GM spec

EMD ELECTRICS

ADVANTAGES OF AC-TRACTION DRIVE OVER DC-TRACTION

ADVANTAGES OF AC-TRACTION DRIVE OVER DC-TRACTION

• Brushless Commutation, therefore AC traction motors practically maintenance free

• AC Traction Motor does not require high currents at low speed for heavy pull operation as for DC motor. Consequently much less heat builds up at low speed

• Overall size reduction of traction motor

• No contactors for reversing of direction

EMD LOCO BUILT AT DLW

WDG4 – 4000 HP –AC-AC WDP4 – 4000 HP –AC-AC WDP4 B– 4500 HP –AC-AC (Hotel load

facility)WDP4D – 4500 HP Dual cab

DTTC/SGUJ

WDG4

WDP4WDP4

LOCO COMPARISONLOCO COMPARISONDescription WDM2 WDG3A WDG4

Service Year 1962 1995 1999

No of stroke 4 4 2

No of cylinder 16 16 16

Piston stroke 10.5”/267mm 10.5”/267mm 11”/279.4 mm

Bore 9”/228 mm 9”/228 mm 9-1/16”/230.1 mm

Compression ratio 12.5 12.5 16

Wheel arrangement CO - CO CO - CO CO - CO

Max axle load 18.8 T 20.5 T 21 T

Gear ratio 18: 65 18: 74 17: 90

Wheel dia 1092/1016 1092/1016 1095/1016

Bogie Cast Fabricated HTSC cast

Loco series 16,17,18 14 12


Engine HP 2600 3100 4000

Engine RPM 1000/400 1050/400 904/269

Weight of loco 112.8 T 123 T 126 T

Adhesion 27% 33% 43%

Max speed 120KMPH 100KMPH 120KMPH

Length 17120 mm 19150 mm 21244 mm

Width 3010 mm 3016 mm 3073 mm

Height 4185 mm 4162 mm 4159 mm

Turbo supercharger Alco 720/ABB/NAP ABB/NAP/GE EMD “G” series

Governor GE/WW GE/WW WW

Fuel oil capacity 5000 L 6000 L 6000 L

Fuel injection system Through separate fuel injection pump and injector

Through separate fuel injection pump and injector

Directly injection by Unit injection

Lub oil capacity 910 L 1270 L 950 L


Booster pressure 1.8kg/cm2 1.97kg/cm2 2.2kg/cm2

Dynamic braking 19 T 21 T 27.5 T

SFC/gm/BHP/hr 156 155 151

Trip schedule 7 to 10 days 20 days 90 days

POH /M- 96 8 Years 8 Years 16 Years

Alternator TA-10102 EV TA-10102 EV TA-17

Alternator NLV 770V1100V3200A

1100V 2300V AC3000V DC1250 A

T M HP 300 300 670

Starting TE 30.4T 30.4T 52T


T / M ISOLATION Defective motor can be isolated

Defective motor can be isolated

Particular truck to be isolated

Brake system IRAB-1/28 LAV-1 IRAB-1/28 LAV-1 CCB, KNORR

Cooling water capacity

1210 L 1210 L 1045 L

Cooling Water System

One water pump, gear driven on radiator fan, Drive from ENGINE through ECC

One water pump, gear driven on radiator fan, Drive from ENGINE through ECC

Two water pump, gear driven, two radiator fan, drive from computer controlled Electric(AC) motors

Cranking Main generator Aux + exciter Two DC Starter motor

MAIN DIFFERENCE BETWEEN WDG4 & WDP4

SL NO. DESCRIPTION WDG4 WDP4

01 MODEL GT46MAC GT46PAC

02 SERVICE GOODS PASSENGERS

03 SPEED 120 KM/H 160 KM/H

04 WEIGHT 126 TONS 115.8 TONS

05 NO OF TRACTION MOTORS 06 04/06

06 UNDER TCC-1 1,2,3 TMS 1,2 TMS

07 UNDER TCC-2 4,5&6 TMS 5,6 TMS

08 GEAR RATIO 17:90 17:77

EMD LOCO LAYOUTEMD LOCO LAYOUT

1. LOCOMOTIVE• Model: GT46MAC G – Single Cab T – Turbo Charged 4- 16 Cylinders 6-710 Series Engine MAC- Modified AC Traction • Horse Power : 4000 HP• Input to Traction : 2780 KW (3726HP)• Dynamic Braking Effort : 27.5 Tonne

2. DIESEL ENGINE• Engine model : 710 G3B• Engine Type : Turbo charged ,Two Stroke Diesel Engine• Fuel injection system : Mechanical Unit Injectors• Cylinder Arrangement : 45° V shape• Crank Shaft Rotation : Counter clockwise (facing fly wheel end)• Max. Engine RPM(Full Speed) : 904 (8th notch)• Min. Engine RPM(Normal Idle Speed) : 269• Low Idle RPM(Speed) : 200• No of Cylinder : 16• Compression Ratio: 16:1• Displacement per Cylinder: 11635 cm3(710 Cu In)• Cylinder Bore: 230.19 mm(9-1/16”)• Cylinder Stroke: 279.4 mm(11”)• Engine Governor: Wood Ward Governor

3.Cooling System

Pump type : Centrifugal Pump capacity : 3785 Lts/Min RPM : 900 Fan Drive : AC Motor Fan Power : 44 KW (59 HP) Water Capacity : 1045 L

4. Bogie Model: HTSC Gear Ratio: 90:17 for MAC, 77:17 for PAC Driving Wheels: 3 Wheel Sets per bogie(truck) Diameter:1095mm(43 inches) Wheel Arrangement : CO-CO Maximum Axle Load : 21T Center Pivot : 1 Per TruckBRAKE RIGGING Type: Single Shoe 406.4 mm(16 inches) Shoe Material: Composite Cylinder Brake: 4 per bogie(truck)

5.Compressed Air System Air Brake System: Knorr CCB EquipmentAir Compressor : Gardener Denver / ELGI Model: WLNA9BB Type: Two Stage,3 Cylinder Coolant: Engine Coolant Displacement at 900 RPM: 7.19 M3/Min Lube Oil Capacity: 9.98 Liters Turbo – Supercharger : EMD “G” Series

6.Nominal Dimensions Height over Cooling Hood: 4.16

M(13’7.75”) Height over Horn: 4.22 M(13’.10”) Height over Cab: 3.94 M(12’.11”) Width over Hand Rails: 2.92 M(9’7.12”) Width over Underframe: 2.74 M(9’0”) Width over Cab: 2.74 M(9’0”) Width over Brake Cylinders: 3.07M(10’1”)

7. Locomotive Storage Battery Model :Surrete (Lead acid battery) Total Capacity of Cell : 32 PD of one cell : 2 Volt Total PD of battery : 64 Volt Capacity : 500 Amp-Hr

8. Capacities Lub oil capacity :950 L

Cooling system capacity : 1045 L

Sand boxes(8) capacity: 0.4m³

Fuel capacity: 6000L

Layout Of Electrical ComponentsLayout Of Electrical Components

POWER DISTRIBUTION

Main Electrical ComponentsMain Electrical Components• MAIN GENERATOR WITH RECTIFIER• COMPANION ALTERNATOR• AC AUXILIARY GENERATOR• INVERTER ( TCCs)• TRACTION MOTORs• ELECTRICAL CONTROL (#1) CABINET EQUIPMENT• ELECTRICAL CONTROL (#2) CABINET EQUIPMENT• ELECTRICAL CONTROL (#3) CABINET EQUIPMENT • CAB EQUIPMENT • DYNAMIC BRAKE GRID and BLOWER ASSEMBLY• RADIATOR COOLING FAN MOTORS • TURBO LUBE PUMP MOTOR /FUEL PUMP MOTOR• STARTING MOTORS AND SOLENOIDS • RADAR

TRACTION ALTERNATOR• Type-TA-17• Weight-8709 kgs.• No. of Brushes-06• No. of Poles- 10• Brush Size-54x32x13mm• Brush Pressure-1.50+/- 0.15kg.• Maximum Ring Eccentricity-

0.15mm• Maximum lateral ring run out-

0.8mm• Condemning limit of Ring outside

Dia.-60mm• The TA rotates at engine speed

generating AC power• TA Rectified Output : 600 to 2600

V DC from 1 notch to 8 notch (DCL Voltage)• Max. Continuous Current : 1250 A

COMPANION ALTERNATORCOMPANION ALTERNATOR• Model – CA6B• Output Voltage : 55 to 230 VAC• Max.Power : 250 KVA• Max Current: 600 A• Frequency at 904 RPM : 120 HZ• No. Of Pole-16• No. of C.Brush-04• Size of Brush- 9.53x19.05x55.56mm• Condemning Length: 38 mm• Wear Limit-19.05mm• Spring Pressure-0.68+/- 0.0668Kg• The companion alternator couples directly

to TA within the MG housing. It supplies current to excite the TA field & to give power to radiator cooling fan, traction inverter blowers etc

• CA rotor field is excited by AG supply of 74 V DC

AC AUXILIARY GENERATORAC AUXILIARY GENERATOR• Model:5A-8147• Rectified output ratings:18 KW (24

HP)• Rectified Nominal Voltage: 74

volts DC • 3phase- alternator and rectified

output• AG is driven by cam shaft at 3

times engine speed.AC power from the AG is supplied to 3 phase full wave rectifier in the battery charging system. Then it is converted into 74V DC for companion alternator, excitation control system & locomotive battery charging. It also supplies 74V DC power to fuel pump motor, lub oil pump motor, locomotive lighting etc.

Traction MotorsTraction Motors• Model: Siemens 1TB-

2622-0TA02• Quantity: 6 (3 in

parallel per bogie)• Type: 3 Phase AC

Induction, Axle Hung with tapered Roller Support Bearings, Forced Air Ventilated

• Nominal Ratings: 500 KW, 2027 VAC, 3220 RPM,200A AC

• Type-3-phase-AC Induction motors

Starting MotorsStarting Motors

• Two 64VDC motors• Both are

connected in parallel.

TCC ( Traction Control Converters TCC-1 & TCC-2)

TCC ( Traction Control Converters TCC-1 & TCC-2)

• Model: Siemens type1GE420 050 9010.00 MB74

• Quantity: 2 (one per bogie)

• Type: Voltage Source Inverter With Gate Turn-Off Thyristors

• Rating: 1430 KW

Technical Specification - TCCTechnical Specification - TCC Input Voltage 600V to 2600 V DC

Input current 580 A

Output Voltage 0V to 2000 V 3 phase AC Variable

Rated Current 900A

Frequency 0 Hz to 130 Hz variable

Gate Unit power supply 24 V DC

Ambient Temperature 0 degree C to 47 degree C

Dimensions 1840 x 1081 x 1450 mm

Weight 1420 Kg

Interface with EM2000 RS485

Port for Downloading RS232

ECC#1 Electrical control cabinet1 (HVC#1)

• It is situated on the back wall of the locomotive cab.

• It houses equipment that controls and powers the locomotive.

• It includes :• Circuit Breaker Panel , Engine

Control Panel, Locomotive Control Computer (EM 2000), Main Control Panel, Computer Power Supply, GTO Power Supply, Excitation Panel,4 Braking Contactors (B1to B4), Power Distribution Panel, Relays

ECC#2• This cabinet is mounted on the

right side of the locomotive, under the locomotive under frame, between the no.1 bogie and the fuel tank. It houses:

• Battery charging assembly• AUX GEN circuit breaker(250 A)

which supplies power to excite companion alternator field.

• Terminal Board for connecting ECC2 components to external system

ECC#3

• This cabinet is mounted on the right side of the locomotive, above the locomotive under frame, between the no.2 bogie and the radiator fan. It houses:

• Radiator cooling fans contractors

• Circuit breakers(300 A) for radiator fan

• Main reservoir pressure transducer

Radiator Cooling Fan• Two 52” cooling

fans (8 blades)• Cooling water

temperature between 79º C to 85º C

• Two Speed(8/16 pole) AC Induction Motors

RadarRadar• It is situated in the left

side of the engine near the truck no 2

• It senses the locomotive speed wrt ground and sends the speed signal to the speedometer in the driver cab.

Turbo Lub/Fuel Pump Motors

• It is a 3/4 HP, 1200 rpm AC motor which has inbuilt inverter to convert the 74 VDC supply into 3 phase 55 VAC.

No Of Cards Used In GM Locomotive• DIO- 300(Digital Input Output)- 3 nos. It acts as an

interface between locomotive 74 VDC control system & computer 54 VDC system.

• ADA- 305 (Analog to Digital & again analog)- 1 no. It handles analog input directly & converts them to digital signals for the computer. It is also responsible for converting digital signals from CPU to analog signal as required by receiving devices like TE Meter, Speedo Meter.

• CPM- 401 (CPU-302 + MEM-300) – 1no. CPU: It is the brain of EM 2000 which controls the total working of the locomotive. MEM: It stores fault data & operational data for locomotive operation.

• COM301(Communication)-1 no. It gives communication interface amongst EM 2000,TCC1,TCC2,KNORR air brake computer & event recorder.

EM-2000 Loco ControlEM-2000 Loco Control

• TROUBLE SHOOTING AND SELF DIAGNOSIS

• ALPHA NUMERIC DISPLAY ON SCREEN(IN WORD & DIGIT)

• ARCHIVE MEMORY AND DATA LOGGING

• RADAR BASED SLIP CONTROL SYSTEM

DTTC/SGUJ

ECP

Circuit breaker panel

EM-2000 screen

Event recorder

TCC Computers and cards

Circuit Breaker Panel

DTTC/SGUJ

Wind shield wiper

MR & ER Gauge

BP & BC gauge

Air flow Air flow indicatorindicator

speedometer

Tractive effort meter

Indicating light panel

Reversor & Throttle handle

Power/dynamic brake handle

Alertor

Auto direct brake

Brake Console-2

BATTERY KNIFE SWITCH

Classification light

EFCO

Dy.brake switch

TE LimitPrime/Start switch

Battery charging ammeter

Alerter alarm

Isolation/Run-switch

ECP

LOCOMOTIVE OPERATION

When the engine start switch is held in PRIME for 10 sec , the locomotive computer EM-2000 starts the fuel pump.

The fuel pump lifts fuel from the fuel tank to the fuel injectors , pressuring the injectors.

The engine can be started by holding START switch for 20 sec.

The locomotive computer initiates engine cranking by two starting motors.

Storage battery supplies current to the starting motors.

When the engine start switch is held in PRIME for 10 sec , the locomotive computer EM-2000 starts the fuel pump.

The fuel pump lifts fuel from the fuel tank to the fuel injectors , pressuring the injectors.

The engine can be started by holding START switch for 20 sec.

The locomotive computer initiates engine cranking by two starting motors.

Storage battery supplies current to the starting motors.

SAFETY AND PRECAUTION Perform the automatic DC link discharge as

follows : Through the locomotive computer (EM2000)

screen, make sure that both inverters, TCC1 and TCC2, are CUT IN.

Set the isolation switch in START/ STOP/ ISOLATE. EM2000 automatically connects the DC link across the dynamic brake grids, discharging the TCC1 and TCC2 input capacitors through the grids. After 10 seconds, the DC link can be considered discharged.

Perform the automatic DC link discharge as follows :

Through the locomotive computer (EM2000) screen, make sure that both inverters, TCC1 and TCC2, are CUT IN.

Set the isolation switch in START/ STOP/ ISOLATE. EM2000 automatically connects the DC link across the dynamic brake grids, discharging the TCC1 and TCC2 input capacitors through the grids. After 10 seconds, the DC link can be considered discharged.

WARNINGWARNING If a cut-out inverter cannot be cut in

because of a fault in the control system, shut down the engine and wait at least 40 minutes before inspecting or performing maintenance.

THANKS

GM spec

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