 Air conditioning is the controlling of air

temperature, its humidity, its purity, noise-free and

its flow rate at a certain place to produce a comfort
zone.

 Ventilation is refreshing the air in a crowded place

by feeding the place with a mount of air at a certain
time and draw the same a mount of air to obtain an
healthy environment empty of dust, gases and bad
smell.
The human needs 1.2 kg. of water, 2.7 kg. of food
and 16 kg. of air per day. The healthy requirements
is:

 One third of the feeding air must be fresh air and

the 2 third return air after purifying.

 Entire air in the air conditioned areas must be

moved at a velocity between 0.15 to 0.25 m/s . This
velocity doesn’t cause a noise.
Comfort means treatment of 5 properties of air

1. Dry bulb temperature(d.b.t) : cooling or heating

2. RH (%) : humidification or de-

humidification.

3. Air purity : Free from dust & bacteria

4. Ventilation : Fresh air to provide the needed

oxygen

5. Air movement : homogeneous flow rate and

distribution
(static air causes temperature difference of about 8-
16 degree C between the breath level and the ceiling
level)
Temperature

◦ Winter 18-21 0C

◦ Summer 23-29 0C

RH 30-70 %
1. DRY BULB temperature(d.b.t.):

Temperature which the thermometer can measure.

2. WET BULB temperature(w.b.t.):

Temperature of a moist wick placed

over a thermometer bulb.

3. DEW POINT (d.p.):

Temperature below which water vapor start to

condense.
4. HUMIDITY
(H):
Presence of moisture or water vapour which affects
the rate of evaporation. or perspiration from the
body.

5. RELATIVE HUMIDITY (% RH):

Amount of moisture in a given sample.

 Air-conditioning deals with Human comfort,
while refrigeration deals with preservation
of perishables.

 Air-conditioning involves both heating & cooling

while refrigeration means only cooling.
i) Domestic Refrigeration:- Freezer, Water cooler.
(10C to 13 C )

ii) Commercial Refrigeration:- Hotel , Restaurant

(Freezer, Water cooler, Deep freezer).

iii) Industrial Refrigeration:

a) Ice Plant
b) Ice cream plant
c) Industrial manufacturing

iv) Marine & transportation:

For carrying the fish, meat, medicine etc.
A) Comfort Air-
conditioning:
i) Fresh Air, Dust & dirt free noiseless,
ii) Temperature control:-
Summer---23-25°C
Winter----19-21°C
iii) Humidity Control :-
Summer---40 to 60%
Winter—50 to70%

B) Industrial Air
1. Kilo-Calorie

It is defined as the amount of heat to be added

/removed to raise /lower the temperature of one kg
of water by one degree Celsius.

2. BTU

It is defined as the amount of heat to be added

(removed) to raise (lower) the temperature of one
pound of water by one degree Fahrenheit.
1 Kilo Calorie = 3.97 BTU.
3. Sensible heat

It is that heat which when applied to a body,

results in a rise of its temperature. It is the heat
which is sensed by a thermometer.
4. Latent heat

It is that heat which when

applied merely changes the
state of substance, whether
solid, liquid or gas, without
causing any change in its
temperature.

Latent heat of fusion 32o

of ice 80 k.cal/kg (144
BTUs/lb).
5. Humidity:

The amount of water vapour present in the air is

called humidity.

6. Relative Humidity:

It is the ratio of the actual amount of moisture

contained to the maximum amount required for
saturation and is expressed as a percentage.

RH = Actual amount of water

vapour present/ maximum amount
required for saturation.
It states that heat and work are mutually convertible and
since energy can neither be created nor destroyed, the
total energy associated with an energy conversion
remains constant.

Mechanical energy can not be obtained from a source of

heat energy unless the source of heat energy undergoes a
drop in temperature.
OR
Heat will not flow ― up a temperature hill‖ unless
energy is supplied to force it to do so.
 The unit employed for designating Air
Conditioning capacity is a ―Ton of Refrigeration‖ .

 The capacity of a plant is said to be one ton, if it is

capable to extracting heat at a rate equivalent to
that required to freeze one American ton (2000lbs)
of water at 0°C into ice at the same temperature in
24 hrs.
 One ton of refrigeration is the heat required to melt
2000 lbs of ice at 0°C into water at the same
temperature in 24 hrs.
1 ton of Refrigeration = 2000 lbs X 80K.cal/kg.
= 907.198 kg x 80 K.cal/kg
=72575.84 K.cal/24 Hrs
=3023.99K.cal/hrs
=3024 K.cal/hr
The refrigerant shall be:
• Non poisonous
• Non –inflammable.
• Non-corrosive.
• Non –irritating.
• Non – toxicity.
• No harmful effect on the taste.
• Cheap & readily available in the market.
• Eco Friendly.
 It shall have high latent heat of vaporisation.
 It shall have low boiling point.
 It shall have high coefficient of performance.
 Easy detection of refrigerant leakage.
 Low freezing point.
 High specific heat.
 Low viscosity.
 High electrical insulation.
o Ammonia (NH₃) : Ice making, cold storage.

o Sulphur di oxide(SO₂) : Domestic refrigerator.

o Methyl chloride (CH₃CL): Small Domestic refrigerator.

o Carbon Dioxide(CO₂) : For manufacturing Dry ice,

o Monoflouro trichloro Methane (F-11)

o Dichloro Diflouro Methane (F-12)

o Trifluro monochloro Methane (F-13).

o Monoflouro dichloro Methane (F-21).

o Monochloro Difluro Methane (F-22).

o Trifluro chloro Ethane (F-113).

o Tetra fluro dicloro Ethane (F-114).

o Tetra fluro Ethane (R-134a)

o Substitute for R22 Refrigerant blend

R407c- containing R32, R125 and R134a
(23/25/52% by weight).
• Relative value that indicates the potential of a
substance to destroy ozone gas as compared with
the potential of chlorofluoro Carbon-11 (CFC-11 or
R11) which is assigned a reference value of 1.

• Thus, a substance with ODP of 2 is twice as

harmful as CFC-11.

• R-22, for example, has an ODP of 0.05.

 Global warming potential (GWP) is a relative
measure of how much heat a greenhouse gas traps
in the atmosphere.

 It compares the amount of heat trapped by a certain

mass of the gas in question to the amount of heat
trapped by a similar mass of carbon di-oxide.
Property R-407c R-134a R-22 R-12

Chemical Tetrafluoro Mono- Di-

name e thane chlorodifluo chlorodiflu
romethane oromethan
e
Molecular 86.2 102.03 86.868 120.91
mass

Boiling pt 0C -46.1 -26.2 -40.8 -29.8

Freezing pt 0C -142 -256 -252

Critical temp
0C 86.22 102 96 112
Critical 4.62
590 psia 722 psia 591 psia
pressure MPa

GWP/ODP 1600/0 1300/0 1700/0.05 2400

Cylinder Orange Light sky blue Green White

colour
 Substitute for R22 Refrigerant blend
containing R32, R125 and R134a (23/25/52% by
weight).
 Temperatur glide approx 7K Refrigerant
e be must liquid phase
charged from
thermodynamic Physicalcomparable
properties and to
R22
Non-flammable and safe to use commercially
available miscible with polyol ester oils.

 Chemical Name: Difluoromethane,

pentafluoroethane, 1,1,1,2- Tetrafluoroethane
Main component of Vapour compression cycle are :

i) Compressor

ii) Condenser

iii) Expansion valve

iv) Evaporator unit.

 CONDENSOR
L.R High
pressure.
D

Compressor.

EXP.
VALV Low
E pressure.

EVAPORATOR

Liquid Vapour mixture Super saturated vapour

 Refrigerant is drawn from evaporator in dry vapour
& low pressure state by suction strokes of the
compressor. In compression stroke, the refrigerant
pressure being increased due to increase pressure of
vapour temperature of vapour increase and send to
the condenser unit for condensation.

(Refrigerant in high pressure & in vapour form )

 It is intended for cooling the hot gas & liquefying
it. It may be air cooled or water cooled. or
condensate the refrigerant.
(Refrigerant in high pressure & in liquid form )
 Its function is to control & regulate the rate of flow
of liquid refrigerant under high pressure and allow
it into the evaporator under low pressure or
expended the refrigerant.

 The expansion valve admits more refrigerant when

air conditioning load is high & reduces it to
minimum when load is low.

(After expansion refrigerant in low pressure &

in liquid form)
 This constitutes the cooling unit, in which the
liquid refrigerant under low pressure evaporates
and do so, it takes away its quota of latent heat,
thereby cooling the medium surrounding the
cooling coil.

(After evaporation refrigerant in low pressure

& in vapour form)
 Supplying clean fresh air at a controlled uniform
temperature.

 Catering, within the confines of the Railway

carriages to the continuously changing number of
passengers.
 Providing for heating as well as cooling on a train
that travels through areas of widely differing
climate during its journey.

 Operation of the equipment from power generated,

stored and controlled on the train.

 Securing sufficient air movement.

Window Type Units :

• Air conditioners of the type,

window
completely self-contained are
compressor, units, with
condenser, evaporator, the
refrigerant
piping and air filter, all assembled in a
very compact assembly.

• The window units are usually of 1/2 to 2.5

tons capacity.
Package Unit :

• These units are functionally similar to the

window models but are very much bigger in size
and therefore arranged for floor mounting.
These are available in several capacities i.e. 4,6,
8 ,12 & 20 tons .
 Central Plant :

• A central plant with full ducting is best suited for

air conditioning of large buildings, theatres, halls
and un-partitioned offices.

• In the central plant system, the air conditioning

plant, comprising two or more heavy compressor
units including the ancillary equipment like
condensers and evaporators are located at a central
point usually at the ground floor or basement.
Desert Cooler :

• The desert cooler works on the principle

of
evaporative cooling. A fan sucks outside
air
through a continuously wetted pad. The air in
passing through the wetted pad gets cooled and
humidified and this air is circulated into the room,
where it picks up sensible heat and maintains
fairly comfortable conditions as fresh air is
continuously pumped into the room.
Phase II - Module No. STC-GS-2
CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

 Air condition system

Air conditioned coaches built so far by ICF

(Integral coach factory), Chennai, RCF kapurthala
CAMTECH, Gwalior

and MCF Rai-Bariely may broadly by classified as:

 Self Generated (SG)

 End-On-Generation (EOG)

 Head-On-Generation (HOG)

Phase II - Module No. STC-GS-2

 Air Condition Coaches
Self generating coach (110 V DC system) are further
classified as:
CAMTECH, Gwalior

 Full AC first class (18Persons capacity)

 Second AC sleeper (46 persons capacity)

 Chair car (72 person capacity)

 Composite coach (1 class AC-10 persons capacity

and 2-AC sleeper -20 persons, 3-tier AC (64
person capacity)
Phase II - Module No. STC-GS-2
 End On Generating coach (EOG system) are
further classified as:

 Full AC first class (18Persons capacity)

 Second AC sleeper (46 persons capacity)

CAMTECH, Gwalior

 Chair car (72 person capacity)

 Composite coach (1 class AC-10 persons capacity

and 2-AC sleeper -20 persons, 3-tier AC (64 person
capacity)

 Pantry car

 Guard compartment
Phase II - Module No. STC-GS-2
 The basic need of power in self generating coaches at
haul or low speed is fulfilled from battery. The battery
power will be used in the above coach to run the AC
plant ,fan , lighting and mono block pump for water
CAMTECH, Gwalior

supply etc. while coach in motion or halt at station.

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

 Heat load calculation of AC-2Tier (sleeper ) coach

 Abbreviations

 Co-efficient of heat transfer

 connected Electrical loads inside AC

compartment.

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

  Passengers in a railway travel are adversely affected
by infiltration of air unpleasantly laden with dust
due to open windows.
CAMTECH, Gwalior

 This is more so in case of high speed

passenger
carrying
trains.
a tropical country like India, the
 Secondly
temperature varies from 48 degree C
for
during summer to 2 degree C during winter.
Phase II - Module No. STC-GS-2
  Air-conditioning of railway coaches is, therefore,
necessary for the maximum comfort and well
being of passengers in a railway travel.
CAMTECH, Gwalior

 In keeping with modern trend, airconditioning of

coaches for upper class travellers and lately even
for lower class travellers has been introduced by the
Indian Railways.

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

 As compared to the normal buildings, air conditioning
of Railway coaches poses the following additional
problems:
CAMTECH, Gwalior

 Requirement of very high reliability standard.

 Equipment should be light in weight.

 Equipment should take minimum space.

 Available power, generally at 110V D.C. has

utilised.
to be 415 V, 50 Hz, 3 Ph, power
industrial available only on a few
nominatedand Shatabdi Express.
Rajdhani is
Phase II - Module No. STC-GS-2
  However, in such cases, the flexibility of attaching
and detaching coaches is lost.

 Due to large number of passengers in small space, the

space left for air circulation is limited.
CAMTECH, Gwalior

 In the Railway coaches, where people move in and out

at all hours of the day, to sudden changes in
temperature, which may cause chill or heat are to be
avoided.

 Rapidly changing ambient conditions as the train

moves from one part of the country to another.

 Excessive vibrations.
Phase II - Module No. STC-GS-2
  Dusty atmosphere.

 Vandalism and abuse.

 Flying ballast hitting the equipment.

CAMTECH, Gwalior

 Safety of passengers and trains.

 Dirty environment for the maintenance staff.

 Restricted time available for maintenance.

All these have to be solved,

problems outlay within a so
comparatively small
travel can become more, common.
that air conditioned
Phase II - Module No. STC-GS-2
  Driving equipment consist of motors for driving
the compressor, condenser impeller fans and
the evaporator blower fans.
CAMTECH, Gwalior

 The driving motors in self generating under slung type

AC coaches are all of D.C. machines needing more
care for attention of commutator and brushes.

 The coaches fitted with RMPU (SG, EOG and HOG)

are provided with 3 phase AC squirrel cage
induction motors for driving the AC equipment.
Phase II - Module No. STC-GS-2
 This consists of the following:
• Evaporator Unit.
CAMTECH, Gwalior

• Compressor.
• Condenser Unit.
• Gauge panel.
• A/C control panel.
• Air Duct.
• Refrigerant piping & joints.
• Wiring etc.
Phase II - Module No. STC-GS-2
CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

 Alternator:

25 kw, 110V, 3 phase, Brush less type, totally enclosed,

reversible shunt Wound.
CAMTECH, Gwalior

RRU/ERRU: 25 kw,

Battery charging transformer cum rectifier : 200

A

Battery: 800/1100 Ah, 110v DC,

LMLA/VRLA

Phase II - Module No. STC-GS-2

 Compressor/comp. motor- -12.5HP

Condenser / condenser motor- -1 hp/ 0.75 hp

CAMTECH, Gwalior

Blower motor -1.5 hp

WRA (Mono block Pump) - 0.5 hp, 415v/ 1.5 hp,

110v DC motor type.
Light & fans

belts, axle pulley, alternator

pulley & v-belts

Phase II - Module No. STC-GS-2

 • OVR / OVP
CAMTECH, Gwalior

• HRC fuse ( 315 A / 250 A / 160A/ 20A/6A)

• Thermostat, Vane relay, MCBs of various capacities.

• Interlocking between vane relay & blower motor.

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

 It is very important to familiar with few official
documents issued by Railways Administration
related to working of TL/AC equipment, our
nature of job and duties:
CAMTECH, Gwalior

 Code of Practice of Train Lighting &

Air Conditioning, issued by RDSO/ Lucknow.

 Compendium of instructions issued by

Railway Board.

 SMI (Special Maintenance Instructions),

issued by RDSO/ Lucknow.
Phase II - Module No. STC-GS-2
  MIs/MS (Modification Instructions &
Modification Sheets), issued by RDSO/ Lucknow.

 Manuals: Issued by RDSO/ Lucknow, OEMs etc.

 Data Book: Issued by RDSO/ Lucknow.

CAMTECH, Gwalior

 RDSO’s approved list of Vendors, Issued by RDSO/

Lucknow.

Phase II - Module No. STC-GS-2

 C AMTECH  Publications issued by CAMTECH, Gwalior
on various topics of Coaching available on
internet.
CAMTECH, Gwalior

IRIEEN  Volumes published by IRIEEN on various

topics of Train lighting and Air-conditioning

IRCA  Volumes on Coaching maintenance

ICF  Manual of coaching maintenance

and design
Technica  Technical instructions issued by RDSO from
l time to time for reliability.
Circular Phase II - Module No. STC-
  Rake link Book, issued by Operating
department
(HQ).

 Working Table, issued by Operating

Time department
(HQ).
CAMTECH, Gwalior

 Agenda and Minutes of MSG meetings, issued

by RDSO/ Lucknow.

 Reliability Reports of RDSO on TL/AC

 Equipment, issued by RDSO/ Lucknow.

Phase II - Module No. STC-GS-2

CAMTECH, Gwalior

Phase II - Module No. STC-GS-2

Noise level DIN 45635
measurements
HVAC UIC 553
AC in coaches- type UIC 553-1
tests
Safety code for AC IS 659

RMPU RDSO specification no.

ELPS/SPEC/AC/03/Rev.2-May, 2009
Control Panel RDSO specification no.
ELPS/SPEC/AC/04/Rev.3-May, 2009
Condensor Fans Air Intake for
the Condensor Fans
Conventional Coaches
Cut In Cut Out
• Winter 190C 210C
• Summer 250C 230C

Garib Rath Coaches

Cut In Cut Out
• Winter 190C 210C
• Summer 270C 250C
 E E
3 3
V K KV
A
W D D WP
A H
R BLOWER R H
E O
E MOTER U A R
P U M T A
A E T
O M R
E
T
R
R E
6KW HEATER (LHB)
R
A ESTI
DUCTING
T
RETURN RETURN
AIR AIR
 Excellent full and part load efficiency

 Very few moving parts (3)

 Proven reliability

 Very quite operation

 Very low vibration

 Non-compliant (no contact between scrolls) have low

friction
 Less wear and tear

 Low condenser temperatures

 Can handle liquid to some extent

 Continuous compression process with almost no pulsation

or vibration

 Compact design
 More initial cost

 Can’t be disassembled in the field

 Prone to damage due to improper phase sequence.

 The temperature in the air conditioned space is controlled
based on fixed selected thermostat settings without any
relationships with humidity or requirement of air conditioning
during different hours of day and night journey. Such
arrangements do not ensure desired comfort level throughout
the journey.

 The thermostats provided for the purpose of temperature

control have only three fixed settings which cannot be changed
and have to be selected manually by operating a rotary switch.
 In the existing system, there is no provision to monitor the
energy consumption in the coach to monitor the energy
efficiency of the AC plant.

 The fault diagnostic assistance for the operator is not

available in the existing system for efficient trouble
shooting and isolation of fault/defect.

 The existing system does not have a data logging system

for recording various faults and defects towards their
subsequent analysis and for initiating corrective measures.
 Controls temperature and humidity through temperature
sensors and humidity sensors.

 System is suitable for maximum ambient temperature of 55°C,

minimum ambient temperatures of 5°C, average ambient
temperature of 35°C and maximum relative humidity of 100% .

 The temperature inside the coach is maintained as per the

temperature setting selected by the operator. It is possible to
alter the assigned value of temperature (in step of 0.1° C.)
through key-board on display unit.
 The difference between cut in and cut out temperature
shall be 2°C. The difference of 2°C reduces the duty cycle
of compressor & eventually the failures of compressors.

 Sleep Mode Operation: The controller automatically enters

the sleep mode operation during predefined night hours.

 The controller monitors duty cycle of compressors.

 Fault storage/diagnostics system: Faults are recorded

automatically. Faults can be downloaded by Laptop.
 Display Unit is available.

 Trouble shooting instructions are displayed on the screen.

 System will monitor supply voltage and current and record

the power consumption.
• The controller automatically enters the sleep mode
operation during pre-defined night hours which can be
changed to suit the requirement for different seasons and
places.

• At the start of sleep mode operation, controller

gradually
increases the coach temperature equal stepsto
in predefined value within time a period
specified the same during the night hours.
maintains and
• At the end of night hours, the processor gradually reduces
the coach temperature to selected value within pre-defined
time period.

• The set temperature during night hour as well as its time

period can be altered by the maintenance staff.
 The controller will continuously monitor the duty cycle of
compressors. If duty cycle of both the compressors is
recorded to be less than 40% for four consecutive cycles,
only one of the compressors will be worked alternatively.
Again if one compressor is not able to achieve the desired
temperature within 10 minutes, both the compressors will
start working simultaneously.
 Once the compressors are switched off, the first compressor
starts after a time delay of 2 minutes and the second
compressor starts after 30 seconds of starting of first
compressor in order to control initial inrush of current.

 During winter season when the coach temperature reaches

2°C below the set value, the heaters are switched ON. The
heaters will remain ON till the set temperature is achieved.

 In the event of any defect, malfunction or abnormality, the

unit isolates the equipment of RMPU or shuts down the
system, depending upon the nature of defect to prevent any
unsafe operating condition for the RMPU.
 A fault storage system records various tripping and faults of
the RMPU along with the instant status of various parameters
like temperature setting, LP & HP pressure and relative
humidity.

 The fault messages along with trouble shooting instructions

are displayed during various fault conditions.

 The system monitors supply voltage and current and records

the power consumption of units.
 One display unit for each control unit is mounted on the
left door of the control panel.

 The control display unit functions as an interface between

operator and system. Display unit have necessary keys for
the purpose.

The following functions are possible through key board.

 Setting of time, date, train no. and RMPU no.

 Clearing of the fault on display.

 Viewing of the stored faults.

 Display of digital inputs and outputs.

 Display of status of the system.

 Setting various for controller by

parameters maintenance staff.
 Power supply- 415 +/-5% V , 3 ph, 50 Hz+- 3%

 Control supply 110V ac, Single phase

 Connections through Harting connectors (plug & socket)

 Two distinct refrigeration circuits

 Made of SS-304 (1.6 mm)

 Self supporting type

 Weight < 700 Kg

 Evaporator unit water tight

 Drip tray depth > 60 mm

 Noise level < 60 db

 Blower static head > 20 mm

 Capacity 7 TR at service conditions

 Power input < 16 KVA

 Coils- Copper grooved tubes with Al

 Motors with built-in thermal protection

 Suck through type arrangement

 Capacity with one condenser- 75%

 Protective mesh of 3 mm SS over condenser fans

 Refrigerant R22 or R 407c (3Kg per RMPU)

 Compressor- hermetically sealed scroll type

 Motors RPM- 1400

 Summer
• Outside(Dry summer) – 50 deg C (DB)
- 25 deg C (WB)
• Outside(Wet summer) – 40 degC (DB)
- 28 degC (WB)
• Inside (Wet & dry) - 22 to 25 degC 60- 40%RH

 Winter
• Outside - 4 deg C
• Inside - 21 deg C
 Conventional RMPU
mounting arrangement
on Coach

Water sealing arrangement

 RMPU being mounted on coach

RDSO specification no. ELPS/SPEC/AC/03(Rev. 2), May, 2009

o New features incorporated

o Additional filter in suction line.

o Electric heaters with fins

o Non metallic halogen free fire retardant anti rodent

conduit (IEC 61386) of polyamide material

o E beam thin walled elastomeric cable

o Fire retardant water proof bellow duct material variety 2
of IS 1424

o Hermetically sealed Scroll compressor only

• OHP setting reduced from 160 deg C to 130 deg C

• Slide in connection of RMPU supply and return air

duct.
• Inefficient working of RMPU results in more working
hours of RMPU, leading to avoidable burden on battery/
alternator.

• Efficient working of RMPU results in less working hours

of RMPU, which reduces burden on battery and
alternators.
To avoid less cooling in AC coaches:
 Ensure effective working of RMPU.

 Ensure working of both alternators.

 Ensure the healthiness of battery.

Ensure effective working of RMPU by:
 Free flow of cool air and air dissipation (evaporator
& condenser).
 Regular cleaning of return air filters & fresh air filters.
 Regular cleaning of condenser & evaporator coils with
water jet.
CLEANING OF EVAPORATOR/ CONDENSER COILS
WITH WATER JET IN DEPOTS AND WORKSHOPS

Evaporator coil before Evaporator coil

cleaning after cleaning
Condensor coil before Condensor coil after
cleaning cleaning
Phase –II- Module No. STC - G S - 2
To overcome following limitations of ICF type conventional
coaches, Indian Railways entered into supply and technology
transfer contracts with M/s. ALSTOM LHB/Germany to
initially supply LHB coaches.
 Speed potential;
 Heavy corrosion;
 Poor riding comfort;
 Wearing of parts in the under gear;
 The bogies for LHB coaches are manufactured by
M/s. FIAT/SIG Switzerland.

 LHB coaches arrived in India and got commissioned

in the year 2001 and put in service. These type of
coaches are far superior with respect to passenger
comfort, safety, speed, corrosion, maintenance and
aesthetics.

 These coaches are also longer as compared to ICF

design resulting into more carrying capacity.
The benefits from these type of coaches are as under:
i. Higher carrying capacity - These coaches are about 2
meters longer than ICF coaches. With this extra length two
additional rows of chairs in chair cars or one additional bay
in sleeper coaches can be accommodated.

ii. Lesser weight: Weight of LHB coach is lesser as

compared to ICF design coaches.

iii. Better tare ratio: LHB coach can accommodate

passengers 72
as compared to 64 in conventional AC
III Tier Coach. Thus giving

iv. Low corrosion – There will be low corrosion of LHB

coaches due to extensive usage of Stainless Steel and better
design and manufacturing techniques.
v. Low Maintenance: Replacement and removal of
sub- systems will be required only after one million kilometers.

vi. LHB Coaches have aesthetically superior interiors

with FRP panels for side wall and roof.

vii. They can be removed easily for maintenance, resist

water
seepage and are wear resistant.
viii. There are no visible screws inside the passenger compartment.

ix. Better passenger comfort: Better Riding

Index has been specified as compared to conventional
ICF coaches.
viii LHB coach offers better passenger safety due to:
• Use of fire retardant materials for furnishing.

• Provision of emergency open able windows.

• Vertically interlocked Centre Buffer Couplers.

xi LHB coach offers better passenger amenities due to :

• More space for pantry;

• Individual reading light in chair car;

• Ergonomically designed chairs with reclining back rest

Sr. Type of Coach Code No. of Weight in
seats tons
/berths Tare

1. AC First Class Sleeper (EOG) LWFAC 24 43.34

2. AC First Class Sleeper- (SG) LWGFAC 24 47.50
3. AC Two Tier Class Sleeper- (EOG) LWACCW 52 44.50
4. AC Two Tier Class Sleeper- (SG) LWGACCW 52 48.40
5. AC Three Tier Class Sleeper- (EOG) LWACCN 72 45.60
6. AC Three Tier Class Sleeper- (SG) LWGACCN 72 50.60
7. AC Double Decker AC Chair Car LWCZDAC 120 49.53
(EOG)
8. AC Hot Buffet Car (EOG) LWCBAC 18 40.80
Sr. Type of Coach Code No. of seats Weight in
/berths tons
Tare

9. First AC + AC Two Tier LFCWAC 10+28 42.50

10. AC Chair Car/2nd LSCZAC 78 40.40
11. AC Chair Car/First Class LFCZAC 56 40.40
12. Generator CUM Luggage & LWLRRM 5 53.00
Brake Van
(4 Crews +1
Guard)
1. Composite 1st
AC & AC Two
Tier (EOG) LHB
Coach

SN Description Parameters
01 No of passenger to sit/sleep AC 1st 10
02 No of passenger to sit/sleep AC IInd 28
03 No of lavatories 04
04 Approx. Linen capacity 2.9 cubic meter
05 Length over body 23540 mm
06 Length over CBC 24000 mm
07 Height of the coach from rail level 4039 mm
08 Maximum width over body 3240 mm
2. AC First
Class (EOG)
LHB type
Coach

SN Description Parameters
1 No of passenger to sit/Sleep 24
2 Door aside 02
3 No of lavatories 03 (02 European and 01 Indian style)
4 4- Berther 04 Nos.
5 Cope 04 Nos.
6 Approx. Linen capacity 1.7 cubic meter
7 Length over body 23540 mm
8 Length over CBC 24000 mm
9 Height of the coach from rail 4039 mm
level
10 Maximum width over body 3240 mm
3. AC
Three Tier
(EOG) LHB
type Coach

SN Description Parameters
1 No of passenger to sit/Sleep 72
2 Door aside 02
3 No of lavatories 04
4 No of passenger per door 18 Nos.
5 No of passenger per lavatories 18 Nos.
6 Length over body 23540 mm
7 Length over CBC 24000 mm
8 Height of the coach from rail level 4039 mm
9 Maximum width over body 3240 mm
4. AC Two Tier
(EOG) With Wider
Cabin Width LHB
type Coach

SN Description Parameter
1 No of passenger to sit/Sleep 52
2 Door aside 02
3 No of lavatories 04
4 No of passenger per door 26 Nos.
5 No of passenger per lavatories 13 Nos.
6 Linen room capacity 3.00 cubic meter
7 Length over body 23540 mm
8 Length over CBC 24000 mm
9 Height of the coach from rail level 4039 mm
10 Maximum width over body 3240 mm
5. High
Capacity Double
Decker AC Chair
Car (EOG)

SN Description Parameter
1 No of passenger to sit 120
2 Door aside 02
3 No of lavatories 04
4 No of passenger per door 60 Nos.
5 No of passenger per lavatories 30 Nos.
7 Length over body 23540 mm
8 Length over CBC 24000 mm
9 Height of the coach from rail level 4366 mm
10 Maximum width over body 3050 mm
 Gauge 1676 mm
 Length over body 23540 mm
 Length over CBC 24000 mm
 Wheel Base 2560 mm
 Maximum width over body 3240 mm
 Maximum distance between inner wheels 12345 mm
 Window opening 1180x760 mm
 Distance between centre pivots 14900 mm
 Height of compartment floor from 1303 mm
rail level under tare condition
 Maximum CBC drop under gross load 75 mm
and worn conditions

 Minimum height from rail level 102 mm

 Maximum height of centre line of side 1105 mm

CBC above rail level for empty vehicle

 Minimum height of centre line of CBC 1030 mm

above rail level for loaded vehicle
Maximum tare weight

 Wheels diameter (New) 915 mm

 Maximum axle load permissible 16.25 tones

 Number of toilets 3 (for Shatabdi coaches), there is
difference in the no. of toilets for
different types of coaches.

 Higher speed potential 160 Kmph upgradable to 200

 Ride index of coach* 2.5 at 160 Kmph but not >2.75

Maximum Moving Dimension of LHB Coaches should be within
“Diagram 1D” of Schedule of Dimension BG (Revised 2004)

Maximum Moving
Dimensions of the
profile proposed for
Revised Schedule of
Dimensions
 Important features of LHB coaches which make them superior
to existing ICF design coaches are summarized below.

 LHB coach is light weight construction made from low corrosive

stainless steel about 10 percent less as compared to the
conventional coach.
 Each vehicle is equipped with complete pantry to store hot meals
and cold beverages except LWLRRM, LWFAC, SCN, GS etc.
 The modular construction and the integration of lights into interior
ceiling and luggage racks are characteristics features of modern
interior design.

 Windows are specious and modern equipment have been

provided which make the coach far superior esthetically.
 The car body shell is of economical weight steel construction
with interlocking technique developed by M/s Alstom.

 Roof is of beaded sheet construction and floor sheet is

corrugated made of austenitic stainless steel.

 Roof structure, side wall and end wall are made of ferritic
stainless steel. IRSM-41 CORTEN steel has been used for
under frame and other parts.
 PU based spray insulation for corrosion protection and sound
insulation on the interior surface of the car body shell.

 Heat insulation of the floor, side walls lower area and end
walls with Resonaflex insulating mats.

 Use of Resonaflex –Alu & Baryskin V60DB in shell, de-

coupling elements in flooring and elastomeric rubber- metal
components in bogie results in superior noise insulation.

 Noise level inside coach is limited to 60 DB.

Three types of windows have been used in LHB coaches.
a. Fixed window unit with sealed glass, 12 per coach
• The sealed unit consists of outer 8.4 mm laminated glass
and inner 4 mm tempered safety glass with 6 mm air gap
with Krypton/Argon gas filling.

• Glasses are held by an aluminum extrusion frame with

rubber profile.

• The aluminum frame is glued to the coach shell.

b. Emergency openable window: 4 per coach

• Emergency window is similar to the fixed unit.
• Four units are provided in each coach to allow emergency
evacuation of passenger.
 • A handle is connected to the
rubber profile to open the glass
unit of the emergency window.

• The breakage of glass unit

while opening is prevented by a
restraining chain.

c. Hopper type windows for

lavatory: 3 per coach

• These windows are provided for lavatories of

the LHB coaches
 Roller Blinds have been provided on the windows in AC
Chair Cars instead of curtains.

 It is a sun protection fabric.

 The roller blind is manually operated.

 These blinds have three positions i.e. full open, half open and
full closed.
 The wire tension enables an wrinkle free
and easy use.
 The luggage racks are made from aluminum extrusion
lengths and tempered safety glass.

 It can withstand distributed load of 1000 N (100 kgs) per

meter length and pointed load of 850 N (85 Kgs) as per UIC
566.
 HALOGEN OFF- ON
OFF- ON LUGGAGE RACK
LAMP SWITCH
LAMP SWITCH

HOLE FOR ADJUSTING

HOLELIGHT
THE FOR FOCUS
ADJUSTING
ON
LIGHT FOCUS ON
THE SEAT
THE SEAT

 Halogen reading lights for individual seats, fitted into outer

extrusion and wiring hidden by polycarbonate lexan sheet
with fire characteristics as per DIN 551/2.
 Aluminum extrusions are used with anodized finish.

 Side cheeks of cast aluminum alloy are provided with powder

coated finish.

 Reading lights and movable coat hooks are provided in

luggage racks.
 For flooring, 16 mm composite board made from cork
panels glued to “MakeOre” wood have been used.

 Flooring panels are lightweight, strong, warp resistant and

also resistant to vibration/impact forces.

 These boards are specially treated for fire resistance.

 These are also resistant to moisture, cigarette burns, staining,

ageing, etc.
In II AC chair car : 78 Chairs
Executive class chair car : 56 Chairs

Weight of a single chair car

for II AC chair car : Approx. 21 kg against
28 kg in existing IR coaches.

The height of the seat cushion above floor level (450 mm), the
width between the arm rests (420 mm in chair car and 500 mm
in Exe. class) and the ergonomically designed upholstery
provides excellent seat comfort without causing tiredness even
on long journeys.
Main assembly comprises

• Welded seat frame

• Seat cushion
• Sleeplessly inclinable backrest (17 degree
in upright and 37 degree in rest position)
• Arm rest
• Foldable table with bottle holder
• Foot rest
• Magazine net

There are 24 berths in First AC, 52 berths in AC 2 tier

and 72 berths in AC 3 tier.
5 passenger emergency alarms per
coach were provided at following
Earlier version of
locations:
Chair Car coaches
• 2 in passenger compartment
• 3 in lavatories.

Alarms are provided only at

two locations and
Present version In Ist AC, 2 tire , 3 tire & sleeper
of chair cars, coaches, Passenger Emergency Alarm
is provided in every bay.
Fluorescent tubes are used for general lighting, vestibule, toilet,
pantry and emergency working at 110VoltsAC/DC with
inverter and polycarbonate diffusers.
 Fluorescent tubes 18 watts
 Incandescent lamps 10 watts (for night lamp and
pantry)
 Halogen lamps 10 watts (reading lights)
 The FIAT ( Fabrica Italina de Automobil Torino) bogie is an
adoption of EUROFIMA design.

 This bogie belongs to the two-axle type, with a primary and a

secondary suspension.
 The bogie frame consists of two side members of Y-shaped
longitudinal beam connected by two tubular steel members.

 Bogie is designed for maximum operating speed of 160 kmph

and
has potential for operation upto 200 kmph.

 Axle guidance is provided by an articulated control arm through a

resilient bush.

 This is a two stage suspension bogie. The car body directly rests on
the secondary stage helical springs, which rests on Y shaped side
beam. The bogie frame rests on primary stage helical spring which
are resting above the axle box crown.
 The and braking force axle to bogie frame is
transferred through
tracking from articulated arm system of
control primary
suspension.
 Centre Buffer Coupler

 The coupler provides a means of mechanically connecting individual

adjacent vehicles to make a train.
 The coupler is located at both ends of each vehicle.
 When connected to a coupler of an adjacent vehicle, it
allows the vehicles to move independently to
accommodate track curvature and elevation change
while remaining connected (coupled) together.
 LHB coaches have both Oriental and European type of lavatories
with controlled discharge toilet system. The salient features of
LHB modular toilets are illustrated below

AIR
Flush Button/Switch
tch

MIRROR

FLUORESCENT LIGHT
Toilet Paper Holder

Hand Grip
ASH TRAY
Water for toilet use
se

Ashtray
or Lotah
WASH BASIN

Drain
 110V/220V Socket
for shaver

Push button for

water supply

Water out let

for hand
wash

Controlled discharge toilet Soap

system (CDTS) Dispenser
LHB coaches are fitted with
controlled discharge
toilet units to avoid soiling of
track in station
and inhabited areas.
Now a days, Bio toilet tanks are being provided in
These tanks are made of stainless steel and having following
constructional features:-

 The size of the tank is 547 X 580 X 1680 MM (HXWXL).

 Provision of 04 nos. mounting brackets at both the sides along the

length of the tank.

 Each bracket is with the provision of 02 nos. M16 Size

bolts which are tighten in the head stock on mounting brackets.
 Main parts of the Bio digester tank:

 Stainless steel tank with

06 partition walls in side 580 mm
the tank

547 mm
 Poly grass mats for
protection of bacteria in
side the walls.
1680 mm

 Ball valve with handle for operation during emergency for making
toilet direct discharge in case of chocking.

 SS fasteners in place of MS on tank covers.

 Stronger bonding of Colonized

rubber mat with vertical walls.
 & And
 Diameter
+ve Positive
0
Degree
0C
Degree Centigrade
A/F Across face
AC Air Conditioned
alt. Alteration
AR Auxiliary Reservoir
BC Brake Cylinder
BP Brake Power
BPC Brake Power Certificate
BPC Bharat Petroleum Corporation
C&W Carriage & Wagon
CAIs Coach Alteration Instructions
CBC Centre Buffer Coupler
CCR Carriage Controller
CDTS Control Discharge Toilet System
CEE Chief Electrical Engineer
cm Centimetre
CME Chief Mechanical Engineer
CMI Carriage Maintenance Instructions
CO2 Carbon dioxide gas
COM Chief Operating Manager
CP Centre Pivot
CR Control Reservoir
CSC Chief Security Commissioner
CSK Counter Sunk
 DA Direct Admission
DC Valve
Direct Current
DEE Divisional Electrical Engineer
dia. (Dia) Diameter
DME Divisional Mechanical Engineer
Drg Drawing
DRS Deficiency in Rolling Stock
DV Distributor Valve
EFT Emergency Feed Terminal
Elect. Electrical
EOT Crane Electric Overhead Travelling Crane
Eq. Equalising
Fig Figure
FP Feed Pipe
FRP Fibre Reinforced Plastic
GRP Government Railway Police
 Hd. Head
hex. Hexagonal
HPC Hindustan Petroleum Corporation
HRC Hardness on Rockwell 'C' scale
I.C. Isolating Cock
ICF Integral Coach Factory
IOC Indian Oil Corporation
IOH Intermediate Overhaul
IRCA Indian Railway conference Association
IS Indian Standards
kg Kilogram
kmph Kilometre per hour
kW Kilo Watt
LHB Linke Holfmann Busch
m Metre
M.R. Main Reservoir
Max. maximum
MCB Miniature Circuit Breaker
Min. minimum
Mm Millimetre
no. Number
nos. Numbers
OBHS On Board House Keeping Services.
O.D. Outer diameter
OCV Other Coaching Vehicle
PCV Passenger Coaching Vehicle
PM Primary Maintenance
POH Periodic Overhauling
Pr. Pressure
PVC Poly Vinyl Chloride
 RCF Rail Coach Factory
RDSO Research Design and Standard Organisation
ref. Reference
rev. Revision
RMPU Roof Mounted AC Package
RPF Railway Protection Force
RTR Rake Testing Rig
SC Security Commissioner
SG Self generating
SM Secondary Maintenance
SMI Standard Maintenance Instruction
Sp. Specific
Spec Specification
Sr. DME Senior Divisional Mechanical Engineer
SS Stainless steel
STR Schedule of Technical Requirements
SWG Standard Wire gauge
t Tonne
TL Train Lighting
V Voltage
-ve Negative
Water Raising System
WSP Wheel Sliding Protection
 LHB EOG coaches are supplied power by End on
generation (EOG) system i.e. by providing power
car in front and rear end of a rake. Each power car
has two DG sets, out of which one DG set is
standby.

 The 750V supply is fed to entire rake through two

feeders running on both sides of coaches along the
full length of rake.
 FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II

GENERATO GENERATO
R CAR R CAR

 LHB EOG 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.
Power cars at both ends take entire load of whole
rake, which includes:
• air conditioning,

• light and fan circuit,

• emergency battery charger circuit and

• pantry equipment.
 COACH
SUPPLY

750 V, 3 Ø AC
LOA
D
FEEDER
415 V, 3 Ø
50/60kVA 415 V, 3
TRANSFORMER LIGHTING
Ø
TRANSFORMER

110 V, 3 Ø
LIGHTING
LOAD
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 on next slide.
 EXHAUST FANS AC PACKAGE UNIT

FRESH AIR
INTAKE

BATTERIE BATTERY FUSE

S BOX
EXT. SUPPLY
IV COUPLER
SOCKET
Electrical Features of LHB EOG AC
Coaches
o IGBT based battery charger.

o Micro-controller based Roof Mounted Package

Unit (RMPU) for Air Conditioning.

o Microprocessor based pump controller unit.

o Integrated, modular single Switch Board

Cabinet with controls of AC, lighting & pantry etc.
o Provision Dry type Transformer without
of
encapsulation
elegant interior light fittings and
o Modular
and reading
o Integrated modular pantry unit.
lights.
o Provision of electron beam irradiated cables.

o Provision of Measuring and Monitoring relays

in Feeder circuit.
o Online insulation monitoring.
o Uniformity of illumination.

o Wheel set earthing equipment for high life of

axle bearings.

o Provision of earthing and disconnecting device.

o Cable protection system with IP-67 protection

and UL-94 V0 fire retardancy.

o Screw less, modular elegant switches.

o Provision of Emergency Battery charger

Switch-Board Cabinet- S1

A modular, integrated single cabinet designated switch

board cabinet comprising all necessary equipments for
control and protection of following coach systems:

 Microprocessor based Heating, Ventilation &

Air conditioning

 Lighting
 Pantry

 Anti skid protection

 Public Address system

 Sanitary system (except W.C. control)

 Regulated IGBT based Battery charger

 Disconnecting and Earthing device.

 On-line insulation monitoring relays

 MCBS

Anti-skid device

Dc-dc converters

Space for the main contactors

Battery charger

Disconnecting and
earthing device
S
w
 MCBs for Lighting and
Pump/ Sanitary
Equipment

Anti Skid Device

Wago Connectors for Cable

Terminators

Microprocessor
Controller for AC
Package Unit (Rotating
Frame)

Space for the

Disconnecting And
Earthing Device
 Cable alleys

Insulation Monitoring device

1 kVA
transformer LV fuses
(transformer)

Switchboard View with Top Right Door Open

Indication and Controls on Left Side Door
Additions / Modifications done later on…
• Provision of individual leaf doors with push type
locking arrangement.

• Provision of stainless steel doors for the bottom

panel doors,

• Left door has been made in two parts.

• Feeder contactors control from 110 volts DC have

been changed to 415 volts AC like the conventional
AC coaches.
 Stainless Steel
Doors

Modified Doors
Disconnecting and Earthing Device
• Disconnecting and Earthing Device is an OFF load
device rated for 125 amps at 750 volts fed from
Generator Car through ZS couplings.

• This is provided in Switch Board Cabinet.

• It has two positions ON & EARTH.

• It disconnects feed at 750V and earths the coach

in of emergency like contactor jamming
case
maintenance of coach even or running
during coaches. of
ON
position OFF
position

Hand
Lever
Disconnecting and Earthing Device
 Microprocessor Controlled AC Package Unit
(RMPU type)
• Microprocessor controlled, two AC package units are
provided in each coach at the ends.

• Both package units are controlled by a microcomputer

based controller, mounted in switch board cabinet S1 and
fed from battery net.

• These units work in fully automatic mode. Depending on

ambient temperature, available modes of heating,
ventilating, cooling and dehumidifying are selected and
controlled.
Technical Data (Output data per unit)
Cooling capacity 7.0TR

Heating capacity 6.0 kW

Compressor motors 4.9 kW

Nominal power 16.5 kVA

Supply Voltage 415 V, 3 Ø, AC, 50 Hz

Fan motor axial (for condenser) 1HP, 415V, 3 Ø, AC, 50 Hz

Fan motor radial (for evaporator) 1.5HP, 415V, 3 Ø, AC, 50 Hz

Air volume

Fresh air supply (m3/hr) 820

Max. power input, cooling (kW) 13.25

Max. power input, heating (kW) 6.0

Max. power input, dehumidifying (kW) 11.0 Approximate

Refrigerant R-22

Weight (kg) 630 Approximate

Dimensions (mm) 2200 x 2000 x 500

Quantity of refrigerant

RMPU Make Approx. Qty. per unit

Fedders Lloyd/ LELL 4.2 kg per unit

Amit 3.2 kg per unit

SIDWAL/ INTEC 2.85 kg per unit

Condenser Fans Air Intake For Condenser
Fans

Roof Mounted AC Package Unit

 Each air conditioning package unit has two separate
cooling circuits consisting of following
components:

• Refrigeration compressors - Two

• Condensers
(nos.) with Copper pipes and
Aluminum fins - Two (nos.)

• Condenser fan - Two (nos.)

• Evaporators with Copper pipes and

Aluminum fins - Two (nos.)

• Heating assembly - One (nos.)

• Twin-sucking radial fans for supply air
(driven by single motor) - One (nos.)
• Maintenance covers - Six (nos.)
• Air inlets for circulating air - Two (nos.)
• Air inlets for fresh air -
Two(nos.)
• Mixed air filters & Fresh air filter - for two (nos.) of each
• Air outlet for supply air - One (no.)

• Control and safety devices - HP-2,LP-

2,OHP-1
ESTI-1,control Pressure-2.
 Condenser Air Intake
Grill
Flexible Conduit For Electrical
Connection To Unit

Electrical Junction Box (One On

Each Side)

Fresh Air
Duct (Canvas/ Latest As
Per Rdso
Spec.)
Mounting
Bracket

Return Air
Duct
 Earthing Cable

Evaporator Motor

Heater Area

Evaporator Motor Unit in RMPU

Compressors Copper Heating
Refrigerant Unit
Evaporator
Pipi
Motor Unit
ng
Compressors Units in RMPU
RMPU Heating Unit
 PRESSURE TRANSDUCERS

Pressure Transducers in RMPU

 Fresh
Air
Damper
Servo Motor

Junction Box

Servomotor Controlled Fresh Air Dampers in RMPU

 LP GAUGE HP GAUGE

Temperature Air Condition Fault Selector Switch

Selector Off-on Switch Indication For Lp/Hp
Switch Lamp Measurement

Control Panel
Micro Controller

Cage Clamp
Connector

Microprocessor Based Controller for RMPU

Thermostat Heating Elements With
Fuseable Cartridge

Heating Unit Elements in RMPU

a) Compressor

i. Hermetically sealed scroll compressor

ii. Each with min 3.5 TR capacity at 60

Deg C condensing and 5 Deg C evaporating
temperature.

iii. Total rating of AC package unit not less than 7 Tr.

b) Heat Exchangers

i. Air cooled

ii. Copper tubes with aluminum fins

c) Filters

i. Each unit has 2 fresh air and 2 mixed air filters

ii. Material is progressively structured, non –

woven break resistant, thermally bonded fire
retardant synthetic material.
d) Humidity Control

i. Restricts the humidity level to 60 %

ii. Monitored by Hygrostat

iii. Desired temperature is achieved by switching on

heaters as per logic, such that the combined
power consumption does not exceed the
permissible power under cooling capacity.
e) Sensors

i. NTC type sensors

ii. Temperature settings are achieved by rotary
switch provided on the Switch Board Cabinet.
Temperature
Position of switch
Cooling Heating
1 20.0 Deg C 17.0 Deg C
2 20.5 Deg C 17.5 Deg C
3 21.2 Deg C 18.2 Deg C
4 21.9 Deg C 18.9 Deg C
5 22.6 Deg C 19.6 Deg C
6 24.3 Deg C 20.3 Deg C
7 25.0 Deg C 21.0 Deg C
g) Refrigerating Piping

i. As per
drawing.

h) Protections
have been provided in the
i. LP, HP cut
outs refrigerant
ii. Overheat
circuit protector has been provided in the heater
circuit
iii. ESTI protection has been provided in the heater
circuit to operate at 130°C in case of failure of
overheat protector for ultimate disconnection of
power supply to heater.

iv. Individual electrical protection has been provided

by MCB’s

v. In-built overheat also been

protection has provided in which
the motors windings,
interlocked with microprocessor. are
 Ratings of Important Electrical Equipment
S Qty/
Equipment Rating Coach
N
Step down 3 Ø, 750 V/ 415V AC,
1 Transformer 1
60kVA

70 Ah, 12 V 9 Mono
2 Battery Monoblock, Lead Tin/ blocks
VRLA
Sealed
3 Compressor 3 Ø, 415 V AC 4

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

5 Blower Motor 1.5 HP, 3 Ø, 415 V AC 2
 Qty/
SN Equipment Rating Coach
6 Condenser Coil Fin on tube type 4
7 Cooling Coil Fin on tube type 4
8 Heater Unit 3 Ø, 415 V AC, 6 kW 2
9 Monoblock Pump 3 Ø, 415 V AC, 0.5 HP 2
Input : 230V±5%, 1 Ø
10 Emergency Charger 1
Output : 110 V DC

Input: 415V, 3 Ø, AC
11 Regulated Charger 1
Output: 110 V DC
• 110V (9 modules of 12 volt, 70Ah) VRLA battery

• Battery fuse box

• Battery charger

• Internal light fittings

110V (9 modules of 12 volt, 70 Ah) VRLA
Battery
 Coaches are provided with 9 modules of 12 volt
70Ah, VRLA battery in series in one battery box.

 The auxiliary power required for charging is supplied

by a battery charger at constant voltage based as
required by the battery.

 Current limit for battery charging is 20 Amp. on

board charging at constant voltage with the voltage
setting at 122.0 ± 1.0 volt.
Battery Module Salient Features
• Capacity : 12 V 70 Ah (at 27° C) battery
module
• Container : PP-CP (Polypropylene Co-Polymers)
V2 grade/ ABS FR V2 grade
• Rate of Discharge : 10 hr
• Overall length : 352 mm
• Maximum height : 178 mm
• Dimensions width : 170 mm
• Maximum weight per module : 26.5 Kg
 9 Modules Of 12 Volts Each
Total Weight 235 Kg

Battery Box

Clamping
Arrgt.

End Cell

Connector
Battery Fuse Box

Battery fuse box is provided in under frame

supported on brackets by fixing bolts. This box is
properly earthed by earth cable. It is totally covered
and locked by hinged bolts.
 Shunt

HRC
Fuses

Clamp
Cage
Connectors
Battery Fuse Box (-ve)
 Mounting

Cable Entry
Holes

Hall Effect

Transduce
r

Box
Cover
IGBT Based Battery Charger

 It is a 19” switch cabinet rack, force cooled

mounted inside switch board cabinet, with current
and temperature sensors.

 It converts transformer’s secondary voltage 3Ø,

415V, AC into 110V, DC for charging battery and
feeding direct voltage loads.

 It has a power capacity of 6.5 Kw.

It has following features:

• Phase angle control for CVCI charging

• Low voltage and current ripples as low as 2% and

THD less than 3%.

• Charging dependent on electrolyte temperature which

is monitored by temperature sensor provided inside
battery box.

• Soft start and quick shutdown

Modifications / changes

• The Hall Effect transducer provided in Battery fuse

box (to control the charging current of the battery) in
the earlier OEM design coaches has been shifted to
the battery charger itself.

• The wiring for the same has also been removed.

Light Fittings

 Light fittings are provided with injection moulded

and extruded diffuser for defused lighting with
uniformity of illumination and lumen as per UIC.

 These fittings are screw less and press fit type.

 Vestibule, toilet, pantry and emergency lighting

works at 110V AC /DC with inverter and poly
carbonate diffusers.
 Reading lights are halogen type.

 Complete lighting is with high frequency ballast (58

kHz) for flicker free comfort lighting.
Ratings of different lightings

Fluorescent tubes (watt) : 18

Halogen lamp (watt) : 10 (reading lights)

LIGHT FITTINGS
Compartment light fitting

CENTRE Incandescent Lamp

RIBBON

FITTING
AC Duct Panelling

Compartment Light Inside View

 Terminal Strip
For Connection

LIGHT
FITTING
Inverter/ Ballast
Mounted
Along
The Fitting

Fluorescent Light Fitting Inverter

Vestibule light fitting

Injection Moulded
End Piece

Polycarbonate
Extruded Diffuser

Vestibule Light Fitting

FITTING

DOOR

Doorway Light Fitting

Reading Light

Focus Halogen Off-on Switch Luggage

Adjustment Lamp Rack
Screw
Reading Light Fitting
 Reading Light Inverter Integrated In Luggage Rack

READING LIGHT
ASSY.

Reading Light Inverter / Ballast

Name Description Supply Voltage

1 AC Compact Controller 110 VDC

2Disconnecting & Earthing Device A-3 750 VAC, 110 VDC
Regulated Battery Charger (RBC) A-5 415 VAC/110 VDC
Pump Controller 110 VDC, 24 VDC
A-6 Insulation Control Relay AC 220 VAC, 110 VAC
110V
A-7 220 VAC
Insulation Control Relay
AC 240V/415V
DC/ DC Converter (110V/24V) for
A-8 Return/ Fresh Air Flap Servo 110 VDC/24 VDC
Motors, Bar Gauges & Transducers
 Supply
Name Description

1. MCB (Triple Pole) 10A for Ventilation Fan Motor Voltag

415 VAC e
Unit 1 (Blower Motor-1)
2. MCB (Triple Pole) 10A for Ventilation Fan Motor
415 VAC
Unit 2 (Blower Motor-2)

3.MCB (Triple Pole) 20A for Compressor Motor 1.1 415

VAC F-04 MCB (Double Pole) 10A for

 Supply
Name Description
Voltag
e
6. MCB (Triple Pole) 10A for Condenser Fan Motor 1.1
415 VAC

7. MCB (Triple Pole) 10A for Condenser Fan Motor 1.2

8. MCB (Triple Pole) 6A for Heater Unit-1 (NPPS)
415 VAC 415 VAC
9. MCB (Triple Pole) 20A for Compressor Motor 415 VAC
2.1
10 MCB (Double Pole) 10A for Crankcase Heaters (for
220 VAC
CP 2.1 & CP 2.2)

11MCB (Triple Pole) 20A for Compressor Motor 2.2 415

VAC F-12 MCB

 Supply
Name Description
Voltag
e

F-13
MCB (Triple Pole) 10A for Condenser Fan Motor 415 VAC
2.2

14 MCB (Triple Pole) 16A for Heater Unit-2 415 VAC

(PPS)
415 VAC
15MCB (Triple Pole) 16A for Exhaust Fans F-
220 VAC
16 MCB (Double Pole) 16A for Water Boiler
220 VAC
F-17 MCB (Double Pole) 10A for Soup Boiler
220 VAC
F-18 MCB (Double Pole) 16A for Hot Case
F-19 MCB (Double Pole) 6A for Bottle 220 VAC
Cooler
 Supply
Name Description
Voltag
MCB (Double Pole) 6A for Refrigerator (Deep e
F-20 220 VAC
Freezer)

MPCB (Motor Protection Circuit Breaker) (1 to

A-21 415 VAC
1.6A) for Water Pump-1

MPCB (Motor Protection Circuit Breaker) (1 to

A-22 1.6A) for Water Pump-2 (Overload Relay for 415 VAC
Water Pump-2)

F-24 MCB (Double Pole) 10A for Light 110

Control VDC
Name Description Supply Voltage

MCB (Double Pole) 10A for Emergency

F-25 Lights 110
VDC

MCB (Double Pole) 10A for Emergency

F-26 Lights 110
VDC
27 MCB (Double Pole) 16A for Reading 110
Lights VDC
28 MCB (Double Pole) 16A for Reading 110
Lights (Double Pole) 16A for DC/ VDC
F-29 MCB 110
Converter
DC
VDC

MCB (Double Pole) 6A for Minimal Voltage

F-30 Relay 110
VDC
Name Description Supply Voltage

MCB (Double Pole) 6A for Telephone (First

F-31 Class only) 110
VDC
(Double Pole) 6A for Diagnosis
F-32 MCB 110
(Indications & ACP
VDC
lights)
33 MCB (Double Pole) 10A for Power 110
Supply VDC
34 MCB (Double Pole) 10A for Night Lights 110
MCB (Double Pole) 6A for AC Compact VDC
110
F-35 Controller
VDC
24 VDC, 110
F-36 MCB (Double Pole) 6A for Pump
VDC
Control
Name Description Supply Voltage

(Double Pole) 10A for

F-37 MCB 24 VDC
Control Sanitary
F-38 MCB (Double Pole) 10A for Loud 24 VDC
Speaker F-39 MCB (Double Pole) 10A for 110
Coach Light F-40 MCB (Double Pole) 10A for VAC

Coach Light 110

MCB
F-41 Socket
(Double Pole) 6A for Electric Razor VAC
110
VAC
HRC Fuse (25A) for 110V (+ve) DC Supply
F-42 to Panel 110
VAC
HRC Fuse (25A) for 110V (-ve) DC Supply
F-43 to Panel 110
VAC
Name Description Supply Voltage

F-44
HRC Fuse (100A) in R-phase of Output 415 VAC
60 KVA
of Transformer
F-45
HRC Fuse (100A) in Y-phase of Output 415 VAC
60 KVA
of Transformer
F-46
HRC Fuse (100A) in B-phase of Output 415 VAC
60 KVA
of Transformer
F-47
HRC Fuse (80A) in Local Main Supply (R- 415 VAC
phase)

HRC Fuse
F-48 phase)
(80A) in Local Main Supply (Y- 415 VAC

HRC Fuse
F-49 phase)
(80A) in Local Main Supply (B- 415 VAC
Name Description Supply Voltage

HRC Fuse HT (63A) in R-phase

for
F-50 Network-1(Feeder-1) 750 VAC

HRC Fuse HT (63A) in Y-phase

for
F-51 Network-1(Feeder- 750 VAC

HRC Fuse HT (63A) in B-phase for

F-52 1) Network- 750 VAC

HRC Fuse HT (63A) in R-phase

for
F-53 1(Feeder-1) 750 VAC

HRC Fuse for

F-54 HT (63A) in Y-phase 750 VAC
Network-2(Feeder-
Name Description Supply Voltage

Fuse HT (63A) in B-phase

F-55 HRC 750 VAC
Network-2(Feeder-2)
for

F-56 Glass Fuse (4A) UIC Remote Control (+ve) 24 VDC

F-57 Glass Fuse (2A) UIC Remote Control (-ve) 24 VDC

Glass Fuse (2A) in Phase

F-58 Insulation Control Relay (A-6)
for AC 110V 110
VAC

Glass Fuse (2A) in Neutral for AC 110V

F-59 Insulation Control Relay (A-6) 110
VAC
Name Description Supply

Voltag
e
Glass Fuse (4A) in Phase for AC 110V
F-60 Insulation Control Relay (A-6) & AC 220 VAC
240V/415V Insulation Control Relay (A-7)

Glass Fuse (4A) in Neutral for AC 110V

F-61 Insulation Control Relay (A-6) & AC 220 VAC
240V/415V Insulation Control Relay (A-7)

Glass Fuse (2A) in Neutral for AC 110V

F-62 Insulation Control Relay (A-6) & AC 220 VAC
240V/415V Insulation Control Relay (A-7)

Glass Fuse (6.3A) in +ve 110V DC for Anti Skid

F-63 110 VDC
Device
 Supply
Name Description
Voltag
e
F-64 Glass Fuse (6.3A) in +ve 110V DC for Brake 110 VDC
Glass Fuse (6.3A) in -ve 110V DC for
F-65 110 VDC
Anti Skid Device
F-66 Glass Fuse (6.3A) in -ve 110V DC for Brake 110 VDC
F-67 Glass Fuse (1A) in Control Supply of K-41 220 VAC
F-68 Glass Fuse (1A) in Control Supply of K-42 220 VAC
Glass Fuse (1A) in R-phase of K-45
F-69 415 VAC
(MMR for LMS)

F-70 Glass Fuse (1A) in Y-phase of K-45 (MMR 415 VAC

for LMS)
Name Description Supply

Voltag
e
Glass Fuse (1A) in B-phase of K-45 (MMR for
F-71 415 VAC
LMS)
F-72 Glass Fuse (1A) in Control Supply of K-44 220 VAC
F-73 Glass Fuse (1A) in Control Supply of K-23 220 VAC
Glass Fuse (10A) in Input Phase of
F-74 220 VAC
Lighting X’mer
Glass Fuse (10A) in Input Neutral of
F-75 220 VAC
Lighting X’mer

HRC Fuse (100A) in R-phase of Output of 60

F-76 KVA Transformer No. 2 (in Pantry car & 415 VAC
German Power car)
 Supply
Name Description
Voltag
e
HRC Fuse (100A) in Y-phase of Output of 60
F-77 KVA Transformer No. 2 (in Pantry car & 415 VAC
German Power car)

HRC Fuse (100A) in B-phase of Output of 60

F-78 KVA Transformer No. 2 (in Pantry car & 415 VAC
German Power car)

HRC Fuse (63A) in R-phase for Radiator Motor,

F-79 415 VAC
Roof Extractor-1 & 2

HRC Fuse (63A) in Y-phase for Radiator Motor,

F-80 415 VAC
Roof Extractor-1 & 2
 Supply
Name Description
Voltag
e
HRC Fuse (63A) in B-phase for Radiator Motor,
F-81 415 VAC
Roof Extractor-1 & 2

F-82 HRC Fuse (63A) in R-phase for Radiator Motor, 415 VAC
Roof Extractor-3 & 4

HRC Fuse (63A) in Y-phase for Radiator Motor,

F-83 415 VAC
Roof Extractor-3 & 4

HRC Fuse (63A) in B-phase for Radiator Motor,

F-84 415 VAC
Roof Extractor-3 & 4

Motor Protection Circuit Breaker (MPCB)

F-85 415 VAC
(0.1 to 2.5A) for Exhaust Fan-I
 Supply
Name Description
Voltage
Motor Protection Circuit Breaker (MPCB)
F-86 415 VAC
(0.1 to 2.5A) for Exhaust Fan-II

Motor Protection Circuit Breaker (MPCB) (0.25

F-87 415 VAC
to 4.0A) for Exhaust Fan-III

HRC Fuse (1A) in R-phase of 750V Volt Meter

F-90 750 VAC
Network-1 (Feeder-1)

HRC Fuse (1A) in Y-phase of 750V Volt Meter

F-91 750 VAC
Network-1 (Feeder-1)
HRC Fuse (1A) in B-phase of 750V Volt Meter
F-93 750 VAC
Network-1 (Feeder-1)
 Supply
Name Description
Voltage
HRC Fuse (1A) in R-phase of 750V Volt Meter
F-94 750 VAC
Network-2 (Feeder-2)

HRC Fuse (1A) in Y-phase of 750V Volt Meter

F-95 750 VAC
Network-2 (Feeder-2)

HRC Fuse (1A) in B-phase of 750V Volt Meter

F-96 750 VAC
Network-2 (Feeder-2)

HRC Fuse (1A) in Control Supply of K-01

F-97 750 VAC
Net-1 Contactor (in Rev.-D only)
HRC Fuse (1A) in Control Supply of K-
F-98 750 VAC
01 Net-2 Contactor (in Rev.-D only)
 Supply
Name Description
Voltag
e
Glass Fuse (2A) in Phase of Insulation Control
F-100 Relay AC 415/240V for Transformer-1 (in 220 VAC
Power Cars only)

Glass Fuse (2A) in Phase of Insulation Control

F-101 Relay AC 415/240V for Transformer-1 (in 220 VAC
Power Cars only)

Glass Fuse (2A) in Phase of Insulation Control

F-102 Relay AC 415/240V for Transformer-2 (in 220 VAC
Power Cars only)

Glass Fuse (2A) in Phase of Insulation Control

F-103 Relay AC 415/240V for Transformer-2 (in 220 VAC
Power Cars only)
 Supply
Name Description
Voltag
e
H-1 Indication Operation Supply Net-1 110 VDC

H-2 Indication Operation Supply Net-2 110 VDC

H-3 Indication Operation Charger Float 110 VDC

H-4 Indication Operation Local Main Supply-1 110 VDC

H-5 Indication Operation Local Main Supply-2 110 VDC

H-6 Indication Operation Charger Boost 110 VDC

 Supply
Name Description
Voltag
e
H-7 Indication Anti Skid Device Defect 110 VDC

H-8 Indication Insulation Failure 110V 110 VDC

H-9 Indication Insulation Failure 415V 110 VDC

H-10 Indication Operation 415V OK 110 VDC

H-11 Indication Operation MMR Net-1OK 110 VDC

H-12 Indication Operation MMR Net-2OK 110 VDC

 Supply
Name Description
Voltag
e
110 VDC,
K-01 Main Feeder Contactor Network-1 (Feeder-1)
750 VAC
110 VDC,
K-02 Main Feeder Contactor Network-2 (Feeder-2)
750 VAC
Measuring & Monitoring Relay (MMR) 24 VDC,
K-03
for Network-1(Feeder-1) 750 VAC 110 VDC,

K-04 Measuring & Monitoring Relay (MMR) 24 VDC,

for 110 VDC,
Network-2(Feeder-2) 750 VAC
K-05 Timer for Anti Skid Device 110 VDC
Name Description Supply

Voltag
e
Contactor for Electro Pneumatic 24 VDC,
K-06
Brake Application 110 VDC

K-07 Contactor for Electro Pneumatic Brake 24 VDC,

Release 110 VDC

Contactor for Level 1 of Minimal Voltage

K-08 Relay (MVR) (96V+120 Minutes for 110 VDC
Emergency Light OFF)

Contactor for Level 2 of Minimal Voltage

K-09 Relay(MVR) (104V+30 Minutes for DC/DC 110 VDC
Converters OFF)
Name Description Supply

Voltag
e
Contactor for Level 3 of Minimal 110 VDC,
K-10
Voltage Relay (MVR) (106V for Reading 220 VAC
Light OFF)
110 VDC,
K-11 Contactor for Main Light Passenger Room
110 VAC
K-12 Contactor for Reading Light 110 VDC
K-13 Contactor for Night Light 110 VDC
Contactor for Main Light Entrance Area 110 VDC,
K-14
& Sanitary Rooms 110 VAC
K-15 Contactor for Emergency Light 110 VDC
Name Description Supply

Voltag
e
K-17 Timer for Light ON/OFF (15-300 Min) 110 VDC
Timer for External Power Supply/ Local Main
K-18 Supply (L.M.S.) (for blinking of outdoor 110 VDC
lamps)

24 VDC,
K-19 Relay for UIC-Light-Remote Control ON
110 VDC

K-20 Relay for UIC-Light-Remote Control OFF 24 VDC,

110 VDC

K-21 Contactor for Fresh Air Flap Motor 24 VDC

Name Description Supply Voltage
110 VDC, 220
K-23 Contactor for 415V OK
VAC

K-24 Contactor for Water Pump No. 1 24 VDC/110

VDC, 415 VAC

K-25 Contactor for Water Pump No. 2 24 VDC/110

VDC, 415 VAC

K-26 Contactor for Ventilation Fan 110 VDC, 415

Motor VAC
Unit-1(Blower-1/NPPS)
K-27 Contactor for Controller OK 110 VDC
Name Description Supply

Voltag
e
Contactor for Ventilation Fan Motor Unit- 110 VDC,
K-28
2 415 VAC
(Blower-2/PPS)
110 VDC,
K-29 Contactor for Exhaust Fan Motors
415 VAC
110 VDC,
K-31 Contactor for Condenser Fan Motor 1.1
415 VAC
110 VDC,
K-32 Contactor for Condenser Fan Motor 1.2
415 VAC
110 VDC,
K-33 Contactor for Compressor Motor 1.1
415 VAC
110 VDC,
K-34 Contactor for Compressor Motor 1.2
415 VAC
Name Description Supply

Voltag
e
110 VDC,
K-36 Contactor for Condenser Fan Motor 2.1
415 VAC
110 VDC,
K-37 Contactor for Condenser Fan Motor 2.2
415 VAC
110 VDC,
K-38 Contactor for Compressor Motor 2.1
415 VAC
110 VDC,
K-39 Contactor for Compressor Motor 2.2
415 VAC
110 VDC,
K-40 Contactor for Heater Unit 2 (PPS)
415 VAC
220 VAC,
K-41 Contactor for Local Main Supply-2 (LMS-2)
415 VAC
220 VAC,
Name Description Supply

Voltag
e
Main Contactor for Local Main 110 VDC,
K-43
Supply
(LMS) 415 VAC
Contactor in the Output of 60 KVA 220 VAC,
K-44
Transformer (After 100A Fuses) 415 VAC
Measuring & Monitoring Relay (MMR) 110 VDC,
K-45
for
Local Main Supply (LMS) 415 VAC
Contactor in the Output of 60
K-46 220 VAC,
KVA Transformer-2 (in Original
415 VAC
German Power
cars & Pantry cars)
Interlocking Contactor for Changeover of
110 VAC,
 Supply
Name Description
Voltag
e
Ampere Meter, AC (0-200 Amp) for
P-1 mV
Panel Load

P-2 Volt Meter, AC (0-800V) for Network-1 (RY) 750 VAC

P-3 Volt Meter, AC (0-800V) for Network-1 (YB) 750 VAC
P-4 Volt Meter, AC (0-800V) for Network-1 (BR) 750 VAC
P-5 Volt Meter, AC (0-800V) for Network-2 (RY) 750 VAC
P-6 Volt Meter, AC (0-800V) for Network-2 (YB) 750 VAC
P-7 Volt Meter, AC (0-800V) for Network-2 (BR) 750 VAC
 Supply
Name Description
Voltag
e
Ampere Meter, DC (+ve 100-0-100 -ve)
P-8 mV
for Charge-Discharge Battery Net

Ampere Meter, DC (0-40Amp) for

P-9 mV
Consumer Current Net

P-10 Volt Meter, DC (0-150V) for Battery Net 110 VDC

 Supply
Name Description
Voltag
e
110 VAC, 110
Switch, Selector Power Supply ON/OFF VDC/
S-01
(Rev.-D) 415 VAC, 750
VAC

110 VDC/
Switch, Selector Net-1, Net-2 & LMS
S-02 415 VAC, 750
(Rev.-D)
VAC
Switch, Push Button for Insulation Test
S-03 110 VDC
Battery Net +ve

S-04 Switch, Push Button for Insulation Test 110 VDC

Battery Net –ve
 Supply
Name Description
Voltag
e
Switch, Push Button for Test
S-05 110 VDC
Indication Lamps

S-06 Switch, Push Button for Train Light ON 24 VDC

S-07 Switch, Push Button for Train Light OFF 24 VDC

S-08 Switch, Push Button for Lighting ON 24 VDC

Switch, Push Button for Night

S-09 110 VDC
Lighting ON

S-10 Switch, Push Button for Lighting OFF 110 VDC

 Supply
Name Description
Voltage
U-1 Anti Skid Device 110 VDC
DC/DC Converter (110V/24V) for Water 110 VDC,
U-2.1
Pump Control & Sanitory Control 24 VDC

DC/DC Converter (110V/24V) for Loud

U-2.2 Speaker System MMRs & UIC Remote 110 VDC,
Control 24 VDC

U-2.3 Minimal Voltage Relay (MVR) 110 VDC

U-3 Amplifier Loud Speaker system 24 VDC

U-4 Air Conditioning Control Switch Panel 24 VDC,

110 VDC
Termina Termina
Description Description
l no. l no.
231 256
232 Ventilation-1 257 CD fan 1.2
233 258
234 Earth 259
235 260 Compressor 2.1
236 Ventilation-2 261
237 262 Earth
238 Earth 263
239 264 Compressor 2.2
240 Compressor 1.1 265
241 266 Earth
 Termina
Termina Description l no. Description
l no.

242 Earth 267

243 268 Heater-2

244 Compressor 1.2 269

245 270
246 Earth 271 Crank Heater-2

247 272
248 Heater-1 273 CD fan 2.1
249 274
 Termina
Termina Description l no. Description
l no.
251 Crank Heater-1 276
252 277 CD fan 2.2

253 278
254 CD fan 1.1 279
255 280 Exhaust fan

281
Fuse Rating
Description (Located in)
No. (A)

75 10 Neutral Input supply to Lighting transformer

74 10 Phase Input supply to Lighting transformer
73 1 Control supply to K-23
72 1 Control supply to K-44
71 1 Blue Phase of MMR of local Main Supply
70 1 Yellow Phase of MMR of local Main Supply
69 1 Red Phase of MMR of local Main Supply
68 1 Control supply to K-42
67 1 Control supply to K-41
Fuse Rating
Description (Located in)
No. (A)
66 6.3 -ve 110 VDC supply for Brake
65 6.3 -ve 110 VDC supply for Anti Skid device
64 6.3 +ve 110 VDC supply for Brake
63 6.3 +ve 110 VDC supply for Anti Skid device
62 2 Neutral of AC 110 V Insulation Control
relay (A-6) & AC 240/415 V Insulation
61 4 Control relay (A-7)

Phase of AC 110 V Insulation Control relay

60 4 (A-6) & AC 240/415 V Insulation Control
relay (A-7)
Fuse Rating
Description (Located in)
No. (A)

Neutral of AC 110 V Insulation Control

59 2
relay (A-6)

Phase of AC 110 V Insulation Control relay

58 2
(A-6)
57 2 -ve of 24 V UIC remote control
56 4 +ve of 24 V UIC remote control
 X 301 X 501
1 OC OC 6
O 1 Controller Fault O 11
2 O1 OK O 11 5
DIGITAL

DIGITAL OUTPUT
3 O2 O 12 4
O 2 Recirculati Out Side O 12
4 O3 on Air Air O 13 3
5 O4 Ventilatio Ventilati O 14 2
O3 O 13
6 O5 n Fan 1 o n Fan O 15 1
2

X 302 X 502
O 4 Not Exhaust O 14
1 OC Active in Fan OC 6
DIGITAL OUTP

System

OUTPUT
2 O6 Bypass Bypass O 16 5
O 5 Cooling Cooling O 15
3 O7 O 17 4
1/1 2/1
1 I1 Compress Compres I 11 11
O8 O 18
2 I2 o r 1/1 sor 2/1 I 12 10

3 I3 Compresso Compres I 13 9
O9 O 19
4 I4 r 1/2 sor 2/2 I 14 8
5 I5 O E.I. Heater E.I. I 15 7
DIGITAL INPUT

O 20
6 IC 1 Heater 2 IC 6

DIGITAL INPUT
10
STA
7 I6 I 16 5
T
RUN : 1
STAT
8 I7 I 17 4
2
9 I8 I 18 3
10 I9 I 19 2
I 1 Air - 'ON' 400V OK I 11
11 I 10 I 20 1
12 IC X 104
Temp Temp
. .
I2 I 12
X 101 Cond. Cond. +
Motor 1.1
OK Motor
2.1

ANALOG INP 4….20 MA

OK

1 RES -
Temp. Temp
Cond. .
I3 I 13
Motor 1.2 Cond.
NETWORK

2 CH
OK
Motor +
2.2 OK
3 CL Ven -
Vent
 X 102 Temp. E.I. 10
Temp. E.I.
I5 Heater I 15
1 RES Heater 1 OK

NETWORK
2 9
OK

2 CH Low Low 8
I 6 Pressure 1.1 I 16
3 CL
OK Pressure 7
2.1

ANA LOG INPUT NTC

OK
4 0V Low Low 6
I 7 Pressure 1.2 Pressure I 17
X 103
OK 2.2 OK 5
RS 232 C Control Control 4
I8 I 18
X 104 Pressure 1 Pressure
2 3
High High
SUPPLY

1 + I 9 Pressure 1.1 I 19 2
Fault Pressure 1
 Lamp no. Lamp no.

SID/ Meaning of Display SID/ Meaning of Display

LHB/ LHB/
Liebh liebh
err err
LEEL LEEL
Glows when controller Glows for fault in
K-118 01 K-119 011
is healthy AC system

Glows when Fresh/ Glows when Fresh/

K-116 02 Recirculating Air flap K-117 012 Recirculating Air flap
is set at Recirculating is set at Fresh Air
Air
Glows when Glows when Ventilation-
K-113 03 K-114 013
Ventilation-I is ON II is ON
 Lamp no. Lamp no.
SID/ Meaning of Display SID/ Meaning of Display
LHB/ LHB/
Liebh liebh
err err
LEEL LEEL
This indication is not for Glows when
K-21 04 K-115 014
AC system Ventilation-II is ON

Glows during
Glows during cooling
cooling operation
K107 05 operation indicates K-108 015 indicates bypass
bypass cooling in Unit-I
cooling in Unit-II

Glows during cooling Glows during

operation indicates cooling operation
K-109 06 pressure switch K-111 016 indicates pressure
functional when CD 1.1 switch functional
in Unit-I starts. when CD
2.1 in Unit-II starts.
 Lamp no. Lamp no.
SID/ Meaning of Display SID/
LHB/ LHB/ Meaning of Display
Liebh liebhe
err rr
LEEL LEEL
Glows during cooling Glows during
operation indicates cooling operation
pressure switch indicates pressure
K-110 07 K-112 017
functional when CD 1.2 switch functional
in Unit-I starts. when CD
2.2 in Unit-I starts.
Glows during Glows during
K-101 08 cooling operation K-103 018 cooling operation
indicates Comp 1.1 indicates Comp 2.1
ON ON
Glows during Glows during
K-102 09 cooling operation K-104 019 cooling operation
indicates Comp 1.2 indicates Comp 2.2
ON ON
 Lamp no. Lamp no.
SID/ SID/
LHB/ Meaning of Display LHB/ Meaning of Display
Liebhe liebhe
rr rr
LEEL LEEL
Glows during Heating Glows during Heating
K-105 010 operation indicates K-106 020 operation indicates
Heater-I, Unit-I ON Heater-II,
Glows when AC Glows when 415V
K-15 I1 system gets ON with K-16 I11 is OK
switch S1U4S1
Glows when winding Glows when winding
temperature of CD 1.1 temperature of CD 2.1
motor is within limit. motor is within limit.
This light goes OFF This light goes OFF
K-1 I2 when winding K-3 I12 when winding
temperature goes temperature goes
beyond limit & the beyond limit & the
motor also switches motor also switches
OFF. OFF.
Lamp no. Lamp no.

LHB/ Meaning of Display LHB/ Meaning of Display

SID SID

LEEL LEEL

Glows when Glows when

winding winding
temperature of CD temperature of CD
1.2 2.2
motor is within motor is within
limit. limit.
This light goes This light goes
OFF OFF
K-2 I3 when K-4 I13 when
winding winding
temperature temperature
goes goes
beyond limit & beyond limit &
the the
 Lamp no. Lamp no.

LHB/ Meaning of Display LHB/ Meaning of Display

SID SID
LEEL LEEL

This is OFF
when This is OFF when
winding temperature of winding temperature of
Ventilation-I motor Ventilation-II motor is
is within limit. This light
within limit. This Glows when winding
light temperature goes beyond
K-13 I4 Glows when K-14 I14
limit & the AC Unit-II
winding
temperature also goes out of service.
goes
beyond limit & the AC
Unit-I also goes out of
service.
 Lamp no. Lamp no.
LHB/ Meaning of Display Meaning of Display
SID
LHB/
LEEL SID
LEEL
Glows when temperature
Glows when temperature of
of Heater-I, Unit-I is
Heater-II, Unit-II is within
within limit. This light
limit. This light goes OFF
K-17 I5 goes OFF when Heater K-18 I15 when Heater temperature
temperature goes beyond
goes beyond limit & the
limit & the Heater also
Heater also switches OFF.
switches OFF.

Glows when LP is OK. Glows when LP is OK.

This light goes OFF when This light goes OFF when
pressure at LP switch of pressure at LP switch of
refrigerant circuit 1.1 goes refrigerant circuit 2.1 goes
K-6 I6 down and switches off K-10 I16 down and switches off
refrigerant circuit 1.1 if refrigerant circuit 2.1 if the
the pressure remains low pressure remains low for
for more then 30 seconds. more then 30 seconds.
Lamp no. Lamp no.

LHB/ Meaning of Display Meaning of Display

SID
LHB/
LEEL SID
LEEL
Glows when LP is OK.
This light goes OFF Glows when LP is OK.
when pressure at LP This light goes OFF when
switch of refrigerant pressure at LP switch of
circuit 1.2 goes down refrigerant circuit 2.2 goes
K-8 I7 K-12 I17
and switches off down and switches off
refrigerant circuit 1.2 if refrigerant circuit 2.2 if
the pressure remains the pressure remains low
low for more then 30 for more then 30 seconds.
seconds.
Lamp no. Lamp no.
LHB/ Meaning of Display LHB/ Meaning of Display
SID SID
LEEL LEEL
Glows when Glows when
Control pressure Control pressure
switch-1 is ON, switch-2 is ON,
which means HP which means HP
is more then 25 is more then 25
bar which will bar which will
K-19 I8 K-20 I18
automatically run automatically run
second condenser second
motor. condenser motor.
Lamp no. Lamp no.
LHB/ Meaning of Display LHB/ Meaning of Display
SID SID

LEEL LEEL

This will Glow

This will Glow when HP gets
when HP gets more more then
then setting of HP setting of HP cut
K-5 I9 cut out switch 1.1 K-9 I19 out switch 2.1
and the compressor and the
1.1, Unit-I will get compressor 2.1,
OFF Unit-II will get
OFF
Lamp no. Lamp no.
LHB/ Meaning of Display LHB/ Meaning of Display
SID SID
LEEL LEEL

This will Glow

This will Glow
when HP gets
when HP gets more then
more then setting setting of HP
of HP cut out cut out switch
K-7 I10 K-11 I20
switch 1.2 and 2.2 and the
the compressor compressor 2.2,
1.2, Unit-II will Unit-II will get
get OFF OFF
 Water is pumped in the coach from under slung
water tanks through Mono-block pumps.
Equipment works continuously and water is
pumped in a Auxiliary tank mounted over the
toilets. The extra water overflows from Auxiliary
tank to the main tank through a recycle pipe.
List of specifications for major equipment:

1. Roof Mounted AC Package

unit RDSO/PE/SPEC/AC/0061

2. Switchboard Cabinet,
EDTS073

3. Regulated Battery Charger,

EDTS074

4. Emergency Battery Charger ,

EDTS163
• The double-decker trains are designed indigenously by Rail
Coach Factory, Kapurthala in association with RDSO,
Lucknow.
 • The train consists of AC double-decker chair car
coaches, with 120 seats in each coach. It has increased
the passenger carrying capacity appreciably.

• Space for the two decks has been generated by using

the space between the two bogies.

• The base of the coach is also below the platform level.

Code for LHB double decker AC chair car over

Indian Railways is LWCZDAC.
• It is using End-On-Generation system.

• The power for train lighting and air-conditioning is

supplied by power cars at each end of the rack
equipped with diesel generating sets at 750 volts, 3
phase and 50Hz ac supply.
 External View of Double
Decker Train

Internal View of
Lower Deck
 The EOG supply system is same as in the case of LHB
EOG coaches.

 In these coaches 2 nos. each 60 kVA step down

transformers are provided for stepping down 750 V, 3
Φ AC, 4 wire, 50 Hz supply to 415 V, 3 Φ AC, 4 wire,
50 Hz supply.

 Each of these two transformers feed coach load and

half AC load.
Figure : Outer View of EOG AC Chair Car
Figure : Outer View of EOG AC Chair Car
1. Most of the features are same as in LHB EOG
AC coaches.

2. Additional features which are different from

LHB EOG AC coaches:

 RMPU capacity increased from 7 TR to 10 TR, and the

refrigerant used is R 407 C, eco- friendly refrigerant.

 2 nos. 60 kVA step-down transformers are provided in

each coach. These are shifted towards ends of the
coach.
60 kVA
 2 nos. water raising mono-block pump assemblies are
provided for raising the water to the coach which
operates on 415v, 3-phase, 50Hz ac supply. These are
shifted behind stairs of the coach.

Mono block pump set

 70AH Lead tin/VRLA sealed maintenance free
(SMF) battery has been housed inside the coach in
upper-frame near down stairs at PP end.
 Battery fuse is integrated in Switch board cabinet inside
the coach PP end.
 Modular Pantry has been specially designed and
provided in each coach for catering the passengers
according to available space.

 In this water bottle cooler designed for keeping 1 litre

bottles is provided in addition to RO water purifier.
Mini Pantry RO Water Purifier
 Hot Case

Bottle cooler/
Deep
Freezer
 As the space for ducting in the centre of the coach
was not available, specially designed ducting along
the sidewall has been provided for upper and lower
deck.
 A Passenger Alarm Coach Indication Light (PACIL)
circuit along with pull chain is also provided in
Double Decker coach for the use of passengers to stop
the train in case of any emergency.

PACI
L
 Mobile charging sockets
are provided in each
bay.

 Door opens automatically with the push of a button and

closes automatically after preset time. If door opening
obstructed by passenger, it remains open. In case of power
failure door operates manually.
 Fire & Smoke Detection & Early Warning system has
been provided.

 G.I. conduits have been replaced with aluminium

conduits for under-frame equipment to overcome the
problem of voltage drop in the coaches.
These coaches are equipped with the following equipment:

Switch-Board Cabinet

 Switch Board cabinet is designed with up-rated switchgear

and additional integration of battery fuse in it.

 This modular, integrated single cabinet designated switch

board cabinet comprises all necessary equipment for
control and protection of coach systems.
 Microprocessor based Heating, Ventilation & Air
conditioning
 Lighting
 Pantry
 Anti skid
protection
 Public Address
system
 Sanitary
system (except
W.C. control)
 Regulated
 Lavatory panel light control
Control unit for AC package and pantry

Control unit for water pump

Control unit for main feeder supply and network
 Two nos.
microprocessor
controlled AC
package units,
each having
10.0TR capacity
are provided in
each coach at the
ends. Condenser Fans
Air Intake For Condenser Fans
 The control and regulation
of both RMPU is performed
by one microprocessor
controller, which is located
in switch board cabinet.
Microprocessor
Based Controller for
RMPU
LCD Display LP HP
GAUGE GAUGE
 The control panel for RMPU is provided with LCD
display and it works on 110 V dc ± 30%.

 It is installed in switch board cabinet.

 There is a rotary switch on switch panel for putting

the unit in manual mode in case of emergency
SN Equipment Rating Qty/ Coach

Step down
1 3 Ø, 750 V/ 415V AC, 60kVA 2
Transforme
r
70 Ah, 12 V Mono- 9 Mono
2 Battery
block, VRLA SMF blocks

3 Sealed Compressor 3 Ø, 415 V AC 4

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

5 Blower Motor 1.5 HP, 3Ø, 415 V AC 2

SN Equipment Rating Qty/ Coach

6 Condenser Coil Fin on tube type 4

7 Cooling Coil Fin on tube type 4

8 Heater Unit 3 Ø, 415 V AC, 6 kW 2

9 Mono-block Pump 3 Ø, 415 V AC, 0.5 HP 2

Emergency Battery Input : 230V±5%, 1 Ø

10 1
Charger Output : 110 V DC

Regulated Battery Input: 415V, 3 Ø, AC

11 1
Charger Output: 110 V DC
 Light fittings are provided with injection moulded and
extruded diffuser for defused lighting with uniformity of
illumination and lumen as per UIC.

 These fittings are screw less and press fit type. Vestibule,
toilet, pantry and emergency lighting works at 110V AC
/DC with inverter and poly carbonate diffusers. Complete
lighting is with high frequency ballast (58 kHz) for flicker
free comfort lighting.
 Provision of central ribbon type light ( T-5
fluorescent tube ) for both the decks (flush type) .
Vestibule and Emergency light fitting

Emergency light fitting

Vestibule light fitting

 Toilet Light Fitting

Toilet Occupancy Indicator

• Schedule D1 : Trip / Weekly

• Schedule D2 : Monthly ± 3days

• Schedule D3 : Half Yearly ± 15 days

• Shop Schedule (SS-1), IOH : 18 Months + 30 days/6

Lakh
kms whichever is earlier

• Shop Schedule (SS-2), POH : 36 Months / 12 Lakh kms

whichever is earlier

• Shop Schedule (SS-3), POH : 72 Months/24 Lakh kms

whichever is earlier
The equipment wise maintenance activities of above schedules
 As per RDSO’s Maintenance Schedule No.
RDSO/PE/SMI/AC/0044-2011 (Rev.0) dated
02/04.11.2011, following maintenance activities to be
carried out on roof mounted AC package unit of
LHB design coaches:
General
TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check the log sheet maintained in

each AC coach and attained the
a.     
defects recorded by escorting staff
during run.

Clean all dust by vacuum cleaner or

by compressed air from the switch
b. --    
board cabinet and tighten the cable
terminals, if found loose.

Replace/ connect defective/ by passed

c.     
components.
d. Cleaning of air grills - - -  
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
e. i) Remove return air filters by opening the
access doors of the unit. Clean these
filters with vacuum cleaner or by
compressed air after taking out the
filters and place them gently in their
places or replace with pre-cleaned/ new

To be replaced
To be replaced
filter/ filter media and close the doors
properly. A cleaning jig should be   
available with AMC holders/ Railways
for this activity.
Note: After this activity, the service doors
shall be latched properly in case of return
air filter. Similarly, the fresh air grill
shall be positioned and locked properly.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

ii) Remove fresh air filters by opening

the access doors of the unit. Clean
these filters with vacuum cleaner or
by compressed air after taking out
the filters and place them gently in
e. their places or replace with pre- --   --- ---
cleaned/ new filter/ filter media and
close the doors properly. A cleaning
jig should be available with AMC
holders/ Railways for this activity.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check looseness of microprocessor‟s

f. --- ---   
input/ output connections.

Check that the

g.     
microprocessor controller is firmly
mounted.
Check analogue type pressure gauges
h. for their working provided on switch     
board panel.

Check working of rotary switches by

rotating forward and backward,
i. provided on switch board panel for     
temperature selection and air control
ON. Replace if required.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check working of set point generator

j. rotary switch provided for temperature     
setting.

Check the tripping of heaters i.e. OHP. The

OHP setting is 65°C. The testing of OHP
setting shall be done by switching off the
blower. During testing, the probe of digital
thermometer shall be placed near the
k. sensor of OHP & the display shall be kept -- --   
outside.
Note : It shall be checked twice a year. In
addition, it shall also be checked as
a pre-winter precaution before the
onset of winter season.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check whether ESTI cartridge

is provided with bulb and
properly screwed.
Note : It shall be checked
l. -- --   
twice a year, in addition, it
shall also be checked as a pre-
winter precaution before the
onset of winter season.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check whether ESTI cartridge

is provided with bulb and
properly screwed.
Note : It shall be checked
l. -- --   
twice a year, in addition, it
shall also be checked as a pre-
winter precaution before the
onset of winter season.
 TI M POH
Activities HY (SS-2)
IOH (D1) (D2)
m. Run the plant for half an hour and then
(D3) (SS-1)
check the current drawn by various
equipment with the help of clamp tester
(tongue tester) duly calibrated.
Normal currents for various equipments
and mode of operation are as under:
 Package unit in cooling mode - 20-23

Amps
 Compressor - 7.5 – 9.5Amps.    

 Condenser fan motor - 1.5 – 2.1
Amps.
 Blower motor - 1.5-2.5 Amps
 Package unit in heating mode
-07-11 Amps
Note: The current also depends
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check visually roof & condenser

n. fan blade and ensure that there is --    
no crack on the blade or hub.

Check and tighten mountings of

blower, compressor and blower
o. -- --   
motors and ensure that they are in
good condition.

Ensure that no capillary tubes are

p. --    
in hanging position.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check capillary tubes provided for

HP/LP cutout for proper support/
q. --    
clamping. Their nuts should be properly
tightened.

Capillary type HP/LP cut out should be

replaced with HP/LP cutout without
capillary during IOH/POH.
r. -- --- --  
HP/LP cut out and its sensors should be
replaced in SS-4 schedule i.e. after 72
months.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check for proper tightening of

s. cover provided over evaporator --    
compartment.

To be replaced
Check that earthing shunts in RMPU
t. are provided. Earthing shunts -- --  
should be earthed with coach body.

Check canvas duct provided at return

u. & supply air. Rectify or replace the -- -- 

laced

laced
same, if torn or damaged.

be

be
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Run the plant in conjunction with

v. micro-processor controller and     
observe for any abnormality.

Check anti-vibration mountings of AVM

compressors, condenser motors, for over
w. -- --   all
blower motor and over all package
package unit. Replace if required. unit to be
replaced
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
If less cooling is noticed, check the leakage
of refrigerant from the system by using soap
solution or leak detector. If leak is detected,
x.  --   
it should be attended and re-charging of
refrigerant in the system shall be made as
per RDSO‟s SMI ELPS/AC/SMI/14.

Check insulation resistance of all the motors

& compressors by the duly calibrated
1000V megger. Attend the motors, if
y. insulation resistance of motor is found less -- -- --  
than 2M ohm.
Important: Disconnect microprocessor
controller during this activity.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check for physically damaged/

z. --  --  
jointed cables. Replace if needed.

Check for the physically damaged

To be
z-i conduits. Replace them, if --  -- 
replaced
needed.

Check for proper working

z-ii -- --   
of servo drive.

z-iii Harting connector to be replaced -- -- --  

Refrigerant Pipe Line/ Capillary
TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

a. Check for proper clamping/ support. -- -- --  

Check for rubbing of capillary

b. with SS sheet/ channel or other -- -- --  
parts of RMPU.

Check leakage from flare nut of

c. -- -- ---  
HP/ LP cutouts with soap solution.

Check leakage from feeler tube

d. -- -- --  
of OHP.
Compressors
TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure holding clamps

a. -- --   
from top are properly tightened.

Check and ensure mounting

b. -- --   
fastenings are properly tightened.

Check leakage from suction &

c. -- --   
discharge port.

Check Accumulator holding/

d. -- --   
mounting, if provided.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Ensure condensing area covers are

e. properly tightened & not -- --   
touching top of compressor body.

Check electrical terminal box is

f. properly tightened & cables -- --   
are terminated with lugs.
Condenser Fans Motor/ Blades
and Blower Motor/ Impeller
TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure mounting

a. -- --   
fasteners are properly tightened.

Check electrical terminal box of

b. motors is properly tightened & -- --   
cables are terminated with lugs.

To be
Ensure double earthing shunts replaced
c. -- -- --- 
are provided. during
POH
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check condition of blade for its

d. fixing/ cracking/ breakage/ damage or -- --   
touching with its cover. Rectify/
replace, if needed.
Ensure proper clamping of cable
e. -- --   
conduits.
Overhauling of Blower and
condenser fan motors shall includes
the following during POH.
f. -- -- -- -- 
 The incoming motors shall be
checked for abnormal noise and
vibration.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
f.  Check bearing make and replace
with
specified make, if found defective.

 The IR value of motor stator shall be

measured between motor terminal and
frame before and after overhauling. The
value of IR shall not be less than 10
-- -- -- -- 
M, when measured with 1000 volt
megger.

 Winding resistance of motors shall be

measured between RY, YB & BR
phases. The winding resistance shall be
± 10% of resistance declared by OEM in
cold condition.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

f.  Check closely terminal block and

connecting lead for any physical
damage or any flash mark over it.
Replace the same, if not satisfactory.

 Perform HV (Di-electric test) on

-- -- -- -- 
stator by applying 1.5 kV AC supply
for one minute. During test the
leakage current shall also be
measured, which shall not be more
than 1.0 mA.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

f.  Run motor on no load for 15

minutes and check the following.

i. Bearing noise –
Normal noise.

ii. Bearing temperature rise above -- -- -- -- 

ambient should not be more
than 10°C.

iii. SPM reading – 20dB

max.

(Green
zone)
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
f.  Measure starting current of motors
on no load. It shall not be more
than 10 times of normal running
current. Similarly, the running
current of motors shall be
measured
and it shall not be more than 1.4A.
-- -- -- -- 
 Spray water over running motor
by jet having 10mm dia from all
side. After spray, check IR value.
There should be no drop in IR
value.
 Ensure the continuity of TOP.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that impellers are properly

g. -- -- ---  
tightened.

Ensure electrical terminal box is

h. properly tightened & cables are -- -- ---  
terminated with lug.
Return/ Fresh Air
Filter
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that filters are not

a.     
damaged.

Ensure that there is a provision

b. to avoid wrong fitment in the -- -- --  
filter as well as in RMPU.

c. Filter media to be replaced --- ---  -- ---

d. Complete filter shall be replaced -- -- --  

HP/ LP/ OHP Cutout
Switch TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
Check that the mounting fasteners are
a. -- --   
properly tightened.

Ensure proper clamping/ support of

b. capillary tube connected to HP/ -- --   
LP/ OHP cutout switch.

Ensure that flare nuts are properly

c. -- --   
tightened.
Ensure that control wires to HP/ LP/
d. OHP cutout switches are -- --   
properly clamped.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Ensure that covers of these HP/ LP/

e. OHP cutout switch are properly ---    
screwed.

Ensure proper clamping of feeler tube

f. -- -- --  
of OHP switch.

Remove the accumulated dust over

g. -- --   
feeler tube of OHP switch.
Heater

TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

a. Ensure proper mounting of heater. -- --   

Ensure proper clamping of electrical

b. -- --   
wires to heater.

Check dust accumulation on heating

c. -- --   
element. Remove gently, if
required.
NTC Sensors
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that the sensors provided at

a. return air path, fresh air and -- --   
supply air are firmly mounted.

Ensure sensor wires are properly

b. -- --   
clamped.

Remove the dust accumulated over

c. -- --   
sensor gently.
Expansion Valve/ Capillary Tubes

TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that the bulb is mounted in the

suction line just after evaporator coil
a. and in a position corresponding to -- ---   
between 1 O‟clock and 4 O‟ clock.
Ensure that it is properly insulated.

Ensure that the equalizing line is

b. connected in the suction line -- --   
immediately after the bulb.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that the bulb is not connected

c. -- --   
at the bottom of the pipe line.

Ensure that bulb/ equalizing line/

d. -- ---   
capillary tubes are not chocked.

Capillary tubes /expansion valve and

e. HP/LP/CP cut out to be replaced on -- -- -- -- *
condition basis

* on condition basis
Evaporator Coil
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that there is no damage to

a. -- -- --  
fins.

Ensure that capillaries of distributors

to evaporator coil are not having any
b. -- -- --  
sharp bend or kinks. They should
also be clamped properly.

Ensure that air passes only through

c. evaporator coils and no air is -- -- --  
bypassed directly to blower chamber.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Clean the coil, if found dirty.

d. (i) cleaning through blower in D2. --    

(ii)Cleaning through water jet in D3.

Check that the mounting fasteners

e. -- -- --  
are properly tightened.
Filter Drier & Sight
Glass TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
a. Ensure that drier is installed with -- -- --  
flow in the direction of the arrow
marked on the filter drier label.

NOTE :
1. Never use “Antifreeze liquids” like methyl alcohol together with a
filter drier. Such liquid can damage the filter.
2. Never re-use a filter drier.
3. To avoid chances of moisture ingress in the system, filter
drier & compressor should be installed immediately after
evacuation and charging the system.
Access Doors
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Insulate service doors, lower portion

a. and side wall from inside of the -- -- --  
evaporator compartment.

Ensure that the latches to lock the

b. service doors are not defective/     
damaged.

Check and replace thermal

c. -- -- --  
insulation
Drip Tray
TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure that there is no leakage of

condensate water from drip tray
a. -- --   
to electrical box & blower
housing area.

Ensure free flow of condensate

b. --    
water.

Roof of coach should be checked

c. for Rain water leakage thoroughly, -- -- -- -- 
especially above electrical panels.
Condenser
Area TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Clean the condenser coil from inside

a. with compressed air/ water jet after --    
opening the cover of condenser area.

Ensure that there is no damage to

b. -- --   
fins.

Check that the mounting fasteners

c. -- -- --  
are properly tightened.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Provide fire retardant thermal

d. -- -- -- --- 
insulation over suction line.

Ensure that there is no damage/

e. -- -- --  
crack in structure frame of RMPU.

Ensure proper clamping of electrical

f. -- -- --  
conduit.
Microprocessor Controller

TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

a. Check control logic of -- -- -- -- 

microprocessor controller on
simulating kit.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

a. Check visually for any damages.     

Check lights and emergency light

b. system for proper functioning     
and replace defective lights.

c. Check and clean lamp shades/ --    

covers

d. Replace broken diffusers, reflectors, -- --   

defective invertors and holders

e. All shortages are to be replenished -- --   

 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Check visually battery boxes and

a.
suspension for any damage or     
irregularity

Check container and inter-cell

b. --    
connections and clean, if necessary.

Check battery connections for

c. -- --   
tightness

Clean battery connections and apply

d. -- --   
petroleum jelly or Vaseline
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Remove the batteries from

e. -- -- --  
battery boxes.

Clean and repair battery boxes and

f. repaint with anti corrosive epoxy -- -- --  
based paint.

Clean thoroughly corrosion/

sulphation of inter-cell connectors
etc. and protect them from further
g. corrosion by applying petroleum -- -- --  
jelly or vase-line. Change cell
connectors and fasteners on
condition basis.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

h. Record lug date to determine the life -- -- --  

of the battery

Charge the battery fully till 3

constant hourly readings of voltage
i. -- -- --  
indicates the conditions of a fully
charged cell.

Tighten the safety vent plugs

j. -- -- --  
if found loose.
Carry out the capacity test
 Charge the battery fully till 3
constant hourly readings of -- -- -- -- 
voltage indicates the condition of
a fully charged cell.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

 Discharge the battery at 10 hours

discharge rate.
While discharging, record the
voltage.
-- -- -- -- 
 Record the capacity of the battery
during discharge. It should not
be less than 80% of the rated
capacity.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

In case while discharging, any of

the cell‟s voltage falls below
specified limit within 08 hours
disconnect the cell from the circuit
k. for treatment with 01 or 02 cycles -- -- -- -- 
of slow charge & discharge as per
manufacturers maintenance manual.
(RDSO/PE/SMI/TL/0024-2012,
Rev. 2)

After 2 cycles of charge

l. -- -- -- -- 
& discharge, recharge the cells
fully.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Open the cover of battery charger

a. --
and clean with soft brush & vacuum -- --  
cleaner

Check the loose connection and

b. overheating marks and take -- -- --  
corrective action.

Take IR of live terminals to body. It

c. -- -- --  
should be more than as specified.

d. Replace sealing gasket -- -- -- -- 

 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Open the cover and clean

a. -- -- --  
with compressed air/ vacuum
cleaner.
Check loose
b. connection, overheating marks and --    
take corrective action.

Take IR of live terminals to body. It

c. -- -- --  
should be more than as specified.

Ensure proper clamping of

d. -- -- --  
cable conduits.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

e. Check tightness of -- -- --  
suspension
arrangement.
f. Check sealing gasket. -- -- -- -- 

Check grommets of all cable-

g. -- -- -- -- 
entry holes.

Check and replace mounting

h. -- -- -- -- 
bolts with grade of10.9 ( high
tensile)
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Check the loose connection,

a. overheating marks and take -- -- --  
corrective action.

b. Take IR of live terminals to body. It -- -- --  

should be more than as specified.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Clean the panel with blower and --

a. vacuum cleaner and check for any    
loose connections.

Ensure all cable entry holes

b. -- -- --  
are provided with grommets

Check the contacts of

c. -- -- --  
power contactors and other
contactors.
Check the connection of switchgear
d. terminals blocks for overheating and -- -- --  
tightness.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Check the fixation and

e. -- -- --  
terminal connections of
microcontroller.

Check rotary switch for

f. -- -- --  
proper working.

Check all the earthing shunts

g. -- -- --  
and replace, if required.

h. Check the working of -- -- --  

gauges,
voltmeters and ammeters.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Take IR of live terminals to body for

i. power and control supply. It should -- -- --  
be more than as specified.

Check cabinet doors for

j.     
proper closing and locking.

Check the door locks and

k.     
hinges also.

Replace MCBs for pantry

l equipment, pumps & Compressor on -- -- -- -- 
condition basis
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check condition of contacts by

measuring the contact area, mili volt
m drop etc.. Replace them on -- -- -- -- 
condition basis if fails in test.

Replace disconnecting &

n -- -- -- -- 
earthing device complete rotary
switch.
Replace open type control fuse unit
o for HT circuit with fuse base -- -- -- -- 
holder assembly unit.

Ensure provision of fuse/MCB safety

p protection in DC to DC convertor -- -- -- -- 
circuit
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Ensure working of MMRs (750Volts

q & 415Volts) & their replacement -- -- -- -- 
with new ones

r Replace defective MVRs. -- -- -- -- 

Replace contactors for compressors

s -- -- -- -- 
& K-44.

t Replace defective/ bypassed -- -- -- -- 

electronic module for contactors.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Replace all defective/bypassed

Microprocessor with latest universal
u -- -- -- -- 
type Microprocessor with adopter/
connectors.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Main fuses

a. Check the availability of --    

proper
rating main fuses.

b. Replace if fuse is blown/ missing.     

Replace old positive and negative

c -- -- -- -- 
fuse box at under frame
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Feeder cable

Check the condition and IR of feeder

a. cable. It should be more than as -- -- --  
specified.

b. Check proper clamping arrangement -- -- --  

Check the connecting terminals

c. -- -- --  
for marks of over heating etc.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Water supply system

Check functioning of water pumping

a. arrangement in test mode/pump     
controller if provided.

Replace old Monoblock pump

b. -- -- -- --- 
with new one.

Visual check the

c. --- --- ---  
mounting arrangement
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Lavatory equipment
Check and ensure working
a. -- -- --  
of lavatory exhaust fans.
Ensure cleaning and availability
b. -- -- --  --
of sealing of covers/grills.
Cleaning the impellers of the exhaust
c. -- -- -- -- 
items

Replace old defective Lavatory light

d fitting with SS body antirust type -- -- -- -- 
light fitting.

e Replace old saving razor socket. -- -- -- -- 

 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Under frame

Check under slung electrical

a. equipment, cables, and connections     
for external damages.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Inter vehicle electrical power couplers

Check HT power jumper

cables for external damage and
a. --- ---   
over heating. Repair if
required.

Check I.V. couplers for proper

b. mating with thermo vision -- --- --  
device.
c. Check the condition of pins. -- -- --  
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

Inter vehicle electrical power couplers

d. Replace loosely crimped pins. -- -- -- --- 

Check the locking arrangement

e. -- --   
& ensure its proper locking.

Take IR of live terminals to

f. body. It should be more than as -- -- --  
specified.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Earthing
Check function of insulation
a. monitoring device by creating single -- ---   
earth fault in supply lines.

Check condition of disconnecting

b. and earthing switch. Replace if -- -- --  
require in SS-2

Check tightness of all the earthing

c. -- -- --  
connections.

Measuring monitoring relay

d. -- -- -- -- 
(MMR) to be calibrated on the test
bench.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check for damages and deficiencies

a. in the pantry equipment and     
fittings and repair if required.

Check functioning of geyser, soup

b.     
boiler, hot case & freezer.

Check water supply and drainage

c.     
of pantry area.

Check the working condition of

d.     
all the equipments.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Clean all the pantry

e. -- -- --  
equipments thoroughly.

Check availability of locks,

f. ---    
covers etc.

g. Check earthing of each equipment. -- -- --  

Check working of
h. -- -- --  
thermostats. Replace if found
defective.
i. Check working of electric chimney     

j. Replace the filter of electric chimney. -- --   

 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

j. Check the working of boilers.     

Clean the boilers for

k. --  --  
removing scaling etc.
Check the heating element of boilers
l. -- -- --  
and replace if required.
Check the working of
m. -- -- --  
indication lamps.

n. Check for any leakage. -- -- --  

Check the working of deep

o.     
freezer, bottle cooler, hot case and
OTG.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check working/cooling of
p. refrigerator. Measure the current of     
compressor of refrigerator.

Check starting capacitor value with

q. LCR meter. If value is low, replace -- -- --  
it.

Check the working of starting

r. -- -- --  
relay for compressors.

Clean the condenser of

s. -- -- --  
refrigerator and deep freezer.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check the insulation resistance of

t. live terminals to body. It should be -- -- --  
more than as specified.

u. Exhaust fans -- -- --  

Replace all 3 pin sockets with 2 pole

v -- -- -- -- 
MCBs of proper rating.

Replace dented/pitted doors of Deep

w -- -- -- -- 
freezer.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)

x Replace all old hot water boiler -- -- -- -- 

/geysers with new one.

Replace complete Heater

y -- -- -- -- 
assembly with new one.

Replace dented/pitted doors of Hot

z -- -- -- -- 
cases.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check working of all mini-pantry

a.     
equipment.

Clean all the pantry

b. -- -- --  
equipments thoroughly.

Check and record current drawn

c. by compressors for bottle cooler -- -- --  
& deep freezer.

Clean the condenser

d. -- -- --  
of refrigerator and deep freezer.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check starting capacitor value

e. with LCR meter. If value is low, -- -- --  
replace it.

Check the working of

f. -- -- --  
starting relay for compressors.

g. Check the working of boilers.     

Clean the boilers for

h. -- -- --  
removing scaling etc
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check working of thermostats

i. --    
of boilers.

Check the heating element

j. --    
of boilers and replace if required.

k. Check for any leakage. -- -- --  

Check the working of hot

l.     
case and its thermostats.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check the working of

m. indication lamps. -- -- --  

Check the insulation resistance of

n. live terminals to body. It should -- -- --  
be more than as specified.

Check earthing of
o. each equipment. -- -- --  

Replenish the item if

p. found deficient. -- -- --  
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Replace dented/pitted doors

q -- -- -- -- 
of Deep freezer.

Replace all old hot water boiler

r -- -- -- -- 
/geysers with new one.

Replace complete Heater

s -- -- -- -- 
assembly with new one.

Replace dented/pitted doors of

t -- -- -- -- 
Hot cases.
Sr. Circuit Capacity of Min. value of IR
No. Megger used required
Voltag
e
1. 750V 1000V 05 M ohms
2. 415V 1000V 03 M ohms
3. 230V 500V 02 M ohms
4. 190V 500V 02 M ohms
5. 110V 500V 02 M ohms
6. 24V 100V 01 M ohms
Pre-Inspection
 Place the coach on the pit line and inspect the electrical
and air conditioning equipments.

 Conduct the pre-cooling test as per Annexure ‘1.2’.

 If the cooling time is less than the specified values, regular

maintenance/ overhauling of air conditioning equipments
is to be carried out.

 If cooling time is more than the specified values, complete

air-conditioning system including supply air duct,
coach sealing etc. needs to be checked.
 Down load the failure data of from
RMPU Microprocessor controller for analysis and
attention.
 Check operation of all the lights, pantry equipments,
exhausts fans, WRA, battery charger, protections etc. and
note down the defects and deficiencies.

Dusting
 Remove dust of the conditioned supply air duct with
the help of compressed air/ vacuum cleaner.
Final Testing
 After installation of all the electrical equipments on the coach
all the electrical equipments shall be checked and tested as per
Annexure 1.1.
The following procedure shall be followed for different tests
on air-conditioning system:
1. Air Delivery Test
 Conduct air delivery test after checking air leakage in
the complete air-conditioning system.
 Calculate the total air delivery for any coach from the
fundamental requirement of the „FRESH AIR
REQUIRED PER PERSON‟ depending upon the type
of coach.
 Minimum fresh air required for per person for AC coach
is 0.35 m³/ min.

 Measure fresh, return and exhaust air velocities with the

help of anemometer using suitable hoods to avoid
turbulence of air.

 Compute the volume of air by multiplying the velocity

with face area.

 For ideal condition, the exhaust air should be equal to

fresh air or it can be less by 10% but no reasons it should
not be more than fresh air.
2. Pre-cooling Test

This test shall be conducted to record the time taken for

cooling the coach without passenger, with fresh air filters
closed, lights switched „ON‟ and after raising the inside
temperature of air-conditioned compartment to 45°C.

Procedure:

1. Place the coach inside the shed.

2. Close all fresh air intake openings.

3. Record dry and wet bulbs temperature of ambient air.

4. A sample calculation for finding out compensating
heat load for AC chair car is given at Annexure 1.4.

5. Calculate the electrical compensating heat load from

the graph chart as per sample calculation given in
Annexure 1.4

6. Provide the electrical compensating load, as calculated

above, inside the coach. This load should be kept in
OFF condition till further instruction.

7. Raise the inside temperature of the coach to 45°C by

switching „ON‟ heater circuit in test mode.
8. Switch „ON‟ all lights. Set the temperature setting at
position no. 6th (i.e. 24.04°C) of both sides and run both
the AC package units in auto mode keeping compensating
load „OFF‟.

9. Record the timings for „cut off‟ of both the plants and other
parameters during the test as per Annexure 1.2.

10. Total time taken by each plant to cool the coach should not
exceed one hour.

11. Feeder testing on 750 volt.

12. Testing of local mains supply system.
13. Measurement of currents for AC plant.
Final Joint Inspection
• Workshop supervisor with divisional supervisor shall
jointly inspect the coach and the performance of
electrical and refrigeration equipments shall be recorded
as per Proforma at Annexure 1.6.

• A details of equipments changed with new assemblies

will also be handed over along with the coach to the
divisional representative. Any attention, if required to
the equipments shall be given before dispatch of the
coach from workshop to division.
Pre-Inspection

Carry out activities as given under SS-I.

Dusting

Remove the dust from conditioned supply air duct

by compressed air / vacuum cleaner.
Striping
Remove the following air conditioning and electrical
equipments for overhauling:
• Roof Mounted AC package
units
• Water raising apparatus.
• Battery and battery Charger.
• Light fittings.
• Exhaust fans
• Pantry equipments.
Before overhauling, measure the insulation resistance of all the
electrical equipments to know the condition of equipment.
Equipping

1. Fit all the refrigeration and electrical equipment to its

respective locations.

2. Connect all the electrical wirings, air supply ducts in the

air-conditioning unit (RMPU) and other electrical
systems wherever required.
Final Testing
• After installation of all the electrical equipments on the
coach shall be checked and tested as per Annexure
1.3.

• The following procedures shall be followed for different

tests on air conditioning system.

1. Air delivery test

Carry out test as given under SS-I.

2. Pre-cooling test

Carry out test as given under SS-I.

3 Pull down test

Pull down test is conducted to see that AC

plant is capable of cooling the coach in
extreme summer condition when the coach is
fully occupied.

Procedure:

1. Adjust all fresh openings as per the

air
requirement of the coach.

2. Switch „ON‟ the electrical compensating load.

3. Raise the compartment temperature to 45 º C by

switching „ON‟ heater circuit in test mode.
4. Set the thermostat setting on both AC control panel at
position 6 (i.e. 24.04°C). Switch „ON‟ all lights and fans.

5. Run both AC package units as soon as compartment

temperature is raised to 45 ºC and record the time.

6. Record timings of „cut off‟ of each AC plant. It should not

exceed 2 hours.

7. Electrical compensating heat load may be reduced (if

testing persons are required to be present inside the coach)
120 W per person inside the conditioned space. (Proforma
for recording pull down test is given in Annexure 1.5).
Final Joint Inspection

• As given under SS-I.

Maintenance of Generator cum Brake Van

For the maintenance of diesel generator set and

its equipment follow the maintenance
instructions of OEM.
 ELECTRICAL TEST REPORT FOR AC COACHES AFTER SS-
I
Type of Coach--------------------- Coach No.---------------
Date of testing--------------------- Railway------------------

INSULATION RESISTANCE

Sr. Capacity of Min. value of Actual value Remarks

Megger used IR required observed
Circuit No.
1. 750V 1000 V 05 M ohm OK / Not OK
Voltage
1. 415 V 1000 V 03 M ohm OK / Not OK
1. 230 V 500 V 02 M ohm OK / Not OK
1. 190 V 500 V 02 M ohm OK / Not OK
1. 110 V 500 V 02 M ohm OK / Not OK
1. 24 V 100 V 01 M ohm OK / Not OK
AIR CONDITIONING EQUIPMENT
Electrical load test
Sr. No. Description Specified Actual observed
Load Current R Y B

AC PLANT No. 01 (PP SIDE)

1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5. CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
AC PLANT No. 02 (NPP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5 CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
Load Current for RMPU
Voltage for RMPU - 415 ± 10% V
Total Power Consumption in kVA
b) Pre cooling test ...........................................as per Annexure
„1.2‟
c) Air delivery test:

Sr. Actual observed

Description Specified
No. PP NPP

Air delivery-
1 Fresh Air (FA) 12.69 12.39
0.35 m / min/ passenger
3
2 Return Air (RA) 7.23 16.83
Approx. 3 x Fresh Air
3 Exhaust Air (EA) 0.50 4.63
Conditioned Air Equal or less than 10% of FA
4 --- ---
(CA) Fresh Air + Return Air

a) Total Fresh Air (PP+NPP) = 20.08 Cub mtr/ min

b) Total Return Air (PP+NPP) = 49.85 Cub mtr/ min
c) Total Exhaust Air (PP+NPP) = 9.63 Cub mtr/ min
d) Total Cond. Air (PP +NPP) = 147.27 Cub mtr/ min
WATER RAISING APPARATUS

Sr. Specified Load Current Actual observed

Description
No. M/s. Elgi M/s Kalsi R Y B

WRA/ Mono Block Pumps Amps. Amps

1. 1 1.2 1.1
2. 2 1.2 1.1
PANTRY
EQUIPMENT
a. For
Coaches
1 Deep Freezer OK / Not OK
2 Bottle Cooler OK / Not OK
3 Hot Case OK / Not OK

b. For Hot
Buffet
1 Hot Case OK / Not OK
2 Deep Freezer OK / Not OK
3 Water boiler OK / Not OK
4 Burners 1,2 & 3 OK / Not OK
5 Chimneys 1,2 & 3 OK / Not OK
6 Insect Killer OK / Not OK
7 Fridge OK / Not OK
LIGHTING CIRCUITS

1 Working of main lighting circuit OK / Not OK

2 Working of emergency lighting circuit OK / Not OK

3 Working of stand alone emergency light OK / Not OK

4 Night Light OK / Not OK

5 Berth Reading Light (in case 2T/ FAC) OK / Not OK

6 Indication Lights OK / Not OK

TESTING OF SWITCH BOARD CABINET

1 Battery Charger OK / Not OK

2 Emergency Battery Charger OK / Not OK

3 Exhaust Fans OK / Not OK

750 V /415 V, 3 Ph OK / Not OK

4
Insulating Monitoring Relay
110 V AC/ DC OK / Not OK

5 Controlled Discharge Toilet System OK / Not OK

EQUIPMENT SAFETY
TESTS
SNo Equipments PP Side observations NPP Side observations
1. Blower Motor OK /Not OK OK /Not OK
2. Cond. Fan Motor 1 OK /Not OK OK /Not OK
3. Cond. Fan Motor 2 OK /Not OK OK /Not OK
4. OHP 1 OK /Not OK OK /Not OK
5. OHP 2 OK /Not OK OK /Not OK
6. Compressor-1 OK /Not OK OK /Not OK
7. Compressor-2 OK /Not OK OK /Not OK
8. LP-1 OK /Not OK OK /Not OK
9 LP-2 OK /Not OK OK /Not OK
10. HP-1 OK /Not OK OK /Not OK
11. HP-2 OK /Not OK OK /Not OK
12 CP-1 (By pass) OK /Not OK OK /Not OK
13 CP-2 (By pass) OK / Not OK OK / Not OK
PERFORMANCE OF EQUIPMENTS
SNo Equipments Performance
1. WRA 1 OK /Not OK
2. WRA 2 OK /Not OK
3. Flasher OK /Not OK
4. 750 V circuit OK /Not OK
5. Feeder 1 OK /Not OK
6. Feeder 2 OK /Not OK
7. Water Cooler OK /Not OK
8. Hot Case OK /Not OK
9. WSP OK /Not OK
10. Battery Charger OK /Not OK
11. Bottle cooler cum deep Freezer OK /Not OK
12. Hot Plate OK /Not OK
13. Refrigerator OK /Not OK
14. PAS ckt OK /Not OK
(Signature of testing In-charge)
 PROFORMA FOR RECORD OF PRE-COOLING
TEST
Conditions:
1. Type and coach No. -------------
2. Supply Voltage -------------V
3. Ambient temperature ---------(DB) -----------WB

POWER PANEL
SIDE:
Coach Coach
Rotary
Temperature Cut-in Temperature Cut-out Time taken
Switch
Deg.C at Cut - Time Deg.C at Cut - Time in min
Position
in out

Position 6 i.e.
24.04˚C
NON-POWER PANEL
SIDE
Coach Coach
Rotary Switch Temperature Cut-in Temperature Cut-out Time taken
Position Deg.C at Cut Time Deg.C at Cut - Time in min
- in out

Position 6 i.e.
24.04˚C

Total pre-cooling time:

PP side --------------min.

NPP side ------------min.

(Signature of testing In-charge)

 ELECTRICAL TEST REPORT FOR AC COACHES AFTER SS -
II
Type of Coach --------------------- Coach No. ---------------
Date of testing --------------------- Railway ----------------

I NSULATION RESISTANCE
S. Circuit Capacity of Min. value of Actual value
Remarks
NO Voltage Megger used IR required observed

1. 750V 1000 V 05 M ohm OK / Not OK

1. 415 V 1000 V 03 M ohm OK / Not OK
1. 230 V 500 V 02 M ohm OK / Not OK
1. 190 V 500 V 02 M ohm OK / Not OK
1. 110 V 500 V 02 M ohm OK / Not OK
1. 24 V 100 V 01 M ohm OK / Not OK
AIR CONDITIONING EQUIPMENT
a) Electrical load test
S No. Description Specified Load current Actual observed
R Y B
AC PLANT NO. 01 (PP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5. CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
AC PLANT NO. 02 (NPP SIDE)
1. BLR 2.6 ± 10% Amp
2. CD1 2.1 ± 10% Amp
3. CD2 2.1 ± 10% Amp
4. CP1 8.25±25% Amp
5 CP2 8.25±25% Amp
6. HTR1 10 Amp
7. HTR2 10 Amp
Load Current for RMPU
Voltage for RMPU - 415 ± 10% V
Total Power Consumption in kVA
Total Power Consumption in kW
 b. Air delivery test ```````````````````

Sr. Description Specified Actual observed

No. PP NPP

1 Fresh Air (FA) Air delivery- 12.69 12.39

2 Return Air (RA) 0.35 m3/ min/ passenger 7.23 16.83

3 Exhaust Air (EA) Approx. 3 x Fresh Air 0.50 4.63

4 Conditioned Air (CA) Equal or less than 10% of FA --- ---

Fresh Air + Return Air

a) Total Fresh Air (PP+NPP) = 20.08 Cub mtr/ min

b) Total Return Air (PP+NPP) = 49.85 Cub mtr/ min

c) Total Exhaust Air (PP+NPP) = 9.63 Cub mtr/ min

d) Total Cond. Air (PP +NPP) = 147.27 Cub mtr/

min
WATER RISING APPARATUS

Specified Load current Actual observed

S No. Description
M/s. Elgi M/s Kalsi R Y B

WRA/ Mono Block Pump Amp Amp

1. 1 1.2 1.1
2. 2 1.2 1.1
PANTRY
EQUIPMENT
a) For Coaches

1. Deep Freezer OK /Not OK

2. Bottle Cooler OK /Not OK
3. Hot Case OK /Not OK

b) For Hot Buffet

1. Hot Case OK /Not OK

2. Deep Freezer OK /Not OK
3. Water boiler OK /Not OK
4. Burners 1, 2 & 3 OK /Not OK
5. Chimneys 1, 2 & 3 OK /Not OK
6. Insect Killer OK /Not OK
7. Fridge OK /Not OK
LIGHTING CIRCUITS

1. Working of main lighting circuit OK /Not OK

2. Working of emergency lighting circuit OK /Not OK

3. Working of stand alone emergency light OK /Not OK

4. Night Light OK /Not OK

5. Berth reading Light (In case 2T/ FAC) OK /Not OK

6. Indication Lights OK /Not OK

TESTING OF SWITCH BOARD CABINET

1. Battery Charger OK /Not OK

2. Emergency Battery Charger OK /Not OK
3. Exhaust Fans OK /Not OK
4. Insulation Monitoring Relay 750 /415V, 3 Ph OK /Not OK
110V AC/ DC OK /Not OK

5. Controlled Discharge Toilet System OK /Not OK

(Signature of testing Incharge)

Pre Cooling Test
TEST CONDITIONS:
Coach Location
----------------
Time from ------------------ hrs. to -------------- hrs.
Ambient Temperature (DB) --------- º C. (WB) --------- º C.

Specified Actual observed

S. No. Time taken for Pre- cooling test
PP side NPP side

From 45 to 24.04 ºC (Temperature Less than

1.0
setting on position 6) 01 hour

Time taken for pre-cooling test: ----------------------------Min/hr.

Satisfactory / Unsatisfactory
Pull Down Test
TEST CONDITIONS
Coach Location -------------------
Time from ----------hrs. to ---------- hrs.
Ambient Temperature at starting (DB) ---- º C. (WB)--- º C.
Ambient Temperature at finish (DB) --- º C. (WB)--- º C.
Average compensation load ………………..k Watts

S.No. Time taken for Pull down test Specified Actual observed
PP side NPP side
From 45 to 24.04º C Not more than 02 hrs.

Pull down time to achieve 24.04 º C --------------------hrs.

Satisfactory / Unsatisfactory
ELECTRICAL TEST REPORT FOR AC
COACHES
Equipment Safety Tests

SNo Equipments PP Side observations NPP Side observations

1. Blower Motor OK /Not OK OK /Not OK
2. Cond. Fan Motor 1 OK /Not OK OK /Not OK
3. Cond. Fan Motor 2 OK /Not OK OK /Not OK
4. OHP 1 OK /Not OK OK /Not OK
5. OHP 2 OK /Not OK OK /Not OK
6. Compressor-1 OK /Not OK OK /Not OK
7. Compressor-2 OK /Not OK OK /Not OK
8. LP-1 OK /Not OK OK /Not OK
9 LP-2 OK /Not OK OK /Not OK
10. HP-1 OK /Not OK OK /Not OK
11. HP-2 OK /Not OK OK /Not OK
12 CP-1 (By pass) OK /Not OK OK /Not OK
13 CP-2 (By pass) OK / Not OK OK / Not OK
Performance of Equipment
SNo Equipment Performance
1. WRA 1 OK /Not OK
2. WRA 2 OK /Not OK
3. Flasher OK /Not OK
4. 750 V circuit OK /Not OK
5. Feeder 1 OK /Not OK
6. Feeder 2 OK /Not OK
7. Water Cooler OK /Not OK
8. Hot Case OK /Not OK
9. WSP OK /Not OK
10. Battery Charger OK /Not OK
11. Bottle cooler cum deep Freezer OK /Not OK
12. Hot Plate OK /Not OK
13. Refrigerator OK /Not OK
14. PAS ckt OK /Not OK
Signature of Testing In-charge
 SAMPLE CALCULATION FOR CALCULATING
COMPENSATING LOAD

To find out electrical compensating load to be provided inside the coach when
coach is tested at other than the designed outside ambient condition say 40º C
(104 ºF) DB and 30 ºC (86º F) WB

Coach: Self generating chair car to CSC layout No. 1559 for 71 passengers.

Designed (outside) conditions = 45 º C (113 º F) DB & 25ºC (77ºF) WB

Designed (outside) conditions = 25 ºC (77 ºF) DR & 40% RH

A. Heat gain inside the coach at designed conditions:
i. Conduction = 11,045 B.Th.U/hrs.
Formulae = Area x Overall coefficient of
heat transfer in B. Th.U/ hr/ ºF/
sq.ft x temperature difference
a) Side wall = 2 x 236 x 0.127 x 36 = 2980.944
b) End partition walls = 2 x 73 x 0.127 x 31 = 667.512
c) Roof = 550 x 0.134 x 36 = 2653.2
d) Floor = 514 x 0.149 x 36 = 2757.096
e) Windows = 2 x 69 x 0.4 x 36 = 1987.2

Where 0.127 is the factor for heat transfer through walls, 0.134 is for
roof and 0.149 is for the floors. For glass windows the factor for
heat transfer has been taken as 0.4.
ii) Solar radiation= 15193.4 B.Th.U/ hrs.
Formula Area x Overall coefficient of heat transfer
x solar temperature difference
=
a) Side = 326 x 0. 127 x 16 = 662.4
wall
b) Roof = 550 x 0.134 x 19 = 1400.3
c) Windows = 69 x 1.1 x 173 = 13130.7

Where 16.19 & 173 are the solar temperature differences as per tranes
air-conditioning manual page 314 and 315 for 30 ºC N latitude at 16 hrs.

iii) Passengers (@ 400 B. Th. C = 28,400 B.Th.U / hr

per passenger 71 x 400)
iv) Light and fans (3.4 B.Th.U/ hrs = 8,275 B. Th. U/
per watt for lights and 3600 hr
B.Th.U/hrs for small motors)
a) Tube lights = 22 x 30 x 3.4 = 2244
b) Carriage fans B.Th.U/hr
= (8 x 35 x 3600)/ 746 = 1351
c) Blower motor B.Th.U/hr
= 2 x 0.65 x 3600 = 4680
v) Ventilation B.Th.U/hr

a) Sensible = 1.1 x Nos. of person =x cfm of air per person x

51,365 B.Th.U/hr
temperature difference.
= 1.1 x 71 x 12.4 x 36
= 34864 B.Th.U/hr
b) Latent = 0.68 x No. of person x cfm of per
person x difference of grains of moisture
between outside air & conditioned air. **
= 0.68 x 71 x 12.4 x (82 -
= 56)
Formula = For sensible heat gain as per tranes air conditioning manual

page 88 and for latent heat gain formula 23 on page 150 of carrier

handbook of air conditioning and ventilation.

Total heat gain = 1,14,729 B.Th.U/hr

Adding 10% for leakage = 1,25,707 B.Th.U/hr

heat gain
B) Heat gain during test at outside ambient = 104 - 77
Conditions of 40 º C (DB) and 30 ºC = 27 º C

(WB) temperature difference

i) = (11046 x 27)/ 36 = 8284 B.Th.U/hrs
Conduction
ii) Light & = 8275 B.Th.U/hrs
fan
iii) Ventilation
a) Sensible = (34867 x 27)/ 36 = 26148
B.Th.U/hrs
b) Latent
= 0.68 x 71 x 12.4 x (161-56)**
= 62861 B.Th.U/hrs
Total heat gain under actual test condition 105568 B.Th.U/hrs
=
Therefore electrical load to be = 125707-105568
B.Th.U/hrs

provided inside the coach to

produce heat units = 20, 139 B.Th.U/hrs

Therefore electrical load in kW = 20139/(3.41x1000)

= 5.906 kW

** To be determined from the outside and inside conditions on

physcrometic chart.
 PROFORMA TO RECORD PULL DOWN
1. TEST
Type and Coach No. : …………
2. Supply Voltage : …………V
3. Ambient temperature : ………….DB…….WB
4. Electrical compensating heat load provided : ………….kW
Temp setting Time when Time when Coach Time of Coach
at position 6 Compensating both temperature plants temperature
Electric Load plants when both cutting when both
(i.e.24.04°C) switched switched plants „OFF‟ plants switched
„ON‟ „ON‟ switched „OFF‟
„ON‟ Plant Plant Plant 1 Plant 2
1 2

Total time taken by both plants to switch „OFF‟

PP side ………………....min.
NPP side ……………….min. 45º C
S
i
 FINAL JOINT INSPECTION REPORT OF LHB EOG
AC COACHES

Coach Particulars
S.No Particulars of the coach Details
Coach No.
Depot / Railways
Workshop name
Coach booked on
Coach booked for SS-I/ SS-II
Date of Inspection
Return Date
Final Checking
S.No. Description of Checks Observations / Remark
1.0 Roof Mounted AC Package Unit (RMPU)

Compressor

Make of Compressor
PP Side 1. 2.
NPP Side 1. 2.

Condition of anti-vibration mountings

PP Side 1. OK / Not OK 2. OK / Not OK
1.1
NPP Side 1. OK /Not OK 2. OK /Not OK

Condition of terminal boxes

PP Side 1. OK / Not OK 2. OK / Not OK
NPP Side 1. OK /Not OK 2. OK /Not OK
Any abnormal noise during run
PP Side 1. 2.
NPP Side 1. 2.
S.No. Description of Checks Observations / Remark
Condenser Motors

Make of condenser motor

PP Side 1. 2.
NPP Side 1. 2.

1.2 Condition of terminal boxes

PP Side 1. OK / Not OK 2. OK / Not OK
NPP Side 1. OK /Not OK 2. OK /Not OK

Abnormal noise noticed during run

PP Side 1. 2.
NPP Side 1. 2.
S.No. Description of Checks Observations / Remark
Evaporator Motor
Make of evaporator motor
PP Side 1. 2.
NPP 1. 2.
Side
1. OK / Not
Condition of terminal boxes
OK 2. OK /
PP Side Not OK
NPP 1. OK /Not OK 2.
1.3 Side OK
/Not OK
Any abnormal noise noticed during run
PP Side 1. 2.
NPP 1. 2.
Side
S.No. Description of Checks Observations / Remark
Servo Motor
Make of Servo motors
PP Side 1. 2.
1.4 NPP Side 1. 2.
Condition of Servo Motors
PP Side 1. OK / Not OK 2. OK / Not OK
NPP Side 1. OK /Not OK 2. OK /Not OK
Heating Elements
Make of Heating Elements
PP Side 1.
1.5 NPP 1.
Side
Condition of Heating Elements
PP Side 1. OK / Not OK
S.No. Description of Checks Observations / Remark
Filters

Make of Filters
Return air
PP Side 1. 2.
NPP 1. 2.
1.6 Side
Fresh air 1. 2.
PP Side 1. 2.
NPP
Side
Condition of Filters
Fresh air 1. OK / Not OK 2. OK / Not OK
Return air 1. OK /Not OK 2. OK /Not OK
S.No. Description of Checks Observations / Remark
Protection Devices

Condition of HP output 1. OK / Not OK 2. OK / Not

PP Side OK
NPP 1. OK /Not OK 2. OK /Not
Side OK

1.7
Condition of LP cutouts 1. OK / Not OK 2. OK / Not
PP Side OK
NPP 1. OK /Not OK 2. OK /Not
OK
Side
Condition of control pressure switch
PP Side OK /Not OK
NPP Side OK /Not
OK
S.No. Description of Checks Observations /
Remark
Condition of ESTI fusible link
PP Side OK / Not OK
NPP OK / Not
Condition of OHP
Side OK
PP Side OK / Not OK
NPP OK / Not
Condition of temperature
Side sensors OK
PP Side OK / Not OK
NPP OK / Not
Condition of humidity
Side sensors OK
PP Side OK / Not OK
NPP OK / Not
S.No. Description of Checks Observations / Remark

Refrigerant Pipe Line

1.8 Condition of Clamping of pipe line

PP Side OK / Not OK
NPP Side OK / Not
OK
2.0 Switch Board Cabinet
Condition of rotary switches OK / Not OK

Condition of MCBs for

Light OK / Not OK
Fan circuit OK / Not
Other MCBs OK OK /
Not OK
S.No. Description of Checks Observations / Remark

Condition of terminals OK / Not OK

Condition of contractors OK / Not OK
Condition of relays OK / Not OK

Condition of meters
Ammeters OK / Not OK
Voltmeters OK / Not
Pressure Gauges OK OK /
Not OK
Condition of cable OK / Not OK
Condition of clamping of cables OK / Not OK
Condition of conduits OK / Not OK
S.No. Description of Checks Observations / Remark
Compartment
Condition of exhaust fans OK / Not OK
Condition of lights OK / Not OK
3.0
Condition of berth lights OK / Not OK
Condition of switches OK / Not OK
Condition of indication lights OK / Not OK
Micro Processor Controller
Micro processor controller OK / Not OK
4.0
Condition of connections OK / Not OK
Condition of LEDs OK / Not OK
S.No. Description of Checks Observations / Remark
5.0 Battery
Make
Lug date
box suspension arrangement OK / Not OK
cells ventilation OK / Not OK
box inside anti corrosion painting OK /Not OK
Condition of battery lugs OK / Not OK
Condition of cell container OK / Not OK
Condition of battery fuse & fuse box OK / Not OK
Earth leakage of battery leakage / Not leakage
no load voltage in volts volts
S.No. Description of Checks Observations / Remark
Charger
Make of battery charger
6.0 Condition of battery charger OK / Not OK

Condition of battery charger

OK / Not OK
mounting arrangement
Pantry Equipments

Condition of Deep freezer OK / Not OK

7.0 Condition of bottle cooler OK / Not OK

Condition of water boiler OK / Not OK

Condition of hot case OK / Not OK

S.No. Description of Checks Observations / Remark
EOG Coupler

Condition of coupler
PP Side 1. OK / Not OK 2. OK / Not OK
NPP 1. OK /Not OK 2. OK /Not OK
Side
8.0 Condition of coupler pins
PP Side 1. OK / Not OK 2. OK / Not OK
NPP 1. OK /Not OK 2. OK /Not OK
Side
Condition of
locking arrangement
PP Side 1. OK / Not OK 2. OK / Not OK
NPP 1. OK /Not OK 2. OK /Not OK
Side
S.No. Description of Checks Observations / Remark
60 KVA Transformer
9.0 Condition of mounting arrangement OK /Not OK
Condition of terminals OK /Not OK
Lighting Transformer
10.0 Condition of mounting arrangement OK /Not OK
Condition of terminals OK /Not OK
Other Equipments
1. OK /Not OK 2.
Condition of WRA
OK
11.0 /Not OK
Condition of micro controller for WRA OK /Not OK
1. OK /Not OK 2.
Condition of pre cooling socket
OK
S.No. Description of Checks Observations / Remark
12.0 Earthing of all Equipments Provided / Not Provided
13.0 Pantry Equipments
Hot Case OK / NOT OK
Deep freezer OK / NOT OK
Water boiler OK / NOT OK
Chimney 1,2,3 OK / NOT OK
Burner 1,2,3 OK /Not OK
Insect Killer OK /Not OK
Fridge OK /Not OK
Working of call station OK /Not OK
Equipments Replaced

S.No Name of Equipment Make Rating/ Serial No.

Capacity

(Signature of Inspecting (Signature of Inspecting

Supervisor from Depot/ Railway) Supervisor from Work Shop)
• The LHB variant of Non AC coaches is quite
similar to LHB AC coaches except AC unit and its
switchgears.

• The maintenance practices for these coaches are

also more or less similar to LHB AC coaches.

• The various maintenance schedules and

their
periodicity are same as in case of
LHB coaches. AC
[Ref.: Railway Boards letter no.95/M(C)/141/1 (LHB) Pt. dtd. 08.05.08].
Period Maintenance Schedules

Schedule D1 : Trip / Weekly

Schedule D2 : Monthly ± 3days

Schedule D3 : Half Yearly ± 15 days

Shop Schedule (SS-1), IOH : 18 Months /6 Lakh kms

whichever is earlier

Shop Schedule (SS-2), POH : 36 Months / 12 Lakh kms

whichever is earlier
• The EOG LHB Non AC coaches mainly comprises of
second class (GS/LS) coaches, 3 Tier Non AC sleeper
coaches and Non AC Chair cars.

• The equipment wise maintenance activities of above

schedules and procedures for SS-1 and SS-2 are
described here.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-
2)
Check visually for
a.     
any damages.

Check function of lights, fans

and emergency lights and
b. replace defective lights/fans if     
any.

Check and clean lamp shades/

c. --    
covers/ fan body
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-
2)
d. Clean and blow internally fan
-- --   
housing.
e. Check working of all light and
    
fan switches.
f. Check working of mobile
-- --   
charging sockets and switches.
g. Replace broken reflectors,
shades, defective invertors and -- --   
holders

h. All shortages are to

-- --   
be replenished.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

a. Visually check battery box and

suspension for any damage or     
irregularity.
Check container and inter-block
b. connections and clean, if --    
necessary.
Check battery connections for
c. -- --   
tightness.
Clean battery connections and
d. apply petroleum jelly or -- --   
Vaseline.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
e. Remove the batteries from battery
-- -- --  
boxes.
f. Clean and repair battery boxes
and repaint with anti corrosive -- -- --  
epoxy based paint.
g. Check intactness/tightness of
suspension arrangement of -- -- --  
battery box.
h. Clean thoroughly corrosion/
sulphation of connectors etc. and
protect them from further
corrosion by applying petroleum -- -- --  
jelly or vase-line. Change
connectors and fasteners on
condition basis.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
i. Record lug date to determine the
-- -- --  
life of the battery. (codal life)
j. Charge the battery fully till 3
constant hourly readings of
-- -- --  
voltage indicates the conditions
of a fully charged cell.
k. Carry out the capacity test
Charge the battery fully till 3
constant hourly readings of
voltage indicates the condition
of a fully charged cell. -- -- -- -- 
Discharge the battery at 10
hours discharge rate. While
discharging, record the voltage.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
k. Record the capacity of the
battery during discharge. It
should not be less than 80% of -- -- -- -- 
the rated capacity.
l. In case while discharging, any
of the battery voltage falls
below specified limit within 08
hours disconnect the battery
from the circuit for treatment
with 01 or 02 cycles of slow -- -- -- -- 
charge & discharge as per
manufacturers maintenance
manual. (RDSO SMI no.
RDSO/PE/SMI/TL/0024-
2012 (Rev.2)
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-
2)
After 2 cycles of charge &
m. discharge, recharge the battery -- -- -- -- 
fully.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
a. Visually check
battery
charger box suspension     
arrangement for
any damage or
irregularity.
b. Check the functions of
-- -- --  
battery charger
c. Check the male &
female connector pin
-- -- --  
for any overheating
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

d. Check intactness/tightness
of suspension arrangement -- -- --  
of battery charger box.

Open the cover of battery --

e. charger and clean with soft -- --  
brush & vacuum cleaner.

Check the loose connection

f. and overheating marks -- -- --  
and take corrective action.
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

Take IR of live terminals

g. to body. It should be -- -- --  
more than as specified.

Replace cover
h. -- -- -- -- 
sealing gasket

Clean and check

i. -- --   
ducts for ventilation in
box
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-
2)
a. Visually check transformer
suspension arrangement for     
any damage or irregularity.
b. Open the cover and clean
with compressed air/ -- --   
vacuum cleaner.
c. Check loose connection,
overheating marks, fuses
condition and take --    
corrective ac n.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)

Take IR of live terminals to

d. body. It should be more than -- -- --  
as specified.

Ensure proper clamping

e. -- --   
of cable conduits.

Check intactness/
f. -- -- --  
tightness of suspension
arrangement.
Check sealing gasket
g. -- -- --  
and replace if required.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)
Check grommets of all
h. cable-entry holes and -- -- --  
replace if required.

Check / replace mounting

i. bolts with grade of 10.9 -- -- -- -- 
( high tensile).

Check/replace Anti
j. Vibration Mounting -- -- -- -- 
(AVM) pad.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Visually check all under-slung
a. panels suspension arrangement     
for any damage or irregularity.

Visually check panel covers

b. for proper fitment along-with     
their securing arrangement.
Clean the panel with blower
--
c. and vacuum cleaner and check    
for any loose connections.
 TI M HY
Activities
IOH POH (D1)
Check panel covers hinges and (D2) (D3) (SS-1) (SS-
d.
gasket for proper condition. 2)
Check the availability
e. --    
of
proper rating HRC fuses.
Replace if fuse is
f. --    
blown/ missing.
Check rotary switches
g. --    
for proper working.
Check intactness/tightness
of
suspension arrangement -- -- --  
h. under-slung of -- -- --  
panels of
mounting arrangement
on- board panelsand
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Ensure all cable entry
i. -- -- --  
holes are provided with
grommets
Check the contacts of power
j. contactors and other -- -- --  
contactors.

Check the connection of

k.
switchgear terminal blocks for -- -- --  
overheating and tightness.

Check the fixation and

l. terminal connections of pump -- -- --  
controller.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check all the earthing

m. -- -- --  
shunts and replace, if
required.
Take IR of live terminals to
body for power and control
n. -- -- --  
supply. It should be more than
as specified.

Replace MCBs for pantry

o. equipment, and MPCB for -- -- -- -- 
pumps on condition basis.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)
Check condition of contacts
by measuring the contact
p. area, mili volt drop etc. -- -- -- -- 
Replace them on condition
basis if fails in test.
Check disconnecting &
q. earthing device complete -- -- -- -- 
rotary switch.
Replace open type control
fuse unit for HT circuit with
r. fuse base holder assembly -- -- -- -- 
unit.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)
Ensure working of MMRs
(750Volts & 415Volts) &
s. their replacement with new -- -- --  
ones in IInd POH.


Replace Harting
t. -- -- -- -- POH
connectors/Cage clamps
2nd


Replace K-01, K02, K24,
u. -- -- -- -- POH
K25 in IInd POH.
2nd
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)

v. Replace all rotary switches -- -- -- -- POH
2nd

Ensure internal wiring

w. dressing and securing -- -- --  
properly.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)
Battery Fuse boxes

Visually check battery

fuse boxes suspension
a. arrangement for any     
damage or irregularity.

Visually check fuse box

covers for proper fitment
b. along-with their securing     
arrangement.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)
Clean the panel with blower
and vacuum cleaner --
c.    
and check for
any loose
connections.
Check panel covers hinges
d. and gasket for proper --    
condition.
e. Check the availability --    
of proper rating HRC fuses.
Check intactness/
f. tightness of suspension -- -- --  
arrangement
of fuse boxes.

Replace old positive
 TI M HY
Activities
IOH POH
Feeder cable (D1) (D2) (D3) (SS-1) (SS-2)

Check the condition and IR

a. of feeder cable. It should be -- -- -- 

more than as specified.

b. Check proper clamping -- -- -- 


arrangement

FuseCheck
Distribution
the Board
connecting
c. terminals for marks foreign -- -- -- 
a.
Remove any of    
 
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Clean and ensure
b. --    
proper fitment of all fuses.
Check all connections
c. --    
and ensure proper tightness.
Ensure proper fitment of fire
d. safety strips /channels --    
external and internal.
Inter vehicle electrical power couplers
a. Check HT power --- ---   
jumper cables for
external damage
and over heating. Repair
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Check I.V. couplers for proper
b. mating with thermo vision -- --- --  
device.
c. Check the condition of pins. -- -- --  

d. Replace loosely crimped pins. -- -- -- --- 

Check the
e. locking arrangement & ensure -- --   
its proper locking.
Take IR of live terminals to
f. body. It should be more than -- -- --  
as specified.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-
2)
Water supply system

Check functioning of water

pumping arrangement in
a. test mode/pump controller     
if provided.

Check mounting
b. the for proper --- --- ---  
arrangement
fitment.
Replace old Mono-block 
c. pump with new one in 2nd -- -- -- --- POH
POH. 2nd
 TI M
Activities
HY IOH
POH (D1) (D2) (D3)
(SS-1)(SS-2)
Lavatory equipment

Check and ensure working of

a.     
lavatory exhaust fans.

Ensure cleaning and

b. availability of sealing of -- -- --  
covers/grills.

Cleaning the impellers of

c. -- -- -- -- 
the exhaust items
Replace old defective
 Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
Earthing
a. Check function of insulation -- ---   
monitoring device by creating
single earth fault in supply
lines.
b. Check condition -- -- --  
of disconnectingand
earthing
switch. Replace if require
in
SS-2
c. Check tightness all the -- -- --  
of earthing
connections.
 TI M HY IOH POH
Activities
(D1) (D2) (D3) (SS-1) (SS-2)
Check working of all
a.     
mini- pantry equipment.
Clean all the
b. -- -- --  
pantry equipments thoroughly.
Check and record current
c. drawn by compressors for -- -- --  
bottle cooler & deep freezer.
Clean the condenser
d. -- -- --  
of refrigerator and deep
freezer.
Check starting capacitor value
e. with LCR meter. If value is -- -- --  
low, replace it.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check the working of starting

f. -- -- --  
relay for compressors.
Clean the boilers for removing
g. -- -- --  
scaling etc.
Check working of thermostats
h. --    
of boilers.
Check the heating element
i. --    
of boilers and replace if
required.
j. Check for any leakage. -- --   
Check the working
k. --    
of thermostats of hot case.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check the working

l. -- --   
of indication lamps.

Check the insulation

resistance of live terminals to
m. body. It should be more than -- -- --  
as specified.

Check earthing of
n. -- -- --  
each equipment.

Replenish the item if

o. -- --   
found deficient.
 TI M HY IOH POH
Activities (D1) (D2) (D3) (SS-1) (SS-2)

Replace dented/ pitted

p. -- -- -- -- 
doors of Deep freezer.

Replace hot water boiler

q. /geysers with new one on -- -- -- -- 
condition basis.

Replace complete Heater

r. assembly with new one on -- -- -- -- 
condition basis.

Replace dented/pitted doors of

s. -- -- -- -- 
Hot cases.
Sr. Circuit Capacity of Min. value of IR
No. Megger used required
Voltag
e
1. 750V 1000V 05 M ohms
2. 415V 500V 03 M ohms
3. 230V 500V 02 M ohms
4. 190V 500V 02 M ohms
5. 110V 500V 02 M ohms
Pre-Inspection

 Place the coach on the pit line and inspect the electrical
equipment.

 Check operation of all the lights, fans, mini pantry

equipment, WRA mono block pump, regulated battery
charger, protection fuses etc. and note down the defects
and deficiencies.
Work to be done

 Carry out all the activity as prescribed earlier in schedule

format for all equipment.

Final Testing

 After installation of all the electrical equipment on the

coach, they shall be checked and tested as per proforma
1.1.
Final Joint Inspection

 Workshop supervisor with divisional supervisor shall

jointly inspect the coach and the performance of
electrical equipment shall be recorded as per proforma
1.2

 A details of equipment changed with new assemblies

will also be handed over along with the coach to the
divisional representative. Any attention, if required to the
equipment shall be given before dispatch of the coach
from workshop to division.
Pre-Inspection

 Place the coach on the pit line and inspect the electrical
equipment.

 Check operation of all the lights, fans, mini pantry

equipment, WRA mono block pump, regulated battery
charger, protection fuses etc. and note down the defects
and deficiencies
Stripin
 Remove the following electrical equipment for overhauling:

 Mono block pumps.

 Battery and regulated battery Charger.

 Light fittings.

 Fans & Exhaust fans

 Mini pantry equipment.

 Before overhauling, measure the insulation resistance

of all the electrical equipment to know the condition of
Equipping

 Fit all the electrical equipment to its respective locations.

 Connect all the electrical wirings and other electrical

systems wherever required.

Final Testing

 After installation of all the electrical equipment on the

coach, they shall be checked and tested as per proforma
1.1.
Final Joint Inspection

 Workshop supervisor with divisional supervisor shall

jointly inspect the coach and the performance of
electrical equipment shall be recorded as per proforma
1.2

 A details of equipment changed with new assemblies

will also be handed over along with the coach to the
divisional representative. Any attention, if required to the
equipment shall be given before dispatch of the coach
from workshop to division.
 Proforma 1.1
EL TRICAL TEST REPORT FOR LHB EOG
NON AC COACHES AFTER SS-1/ SS-2

Type of Coach----------------- Coach No.---------------

Date of testing------------------ Railway------------------
Insulation Resistance
Sr. Circuit Capacity of Min. value of IR Actual value Remarks
No. Megger used required observed
Voltag
e
1. 750V 1000 V 05 M ohm OK / Not OK
2. 415 V 500 V 03 M ohm OK / Not OK
3. 230 V 500 V 02 M ohm OK / Not OK
4. 190 V 500 V 02 M ohm OK / Not OK
5. 110 V 500 V 02 M ohm OK / Not OK
Mono Block Pumps (For 3 Tier Coaches)
Sr. Description Specified Load Actual
No. Current observed
M/s. Elgi M/s Kalsi R Y B

WRA/ Mono Block

Amps. Amps
Pumps
1. 1 1.2 1.1
2. 2 1.2 1.1
Mini Pantry Equipment -For Chair Cars
1 Deep Freezer OK / Not OK
2 Bottle Cooler OK / Not OK
3 Hot Case OK / Not OK
4 Water Boiler OK / Not OK
Lighting & Fan Circuits

1 Working of main lighting circuit OK / Not OK

2 Working of emergency light unit (ELU) OK / Not OK

3 Night Light OK / Not OK

4 Gangway/ doorway light OK / Not OK

5 Lavatory light OK / Not OK

6 PACIL/PARCIL OK / Not OK

7. Fans OK / Not OK

8. Lavoratory exhaust fans OK / Not OK

Testing Of Electrical Panels

1 Regulated Battery Charger OK / Not OK

2 Earthing and disconnecting device OK / Not OK
3 Pump Controller OK / Not OK

Performance Of Other Equipment

SNo Equipments Performance

1. Flasher (L/V) OK /Not OK
2. 750 V circuit OK /Not OK
3. Feeder 1 OK /Not OK
4. Feeder 2 OK /Not OK
(Signature of testing In-charge)
 Proforma 1.2

FINAL JOINT INSPECTION REPORT OF LHB EOG NON

AC COACHES AFTER SS-1/ SS-2

Coach Particulars
S.No. Particulars of the coach Details
1. Coach No.
2. Depot / Railways
3. Workshop name
4. Coach booked on
5. Coach booked for SS-I/ SS-II
6. Date of Inspection
7. Return Date
Final Checking

1.0 Electrical Panels

Condition of rotary switches OK / Not OK

Condition of Rotary switches for
Light OK / Not OK
Fan circuit OK / Not
Mobile Charging OK OK /
Not OK
Condition of terminals OK / Not OK
Condition of contactors OK / Not OK
Condition of relays OK / Not OK
Condition of cable OK / Not OK
Condition of clamping of cables OK / Not OK
Condition of conduits OK / Not OK
2.0 Compartment
Condition of fans OK / Not OK
Condition of lights OK / Not OK
Condition of night lights OK / Not OK
Condition of switches OK / Not OK
Condition of PACIL/PARCIL OK / Not OK
Condition of mobile charging sockets OK / Not OK

3.0 Battery
Make
Lug date
Battery box suspension arrangement OK / Not OK
Battery box insi anti corrosion painting OK /Not OK
 Condition of battery lugs OK / Not OK
Condition of cell container OK / Not OK
Condition of battery fuse & fuse
OK / Not OK
box
Earth leakage of battery leakage / Not leakage
Battery no load voltage in volts volts
4.0 Regulated Battery Charger
Make of battery charger
Condition of battery charger OK / Not OK

Condition of battery charger

OK / Not OK
mounting arrangement
5.0 Pantry Equipment (chair car)
Condition of Deep freezer OK / Not OK
Condition of bottle cooler OK / Not OK
Condition of water boiler OK / Not OK
Condition of hot case OK / Not OK
6.0 EOG Coupler

Condition of coupler
PP Side 1. OK / Not OK 2. OK / Not OK
NPP Side 1. OK /Not OK 2. OK /Not OK

Condition of coupler pins

PP Side 1. OK / Not OK 2. OK / Not OK
NPP Side 1. OK /Not OK 2. OK /Not OK
 Condition of locking arrangement 1. OK /
6.0 PP Side Not OK 2. OK
NPP Side / Not OK
1. OK /Not
OK 2. OK /Not
OK
7.0
9/ 15 KVA Transformer

Condition of mounting arrangement OK /Not OK

Condition of terminals OK /Not OK
Provided/
8.0 Earthing of all Equipment
Not Provided
Equipment Replaced

S.No Name of Equipment Make Rating/ Serial

Capacity No.

(Signature of Inspecting (Signature of Inspecting

Supervisor from Depot/ Railway) Supervisor from Work Shop)
WATER RAISING MONO
SET PUMP
for
RMPU AC COACHES
Phase II - Module No.
 INTRODUCTION
 These pumps are used on Indian Railways coaching stock
for lifting water from under frame mounted main tank to
auxiliary tank located at the ceiling of the coaches to
supply water in toilets & wash basins.

 These are horizontal

centrifugal self priming
mono set pumps which
are driven by 3- phase, 50
Hz. 415 V ac supply.

P
 TECHNICAL DATA
(Ref: Amendment no. 1 to RDSO/PE/SPEC/AC/0022-(Rev.0)-2002 dated
13.01.2004)

• Type Squirrel cage induction motor TEFC

• Rated Output 0.5 HP/0.37 kW
• Rated Voltage 415 V ± 6 %, 3 Phase AC
• Rated Frequency 50 Hz ± 3 %.
• Load Current 1.1 Amps
• Speed 2800 RPM
• Insulation Class F
• Winding Connection Y (Star)
• Duty Continuous (S1 duty a per IS: 325)
• Type of mounting Foot mounted
Phase II - Module No. STC-
• Typ Self Priming, Centrifugal
e
• Total Head 8 Mtrs

• Suction Head 3 mtrs.

• Discharge Head 5 mtrs

• Discharge in LPH 2520 (0.7 liters/second)

• Suction Flange Size 1” BSP (25 mm)

• Delivery Flange Size 1” BSP (25 mm)

Phase II - Module No. STC-GS-1

 GENERAL DESCRIPTION

• Motor body, pump casing, rear

cover and front end bracket
are molded out of high quality
cast iron. Pump casing is
hydrostatic pressure tested at
1.5 times the maximum
discharge pressure.

• The stator is constructed with electrical grade silicon steel

laminated stampings. The rotor is made of high conductivity
aluminium by pressure die casting.
Phase II - Module No. STC-GS-1
 Theshaft for
rotor rotating
is dynamically
balanced, (with
to
impeller) at the highest
vibration
allowed speed minimize
and to
ensure smooth running
and increased life of the
bearings.

 It is made of stainless steel of AISI 410 Grade or as per IS:

6603.
Phase II - Module No. STC-GS-1
 Impeller is the
rotary
element of the pump
and is secured on
shaft
mounted
suitable bearings. It isa
made of brass andon
properly balanced.

Phase II - Module No. STC-GS-1

 The entry of water from pump to
motor is prevented by providing
high quality Nitrile rubber seal.

 Only sealed low function RZ type

bearing of SKF/ FAG makes are
used The minimum life of bearing is
1,00,000 Hrs.

Phase II - Module No. STC-GS-1

 Motor casing is provided with two
independent earthing terminals which
are connected to the coach body.
 Four cylindrical water tanks are fitted under frame of the
coach body which are inter connected to each other with a
pipe.

Phase II - Module No. STC-GS-1

 Non return valve is provided on each pump at out let pipe
to avoid back flow of water while pump is not
working
Phase II - Module No. STC-GS-1
 Inlet pipe is connected to the top of the tank & an
over flow pipe is also provided to allow the flow of
extra
water from main tank while refilling.
 The terminal connection for supply are brought out in a
terminal box on the motor and clearly marked RYB
(embossed) on the terminal plate to obtain correct
direction of rotation.

 The terminal plate is made

of epoxy reinforced glass
fiber material conforming
to BS-3815 and it is also
anti- moisture absorbent
and free from porosity.
P
 Cable entry to the terminal box is made in the bottom at
right angle along with the suitable size of cable gland.
Silver brazed joints/ fused for connecting terminals leads
and wires are used. Soldered joints are not acceptable. The
terminal box cover and lid is made of die-cast aluminium..

 The entire motor portion have ingress protection IP 55

as per IS 4691.

Phase II - Module No. STC-GS-1

 Pump controller is provided in AC
coach power panel.
 It has a selector switch to operate the
pump either in auto or manual mode.
 Pump 1 or 2 may be selected in
manual mode. In auto mode pump
change over takes place automatically
after 4-6 hrs.

 It also displays running time of pump-motor and LED displays

are provided for working status/faulty condition for individual
pump.
Phase II - Module No. STC-GS-1
 WORKING
 Water is pumped in the coach from under slung
water tanks through Mono-block pump.

 Either pump works continuously and water is

pumped in auxiliary tanks mounted over the each
toilets.

 The extra water overflows from auxiliary tanks to

the main tank through a recycle pipe.
Phase II - Module No. STC-GS-1
 OPERATIONAL INSTRUCTIONS
The following points shall be checked:

i. Ensure that the main tanks are filled with water.

ii. Ensure that pump selector switch of pump

controller is on ‘Auto’ mode.

iii. Ensure that the outlet valve of main tank to pump is

in open condition.

iv. Ensure that motor rotates in the

correct direction as painted/embossed.
Phase II - Module No. STC-GS-1
v. Ensure that the pump set runs quickly and smoothly.

vii. Check the availability of the water in toilets and

wash basins.

Phase II - Module No. STC-GS-1

 DISMANTLING AND RE-ASSEMBLY
PROCEDURE

 Isolate supply connections and dismantle the pump from

the pipe lines and foundation.

 Remove the bolts, which are holding the casing to remove

casing from the assembly and slide out the impeller.

 Remove the screw on end cowl then remove fan, remove

bolts on end cover and pull out the end cover. The shaft
with stuffing box can be taken out from the frame.
Phase II - Module No. STC-GS-1
 All parts are to be checked and replace if damaged and worn
out.

 Check bearing condition and replace if necessary.

 Replace rubber seals and gaskets before re-assembly.

 While re-assembly, follow the reverse procedure of dis-

assembly, if the impeller is tight, tap the shaft at the non-
driving end.

 Shaft rotates freely after assembly.

 Ensure that the non return valve (NRV) is kept at right position
while installation.
Phase II - Module No. STC-GS-1
PROBLEMS, CUASES & THEIR REMEDIES

Problem Motor does not rotate/fails to start

Causes Remedial Action

 No power supply.  Ensure 3 phase power

supply at different
locations.
 Over heating .  Remove fan cover and check for
free rotation of motor shaft along
with fan and allow the motor to
cool & switch on.

Phase II - Module No. STC-GS-1

 Causes Remedial Action
 Impeller stuck due to  Rotate shaft by
keeping idle for a longer the hand/with help
time. the
screwdriver of
to ensure
free rotation.
 Motor winding defective  Check winding for
open circuit etc.

Phase II - Module No. STC-GS-1

Problem Pump does not lift water

Causes Remedial Action

 Priming not sufficient  Fill water till it flows
continuously without air lock.
 Air leak in suction  Use proper sealing to arrest leak
pipe or use teflon tape at joints.
 Clean the suction pipe.
 Blocked suction pipe
 Replace the seal.
 Leaking seal
 Tighten the air cock, renew if
required.
 Air cock side leaking
 By changing any one phase of
 Mono block pump running the electrical connection the
direction can be changed.
in opposite direction Phase II - Module No. STC-GS-1
Problem Leaking mechanical seal

Causes Remedial Action

 Running face is damaged  Lap the running face
or replace it.

Problem Insufficient discharge/ Capacity decrease

Causes Remedial Action

 Strainer clogged.  Clean the strainer.

 Wrong direction of  Interchange any two phase

rotation. to correct the direction.

Phase II - Module No. STC-GS-1

Problem Pump set draws more current
Causes Remedial Action
 Defective bearing  Replace defective bearing.
 impure water  Ensure clean water

Problem Pump set making noise

Causes Remedial
Action
 Wrong direction of rotation. Interchange any two phase
 to correct the direction.
 Defective bearings  Replace defective
bearings.
Problem Motor starts with a humming sound, does not
rotate and then trip

Causes Remedial
Action
 Pump jammed  Switch off the supply and
rotate the shaft with the help
of screw driver/by hand.

Phase II - Module No. STC-GS-1

SCHEMATIC DIAGRAM

Phase II - Module No. STC-GS-1

 MAINTENANCE
Sr. ACTIVITIES
Activities TI M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

Check functioning of water

pumping arrangement in auto     
1. mode/ manual mode through pump
controller.

Visually check the

2. mounting     
arrangement for any abnormality.
Check running of pump-motor for
3. any abnormal sound, water --    
leakage from pipe lines, joints etc.

Phase II - Module No. STC-GS-1

 TI M HY IOH POH
Sr. Activities (D1) (D2) (D3) (SS-1) (SS-2)

Check cable connections on

-- --   
4. terminal box for tightness and
for sign of overheating etc.

Check rubber seal/ gasket

5. -- --   
for any damages/ water leakage.

Phase II - Module No. STC-GS-1

Phase II - Module No. STC-GS-1
  Rajdhani/ Shatabdi rakes work on the principle of End-On-
Generation system i.e. provision of two power cars, one on the
front and other on the rear.

 Each power car is equipped with two Diesel Alternator sets to

supply Electrical load to the coaches through two set of feeders
running along the rake and coupled in between with the help of
inter-vehicle couplers.

FEEDER - I
ALT. ALT.
ALT. COACHES COACHES ALT.

FEEDER - II
POWER CAR

POWER CAR
 These couplers also carry the earth wires and 2 wires
for the control circuit.

 Presently the diesel alternator set provided in the

power car is the up rated version, EPCB norms
compliant engine with and installed capacity of 490
BHP at 60 degrees at 1500 rpm.
 The Diesel Engine provided is turbo charged , water cooled
delivering 490 BHP at 60 Deg C at 1500rpm coupled to 500
KVA alternators.

 These powers cars meet the various loads for the coach including
the pantry equipment and air conditioning load of the coaches.

 At present there are following makes of Diesel alternator sets

provided on the LHB Power Cars
 BHEL-EML (formerly KEL, Cochin, taken over by BHEL)
 Kirloskar Electric Company, Bangalore
 Deev Gensets, Silvasa
 Cromptom Greaves
 The engine provided by M/s Cummins i.e. to cat no KTA19G5I is
CPCB (Central Pollution Control Board, Ministry of Environment
and Forests) compliant as regard to emission norms.

 The diesel alternator sets generally conform to the details as

indicated

• Output Power : 500 KVA at NTP

• System Voltage : 750 volts AC , 3-phase

• Frequency : 50 Hz +\- 3 %

• Power Factor : 0.8

Various diesel engine makes and their catalogue nos. are as
indicated below:

Cummins – KTA BHEL – Type -ARES

BHEL-EML
(formerly KEL) 19G5I Model – 3560 L7 SP

Kirloskar Cummins – KTA

KEC – 4AB355/7
(KEC) 19G5I

Crompto Greaves Cotton

CG model 355 MA
n TBD41V12P
Greaves
o The alternator provided has a capacity of 500kVA, 0.8 pf
3phase, 4 wire 750 volts 50 HZ +\- 3 %.

o The alternator used is self ventilated brushless design with

voltage regulation of dual type i.e both electric and
electronic.

o The electrical control is through compound transformer or

magnetic amplifier and

o Electronic regulation through solid state automatic voltage

control and sensing from all the three phases.

o The combined regulation is 2.5 % approximately.

o Standby facility is provided to ensure voltage regulation within 5 %
even in the event of failure of automatic voltage regulator.
o And this standby facility is automatically cut in with the help of
OVR/UVR which indicates through two LED’s of the failure of AVR
and that the system is in manual mode.
o Automatic voltage regulator is suitably mounted in the power panel.

o The alternator has a stator, rotor insulation of H class and exciter

insulation class F.
o The alternator is capable of handling 30% unbalance
load in any of phases with current in any of phases not
exceeding rated current with regulation maintained at
5% or less or 2.5% or better in manual and AVR mode
of operation respectively.
The Diesel alternator sets are placed back to back at the
centre of the power car coach.

o The engine is water cooled and radiator fixed on

separate mounting at a remote location to facilitate
cooling by fan directly driven by 40HP, 3-phase, 415
volts, 50 Hz motor wherein the impeller sucks in
outside air through the radiator fins and blows out
upwards through the duct to the roof.

o Air delivery is approximately 18 cubic metre per sec.

at 60 mm water gauge.
o The exhaust outlet locations are fixed such that the
silencer provided on the dished roof portion is
connected by means of flexible metal hose to the
engine which is lagged and enshrouded all round
with aluminium sheet to provide a positive and
effective thermal insulation.
o Two under-slung fuel tanks are provided in the
under-frame with an individual capacity of 1540
liters.

o The engines are fed through respective tanks and the

tanks are connected through an equalizing pipe
with a cut off valve in-between.
o Two centrifugal type blowers per DG set are
provided at the cant rail level of capacity 25000
CMH.
o Each are provided such that the air is drawn from
the engine room through the opening on the false
ceiling and blown out laterally through rectangular
louvered openings provided on either side on the
sloping roof sheet.
o The blowers are driven by 415volts, 3-phase, ac
motors of 5 KW.
o To minimize the dust into the engine room through
the four hatch doors louvered openings, dry type,
re-usable fire retardant, non-woven synthetic
media panel filters, with a filtering capacity of upto
20 microns size dust particles have been used for
both LHB and Garib Rath power cars.

o Each filters module comprises of 9 detachable

panels.
o The engine installed by Greaves Cotton has a fuel
pump provided to suck the fuel from the diesel tanks
provided at the bottom.

o For starting the engine 290 Ah Lead acid battery is

provided to feed the power to the engine starter
motor for cranking one engine at a time by means of
changeover switch for the two DG sets.
SNo Particulars LHB Garib Rath

1 Coach length 23.5 meters 21.3 meters

2 Speed potential 160 Kmph 130 Kmph

1 x 5 ton
3 Roof mounted ac unit 1 x 7 ton
1 x 1.5 ton
2 x 60 KVA ▲-Y
4 No of transformers 3 x 60 KVA Y-Y
1 x 50/3 KVA

5 Pumps One set of two pumps One set of two pumps

6 Pump controller Provided Provided

SNo Particulars LHB Garib Rath
7 Water storage tank 1 x 685 litre
8 Engine 2 x 490 BHP 2 x 490 BHP
9 Alternator 2 x 500 KVA 2 x 500 KVA
10 Radiator fan 2 x 40 HP 2 x 40 HP
11 Ventilator fan motor 2 x 5 Kw 2 x 5 Kw
12 Starter battery 1 x 290 Ah, 24 V 1 x 290 Ah, 24 V
13 Smoke detector Provided Provided

14 Temperature control Fine control in 7 Coarse in 3 steps

steps
15 Humidity control Provided Not provided
SNo Particulars LHB Garib Rath
16 Window size Bigger Smaller
17 Anti skid device Provided Not provided
Conventional disc
18 Braking Disc braking
braking

IGBT based battery Conventional battery

19 Fitted
charger charger provided

70 Ah for dc 120 Ah for

20 Battery
control of power emergency
panel light
Disconnecting and
21 Fitted Not provided
earthing device
SNo Particulars LHB Garib Rath
Provided inside Provided on the
22 Transformer fuses
the power transformer itself
panel
Insulation and
23 Fitted Not fitted
monitoring device
24 Self diagnosing system Fitted Not fitted
Flap motor to adjust the
25 Fitted Not fitted
air inflow
26 Thermostat NTC type Electronic
Suction and discharge
Provided on the
27 pressure indicated on Not provided
panel board
the panel
SNo Particulars LHB Garib Rath
1 Coach length 23.5 meters 21.3 meters
2 Speed potential 160 Kmph 130 Kmph
1 x 5 ton
3 Roof mounted ac unit 1 x 7 ton
1 x 1.5 ton
2 x 60 KVA ▲-Y
4 No of transformers 3 x 60 KVA Y-Y
1 x 50/3 KVA
One set of two
5 Pumps pumps One set of two pumps

6 Pump controller Provided Provided

SNo Particulars LHB Garib Rath
7 Water storage tank 1 x 685 litre
8 Engine 2 x 490 BHP 2 x 490 BHP
9 Alternator 2 x 500 KVA 2 x 500 KVA
10 Radiator fan 2 x 40 HP 2 x 40 HP
11 Ventilator fan motor 2 x 5 Kw 2 x 5 Kw
12 Starter battery 1 x 290 Ah, 24 V 1 x 290 Ah, 24 V
13 Smoke detector Provided Provided
Fine control in 7
14 Temperature control steps Coarse in 3 steps
SNo Particulars LHB Garib Rath
15 Humidity control Provided Not provided
16 Window size Bigger Smaller
17 Anti skid device Provided Not provided
Conventional disc
18 Braking Disc braking braking
Conventional
IGBT based battery battery charger
19 Fitted
charger provided
70 Ah for dc
120 Ah for
20 Battery control of power
emergency light
panel
Disconnecting and
21 earthing Fitted Not provided
device
SNo Particulars LHB Garib Rath

Provided inside Provided on the

22 Transformer fuses
the power panel transformer itself

Insulation and
23 Fitted Not fitted
monitoring device
24 Self diagnosing system Fitted Not fitted

25 Flap motor to adjust the Fitted Not fitted

air inflow
26 Thermostat NTC type Electronic

Suction and discharge Provided on the

27 pressure indicated on Not provided
panel board
the panel
High water temperature
• The high water temperature switch is mounted on the
engine and senses the temperature of water in the
cooling jacket of the engine.

• The device is set at 97°C for putting off the engine.

• Once the ICHT closes, water temperature indication

comes on and the common fault relay is energized.
Over speed of the engine
• Over speed switch ICOS mounted on the
engine senses the over speed when the
engine governor fails.

• When the engine RPM exceeds the set

value its NO contact closes the over
speed relay OSR. One of the NO
contacts of OSR maintains the
supply and another contact
thecompletes
closes and to the CFR circuit.
OSR
• The over speed is set at 1800  4.5 % RPM
Lube Oil Pressure
• The NC contact of the lube
oil pressure switch remains
open when the lube oil
pressure is sufficient. When
the pressure is below the set
value, the switch closes the
LOP relay.

• The lube oil pressure switch is mounted on the

engine senses the lube oil pressure.
• One of the NO contacts of the
LOP maintains the supply to LOP
relay and another NO contact
energizes the CFR circuit.
Low water level switch
• A low water level switch has been provided on the top of
the radiator for sensing the presence of water in the
radiator.

• If ever the water level goes down below a certain level, it

gives a indication on the panel and the same can be
integrated in the panel control circuit for switching off the
load or the engine
Alternator Overload
 This protection is in-built in
the ACB.

 TheACB has an integrated

solid
state relay of thermal
overload type which
incorporates the
following precautions:
• Short circuit
• IDMT and Overload
• Earth Fault
 Whenever the fault conditions are
sensed, IDMT relay picks supply to
the alternator fault relay.
Under voltage relay
• When the voltage of the
alternator falls below the set
value of 687 volts ( 380 at
415 volts side). The NC
contact of UVR closes on due
to dropout of UVR and
energizes the time delay relay.

• The ON delay contact of the timer closes after few

seconds and energizes the AFR.
• The NO contact of the AFR energizes the auxiliary relay of
the ACB (24 volts DC) and this relay de-energizes the 415
volts trip relay of the ACB resulting in tripping of the air
circuit breaker.

• The technical details of relay are as under :

o Auxiliary voltage – 440 v
ac
o Contact rating 2 amps inductive at 24 V dc

o Monitoring system voltage 750 volts, 3

phase, 50 Hz, 4-wire
o Contacts 2 N/O + 2 N/C independent
Earth Leakage Relay
• The relay supplements the earth leakage feature already
incorporated in the solid state or thermal type relay of the
ACB.

• Core balance transformer operated earth leakage device

detects any earth fault caused either in the alternator
winding or in the cables from the alternator to the control
panel upto the core balance transformer.

• Its NO contact energizes the earth leakage relay ELR.

• One of the NO contacts of ELR energizes the Earth fault
indication lamp and AFR circuit.

• Another NO contact of ELR maintains the supply to ELR

itself, even after ACB has been switched OFF.

• This is mainly for the alternator

protection / cables between
interconnecting the ACB and the
alternators.
The technical details of ELR are as under:
• Size of cable – 150 sqmm
• Auxiliary supply voltage – 440 volts ac
• Contact arrangement 1 N/O + 1 N/C independent
• Contact rating 230volts 50 Hz, 5 amps, ac resistive
• Suitable for 750volts, 3 phase, 50 Hz, 4-wire system

Short Circuit protection

• This feature is incorporated in the ACB .

• This results in the instantaneous tripping of the ACB,
when set value of the current is sensed.
The two individual feeders are protected by individual
contactors, with the following trips:

Earth Leakage

The protection scheme for the conventional (3 wire

system) and LHB type (4 wire system) relay is different.

LHB Type Power Cars

These Power cars are equipped with residual current type

relays of BENDER make.
Feeder Overload

LHB Power cars

• The MICOM make relay is Universal programmable relay

which can be programmed to suit to the usage. The relay
is used an over current relay to protect the feeder.
 Two 60KVA 750/415 volts,
star/star transformers are used to
meet the load of the radiators and
ventilation fan motors. HRC fuse
protection both for the input and
output side with a fuse of 63 amps,
1000 volts and 100 amps, 660 volts
fuse respectively is provided.
 Radiator motor is of 40 HP
for the uprated DG set. This
motors gets the supply through a
star delta starter of 40 HP with a
motor protection circuit breaker
provided in the starter itself. The
rating of the MPCB is 63 amps,
660 volts of Sprecher and SHUH
make or equivalent SIEMENS
make
 Based on the IS:3043, the system of earthing in LHB
Power Car is as follows:

 Neutral of the generator car is earthed through a neutral

reactor i.e. exposed conductive parts are connected to
electrically independent earth electrodes.

 The generators' neutral point is earthed thus creating a

TN-net continuing to coupling receptacles and
transformers.
 Switch cabinet S2 contains a central PEN-bar to which the
earth of generators and bus bars are connected.

 The 60 kVA transformer operates as isolating transformer.

 The secondary neutral point is not earthed, thus an

IT-net exists.

 The working stock bodies are separately or

commonly connected with an earthed protective wire.
 No active IT-net conductor is directly earthed so that in case of
insulation failure only a low fault current caused by the
capacitances of the cables to earth can flow.

 The fuse is not triggered so that the power supply is

maintained even in case of single line-to-earth fault.

 This means that the reliability of this kind of networks is

higher than in other networks

 In case of a second fault one of the two faulty devices will be

switched off before the permissible contact voltage of 50 V is
reached.
 The double-pole 110V DC mains is equally unearthed
which means for the consumers that they are double-pole
protected.

 Keys on the switch cabinet door and the voltmeter permit

to measure the voltage between positive and negative
potential of DC mains and earth. In such a way the mains
insulation condition can be checked.

 For monitoring the AC mains insulation protective

devices are used.
 Accordingly in the Generator-cum-brake van earthing
points are provided. Following items are to be earthed in the
under frame:
• Battery Box
• Battery fuse boxes (positive and negative)
• Transformer container
• Tank for fresh water
• Brake PCB
• Diesel tank
Smoke detectors are provided in the power car to detect any
smoke generated due to any precarious condition arising
during the working of the power cars.

• A two channel control unit with visual indicators for level

of smoke, a built in piezo buzzer and an external socket for
connection of the hooters is provided.

• Two smoke detector units – one unit is located in the power

panel area directly above it and the other unit is placed
inside the engine room.
• These detectors are connected to the unit by four
core shielded cable.

• Two hooters are located inside the engine room and

the power-panel area for annunciation

• The system works on 110 volts dc through 110 v dc

from the coach battery provided in the LHB coaches.
• Use of flexible polyamide
Conduits and End Fittings
with its accessories

These conduits have excellent properties of very high

impact strength at low temperature, is free from halogens
and cadmium, chemically resistant to fuels, mineral oils,
alkalies, weak acids etc. These are suitable for a wide
temperature range of -50 °C to +105 °C.
 This equipment is provided to bypass the fault current
from the bearings and not to allow the current to pass
through the bearings which may become defective and
effect the life of the bearings.
o Due to star-star connection
in power transformer, 3rd
harmonics are generated and triple
frequency which is normally three
times the normal current flowing
through the neutral conductor. To
overcome the problem one reactor
is provided in between the
generator neutral and the local
neutral, which restricts the 3rd
harmonic component to go back to
the generator.
 Insulation Monitoring Device
is provided in the LHB
Power car, which gives
indication in case the
insulation of the system is
less than the preset value of
the device.

 Insulation measuring device monitors the

insulation resistance of unearthed AC and 3
phase mains (IT-NETs).
 A 5-pole plug and socket of
125A rating with pilot contact
is provided for external local
supply at 415V, 3Ph.

 The necessary protective

mechanism is provided to
prevent short-circuiting of two
supplies and danger to the
operating/maintenance staff.
 All the coach wiring for the power cars have
been provided with e-beam cables which are
highly flame retardant, Low Smoke, Low
Toxic, Zero Halogen Emission, Better
Thermal Properties), High Current Ratings -
Operating Temperature up to 230°C, Special
Polymers to cover Wide Temperature range
from -65°C to +230°C, no Risk of
Deformation above Short Circuit
Temperatures Rugged
,Properties – Superior
Mechanical
Abrasion/Scrapes &
Cut-through Resistance, Resistant to Ultra-
Violet (UV) Rays & Impermeable to
Moisture.
A plant selection switch has provided on
Switchboard cabinet been the following
to operation. give modes
of
A Position – I 12’O clock OFF
B Position – II 3’O clock Plant ‘A’ Only
C Position – III 6’O clock Plant ‘A’ & ‘B’
D Position – IV 9’O clock Plant ‘B’ Only

The alternator cannot be paralleled.

• Normally Feeder-I and II are fed through Plant A and
Plant B based on the service experience, it is possible
to supply feeder I and II from Plant A and B through
operating the bus coupler contactor push button and
the respective feeder contactor.
• This rotary switch cuts off the dc supply to the control
circuit in its OFF position. If the generator sets are not
working thus switch should be kept in the OFF position.

Push Buttons and Switches provided on the Switch cabinet

Sr. Name of push Function
button/switch
1 Engine ON To start the engine
2 Rise To increase the RPM of the Engine
3 Lower To decrease the RPM of the Engine

4 Test switch TS-1 To test the condition of the

Engine Failure indications
Sr. Name of push Function
button/switch
To test the condition of the Alternator
5 Test switch TS-2
Failure indications
To test the condition of the
6 Test lamp switch
Feeder Failure indications
7 Alarm isolation To stop the alarm
8 Feeder ON To switch ON the feeder
9 Engine STOP/RESET To stop or reset the engine
To reset the fault conditions (alternator
10 Reset push button A OR B
& feeder)
11 Feeder OFF To switch off the feeder
12 Bus coupler ON To switch ON the bus coupler
 The engines are of two types:

Cummins KTA19G5I and

Greaves Cotton TBD41V12P engine.

 The Greaves Cotton Engine incorporates

Electronic Instrumentation panel for starting the engine
i. Before starting the engine, ensure necessary
quantity of lubricating oil, fuel oil, and cooling
water.

ii. Switch ON the dc control switch.

iii. Switch ON the starter motor Isolation switch.

iv. Press the test push button 1, 2 & 3 to check the status
of the fault indication lamps.
 Press the engine start push button of any one
engine selected for running.

• First NC contact of the start push button ensures that

the engine does not stop for the want of lube oil
pressure build up at the moment of starting.

• Second NC contact prevents the simultaneous starting

of the other engine.

• Third NC contact de-energizes the BIC which

disconnects starter battery charger from supplying to
starter battery during starting.
• One of its NO contact energizes the FSRD (time delay
relay for the starter solenoid ) and FSS (Fuel start
solenoid ) and the other contact energizes SC (solenoid
coil) of the starting motor for cranking the engine.

• When the engine attains full speed, the start push button
may be released.

• The instantaneous contacts of the FSRD maintain the

supply for the FSRD and FSS.
• The NC contact of the start button and one of the delay
contacts of FSRD keep the starter motor circuit open to
prevent accidental restart by means of start push button.

• Another NC delay contact of FSRD keeps the LOP circuit

closed.

• Once the engine starts, lube oil pressure developed opens

the oil pressure switch ICLOP (Internal combustion
Engine Low Oil pressure) which keeps the LOP energized
as long as there is sufficient pressure of Lube oil.
 Watch the frequency meter. Adjust the speed by RISE or
LOWER push button until the frequency meter reads 50
Hz.

 Here the speed of the engine is controlled by controlling

the fuel flow into the engine by means of throttle motor.
The RISE and LOWER push buttons control the
direction of the throttle motor.

 Keep the plant selector switch as

 Plant A
•Only
This is done by switching ON the ACB-A manually.

• If it is desired to feed both the feeders A and B from Plant A.

• Bus coupler contactor K2 can be energized by pressing the bus

coupler push button. Paralleling of the alternators is prevented
by the ACB mechanism.

Plant B Only
• This is done by switching the ACB-B manually.

• If it is desired to feed both the feeders A and B from plant

B , bus coupler ON push button. Paralleling of the
alternators is prevented by the ACB mechanism.
Plant A & B
Both
• Both the ACB’s can be closed simultaneously but in this
condition the bus coupler cannot be energized because the
auxiliary contacts of the two ACBs in the bus coupler close
coil circuit will be open.

• Hence the Plant A will feed only feeder A and Plant B will
feed the feeder B.
• Switch ON the DC Supply from DC ON switch
• Wait till the ready indication comes on EMS.
• Confirm the working of the Fuel transfer Pump.
• Press start Switch to start the Engine.
• Check the frequency and voltage on panel board after
stabilizing.
• Check the working of Radiator
Motor after Turning ON the
i. Operate power supply On push button

ii. Set rotary switch DC-ISO-A to ON

position
iii. Lamp 'DC -ON' on the Panel-II

iv. Set rotary switch ' Plant selector switch' to Position -4.

v. S2K9, S2K11 pulls in

vi. S2K8, S1K10 do not pull in

vii. Close manually the ACB.

viii. Transformer-1 gets supply.

viii. Switch ON the radiator and exhaust fans in the engine room.

ix. Press the push button SAFETY LOOP.

x. Press the push button FEEDER B

ON.

xi. Contactors S2K13 and S2K3 are energized

xii. Switch feeder B off

xiii. After a moment push Feeder B ON

xiv. Push bus coupler push button.

xv. S2K11 and S2K2 pulls in

xvi. Same procedure can be adopted for the

other feeder and plant.
• The safety loop is the most important protective
safety circuit.

• It guarantees the standard operation of generators and power

supply.

• The generators must not work other than in "stand

alone” operation.

• A parallel operation is not possible because the

generators are not designed for synchronous
operation and the compensating currents can grow
up to a dangerous size.
• Normally generator A supplies the bus bar A and the
generator B supplies the bus bar-B.

• To achieve maximum flexibility it is possible to

supply bus bar B via a coupling contactor from generator
A, or bus bar A from generator B, or both bus bars from
one generator, respectively.

• The coupling can only be switched ON if only one

generator operates while the other is disconnected.

• For this purpose a safety loop is created by 2

control current contacts.
Relay used for safety
loop instead of
Darlington pair as
used in conventional
coaches
Interlock Preventing Accidental Paralleling of Alternators in
Rear Car With Alternator In Front Car
a. Standard external power car operation on rear 1
Each of the two alternators of the power car on rear-1 supplies
one feeder. The alternators of the rear power car- 2 are switched off.

REAR-1 REAR-2

ACB-A K-1 K-3 ACB-B

ENGINE FEEDER A ENGINE
A B

K-2 COACHES K-2

ENGINE ENGINE
FEEDER B
B A

ACB-B K-3 K-1 ACB-A

b. Standard external power car operation on rear 2

Each of the two alternators of the power car on rear 2 supplies one
feeder. The alternators of the rear power car- 1 are switched off.

REAR-1 REAR-2

ACB-A K-1 K-3 ACB-B

ENGINE FEEDER A ENGINE
A B

COACHES K-2
K-2

ENGINE FEEDER B
B ENGINE A

ACB-B K-3 K-1 ACB-A

 c. Standard external power car operation on rear 1 and 2

One of the two alternators of the power car on rear 1 and 2 supplies one
feeder. Alternator-A on rear 1 supplies feeder A and alternator-A on
rear 2 supplies feeder B.
REAR-1 REAR-2

ACB-A K-1 K-3 ACB-B

ENGINE ENGINE
FEEDER A
A B

COACHES
K-2 K-2

ENGINE ENGINE
FEEDER B A
B

ACB-B K-3 K-1 ACB-A

 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure proper condition

1.     
and tightness of mounting bolts

Check and ensure proper Tightness of all

2. connections of alternator outgoing & --    
control cables
Check and ensure proper
3. --    
earthing connection

Check and ensure proper Condition of

4. coupling nut bolts and their     
tightness.
Attend them, if required
S TI 3M HY IOH POH
Activity
(D1) (D2) (D3) (SS-1) (SS-2)
N
Check alternator for any unusual
5.     
sound and attend same

Check and ensure generation of

6.     
proper voltage (750V, 50Hz)

Ensure proper Cleaning and tightness of

connection of Excitation System. Use
7. thermal imaginer equipment to check --  --  
temperature of cable nuts, connecting nut
bolts etc. on load

8. Ensure proper Greasing of Bearings -- -- -- -- *

S Activity TI 3M HY IOH POH
N (D1) (D2) (D3) (SS-1) (SS-2)
9. Ensure proper Servicing and Overhauling by -- -- -- -- 
disassembly of Coupling, End covers, Rotor
,Stator and Excitation system etc and
thorough cleaning of all parts including
various windings by blower and thinner and
application of anti track varnish on exposed
portion of windings. Ensuring proper
cleaning and Greasing of Bearings and their
replacement, if required.
Replace rubber bushes of alternator and
diesel engine coupling.
ensure alignment of alternator and diesel
engine coupling with dial gauge
during fitment after servicing and
overhauling.
* greasing of bearing shall be as per
recommendation of OEMs.
S Activity TI 3M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)
N
Check and ensure proper condition
1.     
of mounting and fitment of side body filters

Remove and ensure proper cleaning of side

body filters by dry compressed air at a
2. --   -- --
pressure 1.75 kg/cm2 (25psi) with help of
portable compressor

Ensure proper cleaning of sidewalls

3. --    
and
ceiling of engine room
4. Replace old side body filters with new -- -- --  
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure proper condition of mounting

1.    --
of batteries on frame

Check and ensure proper condition of connection
2. cables, terminal connection tightness and     --
application of petroleum jelly on it
Check and ensure proper condition of Air Vents of
3.     --
batteries
Check and ensure proper Specific Gravity (SPG)
4. of batteries and it’s electrolyte level. Top up with     --
distill water, if required

5. Check and ensure proper battery     --

voltage
6. Replace old starting batteries with new -- -- -- -- 
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Check and ensure proper condition
1.     
of mounting bolts and covers

Check and ensure proper tightness

2.     
of connections

Ensure proper cleaning by dry compressed

3. air at a pressure 1.75 kg/cm2 (25psi) with --    
help of portable compressor

4. Check and ensure proper condition of     

electrical wires and attend them as and
when required
SN Activity TI 3M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

Check operation of battery change

5.     
over switch and replace if required.

Check and ensure proper operation

6.     
of battery charger.

Ensure proper Servicing and Overhauling by

opening the covers and thorough cleaning of
7. all parts by blower and thinner. Replace the -- -- -- -- 
Voltmeter and Ampere meter with new
calibrated meters
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

1. Check and ensure proper condition of mounting     

Ensure its proper working. Replace starter

2. motor, relay, switch gears, cables, terminals etc.,     
if found defective,

Check and ensure proper cleaning by blower/

3. vacuum pump and replace the carbon brush, if -- --   
required

Check and ensure proper condition of electrical

4. wires and attend them as and when required on     
condition basis.
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)

Ensure proper Servicing and Overhauling

by disassembly of Coupling, End
covers, Rotor
,Stator etc and thorough cleaning of all
parts including various windings by blower
5. -- -- -- -- 
and
thinner and application of anti track varnish on
exposed portion of windings.
Ensuring proper cleaning of bearings/ bush and
their greasing and replacement, if required.
Ensure Replacement of Carbon Brushes
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Check and ensure proper condition of mounting
1. --    
bolts /anti vibration pads etc

Check and ensure proper condition of electrical

2. wires/cables /connections and attend/ tighten/ --    
replace them, if required

Check and ensure proper cleaning of Power

Panel, Control Panel by Vacuum Pump and dry
3. --    
compressed air at a pressure 1.75 kg/cm2
(25psi) with help of portable compressor

Check and ensure proper working of

4. indication lamps ,Push Buttons, Switches     
and Fuses and
Replace them , if required
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Check and ensure proper closing of main
5. breaker (ACB) contactor and Attend/Replace, if -- --   
required

Check and ensure proper working

6.  -- -- -- 
of instruments provided on instrument panel
Check and ensure proper working of DC control
7. --  -- -- 
& Panel Wiring System and attend, if required

Check and ensure proper working of different

measuring meters- Ammeter, Volt meter, kW
8. meter, frequency meter, R.P.M. meter and     
replace, if required

Checking of the working of Contactors

9. (C1,C2,C3,C4), Feeder Contactors and     
bus
coupler contactors.
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-
(D2) 2)

Ensure Cleaning and tightness of connections

of Power Panel/Control Panel. Use thermal
10. imaginer equipment to check temperature of --    
cable lugs, connecting nut bolt, contactors etc.
on load

Ensure Thermo Imaging of Power Panel

11. --    
on Load

12. Ensure tightness of Bus Bars --    

 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Strip Contactors, Bus Bars, MCBs, Air Circuit

Breakers and all type of rotary switches etc.
and do thorough cleaning of Panel and its
equipments by blower/ Vacuum Pump and
thinner and Ensure their proper Servicing and
13. -- -- -- -- 
Overhauling.

Replace contacts of Contactors, if required

Ensure Thermo Imaging of Power Panel on

Load after Servicing and Overhauling
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Check and ensure proper condition of mounting
1. --    
bolts and anti vibration pads etc.

Check and ensure proper cleaning of radiators.

Clean by water jet machine 4.9-5.6 kg/cm2 (70-
2. --    --
80 psi) with OGR and ID-27 or any
other suitable cleaning agent

Check Radiator water level and top up

3.     --
with
distilled water, if required.
Check filling cap and condition of radiator
4.     
fan bolts for tightness and attend, if
required
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)
Check condition of radiator pipeline, clamp &
5.     
water leakage and attend, if required

Check condition of radiator chamber, doors,

6. hinges, latches etc. and attend the same to ensure     
proper condition.

ensure proper doors, latches, ceiling

7.     
and intactness of baffles etc. for radiator
chamber
Strip and ensure thorough cleaning by water
jet machine 4.9-5.6 kg/cm2 (70-80 psi) with
8. OGR and ID-27 or any other suitable -- -- -- -- 
cleaning agent.
Remove internal scaling if any, with the help of
suitable descaling agent.
9. Replacement of ‘O’ Ring of radiator pipe line -- -- -- -- 
Fill up the radiator with distilled water, proper
10. -- -- -- -- 
coolant and descaler.
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure proper condition of mounting

1.     
bolts

Check and ensure proper condition of electrical

2. cables/wires and attend them as and when     
required on condition basis

Ensure Cleaning and checking of connection

tightness of starters of radiator motors. Use
thermal imaginer equipment to check
3. temperature of cable lugs, connecting nut bolts --    
etc. on load to find out loose connection. Check
IR.
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Ensure Checking of condition of Radiator Motor,

4.     
connection and its tightness
Ensure Checking of condition of Radiator Motor
Fans and its tightness and attend the defects.
5. Replace motor in sick line/ workshop, if found     
defective.
6. Ensure greasing of radiator motor. -- -- -- -- 
Check and ensure proper working of Starter of
7. Radiator motor and Replace defective     
contactor/overload relay if required
Strip and overhaul radiator motor including
8. ensuring proper condition/ working of its -- -- -- -- 
bearings
9. Strip and overhaul starters of radiator -- -- -- -- 
motor
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure proper condition

1.     
of mounting bolts

Check and ensure proper condition of

2. electrical cables/wires and attend them as and     
when required on condition basis

Ensure Cleaning and checking of connection

tightness of starters of Roof Exhaust motors.
3. Use thermal imaginer equipment to check -- --   
temperature of cable lugs, connecting nut
bolts etc. on load to find out loose connection.
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Ensure Checking of condition of Roof
4. -- --   
Exhaust Motor, connection and its tightness

Ensure Checking of condition of Roof

Exhaust Motor Fans and its tightness and
5.     
attend the defects. Replace motor in sick line/
workshop, if found defective.

Check and ensure proper working of Starter

6. of Roof Exhaust motor and Replace defective     
contactor/overload relay if required

7. Check IR value of Vent Motors. -- -- -- -- 

 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)

Strip and overhaul Roof Exhaust motor

8. including ensuring proper condition/ -- -- -- -- 
working of its bearings.

Strip and overhaul starters of Roof Exhaust

9. -- -- -- -- 
motors.

10. Replace bearings of motors and self starters. -- -- -- -- 

SN Activity TI 3M HY IOH POH
(D1) (D2) (D3) (SS-1) (SS-2)

Check and ensure proper condition/

1. securing of fixing bolts and covers of all --    
trenches

Check and ensure proper cleaning of

2. -- -- *  
all trenches by Brush, Jute/cotton waste
etc
Check and ensure proper condition
3. -- -- *  
of
cables and attend/replace them, if required
Ensure proper securing of cables
4. -- -- *  
against any rubbing, sharp edges

* Alternate
 TI 3M HY IOH POH
SN Activity
(D1) (D3) (SS-1) (SS-2)
(D2)
Check and ensure proper condition of all
1. mounting nuts/ bolts and mounting     
brackets/clamps etc

Ensure Cleaning of fuel tank

2.     
proper
externally
Drain the fuel and clean the tank internally as
3. well as externally including the pipe line and -- -- -- -- 
Sediment Junction Box etc.

Check Condition of diesel filling cap and

4. Fuel Gauge/ diesel leakage and attend, if     
required
 TI 3M HY IOH POH
SN Activity
(D1) (D2) (D3) (SS-1) (SS-2)

5. Replace wheel valves of fuel pipe line -- -- -- -- 

Ensure Opening and servicing of

6. -- -- -- -- 
fuel
gauges and replacement of rubber items
7. Ensure replacement of fuel gauges. -- -- -- -- *

* Alternate
 Calibration/
S.No. Safety System Circuit Checking

Replacement
1. AEL (alternator earth leakage relay) D1, D2, D3,SS1 SS2

2. FEL (feeder earth leakage relay) D1, D2, D3,SS1 SS2

3. FOL (feeder overload relay) D1, D2, D3,SS1 SS2

4. OVR (over voltage relay) D1, D2, D3,SS1 SS2

5. UVR (under voltage relay) D1, D2, D3,SS1 SS2

6. HWT (high water temperature) D1, D2, D3,SS1 SS2

7. LLOP (low lube oil pressure) D1, D2, D3,SS1 SS2

8. OSR (over speed relay) D1, D2, D3,SS1 SS2

9. LWL (low water level) D1, D2, D3,SS1 SS2

Cummins Diesel Engine Maintenance Activities
Periodicity is as follows:
S.No. Activities Periodicity
1. A check Every trip D1
03 Months (OEM recommendation 300 Hrs /
2. B check D2
3 months)
Alternate
3. C check Annual (OEM recommendation 1500 hrs/ 1year)
D3
POH/36 months (OEM recommendation
4. D check SS-2
6000 hrs/ 2 years)
E check
5. (overhauling On condition basis
of
e
ngine)
i. Check all Engine safeties for their proper
functioning.
Replace, if found defective

ii. Check condition of coupling nut bolts and

their tightness. Attend them, if required
iii. Check vacuum indicator and clean air cleaner element at
4.22 kg/cm2 (60 PSI) air pressure, Check air restriction
and ensure that it does not exceed 635 mm (25”)
of water column.
iv. Check lube oil level and condition of lube oil. See reason
of less oil and top up/refill, if required

v. Check governor oil level. Top up/refill, if required

vi. Check leakage of fuel, lubricating oil and coolant. Attend,

if required

vii. Check all hoses, pipes for any leakage. Arrest all leakages
immediately to make Generator Car free from oil & water
tracing
viii. Check and ensure proper condition of safety nut bolts of
fuel tank.

ix. Check and clean engine & its oil tray to make it free from
any oil traces & dust

x. Drain water from fuel water separator through drain valve

xi. Check and ensure proper condition of mounting bolts and

various vibration dampers/ anti vibration pads etc.

xii. Check and ensure proper cleaning of floor,

wall etc in engine room
Carry out B- Check after 300 running hrs/ 03 months for M/s
Cummins make Diesel Engine which shall include all works
mentioned above in A check schedule that must be carried
out in addition to carrying out following additional works
during B- check of diesel engine:
Air system
i) Check condition of element for chocking/ torn sealing
and attend same,

ii) Check and ensure proper condition of Pre-Cleaner,

iii) Check and change Air cleaner element if

required,
iv) Check and ensure proper condition of air hose,

v) Check and clean breather and

vi) Inspect exhaust line and rectify leakage, if any.

Fuel system

i. Change fuel filter,

ii. Check hose condition: fuel supply & drain line,

iii. Check & clean the tank and Non Return Valve
and attend the same, if required

iv. Inspect fuel system and attend same, if required.

Lubricating system
i. Change lube oil filters,

ii. Change lube oil,

iii. Change super by pass filters,

iv. Check Lube Oil Pressure (LOP) Gauge,

v. Check Lube Oil Temperature (LOT) Gauge,

vi. Check the filter for any metal particles due to

wear and tear of any part inside engine,

vii. Change Governor oil

Cooling System
i) Check and ensure proper coolant Ph value,

ii) Check and ensure proper coolant concentration,

iii) Check and ensure proper Cleaning of Breather,

iv) Check and ensure proper Water Temp. Gauge and

v) Check and ensure proper Radiator inlet & out let water
temperature difference. If, found less, then radiator
should be cleaned with OGR & ID-27.
Carry out C-check after 1500 running hrs/Annually for M/s
Cummins which shall include all works mentioned above
in A check schedule and B check schedule that must be
carried out in addition to carrying out following additional
works:
• Replacement of air filter (inner & outer).

• Replacement of tappet cover gasket.

• Proper tappet setting.

• Check and ensure proper condition of Alternator terminal
connection.

• Clean trench by compressed air without disturbing cable

dressing.

• Check and ensure proper condition of accessories drive,

Turbo charger and crankshaft end play.

• Check and ensure proper Greasing of Alternator.

• Takeblow by on full load as per

manufacturer’s guidelines.

• Check and ensure proper setting of injector.

• Check and ensure proper cleaning of turbo
charger’s compressor wheel & diffuser.

• Carry out BORESCOPIC inspection to check condition

of cylinder components.
• D check will include the following in addition to C check
schedule:

• Servicing & calibration of Fuel pump along

with replacement of requisite parts

• Servicing calibration of Turbocharger along with

&
replacement of requisite parts

• Servicing & calibration of Injector assembly along

with replacement of requisite parts
• Servicing & calibration of Water pump along with
replacement of requisite parts

• Replacement of vacuum indicator

• Replacement of all filters and rubber hoses and clamps of

air line, fuel line and water line

• Replacement of HWT, LLOP, LWL

• Remove the heat insulation from Exhaust Pipelines and

Manifold and replace with new after checking of leakage
in exhaust system
• Check condition of complete exhaust system and pipeline
and ensure there is no leakage. Replace the part found
leaky.

• Checking and ensuring that all nut bolts should be

tightened as per specified torque by OEMs
E check will include the following in addition to D
check schedule:

i. Servicing & calibration of Cylinder Head along

with replacement of requisite parts

ii. Servicing & calibration of Hydraulic Governor

along with replacement of requisite parts

iii. Servicing & calibration of Connecting Rod along

with replacement of requisite parts
iv. Replacement of silencer

v. Replace exhaust flexible pipe and ensure no leakage in

exhaust line

vi. Replacement of AVM pads for DG set.

vii. Check and ensure that all nut bolts should be tightened
as per as per specified torque by OEMs

The above is as per OEM recommendation and may

be suitably changed if the OEM issues any change.
The recommendation of the OEM shall be final.
Greaves Diesel Engine Maintenance Activities Periodicity
is as follows:
S.No. Checks Periodicity
1. A Daily
2. M1 Every 500 Hrs/ 6 Months
3. M2 Every 1500 Hrs/ 1 Year
4. M3 Every 4500 Hrs/ 18 months
5. M4 Every 6000 Hrs/ 2 Years
6. M5 Every 12000 hrs
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
Clean/
System Change/
Calibra
te
1. Oil leaks 
Oil Pressure &

Temperature gauges
Existing Oil Filter for
Check metal particles due

to wear & tear of the
internal Engine parts
Lube oil
System Lube Oil Level In

Sump
Centrifugal Filter

Paper Element
Change Lube oil Spin on Filter

(As required)
Front & Rear Oil seals 
Lube Oil 
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. Clean/
System Chang
e/
Calibr
ate
2. Fuel Leaks 
Check Fuel Level In Tank 
Actuator Linkage (Link 
Rod Ball Joint)
Drain sediments form 
Drain
Fuel Water separator
Clean Water separator 
System
(As Required)
Injector Nozzles & Spray 
Clean If Necessary (Only
perform if black smoke
/Not taking load
related problem persists)
 Check/
Sr. Engine Clean/
Description A M1 M2 M3 M4 M5
No. System Change/
Calibrate

Fuel Filter Cartridge


(As required)

Vertical FTP Carbon


Change Brush
Fuel
System High Pressure fuel

Pipes
Mico Bosch Coarse

fuel filter (As required)
Calibrating the Fuel
Calibrate 
Pump
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. Clean/
System Change/
Calibrate
Coolant Leaks 
Coolant Level in

Radiator
Radiator Motor , Fan ,
Check Hub & Bearing 
Cooling Assembly
3. system
Coolant Level &

Temperature Gauges
Check Belt Tension 
Clean Radiator Fins 
Check & Add Coolant Additive

Top Up
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. System Clean/
Change/
Calibrate
Main Water Pump if

Check & required
Change Secondary Water Pump

If Required
Radiator Cap &

Cooling Rubber Ring
system Coolant Water &

Additive
Change Coolant Circuit Hoses 
Flex Master Couplings

- O Rings
Water Pump Belt (As

required)
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. System Clean/
Change/
Calibrate
Air Leaks 
Air Cleaner Restriction 
Check (Vacuum Indicator )
Turbo Charger -Axial
& Radial Play (0.2 
mm)
Air Air Filter Element
4.
system Check & (Max Life of Big Filter

Change is 2000 Hrs / 1 Year
Whichever is earlier)
Clean After cooler 
Vacuum Indicator 
Change Hoses in air intake

system
Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. System Clean/
Change/
Calibrate

Exhaust Leaks 

Exhaust Bellows &


Change If Necessary
Exhaust Check
5.
System
Retorqued - Turbo 
Turbine side Clamp

Clean Exhaust Silencer 

Sr. Engine Check/ Description A M1 M2 M3 M4 M5
No. Clean/
System Change/
Calibra
te
Tappet Clearance &

Set if necessary
External Fasteners
Check Torque & do If 
Necessary
Engine Check Vibration
6. Related 
Damper
Alternator Greasing 
Exhaust Silencer 
Change
Tappet Cover gasket 
Check & Crank Shaft End Play

Record (0.12 mm to 0.2
mm)
Sr. Check/ Description A M1 M2 M3 M4 M5
Engine No. Clean/
Change/
System Calibrate

Check Valve & Insert

Condition, Change
if necessary.(Check 
if any abnormalities
found on valves)
Engine Check
& Check AVM &

Related Change Change
if necessary
Change Liners If

Required
Change Piston

Assembly If Required
Sr. Check/ Description A M1 M2 M3 M4 M5
Engine No. Clean/
Change/
System Calibrate

Checking all critical

fasteners change if 
Necessary
Check Push Rod

Check Change if necessary
Engine
& Check Tappets &

Related Change Change if necessary
Check Rocker Lever &

Change if necessary
Check Shaft & Change

if necessary
 Check/
Sr. Engine Clean/
Change/ Description A M1 M2 M3 M4 M5
No. System
Calibrate
Check Connecting rod Big
Engine Check & & Small end bearing 
Related Change change if required

Main coupling rubber


element
Condition 
Specific Gravity of the

Battery
Check
Electrical
7.
System
Battery Power Cable leads 

Check & Over haul the Self Starter

Change Motor. 
 Check/
Sr. Engine Clean/
Description A M1 M2 M3 M4 M5
No. Change/
System Calibrate

Check & Correct-


Panel Wiring
Check
Check EPS & 
Alarms
Wiring &
8. Magnetic Pick Up
Panel Clean 
Unit

Check Sensors & Safety

& switch, Change 
Change if necessary
 The above is as per OEM recommendation
and may be suitably changed if the OEM
issues any change. The recommendation of
the OEM shall be final.
In LHB rakes pantry equipment are provided
either in the separate pantry cars attached with
the rake or in the coaches itself function as
mini pantry according to the type of train and
requirement of the passenger.
The basic pantry equipment provided in the
LHB rakes are as under:

 Hot case

 Bottle cooler cum Deep Freezer

 Water boiler, 30 litres capacity

 Soup warmer
 Bottle cooler cum deep freezer

 Hot case
 Hot case
 Bottle cooler
 Deep freezer
 Fridge 300 litres capacity
 Horizontal water boiler 3 nos
 Water purifier
 Hot plate 4 x 2000 W
 Hot plate 1 x 5300 W
 Electric chimney
 Oven toaster griller
 Insect killer
A minimum pantry compiling of hot case , bottle cooler, hot
water boiler and soup warmer are provided in each LHB
coach.

 Hot case is meant to keep warm and warm up pre-cooked dishes in

casseroles.

 Vegetarian and non-vegetarian dishes can be kept warm separately.

 In order to fulfill this requirement, hot case is divided into 3

or 2 separate parts.

 Temperature of these divisions is factory preset at 80°C.

o Dimensions : 910 x 1092 x 600mm
o Voltage : 230 Volt, 50 Hz
o Heating element : 3 x 500 Watt or 2 x 500 watt
o Hot air blower : 230 Volt, 50 Hz
o Operating temperature: 80°C
o Thermostat : 30 – 80°C
o Trays : 84 nos., 30 x 280 x 250mm
stainless steel wire mesh.
THERMOSTAT

TRAYS

KNOB WITH LOCKING

ARRANGEMENT

DOOR

CABINET
 Modular pantry unit has a 230 liter capacity deep
freezer with permanent temperature setting of at
least -18°C to be used for freezing/ preserving ice
cream/meat and food etc. Temperature setting range
is from -18°C to - 25°C.
o Dimension : 1157 x 595 x 1195 mm
o Power : 800 Watt
o Voltage : 230 V 50Hz
o Thermostat range : Deep freezer -18 to -
o 25°C Bottle cooler 0 to + 10°C
Cooling compartment 0 to +10°C
o Refrigeration capacity : 560k
Cal/Hr.
o Refrigerant : R22
 Bottle cooler is of 90 liters capacity to cool 1.0 liter
mineral bottles to a temperature level of 3 to 5°C.
 Suitable arrangement has been made to prevent
falling over/ rolling around of bottles inside the
bottle cooler when bottle cooler is not completely
filled up.
 Refrigerating Unit

o Dimensions 910 x 600 x 900mm

: 200 watts.
o Max. Power
230V ±10%, 50 Hz
:
3 to 5°C
o Operating Voltage
 Water boiler of 30 liters capacity confirming to IS: 3412 is
provided along with a control box and necessary plumbing
and tap arrangement on a common base plate.

 There are three nos. of such boilers provided on side wall

of coach.

 Inlet to one of the boilers can be used for preparing tea/

coffee.
 Other two water boilers are connected directly to over head
tank of coach with the help of flexible pipes.

 These are mainly used for cleaning purpose.

o Capacity : 15Litres
o Power : 230V AC+/-10%
o Heating element : 2KW
o Thermostat : 0-75°C
o DIM. : 525 x 300 x 285mm
Water Boiler in Original Vertical Water Boiler in
design Coaches Existing Design Coaches
o Soup Warmer is divided in two major parts i.e. food insert
and kettle insert.
o It is meant to keep warm and warm up the pre-mixed soup
in the food insert.
o The heating medium is water which is to be filled between
food insert and kettle insert.
o The lid should be kept close to prevent water loss.
o It is to be opened when refilling of food insert is required.
o Don’t operate the kettle in dry condition.
o Always turn the kettle control ‘OFF’ when not in use.
Capacity - Food insert - 12 litres.
a.
b. Heating medium – 0.6 litres of water.
Maximum power - 475 watts.
Nominal voltage - 230 V ± 10%, 50 Hz
Nominal current - 2.2A
Weight - 4.5 kg
Thermostat range - Lower temperature range 70-72°C
High temperature range 90-92°C
Thermal insulation - Bonded mineral wool
Soup Warmer
Lid

Mounting
Bracket

Food
Insert

Electric
Kettle

Therm
ostat
Integrated Modular Pantry Unit for buffet car comprises
the following equipment:
 Water purifier
 Hot case
 Hot plate 4 x 2000 W
 Bottle cooler
 Hot plate 1 x 5300 W
 Deep freezer
 Electric chimney
 Fridge 300 litres
 Oven toaster griller
 Horizontal water boiler 3 nos.
 Insect killer
 Pantry arrangement of AC
Buffet Coach

Water Filter

Hot Water Boiler

Pantry Arrangement of AC 2Tier & 3Tier coaches
Integrated cooking and service table
assemblies comprise the following:
i. Cooking table with electric hot plate 2.0 kW x 2 (LH) 1 no.
ii. Cooking table with electric hot plate 2.0 kW x 2 (Centre) 1 no.
Cooking table with electric hot plate 2.0 kW x 2, 1.1 kW
iii. 1 no.
x 1 (RH)
iv. Service table with waste bin (LH) 1 no.
v. Service table with waste bin (RH) 1 no.
Structural frame with front screen and 3 nos. chimneys,
vi. one in each burner suitable for operation in recirculation 1 set
mode with active carbon filters
Cooking Table with Electric Hot Plates

 Cooking table is divided in three parts. Cooking tables are

provided with hot plates of the reputed approved make of
the following ratings:

i) 2.0 kW – total 04 nos. (2 nos. in centre table and 02 nos.

in RHS table)

ii) 5.3 kW – total 1 nos. (1 x 2 kW centre & 1.1 kW x 3

around centre plate in LHS table).
 Height of utensil base support is kept minimum to prevent
heat loss through gap.

 Suitable thermal insulation is provided below heat zones to

avoid overheating of adjoining areas and prevent heat
loss.
 All cooking tables are provided with individual control
boxes which include the following switchgear/ control
gear:

Rotary Switch - Siemens/ Salzer

Indicator – green - GS/ Allen Bradley /

Teknic ELCB - Siemens/ MDS/

L&T
Service Table with Waste Bin (LH & RH)
 A removable type waste bin of stainless steel of size 350 x 450
x 400 mm is provided in each service table.

 Securing arrangement of the waste bin is such that it does not

make rattling sound due to vibrations.

 It is provided with handles to empty the contents

inside the container easily.

 The rest of space beneath the top is converted into

storage racks with doors.

 Hand rail supports are also provided for support to staff and to
prevent falling of items during train run.
 Assembly of the tables is done by employing continuous
structural frame to give a modular appearance. A
protective screen in front of hot plates is provided to form
a partition between the cooking areas and the corridor.

 The cooking table assembly is provided with a frame for

mounting chimneys over each burner. The frame is so
designed that it does not obstruct with the cooking
personnel while cooking.
 Catering and service counter are made in two parts.

 It is manufactured on a robust stainless steel frames of

angles covered with stainless steel sheet for adequate
strength of table top.

 The catering counter (LH & RH) assembly is provided

with a hinged flap for entrance in the counter.

 The counter is mainly required for placing hot and cold

dispensers by the vendors.
 In modular unit of kitchen, front openable cupboards/
racks with adjustable type shelves are provided. Stainless
steel drawn type sinks of are provided.

 Sink units have been provided with fixed type splash

guards suitably integrated with units.

 Stainless steel fabricated top openable waste bins with

covering lids are provided in storage rakes.
Overall sizes of containers are as follows:

Length = 550 mm

Width = 535 mm

Height = 280 mm

Containers are of sliding type design with suitable handles for

frequent and easy removal and cleaning purpose.
 An oven toaster Griller of standard make is provided in
the pantry to bake the dishes as per requirement.
 Two nos. of insect killers of suitable make are provided on
the panty wall at both ends of cooking place to catch and
kill the flies and insects and keep the pantry insect free.
Minimum following points for proper upkeep of Pantry Cars
& Mini-pantries are to be followed:

• Panels should be locked by electrical staff after

pantry service and will be opened whenever
required for maintenance purposes.
• Electrical staff will ensure proper rating of MCBs, overload
relays and contactors and should not allow isolation of any
MCB, overload relay and contactors in panels.

• Filters of chimney should be cleaned regularly after every trip.

• Regular checks of wiring, fittings and fuses/ MCBs of pantry car

& mini-pantries should be ensured.

• Electrical staff in pantry car should lock hot plate switch and
MCB at notified time in the night and morning.

• Lock should be opened by Electrical staff duly making entry in

register and should be signed by Electrical staff and Pantry
manager.
• All pantry equipment should be cleaned regularly
before putting food stuff and after use.

• Pantry staff to ensure that panel area shall be kept

clean all the time and pantry equipment should never
be crowded by putting other utensils/boxes near them
as it hinders their proper operation and result in
premature failure.

• Overloading of refrigerators, deep freezers, bottle

coolers and hot cases should not be allowed.
• Paper trays, polythene bags etc should not be put in hot
cases as this may result in fire.

• Safety devices fitted in equipment (Thermostats, Pressure

switches, fuses & MCBs) shall not be tampered by pantry
staff.

• In case of any failure, electrical staff should be contacted

for assistance.

• Pantry staff should ensure safe operation of all pantry

equipment. No short cuts such as appliances without plug
etc should be used.
• After completion of work, electrical equipment should
be switched OFF by the respective pantry staff.

• Pre heated meals/snacks and pre cooled water

bottles/Ice cream etc should be kept in the pantry
appliances

• Trays of insect catchers should be cleaned regularly.

• Water boilers shall be operated only after

ensuring availability of water.

• Mishandling of equipment shall be avoided, as this results

into damage to doors/locks and wiring.
• Pantry car staff shall use flat bottom utensils with
larger diameter than hot plate.

• Oil container shall not be kept near hot plate or at the floor
of cooking area.

Caution :

• Pantry car cooking staff should take utmost care

while handling with oil. There should not be any oil
spill on or near Electric hot plate as it may cause fire.

• The container of oil should be in store in pantry car

only.
 No smoking should be allowed in pantry cars.

 No inflammable items should be carried in pantry cars.

 Ensure proper closing of panel doors, defective/rattling

doors should not be allowed.

 No extra electrical equipment except standard

scale should be connected in any case.

 No temporary wiring for power supply to any kitchen

appliance is permitted.
 While taking/handing over of charge, Pantry Manager
and Electrical supervisor shall ensure all above, prepare a
joint handing over/taking over sheet and keep proper
records for deficiencies, if any.
 Electricity is the core form of energy, required for running
of the trains on electric traction as well as for working of
various passenger amenity items in the train carriages.

 Theexisting system for generation of electrical energy,

required for non-traction use, (working of passenger
amenities in the carriages such as lights & fans, air
conditioning units, water pumps, pantry equipment etc.) is
by working of generating sets driven by diesel engines,
housed in power cars - End On Generation (EOG) system
and through the alternators driven by train wheel axle in
the Self Generating (SG) coaches.
 The name HOG (Head ON Generation), itself implies that
the electrical energy required for non-traction use is
derived from the driving head (electric traction loco),
which draws the electric supply from the Over-Head
traction wires for traction purpose.

 This high tension over-head traction supply of 25000 VAC

(single phase) is tapped and fed to the converters which
steps down and converts the electric supply to 750 V (3 Ph)
AC supply, which is then fed to all the coaches in the
entire train for non traction use.
 Switching over from ‘End ON Generation’ (EOG)
system to ‘Head ON Generation’ (HOG) system of
power supply, in running of the trains, is one of the steps
taken by the railway ministry, as a contribution towards
the objectives of green initiatives of the Indian
Government.

 Introduction of HOG system will reduce working of

diesel generating sets required in EOG system. The
objectives and the benefits of the HOG systems is
enumerated here.
 Eliminating Air and noise pollution
caused due to working of Diesel Engines.

 Conservation of Petroleum resources

(HSD oil), thus subsequently reducing
effective cost of operation.
 Provision of additional IV coupler and replacement of
the existing coupler at the non vestibule end of the
power car to receive electrical power supply from the
electric loco.

 Provision of two sets of UIC coupler at the non-vestibule

end of the power car along with control cable laying for
transmitting control signals from loco to the power car.

 Existing power cable to be re-routed and modified to

prevent direct supply to the entire rake.
 Modification in the size of existing junction box to
accommodate feeder and control cables.

 Provision of interlocking control panel with wiring.

 Provision of 10 nos. 100 VA transformers along with in-

put and out-put protection fuses, for operation of
contactors which work on 415 V AC. (This is required as
there is no neutral available with the incoming of 750
V
3 phase supply from converter. Thus provision of
750V/415V transformer is essential.)
 Provision of current transformers for measuring
parameters of HOG supply.

 Provision of two nos. RC filters between phase-neutral

and phase-earth at the secondary winding of 60 Kva
Transformer to improve the supply wave form.
 POWER CAR- PASSENGE POWER CAR
LOCOMOTIVE
FRONT R REAR
COACH

HOTEL LOAD DG SET -A Air-conditioning DG SET -A

CONV-A 365KW 490BHP load 26.5KW 365KW 490BHP
(500KVA) plus light and hot
case
HOTEL LOAD DG SET-B DG SET-B
CONV-B 365KW 490BHP 365KW 490BHP
(500KVA)

CONTROL CONTROL
PANEL PANEL
 Provision of 2 nos. 100VA transformers along with in-
put and out-put protection fuses, for operation of feeder
contactors which work on 415 V AC. (This is required as
there is no neutral available with the incoming of 750
V
3 phase supply from converter. Thus provision of
750V/415V transformer is essential.)
 Shifting of full lighting load to 110 V DC supply, to
maintain uninterrupted working of lights in the coach,
while the train is negotiating neutral section during
which, there is intermediate tripping of the converter
supply.

 Provision of two nos. RC filters between phase-neutral

and phase-earth at the secondary winding of 60 kVA
transformer to improve the supply wave form.
 LOCOMOTIVE POWER CAR

IVF COUPLER-02 POWER CAR

A CONV-B B
B B CONTROL PANEL

UIC COUPLER-02

SIEMENS

L PANEL
CONTRO
CAB-1 CAB-2
UIC COUPLER-01

IVF COUPLER-01
B CONV-A A A A

UIC Coupler- 01& 02:

IVF Coupler-01: CONV-A • Control signals to and from the Converter and Loco to the
R, Y,B, E, C1 Power Car.
IVF Coupler-02: CONV-B • Redundant system. If one UIC fails the other will ensure
R, Y,B, E, C1 the Converter and train is healthy.
Inter-locking control panel – provided in the Power Car
Display on Inter-locking control panel
100 VA SINGLE PHASE 750/415 V
TRANSFORMER IN AC COACH AND IN
POWER CAR
Arrangement of 8 nos. 100 VA transformer in power
cars
 Arrangement of two nos. RC filters between phase-
neutral and phase-earth at the secondary winding of 60
kVA transformer to improve the supply wave form
(power cars and coaches)
Provision of IV coupler and
dummy sockets on non
vestibule end of power car
 Provision of two nos. UIC
couplers for control on non
vestibule end wall for
transmitting signal from loco
to power car
Work order for HOG modification in the locos as well as
coaches and power cars of EOG LHB rakes was issued by
CLW and awarded to M/s. Siemens and M/s. Medha vide
letters cited as follows:

 CEE/L&S/CLW letter no. C-D&D/T/05 dt 12/11/2015

 Dy.CEE/D&D/CLW letter no. C-D&D/T/05 dt.19/12/2015

 RDSO specification no. RDSO/PE/MS/AC/0051-

2011 (Rev-2)
 HOG modification work was planned in a phased manner.
Phase – I

• Phase – I covered 5 rakes of Rajdhani Express and

August Kranti Rajdhani Express trains running between
Mumbai Central and NDLS, constituting 111 coaches
and 14 Power Cars.

• The work was commenced from 23/11/2015 and the first

power car was completed on 03/12/2015.
Dates of Rajdhani trains commissioned in service are
as follows:

Rake No. Date of commissioning in service

1 25/12/2015
2 28/02/2016
3 26/04/2016
4 30/05/2016
5 18/07/2016
 Phase – II

• The work quantity in phase – II includes three rakes of

Duronto trains running between BCT-ADI, BCT-IND
and BCT-JP and one rake of BCT-ADI Shatabdi
express trains.
The quantity of coaches and power cars covered
in phase – II are as follows:
22209 BCT- 12009 BCT - 12239/40 Total
12227 BCT- Total
Coach Type NDLS ADI BCT-JP Spare coaches for
IND Duronto coaches
Duronto Shatabdi Duronto modification
Exp
LWFAC 1 1 1 3 2 5
LWACCW 3 2 2 7 6 13
LWACCN 9 8 8 25 8 33
LWFCZAC 2 2 2 4
LWZAC 14 14 5 19
LWCBAC 1 1 1 3 2 5
Total
Coaches 14 12 16 12 54 25 79

LWLRRM 2 2 2 2 8 2 10
G. Total 16 14 18 14 62 27 89
 During the course of modification and study of the circuit
design, some minor alterations in the interlocking circuit of the
power car, that seemed essential to ensure safety in case of
human error while operation of the switches were identified.

 These alterations were advised to the HQ Western Railway

along with the drawings for further referral to RDSO for
approval and incorporation of these modifications in existing
specifications so that same can be uniformly implemented with
the improved features all over India.
Following alterations in the circuit are suggested:
 Alteration – 1: To facilitate automatic restoration of the
HOG supply, when the train passes through the neutral
section without operating the push button switch

 Alteration – 2: To facilitate automatic restoration of the

HOG supply in the non working power car, when the train
passes through the neutral section without operating the
push button switch.

 Alteration – 3: To ensure non operation of the converter

out-put contactor in case the ACB is closed.
 Following procedure has been adopted for
commissioning of the HOG modified coaches:

Sr. Activity Check / Result

1 Check the circuit for proper connections as per the Drawing

1. Check supply at NET 1 contactor output

Select the Net selector – (750 V)
2 switch for NET1
operation 2. Check supply at 100VA
transformer output – (415 V)

Switch ‘ON’ all the

3 All equipments should work normally
Electrical Equipments
Sr. Activity Check / Result

1. Check supply at NET 2 contactor output

Select the Net selector – (750 V)
4 switch for NET2
operation 2. Check supply at 100VA
transformer output – (415 V)

Switch ‘ON’ all the

5 All equipments should work normally
Electrical Equipments
In order to streamline the operational procedure and
speedy troubleshooting in HOG system, guidelines,
based on extensive trials and observations following
procedure for Trouble shooting in HOG modified
coaches and attachment of HOG compliant loco with
HOG compliant rake is devised.
Failure  Net Contactors not getting
‘ON’
Probable Cause a. Power selector switch is OFF
b. 750 V supply is not available
c. Disconnecting & Earthing device is
not switched ON
d. Blowing of fuses of 100VA transformer.
e. 100 VA transformer defective /
damaged.
Action Proposed
a. Select the Net selector switch for
appropriate NET operation

b. Check availability of 750 V supply

c. Switch ON the disconnecting and Earthing

device.

d. Check for Earth fault and short circuit -

Replace blown fuses after rectification

e. Check and Replace the transformer.

Failure  Lights trip when the train Passes through
the Neutral section

Probable Cause a. 110 V DC supply is not available

b. Battery voltage low - K15, K16 and
K17 relays are OFF
Action Proposed
a. Check 110 VDC MCB, whether tripped or not.
Reset MCB after thorough checking for healthiness
of electrical circuit

b. Check proper working of EBC / RBC

 415 V Converter supply not available

Indication  H7 indication on HOG panel is not

glowing (yellow)

Probable Cause a. Input supply to the converter in the

loco is not available.
b. UIC coupler not engaged properly
Action Proposed
a. Contact the Loco pilot to ensure switching ON the
converter in the Loco.

b. Ensure proper engagement of UIC coupler

Indication  H1 Converter A/B ‘ON’ command light
and H5 Converter A/B ‘output available’
light is not glowing (Green)

Probable Cause • SW1 and SW2 selector switch on the

HOG control panel is not selected
for HOG operation
• ACB is not released
Action Proposed
a. Select HOG supply operation through SW1
and SW2 selector switch.
b. Ensure release of ACB
Indication  H3/ H4 ‘Converter faulty’
indication glowing (Red)
Probable Cause • Fault encountered in the Converter

Action Proposed  The converter will restart automatically

within 25 seconds of tripping for three
consecutive tripping. After which the
reset switch is required to be pressed.

In case of converter failure DG set to be started for EOG

operation
Indication  No indication

Probable Cause a. Safety loop open.

b. Blowing of Fuses of feeder contactor’s
transformer.
c. Tripping of Feeder Earth leakage relay,
Feeder Overload relay.
Action Proposed
d. Check safety loop for continuity.
e. Check primary and secondary fuses of
100VA, feeder contactor’s transformers.
f. Reset the tripped relay
In case of converter failure DG set to be started for EOG operation
Indication  No indication

a. DC control supply not available

b. DC control supply fuses F9 / F11 blown

Probable Cause c. SW1 / SW2 selector switch on the HOG

control panel not selecting the DG set
operation.
d. Tripping of Alternator earth leakage relay.
e. Emergency stop switch pressed.
Action Proposed

a. Select DG set operation by plant selector switch

on Power Car main panel.

b. Switch ‘ON’ the power supply switch provided

on main panel.

c. Check and replace blown fuses.

d. Check and replace faulty relays.

e. Reset relay.
Indication  No indication

a. Plant selector switch on main power panel is

not appropriately selected.
b. Power supply switch is ‘OFF’.
Probable Cause c. Blowing of primary / secondary fuses of
instrument transformer for under voltage
relay.
d. Control relay faulty S2K8-21K5 (set A) and
S2K9-21K6 (set B).
e. Tripping of Earth Leakage and under voltage
relay of ACB
Action Proposed

a. Select DG set operation by plant selector switch

on Power Car main panel.
b. Switch ‘ON’ the power supply switch
provided on main panel.
c. Check and replace blown fuses.
d. Check and replace faulty relays.
e. Reset relay.
Indication  No indication

a. Plant selector switch on main power panel

is not appropriately selected.
b. Plant selector switch on HOG control panel
Probable Cause is not appropriately selected.
c. Blowing of Fuses K2-B for A to B and
K2- A for B to A of Bus coupler’s
transformer.
d. Tripping of control relay S2K11-21K8 for
A to B and S2K10-21K7 for B to A of Bus
coupler contactor
Action Proposed

a. Select switch position on main power panel for

operation of bus coupler for ‘A to B’ or ‘B to
A’

b. Select switch position on HOG control panel for

operation of bus coupler for ‘A to B’ or ‘B to
A’

c. Replaced Blown fuses

d. Reset the relays

Consumption of Diesel per year (Ltrs) (49460 x 60) 2978400
cost of diesel per litre (Rs.) 56
Total Annual cost of diesel (Rs.) (4380000 x 56) 166790400

Total energy consumed per year KWH (10504 x 365) 7136480

Rate per KWH in Rs. 5
Energy Cost per year in Rs. 35682400

Net savings =131108000