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ºÉ´ÉÉ®úÒ Êb÷¤¤ÉÉ EòÉ®úJÉÉxÉÉ, SÉäzÉè-600 038 INTEGRAL COACH FACTORY / CHENNAI – 600 038
TECHNICAL INFORMATION BULLETIN (For the period upto December 2009)
Issue No. 2/ TL & AC / 2009
Issued by
Chief Electrical Engineer, INTEGRAL COACH FACTORY,
CHENNAI – 600038
CONTENTS
Topic Pg. No.
I. Provision of LED Based Emergency Light 1
II. Microprocessor based control panel For RMPUs 1
III. 2.5 kVA inverter 2
IV. 100 VA inverter for Mobile / laptop Charging points 3
V. Provision of Thin walled cables 4
VI. Brushless DC Railway Carriage fans 5 VII. Emergency feed terminal
Arrangement in AC Coaches 6
I. PROVISION OF LED BASED EMERGENCY LIGHT
a) 2467 TL coaches from 01.06.07
b) 204 AC coaches from 01.04.08
This is a RDSO approved item.
1. Introduction
The general lighting inside the coaches is provided by 110V AC or 110V DC supply with battery back up
system. But during extreme emergencies like derailment and accidents etc. or regular supply system
failure, causing total darkness inside the coach. To facilitate easy exit of passengers and their immediate
rescue, during such situations an emergency light unit (ELU) system is developed to provide illumination
which are located inside the coaches at the passage and on the doorways for use of movement of the
passengers. This unit will switch `ON’ automatically on failure of normal supply system.
2. Technical Description
The emergency light unit consists of a SMPS charger operating under constant current mode with
floating voltage of 13.5V (approx) and solid state switch with auto start and auto OFF circuit for
supplying voltage to the clusters of LED. The battery charger charges the battery at the rate of 0.7A
(approx) for the entire range of input 90V to 135V DC or 90V to 115V AC. When input voltage goes
below 80V DC or in absence of input, the switch turns on and clusters of LED starts glowing. The LUX of
the unit for first two hours will be 30 at a distance of 2.1 meters and 20 LUX for further 10 hours at a
distance of 2.1m.
GOVERNING SPECIFICATION
The LED based emergency light unit is as per Specification No.ICF/ELEC/917 Rev.1.
II. MICROPROCESSOR BASED CONTROL PANEL FOR RMPUS
14 AC coaches (details given below) provided with MICROPROCESSOR BASED CONTROL PANEL FOR
RMPUS.
M/s A.Paul Instruments make provided in the following Eight Coaches:
NW 09051, SW 09053, ER 09041 & 09042, SER 09026, WCR 09026, WR 090260, CR 09026
M/s Amit Engineers make provided in the following Six Coaches:
ER 08153, ECoR 09151, SW 08151, ER 09043 AND SWR 09026 & 09027
1. Introduction
The purpose of the control panel is to control temperature & humidity in AC coaches in the Railway.
Microprocessor based control panel is intended to replace traditional interlocks in the control of AC
plant while providing for several features not currently provided.
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2. Features of control panel
Energy Monitoring – Energy is measured and provision for load management of the entire train
can be done in Phase‐2.
Energy Saving – By maintaining a higher temperature at night and switching to a single
compressor during hours of low heat load, the system saves significantly on plant energy
consumption.
Temperature Management – The system features a systematic approach towards temperature
management. The temperature and humidity conditions inside the AC coaches are monitored
with respect to the temperature setting and are controlled at the desired level by switching
ON/OFF the compressor.
Humidity Management – By lowering temperature by 2°C when humidity is above 60%.
Parametric Monitoring – Parameters like HP, LP, supply voltage, current of the system and
working of various equipment like condensers motor, evaporators motor, compressors etc. are
monitored.
Fault Logging – Complete fault logging with date and time stamp is maintained on non‐volatile
memory and kept for download to the PC.
‐ Occurrence of faults is notified by a warning alarm and the nature of the fault is
recorded and displayed for its easy identification by operator or service crew.
‐ Faults and status of various other parameters are stored in the memory sequentially
with respect to time.
Parameters such as Coach No., RMPU No., Train No., Coach AC load status, three‐phase power
supply parameters including energy meter, coach temperature, ambient temperature,
percentage humidity, faults and settings etc. can be viewed on a panel door mounted LCD
screen with the help of a user friendly 5‐key standard keyboard.
GOVERNING SPECIFICATION
The microprocessor based control panel is as per RDSO specification No. RDSO/PE/SPEC/AC/2006/(REV
1) JUNE‐2004.
1) 2.5 KVA INVERTER (110V DC/ 110V AC)
245 TL coaches provided with 2.5 Kva inverter from 01.10.08 onwards.(Coach details available in ICF Rail
net website).
This is a RDSO approved item.
1) Introduction
The 2.5 Kva bulk inverter supplies power for the 60W fans installed in non air‐conditioned coaches. The
inverter converts 110V DC supplied from a separately charged battery system, to produce 110V AC, 1‐
phase 50Hz power to supply the distributed fan load.
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2) Technical Description
The inverter uses MOSFET and IGBT technology to convert a DC nominal 110V supply into an AC single
phase 110V rms 50 Hz power supply for the paralleled 40W fan loads that are installed in the coaches.
The inverter operates by boosting the DC input voltage to establish an isolated intermediate de link
voltage, and then pulse width modulating this link voltage with a single phase IGBT bridge to produce a
single phase AC output voltage. The inverter output is internally filtered to produce a pure sinusoidal
output waveform.
3) Technical Specification
Input side
Rated Input Voltage : 110V DC
Minimum Input Voltage : 90V DC
Maximum Input Voltage : 140V DC + 15% ripple
Output Side
Rated output voltage : 110V AC ±5%, 1 phase
Rated output frequency : 50Hz ± 0.5%
Rated output power : 2.5 kVA at 0.8pf
Output waveform : Sinusoidal
General
Efficiency : More than 92%
Operating temp. range : ‐ 5 deg C to 55 deg C
Cooling Medium : Natural air cooling
Construction : Modular
Cubicle dimension (mm) : 650(L) x 600 (D) x 375 (H)
Weight : 38 kg (approx)
Protection : IP 65 for US cubicle
GOVERNING SPECIFICATION
2.5 kVA Inverter for 110 v ac is as per Specification No.ICF/ELEC/926,CS.No.2
IV. 100VA INVERTER FOR MOBILE/LAPTOP CHARGING POINTS
295 BG SCN coaches provided with 100 VA inverter from 01.06.07 onwards.
This is a RDSO approved item.
1) Introduction
This inverter is capable of sourcing one in number either mobile phone or Laptop computer.
This unit operates from Lead Acid battery of 110V DC fitted on the under carriage of the railway
coach. Output of 110V AC 50Hz (pure sine wave) is terminated through 6A – 5 pin domestic
sockets.
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2) Technical Description
This charger is designed to work from 90V‐140V due to variation of the battery voltage. However
inverter shuts down when the supply voltage is less than 90V and more than 140V.
Additional feature includes short circuit protection. Thus unit shuts down as long as short circuit exits
and automatically output appears after a lapse of one minute.
3) Technical Specification
Nominal input voltage : 110V DC
Input voltage range : 90V‐140V DC
Output voltage : 110V +/‐ 5%
Pure sine wave : Better than 3%
(Total harmonic distortion)
Output Power : 100VA
Power Consumption : 125W
Efficiency : 80%
GOVERNING SPECIFICATION
100VA individual Static inverter for Laptop/Mobile charging is as per Specification No.ICF/ELEC/922
Rev.No.00.
V. Provision of thin walled (Electron Beam) Cables:
1. Introduction: Thin walled cables are New generation cables embodying the state of the art Electron Beam Irradiation Cross linking technology to meet today’s demanding requirements of higher performance standard of cables. a. 411 TL coaches from 01.04.2009 b. 317 AC coaches from 01.04.2007
This is a RDSO approved item.
2. Technical Description: The cross linking of polymers with Electron Beam is an innovative process which improves the life of cable significantly compared to the conventional chemically cross linked cables. Electron Beam Cross – linking is caused by interaction of high energy electrons with the polymeric material and results in a three dimensional network structure. Through this transformation the thermal and mechanical properties are improved while its electrical properties remain unchanged, resulting in improved service life upto 25 years.
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3. Properties – All special features built in one: High withstand temperature (Better thermal properties)
High current ratings – operating temperature upto 230°C Special polymers to cover wide temperature range from ‐66°C to +230°C Excellent Electrical Arc Track Resistance Rugged Mechanical Properties – superior Abrasion / scrapes & cut – through resistance. Outstanding Fluid Resistance – Resistant to variety of Reactive chemicals, oils and solvents. Resistant to ultra violet (UV) rays and impermeable to moisture. High tech polymer – Fire resistant, low smoke, low toxic, zero halogen emission. Compact design – Low insulation / sheath wall thickness, space saving, lighter in weight, flexible,
lower bending radii. No environmental hazard.
4. Governing Specification: E‐Beam irradiated think walled flexible Elastomeric cable conforming to RDSO Spec. No. ELRS / SPEC / ELEC / 0019, Rev. 0 of May 2002 with Amendment No. 1,2,3,& 4, 1.8 kV Grade.
VI. Brushless DC Railway Carriage Fan
a. 1491 TL coaches provided with BLDC fans from 01.02.2005. This is a RDSO approved item.
1. Introduction:
Presently 110 V dc fixed and swiveling type fans in different sweeps having commutation with
the help of carbon brushes are being used in the self – generating coaches and dc EMUs.
Maintenance and replacement of fans had been great concern to Indian Railway in addition to
its poor efficiency, reliability and excess noise as compared to fans manufactured with the latest
state of art technology for general service application.
The electrical connection to the armature (rotor) is through the carbon brushes and
commutator in the present dc motor type fans. On the other hand, brushless DC motors utilize
electronic communication with no brushes. The brushless DC motor can be viewed as a
synchronous, permanent magnet AC machines supplied with variable voltage variable frequency
(VVVF) in such a way as to keep the phase angle between stator and rotor magnetic fields
constant. The brushless DC motor is also called as a “ECM” which stands for Electronically
Commutated Motor. The brushless DC motor is also called as an ‘Inverted DC motor’, since
armature is stationary and field is rotating.
2. Technical Description
An electronically commutated BLDC motor consists of a permanent magnet rotor, a stator with a
polyphase winding an an electronic switching device. The device consists of a rotor position
sensor, fixed on the motor shaft, and an electronic switching module, which can supply stator
winding. Operation of BLDC motor is very similar in concept to that of DC Motors.
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The stator will be wound for three phase and the winding will be similar to three phase
induction motor or synchronous motor. The rotor position sensor continuously senses the axes
of the rotor permanent magnet and gives out logical signals. The logical signals are coded and
will be sent to the control module.
The control module decodes the signals and approximately selects the stator windings whose
magnetic field will be perpendicular to the rotor magnetic filed and supplies current to it, a
torque is generated and the rotor moves.
Following the resulting rotation the rotor position logic signal changes after certain rotation (60
electrical degrees). Then the module switches the current to the successive windings so as to
keep the resultant winding field perpendicular to the rotor magnetic field thus ensuring smooth
rotation and torque.
3. Advantages of BLDC fans:
The permanent magnet type brushless dc fans (BLDC) shall have the following advantages as
compared to existing dc carriage fans for 400mm sweep:
a. Wattage consumption will be 32 W against 38 W 110 V dc fans
b. Air delivery 70 cu. Meter / min. as compared to 50 cu. Meter / min.
c. Noise level 55 db (A) as compared to existing around 80 db (A).
d. Fan weight 7 kgs as compared to 15 kgs.
e. FRP blades instead of metallic blades to ensure same profile during its whole service to
avoid painting etc.
f. Substantial reduction in maintenance due to elimination of carbon brush and commutator.
g. Starting voltage is 35 V dc instead of 85 volts of existing dc fans.
h. 12 years life against 10 years of existing dc fans.
4. Governing specification:
Brushless 110 V DC fan, 400mm sweep fixed type to RDSO Specn. No. RDSO / PE / SPEC / TL /
0021 / 2005 (Rev. 1).
VII. Emergency Feed Terminal Arrangement in AC Coaches:
18 AC SCN coaches (details given below) provided with emergency feed terminal arrangement
to ICF dragging No. WGSC WAC7 – 7 – 0 – 704 have been provided.
SW 08052 to SW 08057, SW 09051 & 09052 – 8 coaches
ECoR 09051 , 09052, 09054 & 09056 – 4 coaches
WR 080668 & 080678, WR 090575 & 090588 – 4 coaches
SECR 08052 – 1 coach
NER – 08051 – 1 coach.
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