SG System

SELF GENERATING SYSTEM
Self Generating System- Equipments
• Alternator
– RRU
– Belt
• Battery
• Inverter (AC coach)
• RMPU (AC coach)
• Cable/wiring
• Light and fans
• Distribution, control and protection
Fuse cum Rotary Switch Panel
Emergency feed terminal
Carriage fan
Swivel type DC fan BLDC fan

Carriage Fan
Performance parameters
Parameter DC fan sweep (mm) ac fan sweep (mm)

400 300 200 400 300 200
Air delivery 50 37 20 65 30 14
(m3/min), min
Power input 35 29 18 60 40 28
(max) (W)
Weight (max) 15 14.5 10 15 14.5 10

(kg)
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
Self Generating System- BLDC Fan
(Spec RDSO/PE/SPEC/TL/0021/2005 Rev 1)
• Principle of operation
– Brush and commutator replaced by PM & electronic switching
– PMs embedded in rotor
– Position of rotor detected through hall effect sensors (flux transducers)
– Stator windings switched through electronic controller
• Construction features
– PM ceramic/ferrite type with hardness of 700 HB
– Body of fan deep drawn MS and of fan Al alloy LM-6
– Fan blade of FR plastic
– Electronic components of industrial grade
– IR > 20 Mohm
• Performance parameters
– Discharge: 60 m3/min , Power input : 32 W (max), Weight: 8 Kg (max)
Noise level: 55 dBA (max) ,Service value : 2 m3/min/W (min)
BLDC fan
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
Self Generating System- Code of practice
• Anti theft and fire prevention measures to be ensured
• Cables not to have any joints
• Lux levels
– Ist ,2nd and pantry coaches- 30
– Postal compt -40
– SLR luggage compt -20
– Lav and corridor -16
• Degree of uniformity i.e ratio of lux in least favourable seat and avg
lux level to be 1:1.3
• To be measured 840 (1500 in Lav) mm above FL and 500 mm from
back of seat/in the centre
• Toggle switches used for fan and light control
• All coaches to be fitted with emergency lights and mobile charging
sockets
• Below EFT marking “ Switch off LII before connecting emergency
coupler”
• IR with 500 V megger not to be <2 M ohm
• Fans of 400 mm sweep
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
Code of practice on fire prevention
(EL/TL/56-1992)
• Probable causes of fire
– Excessive current in cable
– Short circuit
– Loose connections
• Excessive current in cable

• Size of cable
– Size of fuse
Circuit Fuse rating Cable size
Positive/Negative 6A 4mm2
branch
L1,L2,F+ 16A HRC 16mm2
SPM1,2 16A HRC 16mm2
Main –ive 35A HRC 35mm2
Battery fuse 32A (20SWG) 35mm2
RRU Phase 32A HRC 16mm2
RRU field 6 A HRC 4mm2
• 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
• Rewiring of coaches
– Life of cable 20yrs
– Cable testing After 15yrs
• Segregation of positive and negative cable
– To run in separate conduit except
– Phase and field cables from alternator to alternator
terminal box to RRU to under frame terminal board
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
110 v lamps
Earth Indicating Lamp

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
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

SG System

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SELF GENERATING SYSTEM

Self Generating System- Equipments

Swivel type DC fan BLDC fan

Parameter DC fan sweep (mm) ac fan sweep (mm)

Weight (max) 15 14.5 10 15 14.5 10

• Excessive current in cable

Earth Indicating Lamp

• Feed to be extended to only one coach

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