1. SELF GENERATING SYSTEM

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

4. Fuse cum Rotary Switch Panel

5. Emergency feed terminal

6. Carriage fan Swivel type DC fanBLDC fan

7. Carriage Fan ParameterDC fan sweep (mm)ac fan sweep (mm) 400300200400300200 Air delivery (m 3 /min), min 503720653014 Power input (max) (W) 352918604028 Weight (max) (kg) 1514.5101514.510 Performance parameters

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

9. Self Generating System- BLDC Fan (Spec RDSO/PE/SPEC/TL/0021/2005 Rev 1) Principle of operation –Brush and commutator replaced by PM & electronic switching –PMs embedded in rotor –Position of rotor detected through hall effect sensors (flux transducers) –Stator windings switched through electronic controller Construction features –PM ceramic/ferrite type with hardness of 700 HB –Body of fan deep drawn MS and of fan Al alloy LM-6 –Fan blade of FR plastic –Electronic components of industrial grade –IR > 20 Mohm Performance parameters –Discharge: 60 m 3 /min, Power input : 32 W (max), Weight: 8 Kg (max) Noise level: 55 dBA (max),Service value : 2 m 3 /min/W (min)

10. BLDC fan

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

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

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

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

15. Code of practice on fire prevention Excessive current in cable Size of cable –Size of fuse CircuitFuse ratingCable size Positive/Negative branch 6A4mm 2 L1,L2,F+16A HRC16mm 2 SPM1,216A HRC16mm 2 Main –ive35A HRC35mm 2 Battery fuse32A (20SWG)35mm 2 RRU Phase32A HRC16mm 2 RRU field6 A HRC4mm 2

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

17. Code of practice on fire prevention Rewiring of coaches –Life of cable20yrs –Cable testing After 15yrs Segregation of positive and negative cable –To run in separate conduit except –Phase and field cables from alternator to alternator terminal box to RRU to under frame terminal board

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

19. Earth Indicating Lamp 110 v lamps

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

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