Breaks and Pneumatics

RS Training Manual
Level - I ROLLING STOCK

DELHI METRO RAIL CORPORATION LIMITED
Revision No: A2 ISO 9001:2008
Date: 01.09.2012 BRAKES & PNEUMATICS
BRAKES AND PNEUMATICS

Brake System
Type of Brakes;
1. Service Brake: Electric Regenerative brake and Electro-Pneumatic (EP) friction brake
blending, Load weighed and Jerk Controlled
2. Emergency Brake: EP friction brake, Load weighed
3. Parking Brake: Spring applied, air-release parking brake
4. Holding Brake: EP friction brake
5. BP (Brake pipe)-back up brake: Pneumatic friction brake
Service Brake -
Priority of braking effort;
- Electric Regenerative brake controlled by C/I of Motor car
- EP friction brake controlled by BECU of Driving trailer car
- EP friction brake controlled by BECU of Motor car (In the beginning and end of
service braking)
- EP friction brake of Driving Trailer car & Motor car (In case of failure of electric
brake)
Brake Blending - The Electric brake of each Motor car is used in preference to the pneumatic
brake, as it works without wearing either brake blocks and is therefore more economical. The
electric brake is controlled by the C/I (Converter/ Inverter),
Page 1 of 20
For Rolling Stock Personnel Only
RS Training Manual

In case that the Electric Regenerative brake cannot provide the braking effort as demanded by the
master controller of the driver, the missing brake effort will be supplied by the pneumatic brake.
This feature is called „blending“.
The M car BECU on a two-car basis controls the brake blending. Blending is carried out between
Motorcar and Driving trailer car of a unit.
Emergency Brake –
The train set is equipped with an emergency brake loop wire. The emergency brake loop is
connected to the emergency brake magnet valve, which is opened when de-energized and closed
when energized (Fail-safe system).
So, in case the emergency brake magnet valve is de-energized by interrupting emergency brake
loop, the emergency brake will be applied automatically.
Holding brake -
The holding brake is provided to prevent the train from rolling backwards on a rising gradient and
the train from moving at the station.
The holding brake is released when C/I sends the signal “Reset Holding Brake” to the BECU. The
tractive effort, which is applied when the signal “Reset Holding Brake Request” is initiated, shall
ensure that the train will not roll backwards at a slope. The holding brakes are 70% of full service
brakes.
Parking Brake –
Parking brake is used for parking the train in depot and these are installed at Driving trailer car
and Motor cars (1 set per axle).
Parking brake can be applied manually or these may apply automatically also when the MR
pressure is low. To apply parking brake put Mode Selector at Standby position and press “Parking
Brake On Push Button”. To release press “Parking Brake OFF Push Button”.
Parking brakes are automatically applied in the event of loss of the main reservoir pipe pressure.
Parking Brake Manual Release - When MR pressure is low, it is possible to release individual
parking brake manually from track level by; pulling out the manual release device installed at the
parking brake cylinder.
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RS Training Manual
Operation of parking brake is monitored through the parking brake lamp installed at driver’s desk
and TIMS screen.
When the parking brake is applied the parking brake lamp will be illuminated and the application
can be read through TIMS screen also.
Load Weighing –
The load dependent pressure limiting valve (B3.C) is used to limit the supply reservoir air pressure
according to the actual car load.
At the same time the average load signal is electrically fed to the BECU from the T pressure
transducer on the EP-BCU. This signal is used for load compensation of the propulsion and air-
conditioning system.
Wheel Slide Protection (Anti-skid control) -

Wheel slide protection is used to optimize the stopping distance and to avoid the wheel flats under
wheel sliding conditions. Wheel slide protection is active in service brake and emergency brake.
The wheel slide protection acts per bogie on each car by the dump valves (G2). Wheel-slide
protection is operational at all speeds down to 3 km/h.
Speed sensor mounted on the cover of each axle box, detects the speed of the associated wheel.
When a potential wheel-slide event is detected, the BECU will release/apply the brakes through
energizing/ de-energizing the magnets of the dump valves.
Wheel slip/slide is also controlled by CI during electric regenerative braking and powering.
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RS Training Manual
BP-back up Brake -
Additional BP (Brake pipe) controlled back-up brake system is provided in order to take over the
brake control function in case of failure of individual electronic or electrical control elements. The
driver can continue to control the pneumatic friction brake by using the driver’s brake valve.
The driver is able to apply or release the pneumatic brake by operating the driver’s brake valve
installed at the driver’s cab.
By the brake valve the brake pipe (BP) pressure can be reduced or increased depending on the
time the brake lever is maintained at “braking” or “driving”. During the normal service brake
operation, the drivers brake valve lever shall be maintained at “driving”.
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RS Training Manual
Brake Application Flow Diagram

DBV EBPB TBC PBPB
MR Pipe ON/OFF
100 lt.Supply
Brake Pipe
BECU
Reservoir
Distributor
Check Analog
Valve EMV Converter
BCU PBMV
Load Limiting Relay
Reservoirs Valve Valve
Two
Relay valve way
Bogie-1 brake cylinder Bogie-2 Cylinder
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RS Training Manual
Pneumatic Air Distribution System -

General
The complete compressed air supply system in each two car (DT & M car) unit consisting of:
- Piston type air compressor VV120
- Dual chamber air dryer unit type LTZ015
- Oil separator
- Micro oil filter
- Auxiliary compressor
-Reservoirs, Pressure governors and switches, Pipe system, Automatic coupling actuating
equipment
Main Compressor –
The compressor is a cylinder piston compressor powered by a 415 V AC, 50Hz motor and it has a
capacity of approximately 900 L/min free air at 10 bar.
The main air-compressor unit is controlled by one relay contact of BECU in the software to 8.0 bar
for cut in and 10 bar for cut out. The second pressure switch (A9) – set to 7.5 bar for cut in and 10
bar for cut out is provided as hardwired back-up in case of failure of BECU. Based on the
electrical signals of the pressure switch A9 and pressure transducer A10 the main motor contactor
is controlled.
In normal service operation the air compressors of each DT car is controlled individually by the
relevant BECU at that trailer car. The BECU in turn communicates with all other BECU installed in
the train consist to determine which air compressor should be operated.
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RS Training Manual
Fig. Main Compressor
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RS Training Manual
Air Dryer and Filtration –

Moisture in compressed air systems often causes the pneumatic equipment to malfunction and
wear prematurely as a result of corrosion and freezing.
The compressed air supplied by the main air compressor is filtered by oil separator and dried by
the air dryer unit and filtered by the oil micro filter.
The air dryer unit consists of two chambers with a adsorptive desiccant. While the main air flow is
being dried in one chamber (I), the desiccant of the other chamber (I) is being regenerated by the
reversed air flow.
Fig. Air Dryer Unit
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RS Training Manual
19 Tower 34.15 KNORR K-ring 71 Valve head for

bypass valve
19.7 Desiccant 34.17 KNORR K-ring A Drainage port
19.11 Oil separator bowl 43 Valve Magnet O.. Exhaust port
with 50 Regeneration choke P1 Air supply port
Raschig rings
24 Valve cone for check 55 Piston for precontrol P2 Air pipe connection
valve valve to main reservoir
25 Bracket 56 KNORR K-ring
34 Duplex piston valve 70 KNORR K-ring V.. Valve seat
Main Reservoir –
Air supply system is provided with main air reservoirs (A7) with a capacity of 200 liters & located in
each DT Car.
Fig. Main Reservoir
Auto Drain Valve –
The automatic drain valve is used for automatic drainage (with manual drain also) of condensates
from compressed air reservoirs and oil/water separators. The drain valves are operated
pneumatically by the magnet valve A17.
1 Body 4.1 Valve stem P Inlet port

2 Body 5 Manual drain V Conical
valve valve seat
3 Spring 6 Sealing ring Z Control air
port
3.1 Spring A Sump O Exhaust port
4 Valve E Drain bore
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RS Training Manual

Fig Auto Drain Valve
The MR pipe feeds air to the following subsystems:
1. Brake system
2. Air suspension equipment
3. Pantograph
4. Pneumatic signaling equipment
5. Automatic couplers
Isolating Cocks –
It is possible to isolate the compressed air supply system to the consumers such as air
suspension equipment, pantographs, air horns and automatic couplers by operating the isolation
cocks with/ without a vent and an electrical switch. The isolation cocks with/ without a vent and an
electrical switch are located on the under frame adjacent to the bogie.
Fig Isolating Cock
1 Housing 4 Handle I Supply port

2 Spherical plug 5 Stop washer II Consumer
port
3 Ball valve 6 O-ring
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RS Training Manual
Single Protection Valve –

The single protection valve (B26) is installed in front of the main reservoir (MR) air hose of each
end of the car. The valve shuts off the air supply through the hose in the event of a break or
damage to the hose or the main piping, maintaining the main reservoir air pressure in the system.
Fig. Single Protection Valve
Auxiliary Air Distribution System -

In the event that the MR pipe is not charged, the required air pressure for pantograph operation is
supplied by the auxiliary motor-compressor unit (U01).
The unit includes a single-stage compressor driven by a 110 VDC motor.
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RS Training Manual
Brake Control Equipment –
Brake Electronic Control Unit –
The BECU commands the brake system and implement anti-skid functions by evaluating the set
points for the brake value out of various input signals (e.g. brake demand signals, speed signals
or load signals.).
BECU calculates the required brake force according to brake demand and send electrical signal to
the BCU. Every car has its individual BECU.
To achieve a comfortable ride in all braking modes, load correction and wheel slide control and
jerk control are active.
Equipment Layouts
Brake Electronic Control Unit
The BECU consists of the following PCB’s
1. MB04B Card - MB04B is a main board. It is loaded with application software. It consists of
a main board MB03B and a man machine interface (MMI).
2. EB01B Card - EB01B is an extension board in the ESRA system. The board is used to
enhance the input and output operations of the main board. The EB01B extension board
provides relay outputs, and optocoupler inputs and outputs. EB01B interfaces with the
peripherals
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RS Training Manual

3. CB07A Card - CB07A is a communication board in the ESRA system. The board
transforms messages between the internal BECU bus and an external RS485 bus.
4. PB03A Card - PB03A is used to power the BECU. It meets the demands of both the
electronic boards and the sensors and actuators.
Brake Control Unit –

One pneumatic brake control unit (B3) is provided in every car. The BCU has following main
components
a. Analog Converter
b. Emergency Brake Valve
c. Double Check Valve
d. Pressure Transducer
e. Load Limiting Valve
f. Relay Valve
The analogue converter (B3.A) in converts the electric friction brake demand signal from
the BECU (B15) into a proportional pre-control pressure (Cv).
The analogue converter is equipped with a charging magnet valve, a venting magnet valve
and a feedback pressure transducer Cv for a closed control circuit.
Brake Control Unit

E A4
B A3
A1
STV A2 R
R
Cv Aw4.1
F PI P
I
A
G M
Cv1
T
C
T
J Cv2 D
R1
Cv R
N Kr6
L C
C
Brake Control Unit (BCU)
The signal of the pressure transducer ”Cv” indicates the actual pressure level in the control unit.
The relay valve provides a large volume air flow a the specific pressure level, pre-controlled by the
analogue converter, to actuate the brake cylinders.
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RS Training Manual

The Cv-pressure sensor B3.G is used to indicate the emergency brake pressure level generated
by the emergency brake magnet valve (system pressure 8 to 10 bar).
The double check valve B3.B is used to change-over between normal service brake and back-up
brake operation by the distributor valve type STV (B41).
The isolating cocks with electrical switch (B4.3) in the brake cylinder pipe isolate the brake per
bogie and allow the air-applied brake cylinders to be released on a per bogie basis.
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RS Training Manual
Equipment Layout –
Almost of all brake equipments including the Main air compressor, Air dryer, Auxiliary air
compressor, BCU and etc are located at the under frame.
The following items are installed at the driver’s cab, interior end part or interior saloon or bogie
part as followings.
Location of Equipment Items
Driver’s brake valve (B61), Relay valve (B62), Magnet

Driver’s cab
valve (B63), BPCON cock (B69)
Interior end part BECU (B15), Isolation cocks (U10 and U12)
Interior saloon Isolation cocks (B4.3A, B4.3B)
Block brake units (C2 and C3), Air hoses (C4 and C5),
Bogie part
Pole wheel (G4), Air spring (L9)
<Colour Coding of Air Pipe>

Air Pipe Descriptions Colour
BP Brake Pipe Green (G)
MR Main Reservoir Pipe White (W)
BC Brake Cylinder Pipe Red (R)
AS Air Suspension Pipe Yellow (Y)
PB Parking Brake Pipe Black (B)
SR SR gauge Pipe Yellow (Y)
PANTO Panto Pipe Yellow (Y)
UNCOUPLE Uncoupling Pipe Yellow (Y)
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RS Training Manual
Isolating Cock and Air Pipe

<Definition of isolating cock>
Colour
Name plate Descriptions
of Cock handle
MRP Main Reservoir Pipe White (W)
BP Brake Pipe Green (G)
CM Compressor Motor White (W)
SR Supply Reservoir Red (R)
EPIC EP Brake Isolation Cock Red (R)
BIC Brake Isolation Cock Red (R)
PARK Parking Isolation Cock Black (B)
AS Air Suspension Yellow (Y)
ASCO Air Suspension Cut-Out Yellow (Y)
HORN Air Horn White (W)
UNCOUPLE Uncoupling Yellow (Y)
BPIC BP Isolation Cock White (W)
BPCON BP Brake Control Green (G)
BPMR Brake Pipe to MR pipe Green (G)
PANTO PANTOGRAPH Yellow (Y)
VCB Vacuum Circuit Breaker Yellow (Y)
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RS Training Manual
APPLICATION OF BRAKES BY DBV
DBV (B61) Handle on Position V (application)
Air Pressure between Relay Valve (B62) and DBV Vents
Control Pressure of Relay Valve reduces
Relay valve vents the BP pressure
Distributor Valve (B41) Activates
Control Pressure to Load Limiting valve

(B03C)
Control pressure to relay Valve (B03D)
Brake Pressure to Brake Cylinder
Brake Application
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RS Training Manual
APPLICATION OF PNEUMATIC SERVICE BRAKE
Brake Demand from TBC
Pneumatic Brake Demand from BECU
Analog Converter (B 03R)
Conversion of Electrical Signal to Pneumatic Signal

(Hot redundant)
Emergency Brake Valve (B 03F)
Check Valve (B 03 B)
B
C
U Electric Load signal from BECU to Pressure Transducer (B 03F)
Control Pressure to Relay Valv3e (B 03 R)
Brake Application
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RS Training Manual
APPLICATION OF EMERGENCY BRAKE
Emergency Brake Loop Interrupted
Emergency Brake Signal from BECU
Emergency Magnet Valve (B 03 E)
B
C Load Limiting Valve (B 03 C) B
C
U
U
Relay Valve (B 03 D)
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RS Training Manual
Brake Cylinder
Emergency Brake Application
Page 20 of 20

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RS Training Manual

Level - I ROLLING STOCK

Date: 01.09.2012 BRAKES & PNEUMATICS

BRAKES AND PNEUMATICS

2. Emergency Brake: EP friction brake, Load weighed

3. Parking Brake: Spring applied, air-release parking brake

4. Holding Brake: EP friction brake

5. BP (Brake pipe)-back up brake: Pneumatic friction brake

- Electric Regenerative brake controlled by C/I of Motor car

- EP friction brake controlled by BECU of Driving trailer car

Date: 01.09.2012 BRAKES & PNEUMATICS

Date: 01.09.2012 BRAKES & PNEUMATICS

Wheel Slide Protection (Anti-skid control) -

Date: 01.09.2012 BRAKES & PNEUMATICS

Date: 01.09.2012 BRAKES & PNEUMATICS

Brake Application Flow Diagram

Bogie-1 brake cylinder Bogie-2 Cylinder

Date: 01.09.2012 BRAKES & PNEUMATICS

Pneumatic Air Distribution System -

Date: 01.09.2012 BRAKES & PNEUMATICS

Fig. Main Compressor

Date: 01.09.2012 BRAKES & PNEUMATICS

Air Dryer and Filtration –

Fig. Air Dryer Unit

Date: 01.09.2012 BRAKES & PNEUMATICS

19 Tower 34.15 KNORR K-ring 71 Valve head for

Fig. Main Reservoir

Auto Drain Valve –

1 Body 4.1 Valve stem P Inlet port

Date: 01.09.2012 BRAKES & PNEUMATICS

Fig Isolating Cock

1 Housing 4 Handle I Supply port

Date: 01.09.2012 BRAKES & PNEUMATICS

Single Protection Valve –

Fig. Single Protection Valve

Auxiliary Air Distribution System -

The unit includes a single-stage compressor driven by a 110 VDC motor.

Date: 01.09.2012 BRAKES & PNEUMATICS

Brake Control Equipment –

Brake Electronic Control Unit –

Brake Electronic Control Unit

The BECU consists of the following PCB’s

Date: 01.09.2012 BRAKES & PNEUMATICS

Brake Control Unit –

Brake Control Unit

Date: 01.09.2012 BRAKES & PNEUMATICS

Date: 01.09.2012 BRAKES & PNEUMATICS

Location of Equipment Items

Driver’s brake valve (B61), Relay valve (B62), Magnet

Interior saloon Isolation cocks (B4.3A, B4.3B)

<Colour Coding of Air Pipe>

Date: 01.09.2012 BRAKES & PNEUMATICS

Isolating Cock and Air Pipe

Date: 01.09.2012 BRAKES & PNEUMATICS

APPLICATION OF BRAKES BY DBV

DBV (B61) Handle on Position V (application)

Air Pressure between Relay Valve (B62) and DBV Vents

Control Pressure of Relay Valve reduces

Relay valve vents the BP pressure

Distributor Valve (B41) Activates

Control Pressure to Load Limiting valve

Control pressure to relay Valve (B03D)

Brake Pressure to Brake Cylinder

Date: 01.09.2012 BRAKES & PNEUMATICS