachment
8. Double open end spanner set ( 8 - 32)
9. Single end open Spanner (36mm)
10. Allen Key set
11. Adjustable spanner length 255 mm

Phase II - Module No. STC-GS-1


S.No. Name of Tool

Test lamp holder (brass) fitted with two mtrs. of 2 core


12.
flexible copper wire

13. Hacksaw frame with blade (12") + Extra Blades


14. Flat, round, triangular files
15. Ball pein Hammer ( 200gm, 300gm, 500gm, 800 gm, 1kg)
16. Nylon hammer
17. Chiesel flat 150mm
18. Infrared Digital Thermometer (Temperature gun)
19. Torch, 4 cell, LED for each staff

Phase II - Module No. STC-GS-1


S.No. Name of Tool
20. Fuse puller 6
21. Crimping tool ( 0.5 - 1.6 mm2 )
22. Crimping tool (1.5 - 16 mm2 )
23. Hydraulic crimping machine (upto 300 mm)

Heavy duty cable cutting knife adjustable in aluminium


24.
casing over all size 140 mm

25. Multipurpose Portable power drill machine


26. Auto ranging Digital Multimeter
27. Hydrometer

Phase II - Module No. STC-GS-1


S.No. Name of Tool

28. Digital clamp meter

29 Bearing/ Pulley Puller

30. Pulley V groove GO , NO GO gauge

31. Portable electric straight grinder

32. Digital lux meter

33. Cell tester (0-12) V DC

34. Digital Tachometer

35. Digital Vernier caliper

Phase II - Module No. STC-GS-1


S.No. Name of Tool
36. Digital Micrometer
37. Digital Meggar (500 V to 5000 V )
38. Heavy duty Pipe wrench
39. Soldering iron
40. De-soldering gun
41. Hot air gun / Hot air blower
42. Portable Blower / Dust extractor

1/2" socket set containing 19 socket (11 to 32) with 6


43.
attachment

Phase II - Module No. STC-GS-1


S.No. Name of Tool
44. Torque wrench 0-5kg-m
45. Shock pulse meter (SPM)
46. All purpose saw
47. Infrared Digital Thermometer
48. Cable cutter 150mm
49. Insulating Tapes 25mm
50. Safety helmet for each staff
51. Gum boot for each staff
52. Tool bag for each technician

Phase II - Module No. STC-GS-1


(In Proper Tool Bag)

S.No. Name of Tools Qty.

Combination plier insulated with thick CA sleeve with


1. 1 no.
joint cutter length 205 mm

2. Insulated Nose plier 6 1 no.


3. Neon bulb tester Screw driver set with 8 nos of blade 1 set

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
Panel key square type size suitable for opening of
4. 1 no.
control panel of AC coaches
4 way key & fitting opening key
5. 1 no.
(FDB/CFL/tubelight/RRU)
DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13,
6. 1 set
14/15, 16/17, 18/19, 20/22
7. T spanner of sizes 10, 13, 15, 17 1
Test lamp holder (brass) fitted with two mtrs. of 2 core
8. 1 no
flexible copper wire
Heavy duty cable cutting knife adjustable in
9. 1 no.
aluminium casing over all size 140 mm

Phase II - Module No. STC-GS-1


S.No. Name of Tools Qty.
10. Allen key ( 3- 15m) 1 no
11. Flat file 150mm 1 no
12. Hammer 200 g 1 no
13. Torch, cells (+2 cell spare) 1 no
14. Auto ranging Digital Multimeter 1 no.
15. Tongue tester A.C. (0-100 A)
16. Adjustable spanner length 255 mm 1 no.
17. Infrared Digital Thermometer (Temperature gun) 1
18. PVC Insulating tape 25mm 1
19. Wire fuse 1

Phase II - Module No. STC-GS-1


S.No. Name of Tools
Combination plier insulated with thick CA sleeve with joint
1.
cutter length 205 mm
2. Insulated Wire Stripper & Cutter 16 sqmm
3. Insulated Nose plier 6
Neon bulb tester cum Screw driver set with 8 nos of blade
4.
equivalent

Phase II - Module No. STC-GS-1


S.No. Name of Tools
5. 4 way key
6. Ring spanner set ( 8- 32)
Set of box spanner with 1/2" socket set containing 19 socket (11
7.
to 32) and 6 attachment
8. Double open end spanner set ( 8 - 32)
9. Single end open Spanner (36mm)
10. T spanner set
11. Allen Key set
12. Adjustable spanner length 255 mm
13. Test lamp/ Hand lamp

Phase II - Module No. STC-GS-1


S.No. Name of Tools
14. Hacksaw frame with blade (12") + extra blades
15. Flat round, file
16. Ball pein Hammer 200 gm, 500gm, 1kg.
17. Nylon hammer 100gm
18. Chiesel (Flat) - 8"
19. C Clamp
20. Crimping tool (0.5 - 6 mm)
21. Crimping tool (1.5 -1 6 mm)

Phase II - Module No. STC-GS-1


S.No. Name of Tools

22. Pinching tool

23. Tube bender (3/8", 5/8", 7/8")

24. Flare tool

25. Tube cutter

26. Torch (4 cell) + extra cells for each staff

27. Digital Tachometer

28. Digital Clamp meter

29. Hydrometer

Phase II - Module No. STC-GS-1


S.No. Name of Tools
30. Auto ranging Digital Multimeter
31. Cell tester (0-12) volt DC
32. Battery analyzer
33. Digital meggar ( 500 V, 1000 V, 2500V, 5000V)
34. Digital Micrometer
35. Digital Vernier calipers
36. Blower / Dust extractor
37. Portable electric straight grinder
38. Torque wrenches
39. Pipe wrench

Phase II - Module No. STC-GS-1


S.No. Name of Tools
40. Multipurpose Portable Power drill machine
41. Soldering iron
42 De-soldering Gun
43 Hot air gun / Hot air blower
44 Shock pulse meter (SPM)
45 All purpose saw
46 Pulley V groove GO , NO GO gauge
47 Pulley/ Bearing puller
48 Digital Anemometer

Phase II - Module No. STC-GS-1


S.No. Name of Tools
49. Infrared Digital thermometer (Temperautre gun)
50. Digital lux meter
51. Winding insulation Resistance meter
52. Cable cutter/ wire cutter
53. Gum boot for each staff
54. Infrared thermal imaging camera
55. Power quality analyzer
56. Leakage current tester
57. Fuse puller

Phase II - Module No. STC-GS-1


S.No. Name of Tools
59. PVC tape
60. Bunching tie
61. Amery paper
62. Amery cloth
63. Digital spirit level
64. Digital thermometer
65. Duster cloth
66. Automatic self adjusting small spanner
67. Spanner multi wrench 10 in one

Phase II - Module No. STC-GS-1


S.No. Name of Tools

68 Multi wrench/ Spanner

69 Ratchet wrench Ratchet type spanner

70 Angular grinder

71 Cord less drill machine

72 Cord less screw driver

73 Knife set

74 Wire brush

75 Nylon brush

Phase II - Module No. STC-GS-1


S.No. Name of Tools

76 Paint brush

77 Portable screw jack

78 Safety helmet for each staff

79 Tool Bag for each technician

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
150mm , 200mm, 250mm.

STEEL.

Cutting, twisting of small


wires and holding round
and flat objects.

Phase II - Module No. STC-GS-1


Dont use as a hammer.

Dont cut steel wires.

Dont hold hot substances.

Dont spoil the handle insulation.

Keep the plier safe from rust.

Lubricate moving part.

Phase II - Module No. STC-GS-1


150mm , 200mm.

STEEL.

Cutting wires at narrow places,


for removing insulation, and
instrument works.

Phase II - Module No. STC-GS-1


Dont cut steel wires.

Dont spoil the handle insulation.

Keep the cutter safe from rust.

Lubricate moving part.

Dont cut hot substances.

Phase II - Module No. STC-GS-1


100mm,150mm , 200mm.

STEEL.

For connecting and disconnecting


small wires and tightening and
loosening of small nuts in narrow
places and also for cutting the thin
wires.
Phase II - Module No. STC-GS-1
Dont use as a hammer.

Dont cut steel wires.

Dont spoil the handle insulation.

Keep the plier safe from rust.

Lubricate moving part.

Phase II - Module No. STC-GS-1


75mm, 100mm,150mm ,
200mm, 250mm,300mm.
Blade in steel, Handle in
wood or celluloid.

For tightening and loosening


screws. and wiring accessories
like switches, holders etc.
Phase II - Module No. STC-GS-1
Dont use with loose handle.

Dont hammer the handle.

Dont use it as chisel.

Correctly fit the blade edge in the


screw slots.

Avoid greasy or oily handle.

Phase II - Module No. STC-GS-1


It is used to open and close
the RJB cover, Pannel
boards, FTL/CFL fittings
etc.

Phase II - Module No. STC-GS-1


8 to 36

Steel

For tightening and loosening


of nuts and bolts.

Phase II - Module No. STC-GS-1


Use correct size spanner .

Dont use as a hammer.

Dont strike with hammer while


tightening or loosening.

Dont apply grease/oil on its jaws.

Phase II - Module No. STC-GS-1


300mm Cast iron

For tightening and loosening nut &


bolt of different sizes with single
spanner thus saving time.
Dont use as a hammer.
Dont strike with hammer while
tightening or loosening.
Dont apply grease/oil on its jaws.
Phase II - Module No. STC-GS-1
For tighten or loosen where nut &
bolts are in narrow and deep places.

For tighten or loosen where nut &


bolts are in narrow and deep places.

For tighten nut and bolts with fixed


torque.

Torque can be adjusted according to


manufacturer recommendations.

Phase II - Module No. STC-GS-1


Used to drive bolts or screws of
hexagonal recess in the head.

Dont apply oil or grease in recess


of heads.

Use only proper size.

Phase II - Module No. STC-GS-1


5m,10m,20m

Used to measure length, width


and heights where ever required.

Dont bend reverse side or twist.


See that paint should not scratched.
Avoid from rust.

Phase II - Module No. STC-GS-1


Two lamps of same wattage and
same voltage must be connected
in series.(+ve red, -ve blue and
earth green or white).

With this arrangement we can


check the coach earth.

Handle the test lamp with care


otherwise it may broken.

Phase II - Module No. STC-GS-1


12

For cutting conduit pipes, G.I.pipes


and small iron pieces etc.

Blade should be fixed tight enough.


Use coolant while cutting.
Teeth of the blade should be away from the handle.
Hold the frame straightly while cutting.
Lift the saw slightly on return stroke.

Phase II - Module No. STC-GS-1


Used to cut the cable of
aluminum or copper up to 240
sqmm.

Dont cut metal pipes or rods.

Phase II - Module No. STC-GS-1


Files are in different shapes and different sizes.

EX : Flat, round, half round, square, triangular etc.

Phase II - Module No. STC-GS-1


For smoothen surfaces and finishing works.

For different places suitable shape of the file will be used.

Handle should not be loose.

Dont apply oil or grease while filing.

Clean the file with wire brush after completion of work.

Phase II - Module No. STC-GS-1


300 gm

For bending, straightening small iron sheets.


For driving nails on wood or walls.
For tap the pulley to know the condition by
observing sound.

Handle should not be loose.


Dont apply oil or grease on bottom surface .
Phase II - Module No. STC-GS-1
500 Volts

For testing availability


of supply.

Dont use on higher voltage than specified.


Dont tight or loose the screws (heavy).
Stand on earth while testing.
Touch the metal clip while testing.
Phase II - Module No. STC-GS-1
4 Cells (each 1.5v)

To observe objects when there


is no lights.
To focus light on narrow and
dark places.
Dont drop the torch.
Dont dip into the water.
Switch off light and remove the cells out after completion
of work.
Phase II - Module No. STC-GS-1
Available in different sizes depends up
on size of the fuse.

For pulling the fuse safely.

Dont drop on hard ground.


Dont apply oil or grease.
Hold the fuse in correct position.

Phase II - Module No. STC-GS-1


Used to check specific gravity of
electrolyte in flooded type cells.

Handle with care.


Take the electrolyte slowly.
Keep it clean.

Phase II - Module No. STC-GS-1


3-0-3Volts DC

For test the voltage of individual


cell and polarity.

Dont use more than one cell.


Dont dip into the water.
Handle with care.

Phase II - Module No. STC-GS-1


Used to measure ac/dc voltages of
different range.

Used to measure ac/dc low currents.

Used to check continuity of the circuit


and to measure resistance.etc.

Phase II - Module No. STC-GS-1


First select the range and units to be
measured.

Disconnect the supply while checking


continuity or while measuring resistance.

Handle with care.

Check the condition of prods.

Keep the meter clean and observe the


error.

Phase II - Module No. STC-GS-1


: Used to skin the insulation of wires.

Dont cut the conductor.


Keep the knife sharp.
Close the safety cap after completion of
work.
Dont spoil the insulation.
Phase II - Module No. STC-GS-1
: Used to tightening or loosening of belt
tension.

Dont use as a hammer.

Dont apply oil or grease.

Phase II - Module No. STC-GS-1


: Used to check the pulley worn out
condition.
Dont bend the leaves.
Keep it clean.

Phase II - Module No. STC-GS-1


: Used to crimp the small lugs on
wires/cables.
Use proper jaw for suitable size of the lug.
Apply oil on moving part.

Phase II - Module No. STC-GS-1


25W, 65W, 125W, 250W.etc.

Used to solder wire joints, commutator


segments and electronic components on PCB.

Iron must be connected to earth.


Flexible wire should be used.
Keep the iron on holder.

Phase II - Module No. STC-GS-1


Used to measure illumination level
in coaches or where ever required.

Handle with care.


Cover the sensor with cap after
completion of work.

Phase II - Module No. STC-GS-1


To measure the temperature on hot
spot by non touching the hot spot .

Dont drop the meter.


Dont dip into the water.
Dont take the meter very near to hot
spot.
Phase II - Module No. STC-GS-1
To measure the high currents in the cable (ac/dc). And
also can used as multimeter.

First select the correct range then measure.


Keep the meter clean.

Phase II - Module No. STC-GS-1


Used to pull the pulley or bearing of the
alternator or any rotating machine.

Fix the puller in correct position while


using.
Dont apply grease on claws while
using.
Apply oil or grease on moving parts.

Phase II - Module No. STC-GS-1


Used to blow or suck the dust from
RJB,FDB, Electrical equipments,
dc fan carbon dust etc.

Check the carbon brush of the


blower.
Use nose mask to protect ourselves
from dust.

Phase II - Module No. STC-GS-1


To make small holes on iron or wood.

Use lubricant while making hole on


metals.
Dont fix the drill bit loosely.
Dont put too much pressure on
machine.
Check the connection of cable
connected to machine.

Phase II - Module No. STC-GS-1


To measure speed of the rotating
machine in RPM.

Touch the spindle to pulley


straightly.

Phase II - Module No. STC-GS-1


To measure the insulation values of wiring,
cables, winding of electrical machines.

Disconnect supply to the equipment


whose insulation to be measured.
Select the voltage range before
measuring.

Phase II - Module No. STC-GS-1


Used to monitor the condition
of bearing of rotating machines.

Fix the sensor in correct place.


Observe the reading keenly.

Phase II - Module No. STC-GS-1


Used to measure inner/outer dia of the object
accurately.

Observe the reading keenly.


Handle with care.
Clean the vernier after completion the work.

Phase II - Module No. STC-GS-1


To find out the dia of very thin wire.
Adjust the thimble gently.
Clean the spindle .
Handle with care.
Phase II - Module No. STC-GS-1
Standard wire gauge (SWG) is a system
of numbering used to measure the
diameters of wire and thickness of sheet
metal. The measurements are represented
in dimensions of inches and millimeters.

Dont put in tool bag.


Keep it clean

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
To measure Insulation Resistance
of all voltage components like
transformer winding, CTs, PTs,
bushings, cables, motor and
Alternator windings etc.

Technical Specifications :
Test voltage 500 V to 5000 V DC
IR Range 0 5 T
Display Digital
Short circuit current < 2mA

Phase II - Module No. STC-GS-1


Healthiness of winding insulation can be checked.

LED based visual indication for discharge condition of


meter ensures safety.

This LED glows after the HT is switch OFF, till the voltage
on test object/ HV terminal is below 50 V approximate.

Equipment have HV, LV & Guard and Internal discharge of


object after test, memory for measurement results, ability to
transfer the data to a PC, polarization index and dielectric
absorption ratio.

Phase II - Module No. STC-GS-1


Thermal imaging infrared camera identifies electrical and
mechanical problems like hot spots, heat development on
loose connections etc. before they result in failures.
Phase II - Module No. STC-GS-1
It is a non-contact device which detects infrared radiations
and converts it into electronic signals. These signals are
then processed to produce thermal image of the object.

Technical Details:
(For more details refer RDSO Spec. No. TI/SPC/OHE/TIPS/1031, December, 2013)

Sr. Features Present Specification


1. Detector Un-cooled focal plane array (FPA) of
320 x 240 pixels or more
2. Temperature measurement 0 to 500 degree centigrade or Higher
Range

Phase II - Module No. STC-GS-1


Sr. Features Present Specification

Minimum Minimum focus distance less than or equal to 40


3.
focus distance cm to infinity.

With 2/o of display or 2c whichever is


4. Accuracy
greater.

5. Focus Auto or Manual

Not less than 75 mm diagonally active matrix


6. Display
colour LCD with high luminance or better.

Phase II - Module No. STC-GS-1


It helps to find out electrical hot spots and faulty
equipment in incipient conditions.

It is an ideal means for maintenance people looking for


safety and reliability when conducting routine surveys of
electrical systems, switchgear and electrical components.

It is non contacting and can be done in live condition


without affecting the operation, production or traffic.

Phase II - Module No. STC-GS-1


It is applicable to most types of electrical, mechanical
equipment and power lines.

It has the storage memory and images are saved with


details. The same can be downloaded with USB port and
detail analysis can be done with the help of software.

Phase II - Module No. STC-GS-1


Electro chemical battery
analyser accurately measures
health of lead acid battery
(chemical and electrical) in
terms of sulfation, dry out,
voltage and impedance.

Phase II - Module No. STC-GS-1


Technical Specifications
Voltage Range 0 to 17 V DC
Impedance Measurement range 50 to 1
AmpHour capacity range for batteries 5 Ah to 2,000 Ah; specified
under test performance range
Sulfation Range 0 to 100%
Dryout Range 0 to 100%
Cell terminal strap impedance ()
Measurement range 50 to 1
Specific Gravity Manual logging
Safety Feature Trigger point 17V DC
Over voltage auto reset breaker Warning 50V DC
Damage point 600V DC max.

Phase II - Module No. STC-GS-1


It can store large amount of data and auto hold and
auto-data storage facility also available.

It has ability to measure AC voltage and low


resistance.

It can memorize the value on the spot.

It can enhance resistance against noise.

Phase II - Module No. STC-GS-1


Power Quality analyzer helps to
locate, predict, prevent, and
troubleshoot power quality
problem in three & single phase
power distribution system.

Phase II - Module No. STC-GS-1


For measuring AC leakage current
blowing into ground conductor.

Phase II - Module No. STC-GS-1


Technical Specifications

Conductor size 30mm. max. (approx.)


Battery Type Two 1.5V SUM-3
Display 3 LCD with 40 segment bargraph
Range Selection Manual
Overload Indication OL
Power Consumption 15mA (approx.)
Dimensions 210 (H) x 72(w) x 36(D) mm
Weight 210 gm (battery included)

Phase II - Module No. STC-GS-1


Crimping of lugs on power cables

Phase II - Module No. STC-GS-1


Removing of wire insulation for termination.

Phase II - Module No. STC-GS-1


Strips wire up to 7/8" or 4mm2

Automatic feature holds jaws open to remove wire


without crushing ends. Practically eliminates all
nicking, cutting, or fraying. Strips teflon, silicon and
PVC wire. Made of aluminium with plastic molded
handles.

Phase II - Module No. STC-GS-1


Cutting of cables, wires (solid / stranded)
upto 10mm2 length 160mm approx.

Cut round cable and wire cutter to multi


- conductor cable Up to 10 mm2

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Cutting work of sheet metal, nut/bolts, iron angles,
pipes etc.

Phase II - Module No. STC-GS-1


Technical Specifications

Saw in wood 130 MM

Saw in steel 20 MM

Power input 600 W

No load stroke rate 2600 stroke/min.

Saw stroke length 28 MM

Weight 3.1 Kg.

Phase II - Module No. STC-GS-1


For grinding, sanding, rust removing etc.

Phase II - Module No. STC-GS-1


Technical Specifications

GRINDING POINTS MAX. 25 MM DIA


NO LOAD SPEED 27000 RPM
POWER INPUT 500 W
TOOL HOLDER COLLET-CAP MAX.8 MM DIA

SPINDLE COLLER
43 MM
DIA

WEIGHT 1.3 KGS.

Phase II - Module No. STC-GS-1


For bending copper tubes used in air conditioning.

Phase II - Module No. STC-GS-1


Calibrated angle marking from 10 to 180 for left,
right or offset bends. Made of tie cast alloy .

3/8", 5/8", 7/8".

Phase II - Module No. STC-GS-1


Checking of alignment of foundations of pumps,
transformers, DG sets etc. and other applications
which require accurate level.

Phase II - Module No. STC-GS-1


Technical Specifications

Length 600mm

Measuring Accuracy at 0/ 90 max. 0, 05

Measuring Accuracy at 1to 89 max. 0, 2

Battery 9V DC6 LR 61

Phase II - Module No. STC-GS-1


To cut copper tubes used
in air-conditioning.

1/8" to 7/8"

Larger knob for greater torque, harden flare


grooved roller

Phase II - Module No. STC-GS-1


For measuring the temperature and
relative humidity.

Phase II - Module No. STC-GS-1


Simultaneous readout of C or F (switchable) and %
RH. Minimum/ Maximum memory functions for both
temperature and humidity

Range 30 to 90% RH, 0-50 C Temp.

Resolution 1% RH, 0.1F or C

Phase II - Module No. STC-GS-1


For squeezing the copper tube used in
air-conditioning.

Product based on IS: 10372

1/4"

Phase II - Module No. STC-GS-1


Removal of solder joint

Rugged, manual loading tool for


volume de-soldering. High vacuum
heavy-duty plastic, fully enclosed
shaft for safety. Plunger locks for
compact storage.

Phase II - Module No. STC-GS-1


For making flare shape for copper pipes used in
air-conditioning.

Phase II - Module No. STC-GS-1


Octagonal Chiesel made from high grade steel,
forged and ground. Differential heat treatment for
cutting edge and striking end to ensure long life.

Length In mm Cutting Edge in mm


150 16
200 25
250 30
300 32

Phase II - Module No. STC-GS-1


Length In mm Cutting Edge in mm
150 25
200 25
250 25

Half round file Bastard 300


Half round file Smooth 200
Half round file Smooth 300
Round file Bastard 200
Round file Bastard 250
Round file Smooth 150
Round file Smooth 250

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Conforming to IS 4003-1978 (Part-I), Heavy
duty housing with integral I-beam handle
made of SG Iron for maximum strength.
Suitably proportioned handle for comfortable
grip (powder coated).
Size mm Capacity mm
250 35
300 44
350 48
450 60
600 76

Phase II - Module No. STC-GS-1


High Grade Chrome Vanadium Steel. As
per IS 6131-1980 & 7381-1986
Bi-hexagonal & Hexagonal One Set

Phase II - Module No. STC-GS-1


Product Item Sockets (mm)

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

Extension bar 125mm,255mm, Universal


5 Accessories
joint T Handle , Ratchet Handle

Phase II - Module No. STC-GS-1


Length in mm

105

205

Phase II - Module No. STC-GS-1


Khadi cloth

Dusting work,panel,
window glass etc
cleaning work.

Phase II - Module No. STC-GS-1


Automatic self- adjusting small spanner having functional capacity
A/F 6 mm to 22 mm or SAE A/F 1/4" to 7/8"

Alloy steel duly hardened jaw, nylon 6 moulded upon steel strip &
insulated up to -1000 volts and stainless steel rivet.

Phase II - Module No. STC-GS-1


Spanner multi-wrench (ratchet type) -16 effective sizes in one
wrench having functional capacity A/F 10,12,16,17,19 mm &
BS 1/4", 4/16, 3/8", 7/16", 1/2" 1/2".

Alloy steel duly hardened jaw; nylon 6 moulded on steel strip


handle.

Phase II - Module No. STC-GS-1


Multi-wrench/ Spanner ( 22 sizes of METRIC and SAE in
two wrenches) having functional capacity A/F MM
5,7,8,10,12,13 & MM 14,15,17,18,21.

Alloy steel duly hardened jaw; nylon 6 moulded on steel strip


handle

Phase II - Module No. STC-GS-1


Ratchet wrench- ratchet type spanner (12 sizes of MM & 5
sizes of SAE in three wrenches). The three spanners cover
12 sizes in MM 8,10,11,12,13,15,16,17,18,19,21,22.

Alloy steel duly hardened.

Phase II - Module No. STC-GS-1


Drying of moisture of silica jel, drying of varnish of
motors coil, drying of moisture of control panels, relays,
CTs, PTs etc.

Phase II - Module No. STC-GS-1


Technical Specifications

RATED POWER CONSUMPTION 2000 W


TEMPERATURE RANGE 100-6000 C
AIR FLOW RATE 350-550 LIT/MIN
STEPLESS TEMP. CONTROL YES
AIRFLOW REGULATION 2 STAGE
WEIGHT 0.7 KGS.

Phase II - Module No. STC-GS-1


To measure the air flow velocity of
blowers.
Phase II - Module No. STC-GS-1
Technical Specifications
Range Resolution Accuracy
Air Flow 80 - 4000 ft/min. 1 +/- 3% FS
0.4 - 20 m/sec 0.01 m/s +/- 3% FS
Battery Life 100 Hours
Display Size 37mm x 42mm
Display Type LCD
Temp. -10C to 50 C 0.1 +/- 1.0C
+14F to 122F 0.1 +/- 2.0 F
Range
Max. Reading 9999
Fan Diameter 70mm ( 2 7/8")

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
For grinding welding spots/
joints back gouging, sanding
and rust removing.
Grinding & cutting discs 100 MM DIA
Rubber packing pad 100 MM DIA
Cup brushes 60 MM DIA
No load speed 11000 RPM
Power input 670 W
Weight 1.4 Kgs.

Phase II - Module No. STC-GS-1


Technical Specifications
Item Parameter
No-load Speed 0-350r/min,0-1350r/min
Keyless Chuck 0.8~10 mm
Max Troque 30 N.m
Battery: Lithium-ion 12V~1400Amh
Charger 60mins fast charger

Phase II - Module No. STC-GS-1


Type: Electronic screwdriver
Dimensions: 27X21X7 cm
Material: PVC & metal
A cordless screwdriver that includes
4 bits, slotted 4.5 mm
Helps illuminate dark work areas
Features LED battery level indicator
Charging time : 3 to 5 hours, one full
charge will last 20 minutes

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Phase II - Module No. STC-GS-1
Floor mounted 4.5 kW AC
test drive complete set for
alternator and regulator
testing.

Floor mounted 25 kW AC test


drive complete set with
regenerative load testing for
alternator and regulator testing.

Phase II - Module No. STC-GS-1


1kW portable motor drive set for
testing alternator and regulator.

Power supply analyzer,


oscilloscope dual
channel, storage type

Phase II - Module No. STC-GS-1


Surge comparison tester for testing windings of motor

Test benches for testing OVP


relays & contactors with
contacts testing with chart .

Phase II - Module No. STC-GS-1


Alternator pulley gap
checking facility Filler
guage.

Alternator pulley
adjusting guage

Phase II - Module No. STC-GS-1


Alternator pulley groove
go-nogo guage

Spring testing facility for


testing of alternator spring

Phase II - Module No. STC-GS-1


V belt pre stretching machine (Grading machine)

Phase II - Module No. STC-GS-1


S.No. Item Reference IS

Open end Spanner


1. (Single & Double ended open jaw IS 2028 2004 (Rev.V)
spanners)

2. Ring spanners IS 2029 (Rev.IV)- 1998

Combination wrenches with equal


3. IS 6389 1998 (Rev. II)
openings

Phase II - Module No. STC-GS-1


S.No. Item Reference IS
Ring slugging wrenches
4. IS 4509 1992 (Rev. I)
(Spanner)
Open ended slugging wrenches IS 4508 1992 (Rev.I)
5.
(Spanners) with amendment 2 Jan. 2003
Single ended open jaw
6. IS 6149 - 1971
adjustable wrenches
Insulated pliers, pincers and
7. nippers Technical supply IS 2615 1989 (Rev.2)
conditions
Combination side cutting pliers
8. IS 3650 1981 (Rev.2)
- specification

Phase II - Module No. STC-GS-1


S.No. Item Reference IS

IS 4003 (Part 1, Rev.I) 1978


Pipe wrenches - General purpose
9.
specification IS 4003 (Part 2, Rev.1) 1986 Heavy
duty with amendment 1 Sept. 1990.

Chain pipe wrenches - IS 4123 1982 (Rev. I)


10.
specification with amendment 2, June 1986

11. Bolt clippers specification IS 5200 1998 (Rev.I)

Bearing puller -
12. IS 9193 1979
specification

Phase II - Module No. STC-GS-1


S.No. Item Reference IS
IS 841 1983 (Rev.2)
Steel hammers
13. Amendment no.1 July 1984
Specification
Amendment no.2 Jan 1987

IS 844 (Part I, Rev.I) 1972 Technical supply


condition
IS 844 (Part II, Rev.I) 1972 Dimensions
Screw drivers
14. IS 844 (Part II, Rev.2) 1979 - Dimensions,
Specification
Reaffirmed 1984.
IS 844 (Rev.I) Part III -1974- Dimensions for
Screw drivers for recessed head screws.

Phase II - Module No. STC-GS-1


Phase II - Module No. STC-GS-1
W : (prefix) Vestibuled

Y : (prefix) Suburban

G : Self-generating (lighting by axle generators)

E : 4-wheeled stock

L : (prefix) LHB coaches


F : First Class

S : Second Class

M : Military
CN : 3-tier sleeper coach

CW : 2-tier sleeper coach

CZ : Chair car

CD : Dining Car

CB : Pantry/kitchen car/buffet car

CL : Kitchen car

CR : State saloon
CT : Tourist car (first class) (includes
bathrooms, kitchen, and sitting and
sleeping compartments)

CTS : Tourist car (second class) (includes


bathrooms, kitchen, and sitting and
sleeping compartments)

C: (except as above) With Coupe

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.

SLR - IInd Class with Brake & Luggage.

GLR - IInd Class with Brake.

DSLR - Disabled IInd Class with Brake &


Luggage.
WGSCN : IInd Class 3-tier Sleeper Vestibuled .

FACC : Air conditioning Coach with First


Class with coupe.

WGFSCWAC : First A.C. cum Second A.C.

WGACCW : Air conditioning Two tier Sleeper


(Vestibuled).

WGACCN : Air conditioning Three tier Sleeper


(Vestibuled).

WSCZAC : Air conditioning II-nd Class Chair Car.


VP : Bogie Parcel Van.

EVP : Four wheeler Parcel Van.

WLLRMEN : Luggage & Brake with Generator.

ER : Inspection Carriage.

RA : Officer Saloon.

RH : Bogie Medical Van.


LGS = Second class self-generating

LSCN = Second class 3-tier sleeper

LWACCW = AC2 tier sleeping Car (52 berths)

LWACCN = AC3 tier sleeping car (72 berths)

LWCBAC = Air-conditioned pantry/kitchen/buffet car

LWFAC = AC1 Air-conditioned first class


LWFCZAC = AC Executive chair car (56 seats)

LWLRRM = Luggage/generator/brake van

LWSCZAC = Air-conditioned chair car (78 seats)

LWSCZ = Non AC Chair car


The basic requirements for rail transportation
system are:

Railway track,

Signalling and telecommunications,

Rolling stock which contains locomotives, coaches


and wagons,

Maintenance and operating personnel of these assets.


Railway track and signals are fixed assets and these are
must for running of trains irrespective of the number
of trains run.

The rolling stock and crew requirement are based on


quantum of traffic to be handled.

Careful planning is required in acquisition and


utilisation of the coaches, especially the A.C. coaches,
since they are costly assets.

Minimum turn-round time will increase the number of


trips & more earning.
To ensure optimum utilisation of coaches with
minimum lie-over period at destination.

Availability of coach for trip.

Schedule inspection on due date so that the same is


maintained in good fettle for reliable service.

Rake links indicate the sequence in which coaches


have to operate.
Rake links give all the information about the movement of
coaches at a glance and can be used as a ready reckoner by
operating staff.

To achieve maximum utilisation of the rakes.

Rake-links are prepared in such a manner that the coaches


are kept on run for the maximum number of hours each
day.

Minimum detention at the terminal stations.

Ideal rake-link is one in which lie-over of coaches at


destination is minimum, utilisation (km earning per coach
per day) is maximum.
Coaches shall be made available for carrying out trip
inspection at terminal stations.

Coaches are to be made available to the owning depots


for carrying out maintenance schedules such as
monthly, three monthly, IOH, POH etc.
At terminal stations, a minimum time of at least 3
hours shall be provided for connecting other link
trains, to avoid link failure as far as possible.

Rake stabling siding shall be available at the terminal


stations close to the station platforms to avoid
unnecessary movement in shunting.

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