FOR TL & AC COACHES - Indian Railways

Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS

egkjktiqj, Xokfy;j & 474005 Maharajpur, GWALIOR - 474005

CAMTECH/E/10-11/OM-Coaches/1.0

October 2011

dsoy dk;Zky;hu mi;ksx gsrq (For Official Use Only)

OPERATING MANUAL FOR

TL & AC COACHES

Camtech/E/10-11/OM-Coaches/1.0

2

2

OPERATING MANUAL FOR

TL & AC COACHES


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FOREWORD

With the growing demand of passenger comfort and expectations it is essential to have

trouble free operation of TL & AC coaches enroute. CAMTECH has prepared this manual to cover all aspects of operation of TL & AC coaches to ensure reliability.

The duties and instructions for escorting staff prescribed in this manual are to ensure safe and comfortable journey. This manual also describes different checks and operating procedure for AC coaches. A very useful compilation of common defects and their remedial, Do’s & Don’ts and disaster management is also included in this manual.

I compliment CAMTECH for bringing out this manual, which will be of immense help to the escorting staff of Indian Railways.

RDSO, Lucknow

Date : 10.10.2011 Executive Director/ PS & EMU


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PREFACE

The perfect operation of TL & AC coaches is necessary to ensure reliability and availability of coaches. Railway Board and RDSO have issued various operating and maintenance instructions from time to time. CAMTECH has prepared this operating manual for TL & AC coaches on the basis of information collected from Railways in consultation with RDSO.

The objective of this manual is to disseminate knowledge among escorting staff and to make them aware of operating and trouble shooting techniques to be followed on line.

This manual includes brief description of control panel as well as ratings of MCBs and fuses, duties and instructions for escorting staff. This manual also includes pre-departure preparation and operating procedure for AC coaches apart from trouble shooting and disaster management.

It is clarified that this manual does not supersede any existing provisions laid down by RDSO or Railway Board/Zonal Railways. This manual is for guidance only and it is not a statutory document.

I am sincerely thankful to Sh. Prafull Chandra, Director, RDSO/ Lucknow and also all field personnel who helped us in preparing this manual.

Technological up-gradation & learning is a continuous process. Please feel free to write to us for any addition/modification in this manual. CAMTECH, Gwalior Peeyoosh Gupta Date: 10.10.2011 Jt. Director Electrical


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Chapter No. Description Page No.

Foreword iii Preface iv

Contents v Correction slip vii Abbreviations viii

1. GENERAL 01

1.1 DUTIES OF AC ESCORTING STAFF BEFORE DEPARTURE 01

1.1.1 DUTIES OF AC COACH ATTENDANT 01

1.1.2 DUTIES OF AC COACH MECHANIC 01

1.2 DUTIES OF AC ESCORTING STAFF DURING RUN 02

1.3 INSTRUCTIONS FOR AC ESCORTING STAFF 02

1.4 LIST OF SPARES REQUIRED FOR AC ESCORTING STAFF 02

1.5 CABLES TO BE AVAILABLE IN AC COACHES 03

1.6 FUSES IN SG CONVENTIONAL (U/S) TYPE AC COACHES 03

1.7 MCBs & FUSEs IN SG RMPU TYPE AC COACHES 04

1.8 RSWs IN SG AC COACHES 04

1.9 COMPONENTS OF AC CONTROL PANEL 05

1.10 SAFETY PRECAUTIONS 05

1.11 SAFETY TIPS FOR PREVENTION OF FIRE 06

2. OPERATION 07

2.1 PREPARATION OF COACH 07

2.1.1 GENERAL CHECKS IN AIR CONDITIONED COACH 07

2.1.2 OPERATING PROCEDURE FOR AC COACHES 07

2.2 PRECOOLING PROCEDURE 08

2.3 TEMPORARY CONNECTION 09

2.3.1 DCV-DC FEED EXTENSION PROCEDURE 09

2.3.2 THROUGH FEEDING PROCEDURE (NON-AC COACHES) 10

2.3.3 THROUGH FEEDING WHEN AC COACH IS IN BETWEEN TWO TL COACHES 11

2.4 WORK TO BE CARRIED OUT ON REACHING THE DESTINATION 11

2.5 PROFORMA FOR AC COACHES LOG BOOK 12

3. DISASTER MANAGEMENT 18

3.0 DUTIES OF ELECTRICAL ESCORTING STAFF IN CASE OF EMERGENCY 18 3.1 DERAILMENT/ COLLISION (INCLUDING LEVEL CROSSING ACCIDENTS) 18 3.2 FIRE IN TRAIN 18

3.3 CYCLONE/ STORM/ FLOOD 18

CONTENTS


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Chapter No. Description Page No. 3.4 REPORTED BOMB IN TRAIN 18

3.5 EXPLOSION OF BOMB IN A TRAIN 19

3.6 EXPLOSION OF BOMB IS REPORTED IN A FIXED INSTALLATION 19

3.7 OPERATION OF FIRE EXTINGUISHERS 19

3.8 ELECTRIC SHOCK 20

4. TROUBLE SHOOTING 21

4.0 TROUBLE SHOOTING INSTRUCTIONS FOR RMPU AC COACHES 21

4.1 NO GENERATION 21

4.1.1 AT POWER PANEL 21

4.1.2 AT ALTERNATOR 21

4.1.3 AT RRU/ ERRU 22

4.2 110 V DC LOW VOLTAGE 22

4.2.1 AT RRU/ ERRU 22

4.2.2 AT BATTERY 22

4.3 INVERTER NOT WORKING 23

4.3.1 AT POWER PANEL 23

4.3.2 AT INVERTER 23

4.4 INVERTER TRIPPING ON “ON LOAD” 24

4.5 INVERTER TRIPPED ON “OFF LOAD” 24

4.6 INVERTER TRIPPING ON STABLLNG 24

4.7 AC PLANT NOT WORKING 25

4.7.1 POWER INDICATION LED NOT GLOWING 25

4.7.2 BLOWER MOTOR NOT WORKING 26

4.7.3 CONDENSER MOTORS NOT WORKING 28

4.7.4 COMPRESSORS NOT WORKING 29

4.8 ALL EQUIPMENT ARE NOT WORKING IN STATIONARY CONDITION 30

4.9 WRA/ MONOBLOCK MOTORS NOT WORKING 30

4.10 ALTERNATOR SEPARATE EXCITATION PROCEDURE 31

4.11 TROUBLE SHOOTING INSTRUCTIONS FOR NON AC COACHES 32

5. DOS AND DON’TS 33

5.1 GENERAL 33

5.2 IN CASE OF BURN 34

5.3 IN CASE OF HEAD INJURY/ BLEEDING NOSE 34

5.4 IN CASE OF TRAUMA 34

5.5 IN CASE OF INJURIES 35

5.6 IN CASE OF 25 KW ERRUs 35

5.7 IN CASE OF 4.5 KW ERRUs 36

APPENDIX – A TECHNICAL KNOW-HOW 37

APPENDIX – B ELECTRICAL CIRCUITS 42

REFERENCES 50


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ISSUE OF CORRECTION SLIPS

The correction slips to be issued in future for this handbook will be numbered as follows: CAMTECH/E/2010-11/OM-Coaches/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. and Item no. modified

Remarks


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8

ABBREVIATIONS

ACCA AC Coach Attendant ACCI AC Coach Mechanic

Ah Ampere hour Alt Alternator

Amp Ampere CD1 Condenser Motor1

CD2 Condenser Motor2 CP1 Compressor motor1

CP2 Compressor motor2 DP Double pole

EFT Emergency Feeding Terminal ELD Earth Leakage Detector

ERRU Electronic rectifier cum regulator unit

FDB Fuse distribution board

HP High pressure HRC High rupturing capacity

INV Inverter IR Insulation resistance

LED Light Emitting Diode LP Low pressure

MCB Miniature circuit breaker MCCB Moulded case circuit breaker

–VE Negative NPP Non Power panel

OHP Over heat protection OP Oil pressure

OVP Over voltage protection OVR Over Voltage Relay

+VE Positive PP Power panel

PVC Poly Vinyl chloride RMPU Roof mounted package unit

RRU Rectifier cum Regulator unit RSW Rotary Switch Way

SG Self generating SMF Sealed Maintenance Free

SMI Special Maintenance Instructions TC Temporary connection

TDR Time delay relay TP Triple pole

VR Vane Relay VRLA Valve Regulated Lead Acid battery

WRA Water Raising Apparatus.


Operating Manual for TL & AC Coaches October 2011

1

CHAPTER 1

GENERAL

1.1 DUTIES OF AC ESCORTING STAFF BEFORE DEPARTURE 1.1.1 DUTIES OF AC COACH ATTENDANT

1. To appear in prescribed uniform and have his badge fixed on it so as to easily identify by the passengers.

2. To be present one hour before the schedule departure of the train.

3. To check that all internal electrical fittings in the coach provided for the comfort and safety of passengers are intact and in working order.

4. To monitor electrical/ mechanical defects developing in the coach and call maintenance staff for attending whenever necessary.

5. To assist the AC coach mechanic in pre-cooling of the coach well before commencement of the journey.

6. Assist AC coach mechanic to take reading of pressure at panel board, discharge pressure of refrigerant and oil pressure of compressor and voltage, current of the alternators and battery etc., from time to time and make entries in the log book and inform AC coach mechanic incase of any abnormalities in the readings.

7. To assist the AC coach mechanic in the rectification of minor faults in the AC coach equipment enroute.

8. Keep doors closed during run & open at station when train is stopped.

1.1.2 DUTIES OF AC COACH MECHANIC

1. Should be available in the coach one hour before schedule departure of the train.

2. Check logbook of the coach for any entry by the maintenance staff and act accordingly.

3. Check the condition of V-belts in stable condition. It should be 6+6 from the primary depot.

4. Check OFF load battery voltage. It should be 118V.

5. Record all parameters of the equipment in the logbook.

6. Check whether the coach is pre-cooled or not. If not, pre-cooling should be done after placement of the train and pre-cooling should be removed 10 minutes before departure of the train.

7. Switch OFF one of the AC plant before removing pre-cooling cable from external supply.

8. Check all the grills inside the coach. These should be in open condition.

9. Check all lights, emergency lights, fans, night lamps, reading lamps & mobile charging sockets.

10. Attend complaint of passengers, if any.

11. Should do temporary connection in TL coach also, if required.


October 2011 Operating Manual for TL & AC Coaches

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1.2 DUTIES OF AC ESCORTING STAFF DURING RUN

1. As the coach picks up speed after its commencement of journey, observe the reading of the voltmeter and ammeters of alternators, to ensure that they are working and write down the parameters in the logbook for every two hours.

2. Observe the function of AC plants by noting the load currents on the inverters and also cooling effect inside the coach.

3. Record temperature in the logbook for every 2 hours.

4. If any abnormality is observed, first note down the same in the logbook and try to solve the problem to the extent possible.

5. Frequently check the AC control panel indicators for any faults.

6. Change the working of WRAs/ monoblock pump for every 6 hours if AUTO mode is not in service.

1.3 INSTRUCTIONS FOR AC ESCORTING STAFF

1. Be cautious about un-claimed baggage /luggage.

2. Check working of AC plant/light/fans & reading lights etc.

3. Check cleanliness of compartment.

4. Keep panel shutter closed with latches already provided.

5. Ensure following in the coach:

a) Pre-cooling cable b) Emergency feed cable.

Carry standard tool kit box.

6. Use fire extinguisher in case of fire.

7. Open emergency window in case of emergency.

8. Troubles shoot line failure immediately.

9. Communicate line failures & Non-AC certification, if any. Inform to base depot & destination depot immediately.

10. Fill logbook details properly.

1.4 LIST OF SPARES REQUIRED FOR AC ESCORTING STAFF

S. No. Description Qty

1. 4 sq mm PVC copper wire in two pieces for manual operation of the ERRU/RRU

15m

2. . Inter cell connection leads along with nut and bolts. 2+2

3. Carbon brushes for blower, condenser & compressor motor for under slung coaches.

1 set

4. HRC fuses 400A, 250A, 160A, 125A, 63A, 40A, 20A, 10A & 6A 2 set

5. CFL & choke 2

6. Cotton cloth for cleaning 1m



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1.5 CABLES TO BE AVAILABLE IN AC COACHES

S. No. SIZE OF E-BEAM COPPER CABLE QUANTITY

1 3 core 70 mm² cables as per RDSO’s specification No. ELRS/ SPEC/ ELC/ 0019 (Rev-1) issued in July 2010.

25 meter length with pre-cooling socket as per RDSO’s drawing No. RDSO/ PE/ MS/ AC/ 0044-2008 (Rev-1) issued vide letter no.EL/ 7.1.83 dated 28.05.2010.

2 2- Core 25 mm² cables as per RDSO’s specification No. ELRS/ SPEC/ ELC/ 0019 (Rev-1) issued in July 2010.

25 meter with proper crimping lugs on both ends for DC-DC feed extension.

3 Single Core 50 mm² cable as per RDSO specification No. ELRS/ SPEC/ ELC/ 0019 (Rev-1) issued in July 2010.

Note: Only 3 cells can be bypassed.

0.5 meter with proper crimping lugs on both ends for bypassing the cells.

4. Single Core 16 mm² PVC/2.5 mm² elastomeric /2.5 mm² e-beam cable for Feed extension in TL coaches as per RDSO’s Technical circular No.RDSO/PE/TL/TC/0002-(Rev-0)

1.5 meter with proper crimping lugs for feed extension in TL Coaches.

1.6 FUSES IN SG CONVENTIONAL (U/S) TYPE AC COACHES

S. No TYPE CAPACITY LOCATION

1 HRC 315A Negative and Positive terminal of cell bank

2 HRC 250A Both plant negative and positive supply

3 HRC 160A Incoming supply from alternator regulator

4 HRC 100A Positive supply of control panel for cooling plants

5 HRC 60A For positive supply of heating control panel

6 HRC 2A For negative control supply

7 Bottle type Cartridge

10A, 20A Blower and condenser motor supply



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1.7 MCBs & FUSES IN SG RMPU TYPE AC COACHES

S. No TYPE & No CAPACITY LOCATION

1 Main MCB TP 63A Power input to RMPU equipment

2 MCB TP 1,2,3 6A Blower motor & Condenser motor

3 MCB TP 4,5 32A Compressor motor

4 MCB TP 6,7 16A Heater

5 MCB DP 8 2A In coming of Control transformer

6 MCB DP 9 4A Out going of Control transformer

7 MCB TP 16A For WRA

8 HRC-F3 10A ERRU field fuse

9 HRC-F1, F2 160A ERRU main fuse

10 HRC 400A Positive and negative of battery

11 MCB DP 0.6A Inverter cooling fan

12 MCCB DP 250A Inverter input

13 MCCB DP 300A

( Siemens make)

Inverter input

14 HRC fuse 20A In ERRU/ RRU before capacitor

1.8 RSWs IN SGAC COACHES (As per RCF drawing no.CC70401, CC72405)

S. No. RSW No. CAPACITY LOCATION

1 RSW1 500A For alt1,alt2 and battery at power panel

2 RSW2 300A For Inv-1 & Inv-2 at power panel

3 RSW3 16A For inverter selector of WRA/ mono block pump at power panel

4 RSW4 16A For Fans circuit at power panel

5 RSW5 10A L1 & L2 circuits at power panel

6 RSW6 2A Night lamps at power panel

7 RSW7 10A For WRA selection at power panel

8 RSW1 63A Power ON RSW at AC control Panel

9 RSW2 16A For blower ON at AC control Panel

10 RSW3 16A For auto/manual mode selector RSW at AC control panel

11 RSW5 6A For compressor selector, bypass RSW at AC control panel

12 COS-1&COS-2

RSW1,RSW2,

RSW3,RSW4

63A Change over switch for selection of power supply

Change over control box



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1.9 COMPONENTS OF AC CONTROL PANEL

1. Overload relay (O/L)

O/L – 1 - For evaporator blower motor.

O/L – 2 & 3 - For condenser motor 1 & 2.

O/L – 4 & 5 - For compressor motor 1 & 2.

2. Timer Delay Relay

T.D.R. – 1 & 2 - For compressor motor 1 & 2.

3. Contactors

C-1 - For blower motor.

C-2 & 3 - For condenser motor 1 & 2.

C-4 & 5 - For compressor motor 1 & 2.

C-6 - For heater bank 1 & 2.

AC-1 - For auxiliary contactor.

4. Rotary switch

R.S.W. – 1 - For 3 AC, main supply ‘ON/OFF’.

R.S.W. – 2 - For control supply ‘ON/OFF’.

R.S.W. – 3 - For VENT/ AUTO/ MANUAL COOLING/ MANUAL HEATING.

R.S.W. – 5 - For compressor by pass mode selection.

5. O.H.P. – 1 & 2 - For over heat protection of heater 1 and 2.

6. Electronic thermostat - For controlling heating/ cooling.

7. V.R. – 1 and V.R. 2 - Vane relay for check air loss in the air supply to both side blower.

8. Transformer - 415V/ 110V, step down transformer for control circuit.

1.10 SAFETY PRECAUTIONS

The following precautions should be observed to reduce risk of injury or death.

1. Keep all covers in place and doors closed during normal operation.

2. Ensure that the test equipment is in good and safe operating condition.

3. When working on the connected motor or motor supply cable, ensure that the input MCCB of the converter is in ‘OFF’ position.

4. If smoke /fire observed anywhere in the coach then switch ‘OFF’ power supply immediately.



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1.11 SAFETY TIPS FOR PREVENTION OF FIRE

1. Ensure provision of two numbers of dry powder type fire extinguishers in A.C. coaches.

2. Ensure that no protection is by-passed.

3. Proper rating of MCBs / fuses shall be used.

4. Look for any overheating sign after putting on all loads.

5. Loose or temporary connection, hanging wires/ exposed joints etc. should not be allowed.

6. Check condition of PVC bushes/ glands provided in junction-boxes. Replace worn-out bushes/ glands during schedules.

7. Check condition of insulation especially in junction-boxes. Don’t permit damaged/ broken/ cracked insulation.

8. Rubbing of cables shall not be permitted.

9. Check physical condition of wire/ cables for external damage and overheating marks, discoloration of lugs due to excessive flow of current/ overheating.



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CHAPTER 2

OPERATION 2.1 PREPARATION OF COACH 2.1.1 GENERAL CHECKS IN AIR CONDITIONED COACH

Before placing the AC coach at starting station, this should be pre-cooled. The AC coach attendant should check the followings:

1. Visually inspect, both upper and under frame and ensure all fittings are intact at their places.

2. In under frame check alternator, axle pulley, ‘V’ belts of alternators, compressor & condensers (in case of under slung), battery etc. if any abnormality found rectify or inform the concerned supervisor/ mechanic, for rectification.

3. In upper frame check control & power panels, fan and light fittings etc..

4. Check the battery voltage. It should be above 118V at ‘OFF’ load & 115V on ‘ON’ load.

5. Check the position of ‘RSW I’ & ‘RSW II’ is normal and ensure that the mains and LVR indication (U/S) is glowing in control panel.

Start the control panel and observe the reading of ‘LP’ HP, OP gauges (U/S).

I. Suction pressure gauge reading should be 2.6 – 2.8 kg/cm2.

II. Discharge pressure gauge reading should 12.6 - 15.5 kg/cm2.

III. Oil pressure gauge reading should be 5.6 - 6.3 kg/cm2.

IV. Feel the temperature suction side cold, delivery side hot and liquid line should be warm.

2.1.2 OPERATING PROCEDURE FOR AC COACHES

1. Ensure coach voltage by pressing voltmeter switch (118V off load).

2. Keep 400A RSW1 in ALT 1, 2 position.

3. Keep the 300A, RSW2 in power panel on Inverter 1&2 position.

4. Latch ON the MCCB in the inverter and keep the inverter switch in ON position and observe input DC voltage in the voltmeter (110 V D.C) and AC output voltage 415V.

5. Put ON the main supply by putting rotary switch RSW1 in ON position. This will cause the RED, YELLOW & GREEN (Power supply) indications to glow. This rotary switch should be switched OFF only in case of repairs/servicing of the unit or control panel. This is necessary to ensure healthy power supply to crank case heaters even the unit is OFF. Normal ON/OFF operation of the unit is achieved using RSW2.

6. Check that all the MCBs are ON and the ‘POWER ON’ (RED) LED is ON. Ensure that RSW5 is at position Comp.1 & 2 ON.



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7. Place RSW3 on AUTO position and ensure the contacts of CD1 & CD2 close immediately and CP1 & CP2 contactors close after a time delay of 120 sec &150 sec respectively.

8. Observe and ensure that there is no trip indication in the LED indication panel of AC control panel.

9. After closing of CP1 & CP2 contacts check the load current in the inverter output side ammeters (21-23 Amps).

10. Follow the same procedure for the other side AC plant.

11. Ensure working of plant on AUTO mode.

12. Switch ON the WRA/ Monoblock pump motor and check for availability of water in the toilets and wash basins.

13. Record the temperature of each unit (PP and NPP side) at Electronic thermostat display unit. If Electronic thermostat is not there, the temperature may be measured by portable thermometer near the return air grill.

14. Do not operate the alternator rotary switches (300 amps capacity) on load. This can cause damage to the switch, electronic components and the V-belts.

15. For failure noticed enroute, if any assistance is required at the enroute station, message should be given to the SE/JE of the station concerned in advance with a copy to the primary and secondary maintenance depots concerned.

The following interlocks have been provided in the control panel to ensure sequence of plant operation:

a. If blower motor is not ON, other equipment cannot get switched ON.

b. If Vane Relay is not ON, “AIRLOSS” LED will glow and no other equipment except the blower can get switched ON.

c. One condenser fan is ON, the compressors can get switched ON.

d. However, if either condenser fan is defective, one of the compressors operation should be disabled by using RSW5.

e. If Heater is ON, compressor cannot be switched ON.

f. Heaters can be switched ON only if both condenser fans are OFF. 2.2 PRECOOLING PROCEDURE

1. Place 63A change over switch in the AC control panel on external position.

2. Switch ‘ON’ one of the AC plant preferably NPP side when the external power supply is not extended to battery charger.

3. Connect Female socket end to the coach and male socket end to the pre-cooling socket.

4. Switch ‘ON’ the MCCB at Pre-cooling male socket.

5. Ensure the 3-Ph supply in the AC control panel and switch ON the other AC plant through inverter only.

6. Ensure that centre zero ammeter reads charging Amperes depending upon battery condition.



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2.3 TEMPORARY CONNECTION 2.3.1 DC-DC Feed Extension Procedure

A. From Power Panel to Power Panel (RMPU)

1. Switch OFF AC plants before extending TC from DC Power Panel to DC Power Panel.

2. Remove 250A inverter +VE, -VE fuses in the power panel for one of the inverter supply.

3. Extend the DC supply from (2514 or 2513) terminals of power panel of healthy coach to terminals of (2514 or 2513) power panel of defective coach with 2 core 35 sq. mm copper cable as shown in the figures.

4. Remove the battery fuse of the defective coach.

5. After ensuring through feeding connections, re-insert the 250A fuses of the inverters in both the healthy and defective coaches.

6. Switch on AC plant by balancing the load on both coaches to avoid over loading of healthy coach alternators and batteries.

B. Power Panel to/from AC Control Panel (U/S Type)

1. Switch OFF AC plants before extending TC from DC Control Panel to DC Power Panel.

2. Remove 250A Inverter +VE, -VE fuses in the power panel for one of the inverter supply.

3. Extend the DC supply from (2514 or 2513) terminals of power panel of healthy/defective coach to terminals (B +VE, B -VE) of control panel of defective/healthy coach with 2 core 35 sq. mm copper cable as shown in the figures.

Healthy RMPU Coach Failed RMPU coach



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4. Remove the battery fuse of the defective coach.

5. After ensuring through feeding connections, ensure no switch is in ON condition then re-insert the 250A fuses of the inverters in both the healthy and defective coaches.

6. Switch on AC plant by balancing the load on both coaches to avoid over loading of healthy coach alternators and batteries.

2.3.2 Through Feeding Procedure (Non-Ac Coaches)

Actions to be take in healthy coach

1. The availability of power supply in the emergency fed terminal should be ensured.

2. Only one dark coach should be extended feed supply from one healthy coach.

3. Before connecting, the polarity of healthy coach as well as dark coach should be checked.

4. L-II circuit of the healthy coach shall be switched off before connecting supply to the dark coach.

5. The rotary switch (socket parreling main) SPM I & II shall be kept in ON position.

Actions to be take in defective coach and feed extension

1. The earth fault shall be checked with the help of test lamp. If earth fault is there then feed extension should not be done.

2. The rotary switch (socket parrelling main) SPM I&II shall be kept in ON position.

3. Remove (+ve) fuse from battery box and (-ve) fuse from main junction box to disconnect the power supply of battery.

4. L-II & fan circuits of the dark coach shall be switched off before connecting supply from healthy coach.

5. The feeding shall be given to L-I circuit only of the dark coach from healthy coach.

Healthy RMPUCoach Failed U/S coach

ROOF JUNCTION BOX

L1 RSW L2 RSW Fan RSW SPM RSW

16A L1 16A L2 HRC HRC

16A Fan 16A SPM 35A -VE HRC HRC HRC

+VE, -VE EFT Terminals



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6. The defective coach shall be attended and feed cable should be removed at the first available opportunity by TL staff.

7. The size of cables for feed extension shall be of 16 mm2 PVC aluminum/ 2.5 mm2 elastomeric cable/ 2.5 mm2 e-beam copper cable.

8. The length of the wire for feed extension shall be 2 x 1.5 meter (for both terminals).

9. Both ends of the cable shall be provided with suitable size of lug.

10. The cables shall be secured tightly by screws or bolts, nuts and plain washer. The proper tightness of the connections should be ensured.

2.3.3 Through Feeding when AC Coach is in Between Two TL Coaches

1. Switch off the SPM RSW in healthy coach.

2. Remove –VE fuse in failed TL coach and switch off Lights and fans.

3. Extend the TC from healthy coach EFT to AC coach EFT.

4. Ensure the connectivity of the EFT cables on both ends of the AC coach.

5. Extend TC from the other end of the AC coach EFT to failed TL coach EFT.

6. Before switching on the SPM RSW, Switch off L2 circuit in the healthy coach.

7. Switch on SPM RSW and ensure the availability of supply in Roof Junction box of failed TL coach.

8. Switch ‘ON’ L1 circuit and Fan circuit in the failed TL coach.

9. Always remember that when extending TC from one coach to other coach, switch off L2 circuit in both the coaches to avoid over loading of alternator of the healthy coach.

2.4 WORK TO BE CARRIED OUT ON REACHING THE DESTINATION

1. The failures which occurred during the outward journey should be reported at the destination to the officials in charge in a written statement and obtain acknowledgement from them. Also ensure that the failures have been attended.

2. Ensure that arrangements are made for charging the coach during stabling at the

destination station. 3. On return to the headquarters, escorting staff will handover the coach to the

platform electrical staff in all respects along with the logbook. In case of any equipment failure or unusual occurrence, it should be reported to the SE/JE in person and submit a detailed report of the problems and explain them besides making entry in the logbook before breaking off duty.

Healthy TL Coach

AC COACH

Defective TL Coach.

TC TC



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2.5 PREFORMA FOR A.C. COACHES LOG BOOK (As per RDSO TC No. RDSO/PE/AC/TC/0004-2010(Rev.0) dt 24.06.2010 issued vide RDSO letter No. El/7.2.1 dt. 19.07.2010)

COACH HISTORY SHEET

Railways:

A. COACH PARTICULARS

Coach Sr No

Coach manufacturer

Year of manufacture

POH done date and place

POH due date

Coach type SG/EOG/LHB/underslung

Remark

B. EQUIPMENT DETAILS (EX- POH)

S.No. Equipments Make and Sr no. of equipment

PP Side NPP 1 AC plant-

RMPU/under-slung

2 Compressor

3 Blower motor

4 Cond. motor

5 Control panel RMPU/ under-slung Power panel

6 Thermostat

7 Alternator

8 Pre-cooling Socket

9 I.V. coupler

10 25 KVA inverter

11 ERRU/RRU

12 V-belts

13 60/50 KVA transformer

14 3 KVA transformer

15 Battery(make/lug date)

16 Pre-cooling transformer

17 Fire extinguishers

18 Emergency Light

C. EQUIPMENT REPLACED/REPAIRED IN BETWEEN POH TO POH

Date of replacement Equipment replaced Make and Sr no. of equipment provided

Reason for replacement

PP side NPP side

D. TELEPHONE/CUG MOBILE NO. OF IMPORTANT AC/TL DEPOT

Depot CUG No. BSNL Land line Railways Auto Phone number



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E. INSTRUCTION TO ESCORTING STAFF

Sr No Instruction

1. Appear in uniform & name badge

2. Join duty one hour in advance from train departure

3. Be cautious about un-claimed/Baggage /Luggage

4. Check working of AC plant/light/fans & reading lights etc.

5. Check cleanliness of compartment

6. Keep doors closed during run & open at station when train is stopped

7. Keep panel shutter closed with latches already provided

8. Carry following

a) Standard tool kit box

b) Pre-cooling cable

c) Emergency feed cable

9. Use fire extinguisher in case of fire

10. Open emergency window in case of emergency.

11. Trouble shoot line failure immediately

12. Communicate line failures & Non-AC etc to base depot immediately

13. Communicate line failures, non-AC etc to destination depot immediately

14 Fill log book details properly

F. 16 POINT ACTION PLAN ON MAINTENANCE OF AC COACHES. (Railway Board letter No. 97/Elec.(G)/180/7 dated 2.9.1999)

1. CESEs of Railways to interact with their counterparts in other Railways to advise the unusual occurrences and obtain feed back.

2. All the Ac coaches to be pre-cooled before placement of rakes on platform. This is the time when passengers require maximum and immediate comfort level. Pre-cooling cum emergency leads should be provided in all SG AC coaches (1 in each coach) and power cars (2 in each power car).

3. No train to leave the Primary Depot with EFTs or equipments in isolated condition.

4. Defects in the coaches to be noticed immediately after arrival of train and remedial action taken accordingly. Escorting staff should report at secondary maintenance depot and advise the status of coach and should sign the register with Depot and Depot staff to sign the Log Book with Escorting Staff.

5. All AC coaches from Primary depot should go with both Alternators working. If an Alternator cannot be replaced/repaired at the secondary maintenance depot, decision to send coach with one Alternator to be taken at officer’s level. Second Alternator to be fully functional with full generation and the coach/rake to be properly pre-cooled.

6. Ac coaches should go from Primary Depot with 6+6 belts on the Alternators and minimum 5+5 from Secondary Depot. Adequate facilities to be built up for changing the belt on rake itself.

7. The knowledge of all the ACCIs & ACCAs should be checked regularly regarding operation of the AC coach equipment as well as handling of the situation in case of failure of the equipment. ACCIs /ACCAs MUST maintain the log book and enter all the unusual occurrences. Training of AC staff of one week duration to be standardized by the Railways.

8. Drive system for generation testing and Regulator setting to be introduced for alternators at all Primary Depots.

9. Unit Exchange Spares (UES) should be available in all despots. Each depot should have authorized holding of UES. Register should be available for each major UES at all the depots.

10. All the major depots should carry out failure analysis of major equipments and the information should be sent to RDSO periodically.



14

11. The power supply system for pre-cooling to be augmented in view the increasing number of AC coaches in the depots. Railways to examine and take corrective action.

12. Railways to revise their EACs (Estimated Annual Consumption) of the material because of increasing AC Coach holding.

13. Cleating of alternator field and phase wires to be properly checked at primary depot.

14. Full load and no load voltage of each cell of SMF batteries to be recorded (weeded out weak cell) every month for subsequent 3 months and if there is no abnormal variation in voltage, it should thereafter be recorded once in 3 months.

15. Working of thermostat should be monitored and recorded in log book. If thermostat is not found in working condition, the same should be attended/ replaced by primary depot.

16. Working of WRA/ Monoblock pump should be checked on arrival of train at primary/secondary depot and its working should be ensured before placement of rake at the platform.

G. LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF

(Circulated vide RDSO letter No. EL/7.2.2 dated 17.01.2006)

S.No. Description Qty

1. Tool box of size 325x440x120 mm (Approx.) with fixing arrangement for tools and locking arrangement with 2 no. keys

1 set

2. Screw driver set with 8 nos of blade similar to Jhalani P. No. 830 or equivalent

1 set

3. Combination plier insulated with thick CA sleeve with joint cutter length 205 mm

1

4. Digital multimeter 1

5. T spanner of sizes 10, 13, 15, 17 1

6. Panel key square type ¼ size suitable for opening of control panel of AC coaches

1

7. Key for opening fittings of AC coaches 1

8. Test lamp holder (brass) fitted with two mtrs. of 2 core flexible copper wire 1

9. Torch, cells (+2 cell spare) 1

10. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 16/17, 18/19, 20/22

1 set

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

12. Heavy duty cable cutting knife adjustable in aluminium casing over all size 140 mm

1

13. Adjustable spanner length 255 mm 1

14. Thermometer digital 1

15. Nose plier 6” 1

16. Tongue tester A.C. (0-100 A) 1

17. Hammer ½ kg 1

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

19. Insulating tap 1

20. Wire fuse 1



15

H. COACH MONITORING LOG SHEET FOR AC COACHES (TO BE FILLED BY ESCORTING STAFF) RMPU type coach

Date------------ Originating/Destination Station------------- Train No. ------------------- AC coach Mechanic (Name /Design) ………….Attendant (Name/Designation) ------ No load voltage ---

1) Every two hour following details are to be filled

a) Status of battery, alternator , inverter and Temperature

Time Battery Voltage

(ON Load)

Alternator Current(A)

Battery current (A)(+ /-)

Inverter-1 Inverter-2 Temp at return air grill/Electronic

thermostat display

Alt.1 Alt.2 A V I V I PP NPP

b) WRA Switching (Use WRAs alternately)

Time 0600-1200

1200-1800

1800-2400

0000-0600

0600-1200

1200-1800

1800-2400

WRA-1

WRA-2

2) Record all line failures and unusual as under

S.No. Date Time Section Clearing Time

Brief details of unusual

Signature of escorting staff with date & time



16

I. COACH MONITORING LOG SHEET FOR AC COACHES (TO BE FILLED BY ESCORTING STAFF) Under-slung AC coaches

Date------------ Originating/Destination Station------------- Train No. ------------------- AC coach Mechanic (Name /Design) …………. Attendant (Name/Designation) ------ No load voltage –

1. Every two hour following details are to be filled Status of battery, alternator ,inverter,

Temperature

Time Battery Voltage

(ON Load)

Alternator Current(A)

Battery current (A)(+ /-)

Pressure (PP) Pressure (NPP) Temp at return air grill/Electronic thermostat display

Alt.1 Alt.2 LP HP OP LP HP OP PP NPP

2. Record all line failures and unusual/public complaint on TL&AC system as under

S.No. Date Time Section Clearing Time Brief details of unusual

Signature of escorting staff with date & time



17

J. FORMAT FOR MAINTENANCE LOG SHEET FOR AC COACHES (Primary/Secondary Maintenance)

Date ----------- Originating/Destination station --------------- Train No. ------------- From ------------ To -----------

Following checks to be done:

Sr No

Item to be checked Arrival condition of coach

Departure condition of coach

PP side NPP side PP side NPP side

1 Temperature (to be taken at Return air grill)

2 Working of RMPU in Auto mode

3 Condition of AC control panel of RMPU

4 Current of compressors

5 Current of condenser motor

6 Current of Blower motor

7 Condition of inverter

8 WRA working

9 Refrigerant pressures (for under slung AC caches

10 Alternator suspension bush /pin

11 Nos. of V-Belts

V-Belt Tension (Tight/loose)

Vane Relay

Lap top/mobile charger Available working Available working

12 Earth leakage Yes/No Yes/No

13 Test working of emergency light 1 2 3 4 1 2 3 4

14 Battery box condition/welding/tightening of fastners

Box-1 Box 2 Box-1 Box 2

15 Battery No load voltage

Full load voltage

No load voltage

Full load voltage

16 SPG of pilot cells 2nd 55th 2nd 55th

17 Availability of cable Pre-cooling Emergency feed

Pre-cooling Emergency feed

Note : Depot mechanic shall ensure the implementation of all the SMIs and modifications issued by RDSO

during primary maintenance. No coach should be given in service until all SMIs & modification sheets are complied for the coach.

BRIEF DESCRIPTION OF MAINTENANCE CARRIED OUT

1.

2.

3.

4.

Name/Designation & Signature of supervisor with date & time



18

CHAPTER 3

DISASTER MANAGEMENT

3.0 DUTIES OF ELECTRICAL ESCORTING STAFF IN CASE OF EMERGENCY

In the event of accident/ disaster, escorting staff shall contact train

conductor/guard and shall be ready for any type of help and same should be informed to electrical controller.

3.1 DERAILMENT/ COLLISION (INCLUDING LEVEL CROSSING ACCIDENTS)

Immediately check lights in the coaches and provide light in dark coaches.

Provide light at accident site.

Take necessary actions as a man of common prudence will take not only to help the stranded passengers but also to arrange such helps as would be demanded by the circumstances.

Help in extricating the trapped passengers/bodies. 3.2 FIRE IN TRAIN

Immediately isolate the affected coach/coaches electrically.

Use fire extinguisher to extinguish fire to the extent possible.

Immediately check lights in the coaches and provide light in dark coaches.



Help in extricating the trapped passengers/bodies.

3.3 CYCLONE/STORM/ FLOOD

Immediately isolate the affected coach/coaches electrically.

Shall immediately check lights in the coaches and provide light in dark coaches.



Help in extricating the trapped passengers/bodies.

3.4 REPORTED BOMB IN TRAIN

Immediately isolate the coach in which the bomb has been reported with assistance from C&W staff/Division.

Immediately check lights in all the coaches including non-AC coaches and provide light in dark coaches.

Immediately isolate the power cars in case of Rajdhani/ Shatabdi trains.



19

Help the passengers in moving out from the coach.

Open/ break the emergency window of affected coach.


3.5 EXPLOSION OF BOMB IN A TRAIN

Immediately isolate the coach/ coaches electrically.

Use fire extinguisher to extinguish fire.

Immediately check lights in all the coaches and provide light in dark coaches.

Help in extricating the trapped passengers / bodies.

Open emergency / break the window of affected coach.

Inform the passenger of other coaches to evacuate to avoid the possibility of casualty due to bomb explosion in other coaches.

Take such necessary actions as a man of common prudence will take not only to help the stranded passengers but also to arrange such helps as would be demanded by the circumstances.

3.6 EXPLOSION OF BOMB IS REPORTED IN A FIXED INSTALLATION

Shall immediately inform the Electrical control/TPC/PPIO through Walkie Talkie or Telephone about the presence of bomb to arrange assistance.

While communicating the incidence to ASM/Control definitely indicate the requirement of fire brigade.

Use fire extinguisher to extinguish fire to the extent possible.

Isolate the electrical equipment/ fitting in the vicinity of affected area immediately to avoid spread of fire before the main supply gets affected and get switched off.

Help in extricating the trapped occupants/ dead bodies if any.

Provide adequate lighting at accident site.

Take such necessary actions as a man of common prudence will take not only to help the stranded passengers but also to arrange such helps as would be demanded by the circumstances.

3.7. OPERATION OF FIRE EXTINGUISHERS

1. Update knowledge on fire extinguisher types and operating them.

2. Do not become panic when coach catches fire.

3. Remove the seal & clamp of the fire extinguishers.

4. Find out the base of the fire.

5. Hold the nozzle and aim towards near to the base of the fire.

6. Hit the operating knob and ensure that the powder is sprayed properly.

7. Ensure the fire is totally extinguished and it is cooled.

8. After extinguishing fire, isolate the fired equipment from the circuit.

Clamp



20

3.8 ELECTRIC SHOCK

Electric shock occurs when an electric current flows through the body. The human body is made up of 60% to 70% water. This makes it a good conductor of electricity. Burns, damage to internal organs, heart rhythm problems, and death can result from electric shock.

What to do when a person received an electric shock:

1. Switch off the current, if possible, by removing the fuse or switching off the circuit breaker

2. Do not touch/ remove the victim from the electric source until the power source has been shut off.

3. Separate the person from the source of electric current using a dry broom handle or other type of non-conducting material such as wood or rubber.

4. Do not touch the victim with your bare hands, as electric current will pass through you as well.

5. Let his head be slightly lower than the rest of the body, and raise his legs.

6. Inform TTE/conductor and call any Doctor, if available in the coach/train to attend the injured person. Inform this incidence to electrical control.



21

CHAPTER 4

TROUBLE SHOOTING

4.0 TROUBLE SHOOTING INSTRUCTIONS FOR RMPU AC COACHES 4.1 NO GENERATION 4.1.1 At Power Panel

1. RSW 1 in Power panel should be on Alternator1, 2 & battery position.

2. Check the incoming and out going supply at

RSW1. If RSW1 defective/ burnt, by pass it and incoming +VE’s of alt1, alt2 & battery to be connected to incoming of RSW2.

4.1.2 At Alternator

1. Ensure the availability of V-belts.

2. Check the continuity of field & phase windings at alternator terminals for open/ short circuit fault with multimeter and earth fault with megger of suitable range.

3. If the coach was in ideal condition for a long time, to gain the residual magnetism, check the field winding of alternator with 110V DC in series with test lamp of 25W/ 40W.

RSW1 in power panel

Alt1 incoming +VE

Alt2 incoming +VE

Battery +VE

Axle pulley

25 KW alternator

V-belts Tention devise device

V-belts

Field wiresPhase wires



22

4.1.3 At RRU/ ERRU

1. Check the condition of OVP. If it is in tripped condition, reset it.

2. Check and ensure the availability of 110V DC in RRU/ ERRU at DC +VE, -VE terminals.

3. Check the condition of field fuse and its tightness.

4. Check the condition of HRC field fuses (6 Amps) & main fuse (160 Amps) in the RRU/ ERRU. Replace them, if blown out.

5. Check the continuity of field & phase windings for open circuit with multimeter.

6. Excite the field separately. If not succeeded, give external excitation to alternator. 4.2 110 V DC LOW VOLTAGE 4.2.1 At RRU/ ERRU

1. Check continuity of field after disconnecting from ERRU field terminals

2. Check for any loose connections at field terminals. If loose, tighten them.

3. Check the condition of field fuse and its tightness. 4.2.2 At Battery

1. Check for loose connection at inter-cell connections and battery end connections. If loose, tighten them by torque wrench only at recommended torque.

2. Record OFF load/ ON load voltages of each cell. If any cell found reverse/dead, bypass them.

3. Even though if the voltage is not improved, provide TC from the adjacent coach DC-DC supply.

OVP Reset button

Universal Voltage controller

Capacitor

HRC Main Fuse 160A

HRC Field Fuse 6,10A



23

4.3 INVERTER NOT WORKING

4.3.1 At Power Panel 1. Check for availability of supply at incoming and outgoing terminals of RSW2 in

power panel and check the position, it should be in INV 1&2 position.

2. Check the condition of RSW2. If found defective, bypass it.

3. Check the 400A, 250A HRC fuses in power panel. If blown out, replace them.

4.3.2 At Inverter 1. Check and ensure the availability of input 110 V DC

supply at the inverter MCCB.

2. Check 350A HRC fuses and replace if blown out.

3. Check 4A glass fuses in 24V control circuit of

inverter. Replace it, if blown out.

4. Check the condition of Earth Leakage Detector (ELD). If it is in tripped condition, reset it. If ELD is not holding, check for earth leakage in the coach. If ELD is found defective, bypass it by connecting wire on terminal 18 to terminal 20 of ELD (On board type Siemens).

HRC Fuses in power

Input to Inverter MCCB

350A HRC Fuse

4A Glass Fuse

18

20



24

4.4 INVERTER TRIPPING ON “ON LOAD”

4.4.1 At AC Control Panel

1. Switch off all MCBs of blower, condensers, compressors, heaters in the control panel (MCB-1 to MCB-6).

2. Switch ‘ON’ the inverter again. If the inverter is working on OFF load, switch ‘ON’ the AC plant equipment MCB’s one after other as following:

a. Switch ‘ON’ blower MCB-1. If inverter not tripped, switch ‘ON’ condenser motor-1 MCB-2.

b. If inverter not tripped, switch ‘ON’ condenser motor-2 MCB-3.

c. If inverter not tripped, switch ‘ON’ compressor-1 MCB-4.

d. If inverter not tripped, switch ‘ON’ compressor -2 MCB-5.

3. Switch ‘OFF’ faulty equipment MCB on which the inverter trips.

4.5 INVERTER TRIPPED ON “OFF LOAD”

1. Check for fault indication in the inverter panel.

2. Check for short circuit/ earthing of power cables between Inverter output and AC control panel terminals.

3. If no fault is found, then give message to next major station for necessary attention.

4. Set on emergency mode and use three compressors only.

4.6 INVERTER TRIPPING ON STABLING

1. Check the individual cell condition. Isolate/ bypass the defective cells.

2. Check the input DC voltage at inverter. It should not be

less than 90V to avoid input under voltage fault.

3. Even though the voltage is not improved, provide TC from the adjacent coach as per

para 2.3.

MCB-1 MCB-7

RSW1 Electronic thermostat

415/110 T/F

Main MCB

Over load-1

RSW-5

+VE terminal -VE terminal



25

4.7 AC PLANT NOT WORKING 4.7.1 Power Indication LED Not Glowing

Check the following at control panel:

1. Check the position of 63A changeover switch. It should be

in Inverter position and ensure the availability of three phase supply at incoming and outgoing terminals of Change over. If found defective, bypass it.

2. Check the healthy condition and availability of 3-phase supply at incoming and outgoing terminals (361,362,363) of 63A RSW1 and 63A Main MCB (358,359,360). If found defective, bypass it.

3. Check the working condition and availability of control supply at incoming (358,359) and outgoing (370,371) terminals of MCB-8 of 415/110V AC control transformer. If supply is not available, extend the supply from bus bar to the control transformer bypassing MCB-8 and record in the logbook for further rectification.

4. Check control transformer, if found defective extend the control supply either from 110V AC fans or adjacent coach AC control panel temporarily.

5. Check working condition of MCB-9 at incoming (36,100) and out going terminals (10,100).

6. Ensure availability of control supply on RSW2 at terminal (10, 12). If found defective, bypass it.

Note: In case of SG AC coaches, control supply to MCB-8 shall be given from two

phases directly from inverter to TC-1 & 2 instead of bus bar.

O/P MCB -9 for T/F

I/P MCB-8 for T/F

Control T/F

Main MCB 63A

RSW1

63 A CHANGE OVER SWITCH



26

4.7.2 Blower Motor Not Working (a) Red light of over load ‘ON’

Check the following at control panel:

1. Check MCB-1 and ensure supply voltage of 415V

AC, 3- Ph at outgoing terminals of MCB-1 (343,344,345). If found defective, bypass it.

2. Check Over load relay (OL-1) a. If it is in tripped condition, check the over load setting (2.1 to 3.1A) and

reset it. b. Check the supply from RSW2 to Blower OLP

NC point wire No.12 and out going wire No.13. If supply not available at wire No.13, short 12 & 13 wires.

Note: Before bypassing OL-1, ensure the 3-ph supply

is available at T1, T2, T3 terminals of blower motor to avoid single phasing.

3. Check the incoming (322, 323, 324) and out going (301, 302, 303) terminals of blower contactor C1. If found defective, bypass it.

4. Check ‘NO’ interlock of Auxiliary contactor (AC-1).

If found defective, bypass by shorting 18, 19 terminals.

Check the following at blower:

1. Check availability of the supply at T1, T2, T3 power terminals of blower.

2. Rotate the blower by hand to check for any jammed bearing or loose blower runners on the shaft.

Note: If blower motor is still not working and it seems to be defective, give message to next major station for necessary attention.

MCB-1

MCB-1

AUXILARY CONTACTOR (AC-1)

18

19

12 13

OVER LOAD RELAY



27

(b) Air loss indication red LED glowing

1. If blower is ON but indication LED not glowing, check as per para (a).

2. Check the direction of rotation of blower motor, if it is rotating in reverse direction, inter change any two phases of T1, T2, T3 (301, 302, 303) power terminals.

3. Check Vane Relay flapper/ switch contact/ connection. If found defective, bypass Vane Relay by shorting 44, 46 control terminals.

Note: Before shorting Vane Relay terminals, ensure that blower is rotating in right direction. Put off MCBs of Heater circuit.

4. Check whether the fresh and return air filters are not clogged. If clogged, clean the filters. Note: Put a handkerchief or paper at return air

grill inside the coach. If it is sucked, it means that the blower is running in correct direction.

(c) Auto/ Manual Indication LED not glowing if mode selector RSW-3 is put to their

respective position

1. If air loss indication LED is glowing, check the cause of air loss as per para (b).

2. Check the condition of RSW-3 incoming supply at wire No.19 and out going wire No. 23 for cooling mode and wire No. 24 for heating mode. If supply not available at 23, 24 wires, short 19, 23 for cooling and 19, 24 for heating.

(d) Cooling Indication LED not glowing in Manual/ Auto mode.

If air loss indication RED LED is glowing when RSW-3 is in manual/ Auto mode, check causes of air loss and take remedial action as per para (b) above.

Air sucking position

RETURN AIR GRILL

INDICATION PANEL

RSW2

RSW3

Short 44, 46 terminals

Control Terminal block in AC PANEL



28

4.7.3 Condenser Motors Not Working

CD1 or CD2 over load indication RED LED glowing when RSW3 is on cooling mode

1. When cooling indication LED is not glowing in manual/ auto mode, then take remedial action as per para 4.7.2 (b).

2. Check mode selections switch RSW3 as per para 4.7.2 (c).

3. Check over load relay (OL-2, OL-3).

a. Check the incoming supply from wire No.23 and 40 at heater contactor (C6). If found defective, bypass it (by shorting 23 & 40).

Note: Heater MCBs should not be kept ‘ON’ while bypassing.

b. If OL-2 and OL-3 are in tripped condition, check the over load setting (1.7 to 2.1A) and reset it.

c. If OL-2 and OL-3 are found defective, bypass them by shorting 40 with 41 and 40 with 43.

Note: Before bypassing OL-2 and OL-3, ensure 3-ph supply is available at T4,

T5, T6 for CD1 and T7, T8, T9 for CD2 terminals of condenser motors to avoid single phasing and measure the load current taken by the condenser motor in each phase.

4. Check MCB-2 & MCB-3 and

ensure supply voltage of 415V AC, 3- ph at outgoing terminals of MCB-2 (346, 347, 348) of CD-1 and MCB3 (349, 350, 351) of CD-2. If found defective, bypass it.

5. Check supply at the incoming terminals of contactor (C2) (325, 326, 327) of CD-1, contactor (C3) (328, 329, 330) of CD-2 and out going terminals of contactor (C2) (304, 305, 306) of CD-1, contactor (C3) (307, 308, 309) of CD2 respectively. If found defective, bypass them.

OL-2 OL-3 AC CONTROL PANEL

C6 Contactor

C2 Contactor

MCB-2

MCB-3

AC CONTROL PANEL

C3 Contactor



29

4.7.4 Compressors Not Working

a Compressor-1/ 2 over load red indication LED glowing

1. Ensure both the condenser motors are working. If not, refer para 4.7.3.

2. Check output at TDR 1 &TDR2

3. Check the working condition of RSW5. If it is defective, bypass it. If supply not available, check the continuity of wire No. 48 at outgoing terminal of RSW5 from C2, C3 contactors.

4. Check over load relays (OL-4, OL-5). If i. They are in tripped condition, check the over load setting (7A -12.5 A)

and reset it. ii. OL-4 and OL-5 are found defective; bypass them by shorting 52 with

54 and 63 with 65.

Note: Before bypassing OL-4 and OL-5, ensure 3-ph supply is available at T10, T11, T12 for CP1 and T13, T14, T15 for CP2 terminals of compressors to avoid single phasing and measure the load taken by the compressors in each phase.

5. Check MCB-4 & MCB-5 and ensure supply voltage of 415V AC, 3- ph at

outgoing terminals of MCB-4 (352, 353, 354) of CP-1 and MCB-5 (355, 356, 357) of CP-2. If found defective, bypass it.

6. Check the incoming terminals of contactor (C4) (331, 332, 333) of CP-1, contactor (C5) (334, 335, 336) of CP-2 and out going terminals of contactor (C4) (310,311,312) of CP-1, contactor (C5) (313, 314, 315) of CP2 respectively. If found defective, bypass the contactors.

RSW5

AC CONTROL PANEL

C5Contactor

C4 Contactor OL-5 OL-4

AC CONTROL PANEL

C5Contactor C4 Contactor

MCB-5 MCB-4



30

(b) HP1 or HP2 red LED glowing

1. Check the working condition of the condenser motors as per para 4. 7.3.

2. Check the condition of HP1/ HP2 cutout switches. If tripped, reset it manually.(Setting 415 PSI)

(c) LP1 or LP2 red LED glowing

1. Check and clean wire mesh 2. Check the load of respective compressors with clip on meter. If current drawn

is less than 6.5 Amps, replenish gas where ever possible.

3. Ensure that return air filters are clean.

4. Check and ensure that all the grills are in open condition.

5. Check the direction of rotation of blower as per para 4.7.2 (b).

6. Check LP1 or LP2. If defective, bypass by shorting 29, 31 for LP1 and 35, 37 for LP2.

4.8 ALL EQUIPMENT ARE NOT WORKING IN STATIONARY CONDITION

1. Ensure the position of RSW1 in Alternator-I/ Alternator-II/ battery position. If it is found defective, bypass it by looping B, Y, R phases to cable 361, 362, and 363 respectively.

2. Check the battery fuses. If blown out, replace it.

3. Check the inter-cell connectors of battery for open circuit.

4. Check the battery fuse bases for tightness.

5. Check the continuity of Battery +VE, -VE cables in the power panel extending from the under-gear junction box.

4.9 WRA/ MONOBLOCK MOTORS NOT WORKING

4.9.1 AC WRA/ Monoblock Motor

1. Check for availability of 3-ph supply at

inverter selector RSW3. If supply not available on output side of RSW3, bypass it.

RSW for WRA Selection

RSW for WRA Selection

Inter cell connector

400 A Battery fuse

AT BATTERY



31

2. Check the incoming (4151, 4152, 4153) and outgoing (4157, 4158, 4159) terminals of MCCB and ensure availability of 3-ph supply. If found defective, bypass it.

3. Check for availability of 3-ph supply at inverter selector RSW7. If supply not available on output side, bypass it.

4. If MCB trips again due to internal fault of the motor, change the position of RSW7 to the another motor.

Note: WRA motors are working but water not

coming in the toilets, release the air lock by pressing flush-out valve in the toilets. Ensure proper tightness of the water filling pipe caps.

4.10 ALTERNATOR SEPARATE EXCITATION PROCEDURE

1. Remove the existing field wires (F +VE, F -VE) at RRU/ ERRU terminal block before extending the separate excitation.

2. Ensure continuity of the alternator field wires with millimeter and healthiness of power diode.

3. Extend 6 cell connections (12V supply) from battery as follows:

a. Connect the wire from first cell positive terminal to alternator field +VE terminal duly providing switch control in between at main door handle, for switching OFF the separate excitation while stabling.

b. Connect 9th cell –VE terminal to alternator field -VE terminal.

c. Incoming supply to extension terminal from RRU/ERRU shall be disconnected.

WRA Overload contactor cum MCB

ON button

OFF button

POWER PANEL

Flushout Valve

Field -VE

Field +VE

RRU/ERRU

+VE of first cell

-VE Cell of 9th cell

1100 AH BATTERY



32

4.11 TROUBLE SHOOTING INSTRUCTIONS FOR NON AC COACHES

S.N. Failure Cause Action to be taken

1. Coach is dark (Lights and fans not working)

Loose contact in rotary switches

Check and attend the defective rotary switch.

HRC Fuses of 16Amps (for L1, L2 & Fans) and 35Amps negative may be blown in main junction box.

Replace fuses with 16 & 35 Amps fuse wires.

40 Amps battery fuses may be blown near battery box.

Check battery fuses. If found blown replace with 40Amps fuse wire.

No generation / belts missing.

Measure the voltage if found below 90V then remove the main –ve fuse from main junction box and then connect TC from the adjacent coach.

Cells defective ( Cells low voltage or/and reverse polarity)

Check the voltage if found below 90 volts then connect TC from the adjacent coach.

2. Coach lights and fans in burnt/ smoke condition & coach is in dark condition.

Over generation due to defective regulator.

Cut the regulator field +ve & -ve wires which are coming from alternator or remove negative main fuse link and battery fuse and then connect TC from adjacent coach.

3. Smoke in individual Fan/ Light

Burning of fans winding or inverter in FTL.

Disconnect supply wires to fans/lights.

4. Spark in junction boxes.

Loose fitment of HRC/ rewirable fuses in main/ distribution junction boxes.

Tightened or replace the fuses.

5. Smoke from battery box.

Cells sulphation. First extinguish smoke/ fire if found then remove battery +ve or –ve fuses and connect TC from adjacent coach.

Low water level or Dry cell

Cell container breakage

Loose connection

6. Belts smoke Alternator pulley jam Cut the belts and connect TC from Adjacent coach.



33

CHAPTER 5

DO’S AND DON’TS

5.1 GENERAL

5.1.1 Do’s

Do keep all the tools, gauges & instruments in working condition.

Do tighten nuts & bolts fully by applying proper torque.

Do keep all commonly used tools and gauges in a handy tool box.

Do ensure that in 3 phase supply system the neutral is available.

Do check continuity only by using series lights bulb of 100 W or higher rating and not with ohm-meter.

Do work with full confidence.

5.1.2 Don’ts

Don’t climb on roof of coach in electrified sections.

Don’t bypass safety devices.

Don’t wear loose clothes and chappals.

Don’t use defective tools, gauges and instruments.

Don’t use oversize/ improper tools.

Don’t apply unsafe method of working.

Don’t leave tools gauges & instruments at work place after completion of work.

Don’t leave nuts & screw/bolts half tighten.

Don’t use nuts & bolts having different pitches together.

Don’t apply excessive pressure for tightening the nuts, bolts & screws.

Don’t use Fork lift, lift package unit from top through hooks only.

Under no circumstances the plant should be run in manual mode for prolonged period of time and without supervision of a qualified technician.

Don’t allow the refrigerant gas to escape to the atmosphere.

Don’t use refrigeration compressor for pulling a vacuum.



34

5.2 IN CASE OF BURNS

5.2.1 Do’s

Do pour cold water immediately on the burn till the burning sensation stops.

Do keep an ice or cold water pack on the burn.

Do make the person roll on the floor, if his clothes catch fire.

Do protect burn from dust, dirt, flies, etc. Cover it with a thin and light cotton cloth.

Do immediately get the help of doctor, if the burn is severe.

5.2.2 Don’ts

Don’t apply any ointment on the burn.

Don’t cover the burn with thick cloth.

Don’t wrap a blanket around a person whose clothes have caught fire.

Don’t tie a cloth tightly. Don’t use a dirty cloth.

Don’t get the help from an unqualified person.

5.3 IN CASE OF HEAD INJURY/ BLEEDING NOSE

5.3.1 Do’s

Do Make the victim lie down with his head in a lower position than the body

Do pour cold water on the victim’s head.

Do put a cold pack on the nose.


5.3.2 Don’ts

Don’t put a pillow under the victim’s head.

Don’t allow victim to put finger in his nose.

Don’t allow victim to blow his nose too often.


5.4 IN CASE OF TRAUMA

5.4.1 Do’s

Do make the victim lie down in a cool place

Do keep an ice or cold water pack on the head of victim

Do Give water or juice to drink to the victim.


5.4.2 Don’ts

Don’t crowd around the victim.

Don’t cover the victim with any cloth, especially woolen cloth.

Don’t give hot tea or coffee to the victim.




35

5.5. IN CASE OF INJURIES

5.5.1 Do’s

Do make the victim lie down in a cool place

Do wash the wounds with clean water & then clean the wounds with an antiseptic solution.

Do give sufficient support to the affected area in case of sprains or tear in muscles.


5.5.2 Don’ts

Don’t crowd around the victim

Don’t apply any oily or greasy ointments

Don’t massage the affected area

Don’t get the help from an unqualified person

5.6 IN CASE OF 25 KW ERRUs

5.6.1 Do’s

Do always connect same make of ERRU with same make CIP (Coach Indication Panel)

Do keep rotary switch on CIP, in normal position i.e. both ERRUs working.

Do changes switch position in case ERRU-1/ ERRU-2 fails, accordingly for emergency mode i.e. control circuit of healthy ERRU will drive both ERRUs. This can be done when train is stationary.

Do check ERRU status before changing the switch position, if OVP is tripped, then reset it.

Do reset CIP and old data cleared, if ERRU is fitted first time in coach. Do ensure the correct parameter set.

Do use only correct rating of HRC fuse i.e. 6A, 10A, 16A and 160A.

Do use controlled supply with maximum output limited to 130V while charging the coach battery with external charger.

Do check connection polarity after attention or replacement; ensure correct setting through the display panel.

5.6.2 Don’ts

Don’t change the rotary switch position while alternators are running.

Don’t reset ERRU, if OVP is tripping repeatedly.

Don’t by-pass the OVP and fuse.

Don’t disturb the setting of ERRUs.

Don’t test the ERRU without connecting battery after installing in coach.

Don’t touch control IGBT with naked hands.



36

5.7 IN CASE OF 4.5 KW ERRUs

5.7.1 Do’s

Do make separate connection for DC+, BC+ and DC-, BC- in case of 4.5 kW ERRU whereas 25kW ERRU, BC+ shall be used in power panel.

Do reset display unit and old data cleared, if ERRU is fitted first time in coach.

Do use only correct rating of HRC fuses i.e. 6A, 10A and 32A.

Do use controlled supply with maximum output limited to 130V while charging the coach battery with external charger.

Do check connection polarity after attention or replacement.

5.7.2 Don’ts

Don’t connect/ short DC+ and BC+ in 4.5 kW ERRU

Don’t reset, if OVP is tripping repeatedly.

Don’t by-pass the OVP and fuse.

Don’t disturb the setting of ERRUs.

Don’t touch control IGBT with naked hands.



37

APPENDIX-A

TECHNICAL KNOW-HOW 1.0 BRIEF DESCRIPTION OF ELECTRICAL COACHING

Based on the type of generation, there are two systems adopted over IR. These are Self Generating System (SG) & End On Generation System (EOG). However, efforts are being done for adoption of more efficient, more economical and more reliable Head On Generation System (HOG).

1.1 SELF GENERATING SYSTEM

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, 3Ø, which is rectified and regulated by Rectifier cum Regulator Units (RRU). 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.

RRU/ ERRU

FIELDWINDING

BATTERY BOX

+-

TO COACH LOAD

1.2 END ON GENERATING SYSTEM

End on generation system envisages equipping of luggage cum brake vans in front and rear end of rake & coaches in between them. Presently on IR three types of coaches are being in use as per voltage i.e. 415 V, 750 V & dual Volt 415 V coaches are available in low capacity rakes, these coaches are not equipped with 50 kVA step down transformer & rating of Inter vehicular coupler of these coaches is lower therefore in future all coaches will be converted into 750 V, 3 Φ AC by equipping 50 kVA step down transformer. Dual volt & 750 V coaches are equipped with 50 kVA step down transformers for stepping down 750 V, 3 Φ AC, 4 wire, 50 Hz supply to 415 V, 3 Φ AC, 4 wire, 50 Hz supply. Supply to entire rake is fed through two feeders running on both sides of coaches along length of rake. Generator cars take entire load of rake, which includes air conditioning unit, light/fan circuit, emergency battery charger circuit and pantry equipments. This system is used for Air Conditioned coaches of Rajdhani/ Shatabdi/ Duronto/ Garib Rath trains.



38

ALT. ALT. ALT. ALT.

GENERATOR CAR

GENERATOR CAR

FEEDER - I

FEEDER - IICOACHESCOACHES

750 V, 3 Ø FEEDER

415 V, 3 Ø 50/60kVA TRANSFORMER 415 V, 3 Ø

LIGHTING TRANSFORMER

110 V, 3 Ø LIGHTING LOAD

ACLOAD

COACH SUPPLY

1.3 TYPES OF COACHES WORKING WITH SG SYSTEM

Under slung type AC coaches

Roof Mounted Package Unit type AC coaches

Non AC coaches 1.3.1 Under slung type SGAC coaches

These coaches are also called conventional type SGAC coaches. These coaches are equipped with following equipment:

SN Equipment Rating Qty/ Coach

1st AC Others

1 Alternator 130 V DC, 18/22.75 kW 1 2

2 RRU 130 V DC, 18/22.75 kW 1 2

3 Battery 800 Ah Low maintenance Lead Acid 56 cells #

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

5 Compressor ACCEL/ Carrier 1 2

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 HP DC motor 2

# Now for better reliability 1100 Ah VRLA batteries are being retrofitted.



39

1.3.2 Roof Mounted Package Unit type SGAC coaches

These coaches are also called RMPU type SGAC coaches. These coaches are equipped with following equipment:


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 1x(6+6) 2x(6+6)

5 Sealed Compressor 3 Ø, 415 V AC 2 4

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

7 Blower Motor 1 HP, 3 Ø, 415 V AC 1 2

8 Condenser Coil Roof Mounted 2 4


10 Heater Unit 3 Ø, 415 V AC, 3 kW 2 4

11 WRA/ Monoblock Pump

3 Ø, 415 V AC, 1 HP 2

12 Inverter Input: 110V DC, 25 kW

Output: 3 Ø, 415 V AC 1 2

1.3.3 Non AC coaches

These coaches are equipped with following equipment:


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

2 RRU/

ERRU

120 V, 37.5 A DC, 4.5 kW

1

3 Battery 120 Ah, 6V VRLA or 120 Ah, 6 V Monoblock

57 cells or 19 Mono blocks, VRLA/ 54 cells or 18 monoblock LMLA

4 V-belt C-122 4



40

1.4 TYPES OF COACHES WORKING WITH EOG SYSTEM

Under slung type AC coaches

Roof Mounted Package Unit type AC coaches

LHB type AC coaches

Generator Cars

AC Pantry Cars 1.4.1 Under slung type EOG AC Coaches

These coaches are also called conventional type EOG AC coaches. These coaches are equipped with following equipment:


1st AC Others

1 Step down Transformer 3 Ø, 750 V AC/ 415V AC, 50kVA 1

2 Battery 120 Ah, 6V Monoblock, Lead Acid 4 Monoblocks

3 Compressor ACCEL 1 2

4 Compressor Motor 15 HP, 415V, 3 Ø, AC 1 2

5 Condenser Motor 1.5 HP, 415V, 3 Ø, AC 2 4

6 Blower Motor 1 HP, 415V, 3 Ø, AC 1 2

7 Condenser Coil Under slung 1 2


9 Heater Unit 415V, 3 Ø, AC, 6 kW 1 2


1 HP, 415V, 3 Ø, AC 2

11 Emergency Battery Charger

Input: 415V, 3 Ø, AC

Output: 24 V DC 1

12 Lighting Transformer Input: 415V, 3 Ø, AC

Output: 110 V, 3 Ø, AC 1

1.4.2 Roof Mounted Package Unit type EOG AC Coaches

These coaches are also called RMPU type EOG AC coaches. These coaches are equipped with following equipment:


1st AC Others

1 Step down Transformer 3 Ø, 750 V AC/ 415V AC, 50kVA 1

2 Battery 120 Ah, 6V Monoblock, Lead Acid 4 Mono blocks

3 Sealed Compressor 3 Ø, 415 V AC 2 4



41


1st AC Others

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

5 Blower Motor 1 HP, 3 Ø, 415 V AC 1 2

6 Condenser Coil Roof Mounted 1 2


8 Heater Unit 3 Ø, 415 V AC, 3 kW 2 4


3 Ø, 415 V AC, 1 HP 2

10 Emergency Battery Charger

Input: 415V, 3 Ø, AC

Output: 24 V DC 1

11 Lighting Transformer Input: 415V, 3 Ø, AC

Output: 110 V, 3 Ø, AC 1



42

APPENDIX-B ELECTRICAL CIRCUITS

1. AC POWER CIRCUIT

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.

RSW -1

RO

YO

BO

63A

415

V A

C 3

Ph.

50 H

z I

N C

OM

ING

363

362

361

MCB63A

360

359

358

R

Y

B

MCB-1

6A345344343

324323322

OL-1 C1

6A303302301

BLOW ERMOTOR

R Y B

MCB-2

6A348

347346

327

326325

OL-2 C2

6A306

305304

COND-1MOTOR

360359358

360

359358

MCB-3

6A351

350349

330

329328

OL-3 C3

6A309

308307

COND-2MOTOR

360

359358

MCB-4

32A354

353352

333

332331

OL-4 C4

32A312

311310

COMP-1MOTOR

360

359358

MCB-5

32A357

356355

336

335334

OL-5 C5

32A315

314313

COMP-2MOTOR

360

359358

MCB-6

16A339

338337

C6

16A318

317316

360

359358

HEATER-1&

HEATER-2

MCB-7

2A360359358

CC-HTR 1

CC-HTR 2

MCB-8

359358

2A

TRANSFORMERTO CONTROL

R Y B

CABLE SPECIFICATION

S.No. SIZE (SQ.MM) SYMBOL USED

1. 1.5

2. 2.5

3. 6.0

4. 16.0

371370

FIRST FERRULE No. 301LAST FERRULE No. 371

FERRULE Nos. NOT USED340,341,342,364 TO 369.

TC2

TC1

TO CONTROL CIRCUITMCB-8

1. IF SEPARATE FILTERED CONTROL SUPPLY OF415V AC FROM INVERTER IS AVAILABLE THECONTROL CIRCUIT (MCB-8) W ILL BE CONNECTEDTO TC1 & TC2 INSTEAD OF BUS BAR.

2. MULTI STRAND ELASTOMERIC CABLES CONFIRMING TO RDSO SPEC. NO. E-14/1 PART-1 (REV.II) FEB. 1993 SHALL BE USED FOR POW ER CIRCUIT.

POW ER W IRING DIAGRAMFLC-RLY-000101/CP/DATED: 04/08/98 (REV 1)

BU

S B

AR

321320319



43

2. AC CONTROL WIRING CIRCUIT

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.

AUTO

1

1212

4412

110 V AC

FROM SHEET NO.2

415 V AC

NO

TE

:-1.

A

LL C

AB

LES

FO

R I

ND

ICA

TIO

N L

IGH

TS

SH

ALL

BE

PT

FE

OF

1.0

SQ

. MM

SIZ

E.

2. A

LL C

AB

LES

FO

R C

ON

TR

OL

CIR

CU

IT S

HA

LL B

E P

TF

E O

F 1

.5 S

Q. M

M S

IZE

.

FIR

ST

FE

RR

ULE

No.

...1

0LA

ST

FE

RR

ULE

No.

.....

100

FE

RR

ULE

No.

11,

20,

37

TO

99

NO

T U

SE

D

100

371

AIR LOSS

BLOWER ON

BLOWER O/L TRIP

AUXILARYCONTACTOR

BLOWER MOTORCONTACTOR

POWER ON

100

100

C1

PCB

R

13

1

O/L

-1

100

100

AC

1

R

PCB

G

100

PCB

R

1514

23

C-1

1716

45

VR-2

46

VR-1

45

21

3637

0M

CB

420

RS

W-2

1. V

EN

T2.

AU

TO

3. M

AN

UA

L C

OO

LIN

G4.

MA

NU

AL

HE

AT

ING

C-1

AC

-1

HEATING

COOLING

MANUAL

100

GG

GG

67

2223

b

8

24b

25

TO

S

HE

ET

No.

4

ELE

CT

RO

NIC

T

HE

RM

OS

TA

T

RS

W -

3

141

23

4

2

23

4

3

24 23

24a

23a

TO

S

HE

ET

No.

4

HR

CR

TO

ELE

CT

RO

NIC

TIM

ED

ELA

Y R

ELA

Y(E

TD

R)

PO

WE

R

SU

PP

LY

SE

NS

OR

TO

BE

LO

CA

TE

DA

T R

ET

UR

N A

IR P

AT

H IN

RM

PU

1011

1819

A1

B1



44

COND.1CONTACTOR

COND.1 O/L

COND.2CONTACTOR

COND.2 O/L

COND.1 ON

COMP.1CONTACTOR

COMP.1 O/L

LP 1

HP 1

COMP.1BYPASS

COMP.2CONTACTOR

COMP.2 O/L

LP 2

HP 2

COMP.2 BYPASS

COMP.1 ON

COMP.2 ON

COND.2 ON

HEATER CONTACTOR

OHP 2 TRIP

OHP 1 TRIP

HEATER ON

FROM SHEET NO. 324 23

C2

C3

C6

C3

C2

O/L

-2O

/L-3

C-2

C-3

4040

4040

4143

4546

42

44

910

111

2

PCB

PCB

RG

RG

C2

C3

PCB

100

100

100

100

NN

NN

N

48

49

T26

T27

T2

9

T3

1

T28 T3

0

51 5257

54

55

1314

151

617

1819

20

2122

2324

25

PCB

PCB

PCB

RR

RR

RR

RR

RR

GG

G

1

2

31

2

3

ab

48T

38

T3

9

T41 T42

T4

0

T43

62

61

63

65

65

6670

6869

71

4848 C4

C5

72

73

8282

82

C6

84

85

C6

C5

C4

NO

TE

:1.

F

IRS

T F

ER

RU

LE

No

. 40

& L

AS

T F

ER

RU

LE

No

. 10

0.

2.

FE

RR

UL

E N

o. N

OT

US

ED

- 4

7, 5

0, 5

3, 5

6,

64,

67,

74 T

O 8

1, 8

5, 8

8 T

O 9

9.3.

R

-RE

D L

ED

IN

DIC

AT

OR

& G

-GR

EE

N L

ED

IND

ICA

TO

R4

. C

AB

LE

SIZ

E F

OR

ALL

IND

ICA

TIO

N L

IGH

TS

SH

AL

L B

E P

TF

E O

F 1

SQ

.MM

.5.

C

AB

LE S

IZE

FO

R C

ON

TR

OL

CIR

CU

IT S

HA

LL B

E P

TF

E O

F S

IZE

1.5

SQ

.MM

.

1.

BO

TH

CO

MP

RE

SS

OR

ON

.2

. C

OM

PR

ES

SO

R-1

BY

PA

SS

3.

CO

MP

RE

SS

OR

-2 B

YP

AS

S

RS

W-5

ET

DR

N1

Ph

1

Ph N

N1

Ph

1

HP

1

LP1

O/L

-4

54

5960

58

T3

2T

34

T3

3

T3

5

T3

7

T3

6

HP

2

LP

2

O/L

-5

66

N

OH

P-1

83

OH

P-1

86

87

ET

DR

FR

OM

S

HE

ET

N

O.3{

FR

OM

S

HE

ET

N

O.3{



45

Control & Power Terminal Block Diagram of AC Panel

(A )

(B )

(C )

(D )

(E)

(F)

(G )

(H )

(J)

(K )

(L)

(M )

(N )

(P)

(R )

(S)

(T )

(U )

(V )

(W )

(X )

(Z)

(g )

(h )

(j)

(k )

(m )

(n )

(p )

(A )

(B )

(C )

(D )

(E)

(F)

(G )

(H )

(J)

(K )

(L)

(M )

(N )

(P)

(R )

(S)

(T )

(U )

(V )

(W )

(X )

(Z)

(g)

(h)

( j)

(k )

(m )

(n)

(p)

26

27

28

F R O M H P1 C O M M O N

N .C .

N .O .

29

30

31

FR O M LP 1 C O M M O N

N .C .

N .O .

32

33

34

F R O M H P2 C O M M O N

N .C .

N .O .

35

36

37

FR O M LP 2 C O M M O N

N .C .

N .O .

38

39

40

FR O M O H P1 C O M M O N

N .C .

N .O .

41

42

43

FR O M O H P2 C O M M O N

N .C .

N .O .

44

45

46

FR O M V R C O M M O N

N .C .

N .O .

47

48

49

FR O M C O O L IN G C O M M O N

M ED

H IG H

T H E R M O STA T L O W

50

51

52

53

FR O M H E A T L IN G C O M M O N

M ED

H IG H

T H E R M O STA T L O W

54

2 6

2 7

2 8

2 9

3 0

3 1

3 2

3 3

3 4

3 5

3 6

3 7

3 8

3 9

4 0

4 1

4 2

4 3

4 4

4 5

4 6

4 7

4 8

4 9

5 0

5 1

5 2

5 3

5 4

T -26

T -27

T -28

T -29

T -30

T -31

T -32

T -33

T -34

T -35

T -36

T -37

T -38

T -39

T -40

T -41

T -42

T -43

T -44

T -45

T -46

T -47

T -48

T -49

T -50

T -51

T -52

T -53

T -54

49

59

51

58

52

61

71

62

69

63

82

83

84

82

86

87

12

17

16

31

27

28

29

35

32

33

34

C O N T R O L T E R M IN A L S

C O N T R O LH A R N ESS

C IR C U L A R S H E L L C O N N EC TO R

C IR C U L A R SH E L L C O N N EC TO RO N P A C K A G E

C IR C U L A R SH E L L C O N N EC TO RO N C O N T R O L PA N EL

T E R M IN A L B LO C K S INC O N T R O L PA N EL

1

2

3

4

5

6

7

8

9

1 0

1 1

1 2

1 3

1 4

1 5

1 6

1 7

1 9

2 0

2 1

2 2

2 3

2 4

2 5

1

2

3

FR O M B L O W ERM O T O R

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

P O W E R T E R M IN A L SPO W ERH A R N ESS

T ER M IN A L B L O C K S N O .

1 8

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

19

20

21

22

23

24

25

18

T -1

T -2

T -3

T -4

T -5

T -6

T -7

T -8

T -9

T -10

T -11

T -12

T -13

T -14

T -15

T -16

T -17

T -19

T -20

T -21

T -22

T -23

T -24

T -25

T -18

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

321

364

366

365

320

T E R M IN A L B LO C K S INA .C P A C K A G E U N ITS

T E R M IN A L B LO C K S INC O N T R O L PA N EL

FR O M C O N D . 1M O T O R

FR O M C O N D . 2M O T O R

FR O M C O M P. 1M O T O R

FR O M C O M P. 2M O T O R

FR O M H E A T ER -1

FR O M H E A T ER -2

F R O M C P -1 C R A N KC A SE H E A TER

F R O M C P -2 C R A N KC A SE H E A TER

V A N E R E L A Y B Y PA S S : SH O R T 44 , 46 .

H P 1 B Y PA S S : S H O R T 26, 27 .

H P 2 B Y P A S S : S H O R T 32, 33 .

L P1 B Y P A SS : SH O R T 29 , 31 .

L P2 B Y P A SS : SH O R T 35 , 37 .

N O T E :



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3. SCHEMATIC DIAGRAM OF POWER PANEL

FROM TB 7 RS W3

R1, Y1, B1

R2, Y2, B2TB2

MPCB

MCB

4151, 4152

RSW7

4157,41584159

PUMP1U,V,W

PUMP2U1,V1,W1

TOTB 8

XR

4154,4155

4156

221,222

223

191,192193,N

TOTB 1

FROM TB 1

191,192193, N

MCB

RSW4

194,195196

197,198199

MCB

MCB

MCB

FR1

FY1

FB1

TOTB 1

N

VOLTMETER

1814FROMTB 3

263 262FROMTB 4

BATTAMMETER

FROM 500A SHUNT

19 201

TO TB 4

700

TB 4FROM

RC

L1

706

RC

L2

707

1 &

370

1

702

FS

L

2 &

4F

SL

TO CL2

RSW-1500A

17

117

19

26 RSW-2300A

261

400A

26

250A

2614

250A

2613

TO

IN

V2

+(D

P)

TO

IN

V1

+(D

P)

TOTB4

19

1911717

17

TO ALT-1

AMMETR

201

FR

OM

U/F

16

16

TO ALT-2AMMETR

TOTB 5

FR

OM

U/F

116

FR

OM

U/F

19

FR

OM

U/F

201

250A

181

250A

181

TO

IN

V2

+(D

P)

TO

IN

V1

+(D

P)

250A

18

TO

40A

MC

BF

RO

M U

/F

- VeT

OVR

ALT-1

16 17

ALT-2

116

117

262,

181

4 3

,4,4

a,5

FROM TB6

16,17,116,117

FROM SHUNT

RSW-6(FL)

300

330

TO6A MCB

FROM 40AMCB

26

RSW-6(IC, L)

26

500

700

TO MCB (+10A)

2611

2612

1814 / VM18 0 2.5A

702.5A

SP5A

18115A

11825A

180310A

180410A

1840A

2640A

70010A

50010A

3305A

3005A

SP5A

72.5A

FROM TB 42.5A

18

TO RSW 5

PAIL

VM 262TO TB 4

SP

L1

L2

IC1

IC2

TO

TB

3F

RO

MR

SW

6

FROM TB 4

FR

OM

RS

W 5

TO

TB

4

4153

N

SCHEMATIC DIAGRAM FOR POWER PANEL

4. SPECIFICATIONS OF EQUIPMENT ( SG )

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



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RRU/ERRU

Capacity : 18/25kW

Voltage : 130V+/-5 % V DC

Current : 18 kW – 140A DC Max 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 AC plant 1&2 supply (U/S) : 160Amps

Transformer for fans, mobile/laptop charging : 2 kVA, 415V/ 110V AC.



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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

5. SPECIFICATIONS OF RMPU EQUIPMENT

Compressor

Make : Maneurop/Compelend scroll Maneurop/Compelend scroll

Power consumption : 5250 W +/- 20 % depending on ambient temperature

5250 W +/- 20 % depending on ambient temperature

Current : 8.5A+/- 25% at 415VAC 3-phase 50Hz depending on Ambient temperature

8.5A+/- 25% at 415VAC 3-phase 50Hz depending on Ambient temperature

Power factor : 0.85 0.85

C.F.M.(Displacement) : 12.033 C.F.M, R-22 Vapour 12.033 C.F.M, R-22 Vapour

Volume : 117.65 CC/Revolution 117.65 CC/Revolution

Evaporator Motor

Type : Centrifugal type Centrifugal type

Diameter : 10” (250mm) 11” (280mm)



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Air flow (CFM) : 4200 Cu.Mtr/Hr+/-10% at 20 mm water guage

4000 Cu.Mtr/Hr at 20 mm water guage

Pressure (External Static)

: 25 mm Minimum water guage 25 mm Minimum water guage

Speed : 1415+/- 10% RPM 1400+/- 10% RPM

Capacity : 1.5 HP 1.5 HP

Current : 2.6A +/-10% at 415 VAC 3-Ph, 50Hz.

2.6A +/-10% at 415 VAC 3-Ph, 50Hz.

Condenser Fans

Diameter : 24” 21”

Air flow : 4000 x 2 (6800 Cu.Mtr/Hr x 2) at 7mm static.

3825 x 2 (13000 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 Ph 50Hz.

2.2A+/- 10% x2 at 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 circuit

R-22 less than 3.0 kg each circuit

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

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



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REFERENCES

1. Technical circular for standardization of logbook for AC coaches.

No. RDSO/ PE/ AC/ TC/ 0004-2010 (Rev.0) dt 24.06.2010 issued vide RDSO letter No. El/7.2.1 dt. 19.07.2010

2. 16 Point action plan on maintenance of AC coaches. Railway Board letter No. 97/Elec.(G)/180/7 dated 2.9.1999.

3. Trouble shooting directories received from East Coast Railway vide letter no. ECoR/ EL/G/460/05/3554 dt. 18.11.2009.

4. Operating instructions to AC coach accompanying technicians received from Southern Railway vide letter no. E.227/XX/20 dt. 27.10.2009.

5. Installation, operation, trouble shooting and maintenance manual of M/s Sidwal for RMPU AC coaches.

6. Comments received from Sr. DEE/ P/ Ratlam vide letter no. EL 254/ 123/ 3 dt. 19.07.2010.

7. Comments received from Southern Railway HQ vide letter no. E.227/XX/20 dt. 07.09.2010.

8. Comments received from Sr. DEE/ G/ Mughalsarai, ECR vide letter no. MGS/ EL/G/197/ACC dt. 23.06.2010.

9. Comments received from Northern Railway HQ vide letter no. 3-Elect/1/ TL/ CAMTECH/ Pt-I dt. 14.09.2010.

10. Presentations given by participants from various Railways during seminar conducted on 09-Sep 2010 at CAMTECH.



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To upgrade maintenance technologies and methodologies and achieve improvement in productivity, performance of all Railway assets and manpower which inter-alia would cover reliability, availability, utilisation and efficiency.

OUR OBJECTIVE

If you have any suggestions and any specific Comments please write to us.

Contact person : Director (Elect.) Postal Address : Indian railways

Centre for Advanced Maintenance technology, Maharajpur, Gwalior. Pin code – 474 005

Phone : 0751 – 2470740

0751 – 2470803 Fax : 0751 – 2470841 E- mail : [email protected]

FOR TL & AC COACHES - Indian Railways

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