SELF GENERATING SYSTEM

1. SELF GENERATING SYSTEM

2. Self Generating System- Equipments • Alternator • RRU • Belt • Battery • Inverter (AC coach) • RMPU (AC coach) • Cable/wiring • Light and fans • Distribution, control and protection

4. Fuse cum Rotary Switch Panel

5. Emergency feed terminal

6. Carriage fan Swivel type DC fan BLDC fan

7. Carriage Fan Performance parameters

8. Carriage Fan • Major problems experienced • Abnormal noise (> 80 dB) and vibration • Abnormal sparking/ blackening of commutator • Abnormal wear rate of carbon brushes • Sluggish movement • Inadequate air delivery • Weak insulation (< 2 MΩ) • Aesthetic not pleasing • Poor power to weight ratio

9. Self Generating System- BLDC Fan (Spec RDSO/PE/SPEC/TL/0021/2005 Rev 1) • Principle of operation • Brush and commutator replaced by PM & electronic switching • PMs embedded in rotor • Position of rotor detected through hall effect sensors (flux transducers) • Stator windings switched through electronic controller • Construction features • PM ceramic/ferrite type with hardness of 700 HB • Body of fan deep drawn MS and of fan Al alloy LM-6 • Fan blade of FR plastic • Electronic components of industrial grade • IR > 20 Mohm • Performance parameters • Discharge: 60 m3/min , Power input : 32 W (max), Weight: 8 Kg (max) Noise level: 55 dBA (max) ,Service value : 2 m3/min/W (min)

10. BLDC fan

11. Self Generating System- Code of practice (RDSO spec no EL/TL/48) • Covers only Non-AC coaches • Two lighting circuits, emergency + 50% & other circuit • Circuits are protected by fuses on both sides • +ve and –ve circuits are segregated • Cables and equipments are colour coded • PM and fan +ve cables - Red • Light +ve cables - Yellow • Fan –ve cables - Black • All other –ve cables - Blue • Cable laid in PVC conduits in super structure and in metallic conduits under frame • Voltage drop not to exceed 3 volts for battery voltage of 108 • Bending radius of cable not to be less than 4D • Cables to be protected through cleats (<150 mm) & grommets • Cable ends to be provided with numbered ferrules • All equipments to be directly fitted on coach body

12. Self Generating System- Code of practice • Anti theft and fire prevention measures to be ensured • Cables not to have any joints • Lux levels • Ist ,2nd and pantry coaches- 30 • Postal compt -40 • SLR luggage compt -20 • Lav and corridor -16 • Degree of uniformity i.e ratio of lux in least favourable seat and avg lux level to be 1:1.3 • To be measured 840 (1500 in Lav) mm above FL and 500 mm from back of seat/in the centre • Toggle switches used for fan and light control • All coaches to be fitted with emergency lights and mobile charging sockets • Below EFT marking “ Switch off LII before connecting emergency coupler” • IR with 500 V megger not to be <2 M ohm • Fans of 400 mm sweep

13. Code of practice • Battery Box • Secured to under frame • Part opening of front cover • Ventilating grills • 150 mm clearance (min) over top of cells • Antitheft measure, MS threaded rod fixed in front of cells. • FRP tray & drain pipe at bottom of battery • Cable • E beam irradiated thin walled elastomeric copper • cable to RDSO spec ELC/00199(REV 2) 2011

14. Code of practice on fire prevention (EL/TL/56-1992) • Probable causes of fire • Excessive current in cable • Short circuit • Loose connections

15. Code of practice on fire prevention • Excessive current in cable • Size of cable • Size of fuse

16. Code of practice on fire prevention • Loose connections • Crimping and connection of cable • No joint in running length in conduit • Use of grommets • Flammability test as per IS 10810 Pt 53 • Earth checking

17. Code of practice on fire prevention • Rewiring of coaches • Life of cable 20yrs • Cable testing After 15yrs • Segregation of positive and negative cable • To run in separate conduit except • Phase and field cables from alternator to alternator terminal box to RRU to under frame terminal board

18. Self Generating- Earth test on coaches Two lamp system • Connect earth indicating device to EFTB as shown in fig • Lamp do not glow, lamp (s) defective • Both lamps glow equally; Coach wiring healthy • Both lamps glow unequally; • Battery box leaky • Partial earth on PM or NM (not serious) • One lamp bright & other not glowing at all • Polarity of Earth fault given by glass window of device (+ve earthed or -ve earthed) • Examine Jn box, Fuse distribution board and EFTBs etc • Isolate earthed Positive or negative sub circuit by dis-connecting one by one starting from under frame

19. 110 v lamps Earth Indicating Lamp

20. Self Generating- Emergency feed extension ( RDSO tech circular No RDSO/PE/TL/TC/002 rev 0) • Feed to be extended to only one coach • Resorted to if any of the coach is dark due to failure of alternator/battery • Check the dark coach for earthing, if earthed do not resort to feed extension • Ensure availability of supply in EFTB of healthy coach • Check the polarity of healthy and dark coach • Switch OFF, LII circuit of healthy coach keeping SPM I& II rotary switch in ON position

21. Self Generating- Emergency feed extension ( RDSO tech circular No RDSO/PE/TL/TC/002 rev 0) • Switch OFF LII & fan circuit of dark coach keeping SPM I & II rotary switch in ON position • Remove + ve fuse from battery box and –ve main fuse from Jn box in dark coach. • Extend feed by connecting emergency 1.5 m long feed cable (16 mm2 Al or 2.5 mm2 Cu) duly crimped on both ends tightly • Defective coach to be attended emergency cables removed at the Ist available opportunity