BOOKLET ON REGULATED CUM EMERGENCY ......Since coach needs to provide essential amenities like...

i

BOOKLET ON REGULATED CUM

EMERGENCY BATTERY CHARGER

FOR LHB COACHES

CAMTECH/EL/2020-21/REBC/1.0

September, 2020

END USER: Coaching (Electrical) Maintenance Staff

Maharajpur, GWALIOR - 474 005

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

(For Official Use Only)

ii

BOOKLET

ON

REGULATED CUM EMERGENCY

BATTERY CHARGER FOR LHB

COACHES

iii

“We at RDSO, Lucknow are committed to maintain and update

transparent standards of services to develop safe, modern and cost

effective railway technology complying with statutory and regulatory

requirements, through excellence in research, designs and standards

by setting quality objectives, commitment to satisfy applicable

requirements and continual improvements of the quality

management system to cater to growing needs, demand and

expectations of passenger and freight traffic on the railways through

periodic review of quality management systems to achieve continual

improvement and customer appreciation. It is communicated and

applied within the organization and making it available to all the

relevant interested parties.”

QUALITY POLICY

iv

FOREWORD

Electricity is Essential in a coach for operating lights and fans, mobile charging

points as part of the minimum amenities to be provided to the passengers travelling in a

train.

In existing LHB coaches electricity is fed by EOG/HOG supply with 750 Volt AC

Bus which again stepped down in each coach with under slung transformer up to

415±15% Volt ac for RMPU and other equipment.

Since coach needs to provide essential amenities like lights and fans with battery

backup hence 4.5 KW Regulated Battery Charger under slung type has been provided

in both type of AC & non AC LHB coaches. The new modified unit also has Emergency

Battery Charger which comes in role while there is any type of failure with Regulated

Battery Charger circuits.

To ensure wide dissemination of knowledge on Regulated cum Emergency

Battery Charger of LHB Coaches, CAMTECH, Gwalior has prepared this booklet. This

booklet comprises brief on technical and constructional features, circuit description,

working principle of both regulated and emergency battery charger circuits.

Maintenance activities, fault indications along with trouble shooting for various makes

are also given.

I am sure that this booklet will be useful for field maintenance staff of coaching

stock in their day to day working and improving the reliability and safety of coaching

stock on Indian Railways.

CAMTECH Jitendra Singh

Date: 28.09.2020 Principal Executive Director

v

PREFACE

The under slung mounted Regulated Battery Charger (RBC) is used for charging

the batteries of LHB coaches and to supply power to all DC loads in the coach. This

battery charger is fed power with three phase 415 volts AC from the750/415 V step

down transformer fitted under slung on LHB coaches.

This is modified to single unit Battery Charger for both AC & Non AC coaches

vide RDSO specification no. RDSO/PE/SPEC/AC/0183 (Rev.1)-2018 for ease in

maintenance and to reduce inventory.

This is IGBT based Regulated cum Emergency Battery Charger, natural cooled

and without on-board display panel and also incorporates Emergency Battery Charger

unit into it.

This unit also have some advanced features, viz., Over voltage/ under voltage,

Overload, short circuit and other protection features with fast corrective response,

battery charging with constant voltage, current limit, LCD based data display unit with

data downloading on commercial USB pen drive facility.

This booklet on "Regulated cum Emergency Battery Charger of LHB Coaches” is

prepared with the objective to disseminate knowledge on subject.

It is clarified that this booklet does not supersede any existing provisions laid

down by Railway Board/ RDSO, OEMs. This booklet is for guidance only and it is not a

statutory document.

I am sincerely thankful to Shri B. C. Agrawal, SSE/EL, Smt. Sangeeta

Shrivastava, JE/IT, and all field personnel who helped us in preparing this handbook.

Technological up-gradation & learning is a continuous process. Please feel free to write

us for any addition/ modification in this booklet.

CAMTECH, Gwalior Himanshu Maheshwari Date: 28.09.2020 Dy. Director /Electrical

vi

CONTENTS

FOREWORD .................................................................................................................... iv

PREFACE .......................................................................................................................... v

CONTENTS ...................................................................................................................... vi

LIST OF FIGURES .......................................................................................................... viii

LIST OF TABLES ............................................................................................................. ix

ISSUE OF CORRECTION SLIP ........................................................................................ x

DISCLAIMER .................................................................................................................... xi

OUR OBJECTIVE ............................................................................................................. xi

1 INTRODUCTION ......................................................................................................... 1

2 IMPORTANT SAFETY INSTRUCTIONS .................................................................... 2

3 TECHNICAL DETAILS ................................................................................................ 3

4 PROTECTIONS AND INDICATIONS .......................................................................... 4

4.1 Protections for Regulated Battery Charger ....................................................... 4

4.2 Protections for Emergency Battery Charger ..................................................... 6

5 CONSTRUCTIONAL FEATURES ............................................................................... 7

5.1 Cubicle (Housing) Front .................................................................................... 7

5.2 Power/Control Section ...................................................................................... 7

5.3 Input/ Output Interface Section ......................................................................... 9

5.4 Cubicle Rear Part ........................................................................................... 11

5.5 Heat Sinks ...................................................................................................... 11

5.6 Step Down Transformer ................................................................................. 12

5.7 Cover Gaskets ................................................................................................ 12

5.8 Indications ...................................................................................................... 12

5.9 Earthing Shunt ................................................................................................ 13

5.10 Mounting Arrangement ................................................................................... 13

6 CIRCUIT DESCRIPTION &WORKING PRINCIPLE ................................................. 14

6.1 Regulated Battery Charger ............................................................................. 15

6.2 Emergency Battery Charger ........................................................................... 17

7 SPECIAL FEATURES ............................................................................................... 19

7.1 Auto Battery Mode .......................................................................................... 19

7.2 Operating Modes ............................................................................................ 19

7.2.1 Normal mode ................................................................................... 19

7.2.2 Emergency Mode ............................................................................. 19

7.3 Fault Diagnostic .............................................................................................. 19

vii

8 PREVENTIVE MAINTENANCE ................................................................................ 20

8.1 Insulation Resistance table ............................................................................. 21

9 TRANSPORT AND STORAGE ................................................................................. 21

10 FAULT INDICATIONS & TROUBLE SHOOTING ..................................................... 22

10.1 For Signotron make REBC ............................................................................. 22

10.2 For AAL make REBC ...................................................................................... 23

10.3 For PI make REBC ......................................................................................... 26

10.4 For IC Make REBC ......................................................................................... 28

10.5 For Sydler Make ............................................................................................. 28

ANNEXURE-1 ................................................................................................................. 30

REFRENCES .................................................................................................................. 31

viii

LIST OF FIGURES

Figure 1: Regulated Cum Emergency Battery Charger (External Front View) ............. 1

Figure 2: 3 Pole MCB for RBC ..................................................................................... 5

Figure 3: Output 40 A Fuse for DC+ ............................................................................ 5

Figure 4: RBC cum EBC Layout (Exterior – Front) ...................................................... 7

Figure 5: Power Section (Front side) ........................................................................... 8

Figure 6: Power Section (RBC and EBC) .................................................................... 8

Figure 7: Control and Power Section ........................................................................... 9

Figure 8: Output Section (Upper Side) ......................................................................... 9

Figure 9: Input and Output Section ............................................................................ 10

Figure 10: RBC cum EBC Interior –Connection Terminals ......................................... 10

Figure 11: Magnetics Section ...................................................................................... 11

Figure 12: Heat Sinks .................................................................................................. 11

Figure 13: Cover Gaskets for Ingress Protection ......................................................... 12

Figure 14: Front LED Card .......................................................................................... 12

Figure 15: Earthing Shunt ............................................................................................ 13

Figure 16: Mounting Arrangement ............................................................................... 13

Figure 17: Single Line Diagram of 4.5 kW RBC with EBC ........................................... 14

Figure 18: Circuit Diagram of RBC Converter-Inverter Section ................................... 15

Figure 19: Circuit Diagram of RBC Output Rectifier Section ........................................ 16

Figure 20: Block Diagram of Regulated Battery Charger ............................................. 17

Figure 21: Circuit Diagram of Emergency Battery Charger .......................................... 18

Figure 22: Block Diagram of Emergency Battery Charger ........................................... 18

ix

LIST OF TABLES

Table 1: Technical details of 4.5 kW Regulated Battery Charger (RBC) .................... 3

Table 2 : Technical details of 2.5 Emergency Battery Charger (EBC) ......................... 4

Table 3: Maintenance Activities for Battery Charger................................................. 20

Table 4: Insulation Resistance ................................................................................. 21

Table 5: Fault Diagnostics for Signotron Make REBC ............................................. 22

Table 6: Trouble Shooting for Signotron Make REBC .............................................. 22

Table 7: Trouble Shooting for AAL Make REBC ....................................................... 23

Table 8: Trouble Shooting for PI Make REBC .......................................................... 26

Table 9: Trouble Shooting for IC Make REBC .......................................................... 28

Table 10 : Trouble Shooting for Sydler Make REBC ................................................... 28

x

ISSUE OF CORRECTION SLIP

The correction slips to be issued in future for this handbook will be numbered as

follows:

CAMTECH/ EL/2020-21/REBC/1.0/C.S. # XX date--- Where “XX” is the serial number of the concerned correction slip (starting from

01 onwards).

CORRECTION SLIPS ISSUED

Sr. No. Date of Issue Page no. & Item no. modified Remarks

xi

DISCLAIMER

It is clarified that the information given in this booklet does not

supersede any existing provisions laid down by the Railway Board, RDSO

and OEM’s Manual. This document is not statuary and instructions

given are for the purpose of guidance only. If at any point contradiction

is observed, then Railway Board/RDSO guidelines and OEM’s

Maintenance and Operating Manuals may be referred.

OUR OBJECTIVE

To upgrade maintenance technologies and methodologies and achieve

improvement in productivity and performance of all Railway assets

and manpower which inter-alia would cover reliability, availability,

utilization and efficiency.

If you have any suggestion & any specific comment, please write to us: Contact person: Dy. Director (Electrical) Postal Address: Centre for Advanced Maintenance Technology,

Opposite Hotel Adityaz, Near DD Nagar, Maharajpur, Gwalior (M.P.) Pin Code – 474 005

Phone: 0751 - 2470740 Fax: 0751 – 2470841 E-mail: [email protected]

CAMTECH/E/EP-01/2020-21/REBC/1.0 1

Booklet on Regulated cum Emergency Battery Charger for LHB Coaches September, 2020

1 INTRODUCTION

The Regulated Battery Charger (RBC) is used for charging the batteries of LHB coaches and to supply power to all DC loads in the coach. This battery charger is fed power with three phase 415 volts AC 4 wire at 50 Hz from the750/415 V step down transformer fitted on LHB coaches.

Initially 6.5 kVA Regulated battery Charger as per RCF specification no. EDTS-074 was provided for charging of 70 AH Lead Tin batteries and to feed DC loads of the coach. Due to more failure of this battery charger and Lead Tin batteries, this battery charger was modified as per RDSO specification no. RDSO/PE/SPEC/AC/0129-2009.

This was suitable for VRLA batteries and retro fitment in existing coaches.

According to this specification, 6.5 kW capacity on-board mounted forced air cooled, Regulated Battery Charger were being provided on LHB coaches for charging VRLA battery and feeding direct voltage loads.

Further two types of Regulated Battery Chargers (RBCs), 4.5 kW under-slung

with on-board display unit and without on-board display unit are in use respectively on LHB AC and Non AC type of coaches as per RDSO specification no. RDSO/PE/SPEC/AC/0183 (Rev.0) issued on 15.02.2016.

This is further revised vide revision specification no. RDSO/PE/SPEC/AC/0183

(Rev.1)-2018, and two types of battery chargers have been standardized and modified to single unit Battery Charger for both AC & Non AC coaches. Now this unit also incorporates Emergency Battery Charger into it. This will help in reducing maintenance and also maintaining different inventory.

This IGBT based Regulated cum Emergency Battery Charger, is natural cooled

and without on-board display panel, suitable for both AC & Non AC LHB EOG/HOG coaches.

Figure 1: Regulated Cum Emergency Battery Charger (External Front View)



2 IMPORTANT SAFETY INSTRUCTIONS

This is a advanced technology power electronics battery charger and to be serviced by only qualified technical personnel.

Ensure that only well-trained and authorized personnel handle the equipment.

Opening by unqualified personnel may cause electric shock or fire hazard.

Isolate high voltage circuit before attempting any repair work on charger.

Do not touch any un-insulated parts of the Charger, especially the input and output connections, as there is the possibility of electrical shock.

To reduce risk of electric shock, disconnect all wiring before cleaning. Use the correct tools to make wiring connections.

Even when complete system is switched off, built in capacitors can remain charged up. Before making contact with the connections, check voltages across its terminal and it should be suitably discharged.

Please note reverse battery protection is provided in battery terminal only. So proper connection of battery and load is necessary.

During normal operation, batteries may produce explosive gas. Never smoke, use an open flame, or create arcs in the vicinity of the Charger or the battery.

Turn the Battery Charger off before connecting or disconnecting the battery to avoid shock hazards and/or equipment damage.

Environment of the system should be kept as clean as possible and metallic or other electrically conducting dust particles in particular must be prevented



3 TECHNICAL DETAILS

Table 1: Technical details of 4.5 kW Regulated Battery Charger (RBC)

Sr. No. Parameter Details

i. Type Constant voltage with current limiting feature

ii. Input Voltage

a. Mains nominal voltage 415 V AC, three Phase, 4-wire system

b. Minimum voltage 350 V AC, three Phase

c. Maximum voltage 480 V AC, three Phase

d. Frequency 50 Hz ± 3%

e. THD (max) Voltage 10%

iii. iii. Output (DC)

a. Type Fully insulated from coach body on both positive and negative sides

b. Output voltage 110 to 135 volts (settable with the help of key pad)

122 volts±2% (During normal operation of battery charging)

c. Output current 35A

d. a. Battery charging current

10A to 15A (settable with the help of key pad)

e. b. Other loads 20A

f. Output Power 4.5 kW (max.)

g. Type & Ah rating of Battery

Lead acid, 70/ 120 Ah (both flooded and VRLA)

h. Efficiency ≥ 92% @ Full Load, ≥ 85% @ Half Load

i. Voltage ripple ≤ 2 % of set voltage

j. Current ripple ≤ 3 % of set current

k. Dimension(charger unit)(as per RDSO/PE/SK/AC/ 200 -2018 (Rev.0)

Length (max)- 900mm

Depth (max) - 440mm

Height (max) - 650mm

l. Weight (Charger unit) <120 kg.



Table 2 : Technical details of 2.5Emergency Battery Charger (EBC)

Sr. No. Parameter Details

i. Input nominal voltage 240 V ± 15% AC Single phase

ii. Frequency 50 Hz ± 3%

iii. Output voltage 110V ± 5% DC

iv. Output current 22A

v. Output power 2.5 kW (max.)

vi. Efficiency ≥ 90% @ Full Load

vii. Output voltage ripple ≤ 2 % of set voltage at full load

(iii) Regulation

Regulated Battery Charger (RBC) maintains a constant DC output voltage of 122±2% volts for battery charging during normal operation in the entire range of input supply and load (Charging load 15A and other load 20A)

(iv) Efficiency

Efficiencies of the Regulated Battery Charger (RBC) at minimum (350V), nominal (415V) and maximum (480) input voltage shall not be less than 85% and 92% at half load and full load respectively and efficiencies of the Emergency Battery Charger (EBC) at nominal input voltage is shall not be less than 90% at full load.

(v) Ripple Contents

Output voltage and current ripple factors (r.m.s.) shall be less than 2%r.m.s.of set value for voltage and 3% r.m.s. of set value for current for Regulated Battery Charger and shall not be more than 2% r.m.s. of set value for voltage at full load for Emergency Batter Charger, when measured across a resistive load.

4 PROTECTIONS AND INDICATIONS 4.1 Protections for Regulated Battery Charger

(i) Input (AC) over/ under voltage protection

Regulated Battery Charger delivers 100% load (i.e. 35 Amps.) up to input of 350V and 35% load (i.e. 12.25 Amps.) from 350V to 300V or in the event of single phasing. Input AC under and over voltage protection set at 300 ± 5V and 480 ± 5V. Input AC under and over voltage is auto reset type. RBC automatically restarts when input voltage is over 300 volts or below 480 volts. In case of any phase failure, the charger will work normally but at reduced 35% load. The corresponding phase on indication does not glow.



(ii) Output Over voltage protection

Output over voltage protection is provided for tripping of the Regulated Battery Charger at 136± 2 V DC. If output voltage goes beyond this setting for more than 2 seconds, over voltage protection will act and trip Regulated Battery Charger. Time delay of 2 seconds is given to avoid spurious tripping.

(iii) Over Load Protection (Output Current limit)

Battery charging current is limited to set value (10-15 Amps) and total output is limited to 35 Amps. Over load protection is set at 35+20% Amp (i.e. 42 Amps) for 60 seconds. During overloading for first 60seconds, over load limit will be 42 Amps, after that the over load limit will reduce to 35 Amps. It means if output current is more than 35 amps for 60 seconds, after 60 seconds current limit will be 35 amps. If the system is given load beyond its capacity, it limits output current and output short circuited (without battery). The unit will trip and retry again to prevent damage.

(iv) AC input protection

20 Amps three pole MCB for RBC circuit is provided on input side in the terminal box for input protection and isolation.

Figure 2:3 Pole MCB for RBC

(v) Output fuse: 40 A HRC fuse in +ve other load circuit is provided in the terminal box.

Figure 3: Output 40 A Fuse for DC+



(vi) Self-reset feature

Regulated Battery Charger have self-reset feature for trips on output short circuit, output over voltage, output over load etc.. The system is locked in trip condition after three consecutive restart attempts at an interval of 5 seconds. For other trips RBC automatically resets it trip condition to normalize.

(vii) Over temperature protection

Whenever the temperature of heat sink of the unit crosses pre set value, then unit trips.

(viii) Earth leakage protection

Earth leakage detection for both positive and negative lines are provided. Regulated Battery Charger functions normally even after detection of earth leakage on one of the lines or both the lines. Earth leakage will be detected if earth leakage current is > 30mA. Earth leakage in respective lines (positive or negative) is indicated through an LED. (Permanent lit).If earth leakage is detected on both the lines, the RBC shall continue to function normal but earth leakage indication LEDs will flash (blink) to attract the attention of Railway staff. However, if leakage current leads to over load condition, the RBC shall trip at pre-set value.

(ix) Battery Reverse Protection

If accidentally battery is connected in reverse polarity, then system will show rev fault & system will not start.

(x) Ingress Protection

The complete unit is IP65 protected against ingress of water and dust.

4.2 Protections for Emergency Battery Charger

The EBC have the following protective features:

Input supply over voltage set at 240 +15%V

Input supply under voltage set at 240 - 15% V

20 Amps single pole MCB for emergency circuit is provided on input side in the terminal box for input protection and isolation.

Output current limit at 24 Amps.

Output short circuit protection.

Battery Reverse polarity protection



5 CONSTRUCTIONAL FEATURES The constructional features and photographs may slightly differ for different makes. Herein the photographs of some makes are given for illustration purpose and easy understanding.

5.1 Cubicle (Housing) Front Cubicle is made of stainless steel sheet and without exterior/ interior painting. The battery charger cubicle consists of current controlled regulated battery charger and emergency battery charger with their control Electronics. The input & output connections are available on the front side of the cubicle.

Figure 4: RBC cum EBC Layout (Exterior – Front)

a. Front Door c. Caution Plate e. Terminal Cover g. Troubleshooting Plate b. Front Door

Hinges d. Front Door

Tightening Bolt f. Terminal Cover

Bolt

5.2 Power/Control Section Power section consists of rectifier and inverter stacks of both Regulated and Emergency Batter Chargers mounted on casted aluminium heat sinks. This section also contains DC link filter capacitor, protection module and other sub-assemblies and control cards of RBC & EBC. Section is provided with front LED card having LED indication for various features.

b

f

e

d

c

a

g



Figure 5: Power Section (Front side)

Figure 6: Power Section (RBC and EBC)



Figure 7: Control and Power Section

Figure 8: Output Section (Upper Side) 5.3 Input/ Output Interface Section

It consist three phase input MCB for RBC, single pole MCB for EBC, output fuse, terminal blocks for input and output connections, this section is also provided control terminal block for charger.



Figure 9: Input and Output Section

For Regulated Battery Charger, 3phase input AC terminals are marked as R, Y , B & output DC terminals are as DC +, DC+(WSD), DC- & BC+.

For Emergency Battery Charger input AC & Neutral terminal are marked.

Spare terminal blocks are also provided.

Figure 10: RBC cum EBC Interior –Connection Terminals

O/P Load Connection

For Future Use

Spare

Battery & DC Common -ve

Input AC R-Phase

Input AC Y-Phase

Input AC B-Phase

Spare

Input AC Neutral

Potential free contact for charger ON

Potential free contact for charger fault

Spare

Battery Connection



5.4 Cubicle Rear Part Rear part of cubicle consist heavy components such as inductor and transformers used for both RBC and EBC. This section also has input voltage sensing transformer, output load resistances. Some of components are provided on the rear part section on the back side heat sink.

Figure 11: Magnetics Section 5.5 Heat Sinks

Heat generated by the power devices is dissipated through adequately sized heat sinks. Heat sinks are so designed that temperature rise within prescribed limits is maintained. The heat sinks are cooled by natural cooling.

Figure 12: Heat Sinks



5.6 Step Down Transformer High frequency natural cooled transformer with H-class insulation is used to step down the voltage and to provide isolation.

5.7 Cover Gaskets Suitable zero halogen, low smoke, fire retardant, neoprene rubber gaskets are provided on the covers to prevent ingress of water, dust and moisture.

Figure 13: Cover Gaskets for Ingress Protection

5.8 Indications

Following indications through 5mm LEDs, visible through fire retardant UV resistant poly carbonate sheet on front wall of the unit are provided. Marking of indications are done.

Input AC ON (R-Phase)

Input AC ON (Y-Phase)

Input AC ON (B-Phase)

Battery charging “ON”

Shingle phasing indication

Positive earth leakage (>30mA)

Negative earth leakage (>30mA)

Battery not healthy.

Emergency mode ON.

Figure 14: Front LED Card



5.9 Earthing Shunt Earthing Shunt is provided to connect between unit and coach body.

Figure 15: Earthing Shunt 5.10 Mounting Arrangement

The Battery Charger is mounted through mounting screws for which mounting holes are provided in the top side of the charger.

Figure 16: Mounting Arrangement



6 CIRCUIT DESCRIPTION &WORKING PRINCIPLE

The circuit description may slightly differ for different makes. Herein the Signotron make REBC circuit is described for illustration purpose and easy understanding.

Figure 17: Single Line Diagram of 4.5 kW RBC with EBC

IGBT DRIVER

BV-D1 BV1 -

DC1-

Q1 Q2

T1

C2A

BV1+

C2

CT1

C1 C1A

L1BV+

R2

Y2

B2

CS1

S1

R1

Y1

B1

CN1

R

Y

B

SP

N

CT2 CT3

CT4

DIODE

RECTIFIER

OP1

L2

OP2OP2

TH1DC1+ +DC+

F1

VT2

C6

C5

DC+

DC+

BC+

SP

DC-

(WSD)

BC1

PSA 871

T2

PSA 617 B

D2PSA 870S2

Single Line Diagram of 4.5kW RBC with EBC



6.1 Regulated Battery Charger

A three pole MCB (S1) is provided at the input side which acts as input dis-connector as well as overload protection.

The Regulated Battery Charger unit has a 3 phase AC to DC full wave bridge rectifier made up of 6 diodes or 3 thyristors and 3 diodes at the front END. This is fed by three phase AC supply and converts to DC at around 600V. This DC bus of around 600 V is filtered by LC filter.

Then there is a two arm full bridge IGBT converter of Q1and Q2, which inverts smooth DC link voltage into a high frequency Pulse Width Modulated (PWM) AC voltage at high frequency. Dedicated IGBT drivers are used to drive the IGBT gates to switch the IGBTs at high frequency. The AC voltage is generated at high frequency to reduce the size and weight of the equipment.

There is DSP (digital signal processor) controller card with ADC inputs and PWM outputs which monitors all these analog signals and generates PWM pulses for IGBT switching current to remain within the desired operating point.

This high frequency AC supply is fed to a high frequency ferrite core transformer T1at its input terminals. This high frequency AC voltage is stepped down and the secondary of this transformer provides low voltage isolated AC supply.

Figure 18: Circuit Diagram of RBC Converter-Inverter Section

IGBT DRIVER

BV-D1 BV1 -

DC1-

Q1 Q2

T1

C2A

BV1+

C2

CT1

C1 C1A

L1BV+

R2

Y2

B2

CS1

S1

R1

Y1

B1

CN1

R

Y

B

SP

N

CT2 CT3

CT4

DIODE

RECTIFIER

OP1

L2

OP2OP2

TH1DC1+ +DC+

F1

VT2

C6

C5

DC+

DC+

BC+

SP

DC-

(WSD)

BC1

PSA 871

T2

PSA 617 B

D2PSA 870S2




Again it has a full wave bridge diode rectifier and the isolated stepped down AC voltage is fed to this full wave bridge rectifier and rectified to 122 V DC.

This DC output voltage is filtered by L2 and C5,C6 capacitors to ripple free DC .

Total 4 current transducers (sensors) are provided. CT1 for input IGBT current sensing, CT2 for output Inductor current sensing,CT3 for total load current sensing and CT4 for battery charging current sensing.

Voltage transducer VT2 is provided for output voltage sensing.

ThyristorTH1 is provided for reverse battery protection.

RBC starts functioning without an human intervention with the availability of input power supply without any need for switching „ON‟ and „OFF‟.

Figure 19: Circuit Diagram of RBC Output Rectifier Section

IGBT DRIVER

BV-D1 BV1 -

DC1-

Q1 Q2

T1

C2A

BV1+

C2

CT1

C1 C1A

L1BV+

R2

Y2

B2

CS1

S1

R1

Y1

B1

CN1

R

Y

B

SP

N

CT2 CT3

CT4

DIODE

RECTIFIER

OP1

L2

OP2OP2

TH1DC1+ +DC+

F1

VT2

C6

C5

DC+

DC+

BC+

SP

DC-

(WSD)

BC1

PSA 871

T2

PSA 617 B

D2PSA 870S2




Figure 20: Block Diagram of Regulated Battery Charger

6.2 Emergency Battery Charger

The Emergency Battery Charger System is a PWM controlled IGBT based battery charger. This is a separate identical circuit within the same unit.

A single pole MCB (S2) is provided at the input which acts as input dis-connector and overload protection for EBC.

This converts the single phase AC to DC by a full wave diode bridge rectifier. The DC bus of around 300 V DC is filtered by capacitors.

Then this dc voltage is inverted to high frequency AC voltage by a two arm full bridge IGBT converter. Dedicated IGBT drivers are used to drive the IGBT gates to switch the IGBTs .

This high frequency AC output is fed to primary of a high frequency ferrite core transformerT2 and stepped down.

This isolated output of this T2 transformer is rectified to DC by a full wave bridge diode rectifier to 110 V DC.

This output DC supply is filtered by LC filter to get ripple free DC supply.

Thyristor is also provided for reverse battery protection The unit supply to dc load .

AC

=

DC

=

=

Bridge Rectifier

Rectifier

Control

DC Current

LC Filter

VDCLink

IGBT Inverter Output

Transformer

Full Wave

Rectifier

LC Filter

Rev. Pol.

Protection

To Load

RBC

Data Acquisition &

Control

Inverter control

Data logging

Display

Rectifier control

VIN

EBC Status

DC Current

VBatIBatTBatTHeat Sink TTotal

ITotal

VBat

IBat

To Battery

VIN

415 V, Three

Phase Inverter

Control



Figure 21: Circuit Diagram of Emergency Battery Charger

Figure 22: Block Diagram of Emergency Battery Charger

IGBT DRIVER

BV-D1 BV1 -

DC1-

Q1 Q2

T1

C2A

BV1+

C2

CT1

C1 C1A

L1BV+

R2

Y2

B2

CS1

S1

R1

Y1

B1

CN1

R

Y

B

SP

N

CT2 CT3

CT4

DIODE

RECTIFIER

OP1

L2

OP2OP2

TH1DC1+ +DC+

F1

VT2

C6

C5

DC+

DC+

BC+

SP

DC-

(WSD)

BC1

PSA 871

T2

PSA 617 B

D2PSA 870S2


AC

=

DC

=

=

Bridge Rectifier

Rectifier

Control

DC Current

LC Filter

VDCLink

IGBT Inverter Output

Transformer

Full Wave

Rectifier

LC Filter

Rev. Pol.

Protection

To Load

EBC

Control

Display

Rectifier control

VIN

IIN

RBC Status

VOut IOut

VBat

VIN

230 V, Single

Phase Inverter

Control



7 SPECIAL FEATURES 7.1 Auto Battery Mode

At pre-fixed time (settable) every day, Regulated Battery Charger automatically switches „OFF‟ (zero output) and the DC load will be transferred full to Battery for one hour (max.) Emergency Battery Charger does not activate in this condition. During this period Battery voltage shall be monitored. RBC should start functioning normal after one hour or before, if Battery voltage falls below cut off voltage (settable through key pad). If Battery voltage drops below cut off voltage i.e. 100V (settable through key pad) in less than one hour, „Battery not healthy‟ indication glows on indication panel.

7.2 Operating Modes

Regulated Battery Charger (RBC) has the following two modes:

7.2.1 Normal mode

In normal mode, RBC gives full output i.e. 4.5 kW & main circuit of RBC operates and 2.5kW EBC circuit output remains in standby mode.

7.2.2 Emergency Mode

In the event of failure of normal mode i.e. failure of RBC circuit, emergency mode automatically activates and EBC circuit operates. EBC is separate identical circuit but operating at 240V input (any of the phase & neutral) for feeding 2.5kW coach load at 110V DC (nominal). Activation of emergency mode is indicated on indication panel through an LED.

7.3 Fault Diagnostic

The RBC has following fault diagnostics features accessible through key pad/ down loading.

i. Display of following faults with brief description

Input under voltage <300 Volts.

Input over voltage > 480 Volts

Reverse polarity for Battery circuit.

Input single phasing

Output short circuit

Over temperature

Output over voltage > 135 V

Over current

Earth leakage for both lines



Liquid Crystal Display (LCD) is provided for display parameters and fault data along with its associated keys / push buttons on MCU card of RBC and EBC.

Diagnostic system is capable of recording at least last 300 latest faults with real time clock with override feature i.e. first in first out (FIFO). There is no provision for detection or clearing of the fault data.

ii. Communication port for down loading of faults

RBC is provided with self-checking watch dog feature and facility to down load data through USB port on commercially available USB pen drive.

8 PREVENTIVE MAINTENANCE

For maintenance of Battery Charger, refer the maintenance instructions for AC and Non AC LHB coaches. The various maintenance activities for battery charger are prescribed below:

Table 3: Maintenance Activities for Battery Charger

S. No.

Maintenance Activity

Work to be done TI

(D1)

M

(D2)

HY

(D3)

IOH

(SS-1)

POH

(SS-2)

1. Visual check Visually check battery charger box suspension arrangement for any damage or irregularity.

2. Working Ensure proper working/ functioning of battery charger.

3. Functional test

Checking of all the system parameters (Input voltage / Input current, DC link voltage, output voltage / output current using multi-meter and clamp meter

4. Cleanliness Open the cover of battery charger and clean with soft brush & vacuum cleaner.

5. Intactness/tightness of electrical connections

Check input and output interface connections for any overheating mark.

6. Insulation resistance

Take IR of live terminals to body. It should be more than



test as specified in insulation resistance table below.

7. Measure the capacitance of DC Link Capacitor

Measure the capacitance of DC Link Capacitor and if the capacitance value decrease below specified value + / - 10 %, then replace the capacitor.

8. Cleaning heat sink

Clean heat sinks by vacuum cleaner and soft brush.

9. Replacement Replace sealing gasket

8.1 Insulation Resistance table

Table 4: Insulation Resistance

S. No Circuit Voltage

Capacity of Megger used

Min. value of IR required

1. 415 V 500 V 03 M ohm

2. 230 V 500 V 02 M ohm

3. 110 V 500 V 02 M ohm

9 TRANSPORT AND STORAGE

Transport the Battery Charger in its original packing to the final destination.

Use a fork lift or lift truck for transportation and for lifting if lifting is necessary.

Ensure that the equipment is only transported in the upright position and not tilted or turned over.

Always avoid sharp impacts. Generally hard impacts must be avoided for all devices with electronic components.

Environmental conditions must be clean for transportation.

Openings in the enclosure must be closed with some suitable material.

It is advisable to store the equipment in its original packing till installation.

Equipment should be stored in a clean, dry, well-ventilated room that is free of corrosive materials.

Where possible, the original packing should not be removed during storage.

In no circumstances, the Regulated Battery Charger must not be stored outside.

Do not stack the converters on top of each other.



10 FAULT INDICATIONS & TROUBLE SHOOTING 10.1 For Signotron make REBC

Table 5: Fault Diagnostics for Signotron Make REBC

Nature of Fault

LED Indications LCD Display

Message System

ON R

Phase ON

Y Phase

ON

B Phase

ON

BAT CHR ON

BAT Not

Healthy

Single Phase

+VE Earth Leak

-VE Earth Leak

EMERG

Mode ON

AC input under Voltage

OFF ON ON ON OFF OFF OFF OFF OFF OFF I/P UV Fault

AC input over voltage

OFF ON ON ON OFF OFF OFF OFF OFF OFF I/P OV Fault

Battery Reverse Polarity

OFF ON ON ON OFF OFF OFF OFF OFF OFF REV BAT

Input Single Phasing

ON OFF/ ON

OFF/ON

OFF/ ON

ON OFF ON OFF OFF OFF Single Ph

Output Short Circuit

OFF ON ON ON OFF OFF OFF OFF OFF OFF O/P OC

Over Temperature

OFF ON ON ON OFF OFF OFF OFF OFF OFF Temp HI

DC Output Over Voltage

OFF ON ON ON OFF OFF OFF OFF OFF OFF O/POV

Load Fuse Failure

ON ON ON ON ON OFF OFF OFF OFF OFF NA

O/P +VE Earth leakage current >30mA

ON ON ON ON ON OFF OFF ON OFF OFF +EARTHL

O/P -VE Earth leakage current >30mA

ON ON ON ON ON OFF OFF OFF ON OFF -EARTHL

Both O/P +VE & -VE Earth leakage current >30mA

ON ON ON ON ON OFF OFF Blink Blink OFF -EARTHL & +EARTHL

Table 6: Trouble Shooting for Signotron Make REBC

Sl. No.

Description Fault / Reason Remedial Action

1. All connections are OK. RBC is working. Battery is charging. But load is not working.

Voltage supply to load not available.

Check the load fuse F1 and replace if it is blown out.

2. Load is ON but Battery is not charging.

RBC is off. Check the RBC input voltage is OK and MCB is ON. If any problem found correct it.



3. Three Phase input off load is ON and Battery Charging indication is ON.

Battery and load connections are wrongly interconnected.

Interchange the load and Battery connections.

4. RBC is OFF or defective. EBC is also OFF.

R Phase faulty (R-Phase LED OFF).

Neutral is not properly connected.

Correct R phase.

Neutral to be properly connected.

5. RBC is OFF or defective. EBC is ON but not giving power to Load or Battery. Supply to load coming from Battery.

Battery Voltage above 110V.

As EBC output is 110 V. So if Battery Voltage is more than EBC output voltage, Load will be supplied from Battery.

When Battery voltage will decrease below EBC output voltage, EBC will start charging the Battery in Float mode and will supply power to Load.

6. Input supply is connected to RBC but RBC is not working, No LED indication.

Input supply 415 V not coming to RBC.

Check the connections of both sides of MCB. 3 pole MCB for RBC and 1 pole MCB for EBC. If MCB tripped or Faulty rectify the problem.

7. Output current is restricted to 35% of its capacity (about 13 Amp).

Any of the input phase is OFF. Check that phase LED indication will be OFF.

Rectify the particular phase.

10.2 For AAL make REBC

Table 7: Trouble Shooting for AAL Make REBC

Sr. Fault Code Description Possible Cause Rectification

1. INV_OV_FT Input over voltage

Input voltage>480V, Error in the input voltage sensing circuit of PS card

Input voltage Sensor TR2, TR3

Check input sensing circuit.

Check interconnection cable between MCU card and Input voltage




and TR4) may be faulty,

Feeder transformer(750 V:415V) at railway side may be faulty

transformer.

Check MCU card

Check output feeder of transformer or battery charger input

2. INV_LV_FT Input under voltage

Input voltage<300V, Error in the input voltage sensing circuit of PS card

Input voltage Sensor TR2, TR3 and TR4) may be faulty,


Check input sensing circuit.

Check interconnection cable between MCU card and Input voltage transformer

Check MCU card

Check output feeder transformer or battery charger of input.

3. S Phase FT Input Single phase fault

One or more phase at input side may be missing or faulty

One or more three phase input voltage sensing channel in MCU card may be faulty.


Check each individual phase voltage channel. If there is difference between phase voltages, then isolate input of charger from feeder transformer and check by which problem is coming.

Check loose connection in particular phase which is showing abnormal voltage or no voltage

Check Burden resistance of all input voltage transformer.

4. GDUF_FT Gate Driver Fault

GDU card may be faulty

Loose connection

GDU or MCU side.

IGBT may faulty

Check for loose connection between I IGBT & GDU card.

Check GDU pulse in simulation mode, it should be (+16±1.6V &-11±1.1V) with the




help of CRO.

If pulse is normal and fault is still persisting in simulation mode, then check healthiness of IGBT

If all ok still fault persisting, replace the GDU card and then MCU card.

5. Fuse fault Output Fuse

Micro Switch of Fuse

MCU card (4.5 KWRBC)

Check micro switch connection of fuse.

Check fuse for healthiness.

If all devices are ok and still fault persisting, replace the MCU card.

6. Input MCB tripping

MCB defective

Short circuit

Loose connection

Check healthiness of each pole of MCB with the help of a multi-meter in continuity mode and by switching ON/OFF at least 5 to 6 times.

Check the loose connection at MCB.

Check for short circuit through wire or any Power devices like Input Diode/Thyristor module.

7. Battery Charger reverse polarity

BATV_RV_FT

Wrong connection of battery charger

MCU card may be faulty

Check Battery connection to battery charger output side.

8. Heats in over temperature

BCH OTH

BACK_FT

BCH OTH

UPPER_FT

Thermostat may be faulty

MCU card fault

Check thermostat OT1 andOT2, may be short

If all above ok &problem still persisting, replace




MCU card.

9. Output

under and

over voltage

OUTV_LV_FT

Battery may be faulty


Output Diode module may be faulty

Output capacitor may be faulty.

Check battery voltage

Check MCU card and if required replace it

Check, if there is any diode module is defective.

Check output capacitor

10. Output over

current

LOAD_OC_FT

Output short circuit


Any load may be fault.

Check battery

Check MCU card and if required replaced it

Check output capacitor, and if not OK replace it.

11. Negative line earth leakage

Positive line earth leakage

Both line earth leakage

N_ELD_FT

P_ELD_FT

P_N_ELD_FT

ELD sensing card may be faulty


Positive(DC),

Negative (DC) or both line earthed.

Correct if any of line is earthed.

If problem still persisting replaced ELD sensing card, then MCU card.

10.3 For PI make REBC

Table 8: Trouble Shooting for PI Make REBC

Sr. Fault Indication To Be Check

1 Single Phasing

Any one of the 3 LEDs (1,2,3) for input indication not glowing.

Single phasing LED glow.

i. Check 3 phase input supply to the Battery charger unit.

ii. Check input 3 phase MCB, one terminal of the MCB may be faulty.

iii. Check wire from three phase MCB to main contactor placed inside the cubicle.

2 Input UV, input OV,

LCD Display shows Input UV

i. I/P supply less then 300VAC.

ii. Check I/P voltage it should be within



Sr. Fault Indication To Be Check

reverse polarity, O/P Short circuit,

range (300VAC to 400VAC PH to PH).

iii. Check 3 PH MCB.

LCD Display shows Input OV

i. I/P supply less then 480VAC.

ii. Check I/P voltage it should be within range (300VAC – 400VAC PH to PH).

LCD Display shows Reverse polarity

i. Battery connection is reverse.

ii. Check the battery connection in terminal box.

LCD Display shows O/p Short circuit

i. Check for shorting between Battery positive and negative.

ii. Check for shorting between load terminals (positive & negative).

3 Earth fault

Positive earth leakage LED glowing

Check shorting/ Earthing between battery/load positive terminal to earth.

Negative earth leakage LED glowing

Check shorting/ Earthing between battery/load negative terminals to earth.

Both Earth leakage flashing

Check shorting/ Earthing between battery/load positive and battery/load negative terminal to earth.

4 HV bus low

Display shows HV BUS LOW

i. Check wire between main contactor to input 3 phase bridge.

ii. Check input 3 phase bridge.

iii. Check connection between 3 phase bridge to Dc bus capacitor.

iv. Check IGBT.

5 No output voltage

Charger OFF and showing battery healthy check

No display on main card

i. Check display of LCD if it showing battery health check mode in day/night except midnight

ii. Check date and time and set date and time as per instruction and restart unit

iii. If no display of LCD of main card in main card check power supply and replace it



10.4 For IC Make REBC

Table 9: Trouble Shooting for IC Make REBC

Sr. Fault LEDs Status Reason Remedial measures

1. Single Phasing Indication

ON Any of the Input Supply Phase is Unavailable

Check all Three Phases on Input Supply Terminals, Input MCB and Respective Terminals.

2. Positive Earth Leakage (>30mA)

ON Low Impedance detected between Positive Line and Earth

Check the Low Impedance Path between BC+ to Earth and DC+ to Earth Separately

3. Negative Earth Leakage (>30mA)

Low Low Impedance detected between Output Negative Line and Earth

Check the Low Impedance Path between DC- to Earth.

4. Earth Leakage for Both Lines

Flashing (Both Earth Leakage LEDs)

Low Impedance detected from Earth to Both Output Positive and Negative Lines.

Check the Low Impedance Path between BC+ to Earth, DC+ to Earth and DC- to Earth Separately.

5. Emergency Mode On

ON URBC not Working, EBC Mode ON

1. Check the input supply and MCB status of URBC

2. Check for any Fault or Internal Loose contacts in URBC circuits.

10.5 For Sydler Make

Table 10 : Trouble Shooting for Sydler Make REBC

Sr. No Symptom Reason

1. RYB LEDs NOT Glowing Power Not Available MCBs are OFF

2. LEDs (RED)on the Control Card Not Glowing

Input Power Not available, P/S on control card

3. System Trips after 3 Cycles of Input not within Limits/Fault sensed by



Restart the control card

4. System O/P Voltage is Reduced

Operated in CC mode-Reduced load

5. System ON LED Glowing , O/P Voltage available on Display –But No Load Current

Fuse Blown, Replace Fuse

6. +ve & -ve LED Blinking (>30mA)

Check Earth Leakage at Output side

7. Single Phasing LED ON Input Side One Phase Missing

8. Battery Not Healthy LED ON Disconnect the Battery or ON RBC

9. System Trip See any Fault Reason



ANNEXURE-1

Developmental Vendors for 4.5 kW Regulated Cum Emergency Battery Charger for LHB coaches.

(Ref: RDSO EL (QA) Vendor Directory No.QAE-M-7.1-1, Ver. 10.0 effective from 01.07.2020 to 31.12.2020)

S.N. Firms Name & Address Contact Details

1. Signotron (India) Pvt. Ltd., (SIPL) Office: Plot No.J1-6, Block-EP, Sector-V, Salt Lake Electronic Complex, Kolkata – 700 091

[email protected] [email protected] Mob. 9831290695, 23577877, 23573481

2. M/s IC Electricals Company Pvt. Ltd., E-94, Industrial Estate, Bahdarabad, Haridwar, Uttarakhund – 249402.

[email protected] Sh. Udit Sharma, Plant Head [email protected] 9258017266,

3. M/s Electrowaves Electronics Pvt. Ltd., Office: Plot No. 37, Sector-5, Parwanoo, Distt.-Solan(HP)-173 220.

[email protected] [email protected] Fax/Ph. 01792-234410/233412

4. M/s Electronic Equipment Company Pvt. Ltd., Office:146/2, Old China Bazar Street, 1st Floor, Kolkata-700001

[email protected] Fax 033-22901191 Ph 033-22901192

5. M/s PI Engineering Works, Office: Khasra No. 92, Shikheda Road, Industrial Area, Modinagar, Ghaziabad- 210 204(UP).

[email protected] Mob.: 9218656849

6. M/s Hitachi Hi-Ref Power Electronics Pvt.Ltd. B-52, Corporate House Judge Bunglow Road, Bodakdev, Ahmedabad-380054 (Gujrat)

[email protected] Fax No.: 02717-678999 Sh. Desh Raj Sharma: 9650016527

7. M/s Hind Rectifiers Ltd., P.B.No. 17303, Lake Road, Bhandup(W), Mumbai- 400078

[email protected], [email protected] Ph. 022-25968027 Fax no. 022-25964114

8. M/s Autometer Alliance Ltd. Office address:C-63, Sector-57, Noida-201307(UP).Works address:C-63, Sector-57, Noida-201307(UP).

[email protected], [email protected] Phone-0120-2583545-46 Fax no.0120-2583542

Sh. AnkurTiwari: 9999884085

9. M/s Sydler Electronics Pvt. Ltd., Pune [email protected]

Phone-+91-22-4931 1555



REFRENCES

1. RDSO specification no. RDSO/PE/SPEC/AC/0183 (Rev.1)-2018 for 2.5 kW Under-slung constant voltage regulated cum emergency battery charger for LHB Coaches.

2. Maintenance manual for AC EOG LHB coaches issued by CAMTECH, Gwalior.

3. Photographs received from CRWS/ Bhopal and LHB Coaching depot, New Delhi.

4. Presentation by Signotron India Private Limited for “Basic Training Program for maintenance of 4.5 kW RBC cum EBC for LHB Coaches.

5. Operation and Maintenance manual-1 for 4.5 kW REBC issued by TI Engineering works, Gaziabad.

6. Operating instruction for 4.5 kW REBC issued by TI/ Engineering works, Gaziabad.

7. Operation and Maintenance Manual of 4.5 kW REBC issued by IC Electricals company Pvt. Ltd., Haridwar.

8. Operation and Maintenance Manual of 4.5 kW REBC issued by Hitachi Hi-rel Power Electronics Pvt Ltd., Secunderabad.

9. Installation, commissioning and Operation and manual of 4.5 kW REBC issued by Auto Meter Alliance Ltd., Noida.

10. Operating Manual of 4.5 kW REBC issued by Sydler Electronics Pvt. Ltd., Pune.

11. Comments and suggestions received during the webinar held on 18.09.2020 by CAMTECH, Gwalior.



NOTE



CAMTECH is continuing its efforts in the documentation and

up-gradation of information on maintenance practices of

electrical assets. Over the years a large number of

publications on electrical assets have been prepared in the

form of handbooks, pockets books, pamphlets & video films

etc. These publications have been uploaded on the internet as

well as rail net.

For downloading these publications please do following: 1. On internet visit :www.rdso.indianrailways.gov.in

Go to Directorates CAMTECH Publications for download Electrical Engineering

2. On Railnet visit RDSO website at 10.100.2.19

Go to Directorates CAMTECH Publications for download Electrical Engineering

For any further information regarding publications please contact:

Dy. Director (Elect.) BSNL: 0751- 2470740 (O) Rly. : 03747203

: 9752447030 (CUG) SSE/Electrical : 9755549297 (CUG)

E-mail : [email protected]

Fax : 0751- 2470841

Write at : Dy.Director (Electrical) Indian Railways Centre for Advanced Maintenance technology, In front of Hotel Adityaz, Airport Road, Maharajpur, Gwalior, Pin code – 474 005

http://www.rdso.indianrailways.gov.in/

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