LHB AC Coach Maintenance Manual (2022) PDF

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS Revised (2022) ELECTRICAL September 2022 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches 11. LHB AC COACHES VERSION 1.1 IRCAMTECH/GWL/ELECT...

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS Revised (2022) ELECTRICAL September 2022 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches 11. LHB AC COACHES VERSION 1.1 IRCAMTECH/GWL/ELECT./2022-23/LHB Manual/1.1  LHB Maintenance Manual (Electrical) 11. LHB AC Coaches CONTENTS CHAPTER 11 LHB AC COACH........................................................................................ 1 11.1 Type of System..................................................................................................... 1 End on Generation (EOG) System........................................................................ 1 Head on Generation (HOG) System..................................................................... 1 11.2 LHB TYPE EOG/ HOG AC COACHES................................................................. 2 Classification of LHB AC Coaches........................................................................ 2 Codes of Different LHB Coaches over Indian Railways........................................ 3 11.3 Electrical SYSTEM IN AC Coaches...................................................................... 4 11.4 Power Supply........................................................................................................ 4 Step Down Transformer........................................................................................ 5 Regulated Cum Emergency Battery Charger........................................................ 5 Battery................................................................................................................. 14 Battery Fuse Box................................................................................................ 15 Switch-Board Cabinet- S1................................................................................... 16 11.5 Air-Conditioning.................................................................................................. 18 Roof mounted AC package unit.......................................................................... 18 Microprocessor Based Controller for RMPU....................................................... 25 11.6 Light Fittings........................................................................................................ 37 11.7 Water raising appratus (MONO-BLOCK PUMP SET)......................................... 39 11.8 Supply arrangement in switch board Cabinet (SBC)........................................... 39 Main feeding Supply (750 V 3 Phase AC supply system)................................... 39 Supply feeder from power CAR to Disconnecting & Earthing device in SBC...... 40 Supply feeder from Disconnecting & Earthing device in SBC to under sludge Transformer (60KVA).......................................................................................... 41 Local Main Supply............................................................................................... 42 415 V 3 Phase AC supply system....................................................................... 43 110V DC Supply................................................................................................. 49 Comparison of Specifications for switch board cabinet for LHB AC coaches...... 54 11.9 MICROPROCESSOR TERMINALS (SIDWAL/Liebherr MAKE)......................... 78 11.10 LSLRD COACH.................................................................................................. 78 Switch Board Cabinet for HOG compliant LSLRD Coach................................... 78 IRCAMTECH/GWL/ELECT./2022-23/LHB Manual/1.1  LHB Maintenance Manual (Electrical) 11. LHB AC Coaches LIST OF FIGURES Figure 1: End ON Generation System................................................................................. 1 Figure 2: Block diagram (Head ON Generation System)..................................................... 2 Figure 3: Power supply diagram (Head ON Generation System)........................................ 2 Figure 4: Type of LHB EOG Coaches.................................................................................. 3 Figure 5: Electrical Features of LHB EOG Coaches............................................................ 3 Figure 6: Regulated Cum Emergency Battery Charger (External Front View).................... 6 Figure 7:RBC cum EBC Layout (Exterior – Front)............................................................... 8 Figure 8:Power Section (Front side).................................................................................... 9 Figure 9:Power Section (RBC and EBC)............................................................................. 9 Figure 10:Control and Power Section................................................................................ 10 Figure 11: Output Section (Upper Side)............................................................................. 10 Figure 12: Input and Output Section.................................................................................. 10 Figure 13:RBC cum EBC Interior –Connection Terminals................................................. 11 Figure 14: Magnetics Section............................................................................................. 11 Figure 15:Heat Sinks......................................................................................................... 12 Figure 16: Cover Gaskets for Ingress Protection............................................................... 12 Figure 17: Front LED Card................................................................................................. 13 Figure 18:Earthing Shunt................................................................................................... 13 Figure 19:Mounting Arrangement...................................................................................... 13 Figure 20:Single Line Diagram of 4.5 kW RBC with EBC.................................................. 13 Figure 21:Block Diagram of Regulated Battery Charger.................................................... 14 Figure 22: Block Diagram of Emergency Battery Charger................................................. 14 Figure 23: Battery Module Details...................................................................................... 15 Figure 24: Battery Fuse Box (-ve)...................................................................................... 15 Figure 25: Battery Fuse Box (+ve)..................................................................................... 16 Figure 26: Switch Board Cabinet- S1................................................................................. 16 Figure 27: Inside View of Switch Board............................................................................. 16 Figure 28: Switch Board View with Top Right Door Open.................................................. 17 Figure 29: Ventilation in Switch Board.............................................................................. 18 Figure 30: Indication and Controls on Left Side Door........................................................ 17 Figure 31: Modified Doors Arrangements.......................................................................... 17 Figure 32: Disconnecting and Earthing Device................................................................. 18 Figure 33: Compressors in RMPU..................................................................................... 20 Figure 34: Axle fans (Condenser Fans) along with motors in RMPU................................ 21 Figure 35: Condenser units in RMPU................................................................................ 21 Figure 36: Evaporators units in RMPU.............................................................................. 21 IRCAMTECH/GWL/ELECT./2022-23/LHB Manual/1.1  LHB Maintenance Manual (Electrical) 11. LHB AC Coaches Figure 37: Twin-sucking radial fans for the supply air in RMPU........................................ 21 Figure 38: Heating Unit in RMPU...................................................................................... 22 Figure 39: pressure transducers (pressure switches)....................................................... 22 Figure 40: Humidity sensor............................................................................................... 23 Figure 41: NTC type temperature sensor.......................................................................... 23 Figure 42: HP/ LP Cut Out (Cartridge type)....................................................................... 23 Figure 43: Overheat protector (Bimetallic type thermal switch)......................................... 23 Figure 44: Fresh Air Screens............................................................................................ 24 Figure 45: Control Panel for RMPU................................................................................... 25 Figure 46: Different type LED Fittings................................................................................ 38 Figure 47: Monoblock pump set......................................................................................... 39 Figure 48: Power Supply Flow Chart from Main feeding supply to Transformer Outgoing. 40 Figure 49: Power CAR to Disconnecting & Earthing device power supply circuit diagram 41 Figure 50: Disconnecting & Earthing device to under sludge Transformer power supply circuit diagram................................................................................................... 41 Figure 51: Local Main Supply Circuit Diagram................................................................... 42 Figure 52: 415V AC Supply Block diagram........................................................................ 43 Figure 53: Exhaust Fan power supply circuit diagram....................................................... 44 Figure 54: Air-Conditioning Unit-1 power supply circuit diagram....................................... 44 Figure 55:Air-Conditioning Unit-2 Power Supply Circuit Diagram...................................... 45 Figure 56: Pantry Equipment Power Supply Circuit Diagram............................................. 47 Figure 57: Water Pump Circuit Power Supply Circuit Diagram.......................................... 47 Figure 58: Laptop/Mobile Charging Sockets & Insulation Control Relay Power Supply Circuit Diagram................................................................................................. 48 Figure 59: REBC Power Supply Circuit Diagram............................................................... 49 Figure 60:110V DC Power Supply Block Diagram............................................................ 50 Figure 61: Anti-Skid Device/Telephone (first class only)/DC/DC Converter/Power Supply/AEL Power Supply Circuit Diagram....................................................... 50 Figure 62: Coach Lighting Power Supply Circuit Diagram & Lighting Part in Panel........... 51 Figure 63: Diagnosis display/Emergency Brake system Power Supply Circuit Diagram... 52 Figure 64: AC Control Power Supply Circuit Diagram....................................................... 53 LIST OF TABLES Table 1: Detail of Electrical Equipment in LHB AC Coach Related to Power Supply...... 4 Table 2: Detail of 60KVA Transformer ()......................................................................... 5 Table 3: Technical details of 4.5 kW Regulated Battery Charger (RBC)......................... 6 Table 4: Technical details of 2.5Emergency Battery Charger (EBC).............................. 7 Table 5: Detail of RMPU............................................................................................... 19 IRCAMTECH/GWL/ELECT./2022-23/LHB Manual/1.1 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches CHAPTER 11 LHB AC COACH INTRODUCTION A passenger train is mainly consist of Locomotive, AC, NON-AC coaches, Pantry car etc. There are various Electrical equipment i.e. Exhaust fans, coach lighting, vestibule lighting, AC system, water pumps, in the coaches and other equipment’s like hot cases, bottle coolers, refrigerators, electric burners, insect killers, water filters, coach lightings, AC system etc. in the pantry car exist. Electrical power is required for running of all these electrical load i.e. hotel load. The following systems of supply of Electrical power are in use on Indian Railways: 1. Self Generation (SG) 2. End On Generation (EOG) 3. Head on Generation (HOG) Linke Hoffmann Bosch (LHB) Design Coaches: These are being presently manufactured by all production units of Indian Railways. Power supply for these coaches is generated by End On Generation (EOG) or Head on Generation (HOG) system. The LHB variant coaches based on EOG/HOG can be broadly classified as given below:- a) LHB AC Coach b) LHB NON-AC Coach c) Power CAR d) Pantry Car 11.1 TYPE OF SYSTEM End on Generation (EOG) System End on generation (EOG) system envisages providing power car in front and rear end of a rake for coaches for power requirement in between them. These coaches are equipped with 60 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. The 750V supply is fed to entire rake through two feeders running on both sides of coaches along the full length of rake. Power cars at both ends take entire load of whole rake, which includes air conditioning, light and fan circuit, and emergency battery charger circuit and pantry equipment. Each power car has two DG sets, out of which one DG set is standby. FEEDER - I ALT. ALT. ALT. ALT. COACHES COACHES FEEDER - II GENERATOR GENERATOR CAR CAR Figure 1: End ON Generation System Head on Generation (HOG) System In Electric locomotives, power is taken from the OHE through pantograph to traction transformer of the locomotive, which is provided with a hotel load winding of 2 x 622.5 kVA, at nominal voltage of 960 V single-phase, which shall vary with the OHE voltage variations. This 960 Volts single-phase supply is fed IRCAMTECH/GWL/ELECT/2022-23//LHB/Manual/1.1 Page 1 of 79 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches to Hotel Load Converter (capacity 2x500KVA i.e two units of 500KVA in each loco), which gives 750 Volts 3-phase 50 Hz supply as output, for feeding the hotel load of the train The system in which power is fed from the electric locomotive to the coaches to cater the Hotel Load is called HOG system. The supply flow for HOG system is as follow:- Figure 2: Block diagram (Head ON Generation System) The three phase output supply of the hotel load converter i.e. HOG system is transmitted to both the feeder of the existing EOG train through IV coupler. Figure 3: Power supply diagram (Head ON Generation System) 11.2 LHB TYPE EOG/ HOG AC COACHES Classification of LHB AC Coaches These new generation passenger coaches have better parameters of passenger comfort, safety and reliability. The End on Generation (EOG), Linke Hoffmann Bosch (LHB) variant AC coaches can be broadly classified into AC sleeper coaches and AC chair cars as given in figure. IRCAMTECH/GWL/ELECT/2022-23//LHB/Manual/1.1 Page 2 of 79 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches Figure 4: Type of LHB EOG Coaches Figure 5: Electrical Features of LHB EOG Coaches Codes of Different LHB Coaches over Indian Railways SN Code Type of SN Code Type of SN Code Type of coach coach coach 6 Executive 11 LS Second First AC LWFC AC chair Class 1 LWFAC EOG ZAC car EOG LHB LHB 7 AC Chair 12 LSC Second class AC 2 Tier LWSC 2 LWGACCW Car EOG N 3-tier sleeper SG LHB ZAC LHB IRCAMTECH/GWL/ELECT/2022-23//LHB/Manual/1.1 Page 3 of 79 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches 8 13 LWS Non AC AC 2 Tier AC LWCB CZ Chair 3 LWACCW EOG Pantry AC car LHB Car LHB 9 14 LWF EOG AC Generato AC 3 Tier LWLR CAC First Class 4 LWGACCN r Car SG LHB RM CW Cum Ac LHB Two Tire LHB Coach 10 AC 15 LSLR Second Double D Luggage, AC 3 Tier LWCZ Decker Guard & 5 LWACCN EOG DAC Chair Car Divyaang LHB EOG Compartme LHB nt 11.3 ELECTRICAL SYSTEM IN AC COACHES Electrical system in AC Coach consists of following part:  Power Supply  Air-Conditioning  Train Lighting  Water Supply arrangement 11.4 POWER SUPPLY The power supply system for the AC coach is being designed to feed the various electrical loads in the system operating at different voltage. Feeding of power supply for all these load to be executed through following items: Table 1: Detail of Electrical Equipment in LHB AC Coach Related to Power Supply S.N. Description of ITEM Specification Specification No. Issued by 1 60 KVA Step down RDSO/PE/SPEC/AC-0080- RDSO Transformer 2007(Rev.2) 2 4.5 kW Underslung Constant RDSO/PE/SPEC/AC/0183 RDSO Voltage, Regulated Cum (Rev.'1') - 2018 Emergency Battery Charger 3 12 V, 70 Ah VRLA battery RDSO/PE/SPEC/AC/0009-2014 RDSO (Rev.2) 4 Feeder Junction Box for LHB EDTS-328, REV-C, AM-5, CORR- RCF EOG AC/NAC Coaches with 1,2, TYPE II Bio-Toilet 5 Wheel Set Earthing EDTS-101, REV-C, AM-1, CORR- RCF Equipment for LHB Coaches 6, ANNEXURE-1 6 Switch Board Cabinet IRCAMTECH/GWL/ELECT/2022-23//LHB/Manual/1.1 Page 4 of 79 LHB Maintenance Manual (Electrical) 11. LHB AC Coaches (i ) Microprocessor based Smart RDSO letter for BOM RDSO switch Board Cabinet Standardization dated (MSSBC) for LHB EOG/HOG 17.09.2021, Control and Type AC Coaches Measuring Voltage Transformer Sources and letters, RDSO/ PE/ SPEC/ AC/0192-2018 Rev.1 (ii) Switch Board cabinet for RDSO/ PE/ SPEC/AC/0184- RDSO LHB EOG AC coaches 2015 (Rev.'1) dated 02.09.2019 (iii) Switch Board cabinet for LHB EDTS073,Rev-D,Amend.6 dated RCF type coaches 20.12.2012 Step Down Transformer EOG AC coaches/Power car/Pantry Car requires 750 V/415 V 3-phase dry type air-cooled power step down distribution transformer for coach power supply. Their capacity requirement is 60 KVA and these transformers are mounted underslung. Table 2: Detail of 60KVA Transformer () KVA Rating 60 KVA Nominal input voltage 3 Phase, 4 wire, 750 V ± 5% (line to line), 50Hz ±3%,THD