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Goverment Of India Trainee at Kanchrapara Workshop, Eastern Railway electrical traction - subhamoy singha roy

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Goverment Of India Trainee at Kanchrapara Workshop, Eastern Railway electrical traction - subhamoy singha roy

  1. 1. 0 | P a g e NAME : SUBHAMOY SINGHA ROY REGISTRATION NO. :B1/WB/0429201/14/16 DESIGNATION : DIPLOMA HOLDER TRAINEE ( GOI/ ELECTRICAL) TRAINING PERIOD : 02.04.2014 TO
  2. 2. 1 | P a g e ACKNOWLEDGEMENT  I Express my deepest gratitude to the Vice Principle, Mr. Sunirmal Basu For his invaluable guidance and blessings  I am very grateful to Chief Instructor, Mr. P. P. Saha for providing us with an environment to complete our project successfully.  I also thank all the staff member of the workshop and technicians for their help in making project a successful one.  Finally, I take this opportunity to extend my deep appreciation to my family and co – trainees for all that they meant to me during the crucial times of the completion of my project
  3. 3. SL NO. 1. Brief History Of Kanchrapara Workshop 2. SHOP NO. Shop No.- 09 (Panel Sec.) 3. Shop No. - 09 A (i)Aux. Motor Sec. (ii) TM – Frame Sec. (iii) TM – Sec. (iv) TFP & GR Sec. 4. Shop No. - (i)Heavy Armature Section (ii)Core and Commutator Section (iii)Coil Section (iv)Transformer Section (v)ABFCR & SL (Armature Bearing and Field Coil Reclamation Section and Smoothing Reactor[SL CONTENTS SUBJECT Brief History Of Kanchrapara Workshop SHOP NO. DURATION OF TRAINING PERIOD (Panel Sec.) 02/04/2014 to 10/08/2014 09 A 11/08/2014 to 31/12/2014 - 14 Armature Section (ii)Core and Commutator Section (iv)Transformer Section (v)ABFCR & SL (Armature Bearing and Field Coil Reclamation Section and Smoothing Reactor[SL – 30]) 01/01/2015 to 01/04/2015 2 | P a g e PAGE NO. 3 - 4 5 - 20 TRAINING PERIOD 11/08/2014 to 31/12/2014 21 - 54 01/01/2015 to 01/04/2015 55 - 72
  4. 4. 3 | P a g e History Of Kanchrapara Railway Workshop Kanchrapara Workshop is one of the oldest Railway workshops in the country. It was set up by the then Eastern Bengal Railway during the year 1863 at the present Loco Complex site in Kanchrapara. It was developed as an integrated shop to carry out repairs to Steam Locomotives, wooden body Carriage and Wagons. The management of the workshop was taken over by the state on 1st July, 1884. In the year 1914 a separate carriage and wagon shop was completed. This shop has displayed high level of flexibility by adapting to the changing environment and product-mix from time to time. During the World Word II ( Since 1939 – 45) , the workshop served the Defence Department for repairs to aircrafts and manufacture of armoured cars and hand-grenade shells. Today Kancrapara Works ranks First Indian Railway Workshop in terms of EMU Coaches overhauled. POH Of electrical Locomotive is the major maintance and repairing work and is the most vital activity in this workshop. In 1962, with the introduction of 25 KV Electric traction in Eastern India, a decision was taken for remodeling Kanchrapara Workshop to make it a base workshop for Periodic Overhauling of Electric Locomotives and Electric Multiple Unit (Suburban Electric Trains) stock of Eastern and South Eastern Railways. This workshop also had the privilege of turning out the first electric locomotive after Periodic Overhauling (POH) in 1965 and the first Electric Multiple Unit motor coach was turned out after POH in the very same year. At present Loco Complex mainly deals with repair and overhaul of Electric Locomotives and Electric Multiple Unit Motor Coaches. The Carriage Complex deals with Periodical Overhauling of Electric Suburban Trains, Mainline Electric Multiple Unit trains, Diesel Electric Multiple Unit trains, Non-Air Conditioned Coaches, Accident Relief Train vans and 8 wheeler Tower Cars. Passenger Electic Locomotive are overhauled after the period of 6 years or 12 lack kilometre of running which is of earliar. Reck of the Loacal EMU trains and convenantional LOCO coaches come for POH after 18 months. The periodic overhauling of Electric Locomotive distributed over 22 shops through out the loco complex and 18 shop through out the Carriage complex.
  5. 5. 4 | P a g e Setting up of 2.7 million litters/day Effluent Water Treatment Plant in September’ 2002 was a landmark in environmental pollution control. The workshop was accredited with ISO-9001:2000 certificate in September 2005. With up gradation of ISO-9001 certification to the latest 2008 standard recently, the workshop is geared up to meet the ever-changing requirements of Indian Railways and serve the nation with high quality output HISTORY OF MAJOR ACTIVITY ACTIVITY YEAR FROM YEAR TO POH of Steam Loco 1863 1972 POH of Freight Wagon 1863 1987 POH of Conventional coaches 1863 Continuing Manufacture of 4-Wheeler OHE Tower Wagon 1957 1986 POH of Electric Loco 1965 Continuing POH of Electric Multiple Unit 1968 Continuing Rewinding of Traction Machines 1975 Continuing POH of Diesel-Electric Multiple Unit 2000 Continuing POH of self-propelled ART 2003 Continuing POH of 8-Wheeler Tower Car 2003 Continuing
  6. 6. 5 | P a g e Shop No. – 9 is Apparatus Shop of Kanchrapara Railway Workshop, Where both Periodic Overhauling (POH) and RC of Relay, meters, gauges, DJ/VCB, Pneumatic Apparatus, Compressor and Pentograph are done. In Panel Section Has a three Section : (i) BA Panel Overhauling Section (ii) EMU Switch Group Overhauling Section. (iii) TK Panel Overhauling Section. Mr.Subrata Dutta SSE is the Incharge of Shop No.-09 and Others SSE and JE are as follows:  Panel Section:  Mr. Mahmud Alam (SSE)  Mr. Amit Kr. Ghosh (JE)  Mr. Bibhash Das (JE)  Mr. Sushil Kumar( JE)
  7. 7. 6 | P a g e BA PANEL B.A Panel stands for "Block Apertures Panel". The BA Panel is a device by which speed of the traction motor is controlled; it’s also responsible for rotating the motor in forward or reverse direction. This section of the shop does the POH of BA Panel for both LOCO .There are tree B A panels in a loco viz. BA-1, BA-2, BA-.3. It is also called as the heart of loco. BA panel has following parts: 1. Various rating resistors. 2. Shunting Contactors:- These are used to increase the speed of the loco. These are kept in parallel with the field of the traction motor. As these contactor introduced in the circuit the field gets weakened and there by the flux reduces hence increases the speed. All shunting contactors are pneumatically controlled. This pneumatic control is done by electro valve assembly. 3. Relay QD- 1 (Differential Relay). 4. CTF-1 Inverter TR/BR or change over switch: - These are two electro valves assembly for CTF-1, one for TR (traction) side operation and another for BR (Breaking) side operation. 5. J-1 (Reverser):- The electro valve assembly for J-1 reverser one for forward direction (- ->) operation of J-1 and another for reverse direction (<---) side operation of J-1.  BA-2 and BA-3 contains the following accessories:- 1. Field weakening resistance. 2. 2 Line contactor-All are pneumatically controlled. 3. Shunting contactor. 4. CTF-2(BA-2), CTF-3(BA-3). 5. J-2 reverser. 6. QD-2: Differential relay for slipping. 7. Q-20: Relay o/p voltage.  Short Description of BA Panel Parts :-  Line Contactor : These Contactors are used for forming the circuit of the Traction Motors. Line Contactors L1 to L6 are used to connect the motors in circuits. These Contactors are designed to open at off load. Auxiliary inter locks are provided to the Contactors, wherever necessary. These interlocks ensure the sequence of operations in the different circuits. There are six line contactors L1 to L6 to give path to TMs 1 to 6 respectively. These line contactors are controlled by switches HMCS-1, HMCS-2, HVSI-1, HVSI-2, HVMT-1 & HVMT-2.  Drum Contactor (J1 & J2, Reverser Switch and CTF – 1 or CTF – 2 or CTF – 3 , Traction Commutator Switch ) :- Drum contactor is closed and opened with the rotation of a Drum. The Drum is made up of an insulated material. The movable contact is in the form of copper segment, which is fitted on the drum. These contactors are always operated on no-load, hence arc-chutes are not required. The reversers J1& J2 provided in Loco are Drum contactors. From CAB 1 leading direction, the manual operating handles of both J1& J2 should be upward. When MPJ is moved to ‘F’ position from ‘O‘ position. When MPJ is moved to ‘ R ‘ from ‘ O ‘, both the reverser J1& J2 should be thrown to downward direction and the CAB2 is in the leading direction. Mainly for change the direction of rotation of Traction motor The CTF 1, 2, Drum Contactors are having
  8. 8. 7 | P a g e two positions (i) Motoring or Traction, (ii) Braking When MP is on motoring side, the CTFs are thrown upwards and when MP is on Braking side, the CTFs are thrown downwards. For ensuring the position of operation, manual operating handle is also provided  CAM CONTACTOR :- Cam contactor is opened or closed by the position of cam with movable contact. The cam contactors can be operated by SMGR or manually with a handle. While progression or regression of notches any of 3 CGRs should be closed to avoid intermittent supply. So, minimum one CGR should be in close position at any notch. When the roller is in the cavity, the movable jaw gets lowered and CGR gets opened. When the roller is on projected surface of the cam, the CGR gets closed as the movable jaw lifts up. By means of an auxiliary contact [cam contact] the GR position is indicated in Loco Pilot’s Desk by pilot lamps. Heavy ARC-CHUTES are provided with locking clips on either sides, as heavy arcs are formed while opening the CGRs. TFPs gets supply from TFWR through CGRs. CGR 12&3 are located in HT2 compartment. To arrange different type of power circuit during breaking mode. Six (6) “T” Shape Segment, Two(2) “T” Shape Segment + Three(3) “C” Shape Segment and six (6) “C” Shape Segment  Shunting Contactor : All Contactor either 9 Shunting Contactor or 12 Shunting Contactor Rated Voltage = 1270 V DC Rated Current = 125 A DC Rated Air pressure = 7kg/cm² Rated Aux. Coil Voltage = 110V DC Electro Pneumatic Contactor is use It weak the motor field coil, increase the speed of the motor. Generally Shunting contactor is use where low level to high level load is use or wagon is use. Breaking Excitation Extractor(C – 145) : - Rated Voltage = 75V AC Rated current = 850 AC, 50 Hz Rated Air Pressure = 7Kg/cm² Rated Aux. & Coil Voltage = 110V DC  Relay Q50 : - This is main control relay, which is suitable in relay board. This relay supervise of following equipments Revrerser J₁ and J₂ CTF – 1, CTF – 2, or CTF – 3 C – 145 Rated Current = 1000 A DC Rated Voltage = 1500 A DC or 1270 V DC  Electro Valve Rating (MTDJ) :- Rated Voltage : 110V Air Pressure : 8 kg/cm²
  9. 9. Fig : BA Panel ( Model No.  Work Instructions For Overhauling Of BA Panel Of Conventional Electric Locomotives  SCOPE :- Work instruction for overhauling of BA POH/RC  RESPONSIBILITY:- SSE/PANEL Section of SHOP  PROCEDURE :- Overhauling of BA  INCOMING CHECKING & STRIPPING OF BA1/BA1+4 PANEL (i) Open the arc chute of all EP Contactors from the Panel. (ii) Open Electrical Connection of Magnetic coils of EP Contactors, Reverser and CTF and their Inter Lock Contacts also (iii) Open Pneumatic Connection of EP Contactors, CTF and Reverser. (iv) Open fixation bolts of EP Contactors ( Shunting are line also in some cases). Rev and CTF and dismount from panel by crane with sling and put them on work bench. (v) Open all power circuit bus bar connection, including RS Connection, LTBT/LTSB all connection of control cable in POH work. In case of POH+RC work, cut all the control cables at LTBT connection ends. Collect the stripped material and keep it in custody room. (vi) Open the foundation bolts of LTBT, LM fitting, PCL Crate from panel by crane with sling and put them on the work bench. (vii) Cut the old benching tapes and remove control aux. cable and old glass tape from all Stiffeners. (viii) Necessary repair to be made of panel frame including stiffeners also by welding or otherwise etc. if any damage.  CLEANING & ATTENTION OF STRIPPED MATERIALS (i) Clean The Panel frame with Stiffeners and foundation Porcelain insulator of RS create as well as RS element with K. Oil, nylon brush, wire brush and cotton waste. Fig : BA Panel ( Model No. –L/27787- BA₂) Work Instructions For Overhauling Of BA Panel Of Conventional Electric Locomotives Work instruction for overhauling of BA-1, BA-4, BA-2 & BA-3 Panel During POH & SSE/PANEL Section of SHOP-9/KPA Overhauling of BA-1 & BA-4Panel During POH/POH+RC of LOCO INCOMING CHECKING & STRIPPING OF BA1/BA1+4 PANEL :- Open the arc chute of all EP Contactors from the Panel. en Electrical Connection of Magnetic coils of EP Contactors, Reverser and CTF and their Inter Lock Contacts also Open Pneumatic Connection of EP Contactors, CTF and Reverser. Open fixation bolts of EP Contactors ( Shunting are line also in some cases). Rev and CTF and dismount from panel by crane with sling and put them on work bench. Open all power circuit bus bar connection, including RS Connection, LTBT/LTSB all connection of control cable in POH work. In case of POH+RC work, cut all the control les at LTBT connection ends. Collect the stripped material and keep it in custody Open the foundation bolts of LTBT, LM fitting, PCL-X-Socket, SHAA Crate from panel by crane with sling and put them on the work bench. ng tapes and remove control aux. cable and old glass tape from all Necessary repair to be made of panel frame including stiffeners also by welding or otherwise etc. if any damage. CLEANING & ATTENTION OF STRIPPED MATERIALS :- rame with Stiffeners and foundation Porcelain insulator of RS create as well as RS element with K. Oil, nylon brush, wire brush and cotton waste. 8 | P a g e Work Instructions For Overhauling Of BA Panel Of Conventional Electric Locomotives : Panel During POH & 4Panel During POH/POH+RC of LOCO en Electrical Connection of Magnetic coils of EP Contactors, Reverser and CTF and Open fixation bolts of EP Contactors ( Shunting are line also in some cases). Reverser and CTF and dismount from panel by crane with sling and put them on work bench. Open all power circuit bus bar connection, including RS Connection, LTBT/LTSB all connection of control cable in POH work. In case of POH+RC work, cut all the control les at LTBT connection ends. Collect the stripped material and keep it in custody Socket, SHAA-1 Shunt and RS Crate from panel by crane with sling and put them on the work bench. ng tapes and remove control aux. cable and old glass tape from all Necessary repair to be made of panel frame including stiffeners also by welding or rame with Stiffeners and foundation Porcelain insulator of RS create as well as RS element with K. Oil, nylon brush, wire brush and cotton waste.
  10. 10. 9 | P a g e (ii) Clean the control cables, in case of POH only HTSB/HTBT ( after unscrewing the HT terminal bolts to open HT separators) LTBT SHAA-1 Shunt, HT Terminal Bolt, HT separators etc. with K. Oil & then by petrol and soft nylon brush along with cotton waste. (iii) After drying the natural air, apply paint on Panel frame, RS frame, air pipe line etc. (iv) Clean Copper bus bar ends with steel wool/emery Paper and then do necessary tinning. (v) Apply anti-track red varnish on all stiffeners , cupper bus bars except tinning portion, HTBT, contractor fixing insulated bar etc. (vi) Prepare and replace all the control cables in case of RC work and change practically/ fully these cables on condition basis in case of POH work. (vii) Provide nomex paper in gap of EP Contactor fixation clamp. (viii)Blow air pipe with compressed air in order to clean out any dust Particle if available. (ix) Check IR value of insulated support tube/ Base.  ASSEMBLING OF MATERIAL :- (i) Assembling LTSB/LTBTs with proper order of number and HTSB/HTBT along with terminal bolt and HT separator. (ii) Fit all LTSBs, HTSBs, PCLX Socket, SHAA-1 Shunt, LM fittings etc. in the Panel. (iii) Make LTSB connection of control cables in proper route as incoming in POH Work. (iv) In case of RC work, make new LT cables with lagging, numbering, layout with proper route as per CLW’s cabling chart in the panel. (v) Do control cable connection of all the components such as PCLX Socket, SHAA-1, LM fitting holder etc. (vi) Lift reverser & CTF (after overhauling & Testing) and then RS create also by crane with sling from work bench and place on the Panel and mount. Fit/mount overhauled all EP connectors on the Panel. (vii) Make all LT control cable connection at the contactors and reverser/CTF interlock ends and all the magnet coil also. Ensure fitting of interlock cover in case of Reverser/CTF. (viii)Make Pneumatic connection of all EP Contactors, reverser and CTF where applicable. (ix) Check IR valve of contactor fixing insulated support tube and flylane HTSB with megger. (x) Make all the HT Bus bar connection at the both ends in the panel. (xi) Fit all the Chute of EP Contactors in the Panel.  TESTING OF PANEL :- (i) Connect air Pressure to air Pipeline and Check the air Leakage with Soap Water. (ii) Check cable continuity from SB ends to other ends. Give 110V DC Supply to LTSB and also check Operation manually. (iii) Check RS element valve with micro-ohms meter and also IR valve with megger. (iv) Offer for inspection and attend booking, if any. (v) Write name plate, apparatus number and also LOCO number with paint. (vi) Record all the best result in the Check Sheet. (vii) Hand Over BA-1 & BA-4Panel to Shop no-11 for equipping.  OVER INSTRUCTION FOR OVERHAULING OF BA-2 & BA-3 PANEL DURING POH/POH + RC OF LOCO :- (i) Open the arc chute of all EP contactors from panel frame. (ii) Open Electrical Connection of magnetic coils of EP contactors, reverser, and CTF and their interlock contacts also. (iii) Open pneumatic connection of EP contactors. CTF and reverser. (iv) Open Foundation bolt of EP Contactors ( Shunting, line & C 145 also in some cases) and CTFs and reverser dismount from panel by crane with sling and put hem on work bench.
  11. 11. 10 | P a g e (v) Open all the power circuit bus bar connection including RS connection, LTBT/ LTSB all connection of control cable in POH work. In case of POH + RC work, Cut all the control cables at LTBT connection ends. Collect and put bus bars in custody rooms. (vi) Open the foundation bolts of LTBT, LM fitting, PCLX socket, SHF 1+2, SHAA-2, HQOP 1+2, RQOP 1+2, RQ-20 and RS crate from panel by crane with sling and put them on the work bench except RQOP 1+2 and RQ20. (vii) Hand over RQOP 1+2 & RQ20 to relay Section. (viii)Open the Electrical connection ( Both LT & HT) of C118 contactor along with surge trap unit While Fitted in BA 2+3 panel in some LOCOs. Hand over C118 contactor to EM contactor panel section & surge trap unit to Misc. section. ( All relay are to be collected by relay section) (ix) Cut the old bunching tape and remove control auxiliary cables and old glass tape from all stiffeners. (x) Necessary repair to be made of panel frame including stiffeners also.  CLEANING AND ATTENTION OF STRIPPED MATERIALS :- (i) Clean the panel frame & porcelain foundation insulator of RS crate as well as RS elements with K.oil, nylon, wire brush and cotton waste. (ii) Clean all the control cables in case of POH only, HTSB/HTBT ( after unscrewing the HT terminal bolt to open HT Separators) LTBT, SHAA-2 Shunt, HT terminals bolt, HT Separators, HQOP 1 + 2, SHF 1 + 2 etc. with K. Oil and then Petrol and soft nylon brush along with cotton waste. (iii) Apply paint on panel frame, RS frame air pipe line etc. after drying with natural air. (iv) Clean copper bus bar ends with steel wool, emery paper and then do necessary tinning. (v) Apply red anti track varnish on all stiffeners copper bus bars except tinning portion, HTBT, Contactor fixing insulated bar etc. (vi) Prepare and replace all the control cables in case of RC work and change fully/Practically on condition basis in case of POH work. (vii) Provide nomex paper in gap of EP contactor fixation clamp. (viii)Blow the air pipe with compressed air of 8kg/cm sq. in order to clean out any dust particle, if available. (ix) Check IR value of insulated support tube/bar.  ASSEMBLING OF MATERIALS :- (i) Assemble of LTSB/LTBT with proper order of numbers and HTSB/HTBT along with terminal bolts and HT separator. (ii) Fit all LTSBs, HTSBs,PCLX Socket, SHAA-2 LM fitting, HQAP 1 + 2 switches RQOP 1 + 2 & RQ- 20 (both coming from relay section ) etc in the panel. (iii) Make LTSB Connection of control cables in proper route as incoming in POH work. In case of RC work, make new LT cables with lagging, numbering, sleeving and layout with proper route as per CLW’s cabling chart in the Panel. (iv) Do control cables connection of all components such as PCLX socket, SHAA-2, LM fitting Holder, HQOP 1 + 2, RQOP 1+2, RQ – 20 etc. (v) Lift reverser/ CTF and then RS crate also by crane with sling from work bench and place on the panel and mount. Fit/ mount over haulted all EP contactors on the Panel. (vi) Make all the LT control cable connection at the contactors and reverser/CTF interlock end and all magnet coils also. Ensure fitting of inter lock over in case of reverser/CTF. (vii) Make Pneumatic connection of all EP contactors, reverser and CTF where applicable.
  12. 12. 11 | P a g e (viii)Mount C-118 contactor (Coming from EM contactor panel section) along with RC surge trap unit on the panel in case of incoming available and make the necessary LT and HT connection. (ix) Check IR value of conductor fixing insulated support tube and nylon HTSB with megger. (x) If any defects found in above apparatus replace by new. (xi) Make all the HT bus bar connection at the both ends in the panel. (xii) Fit all the arc chute of EP contactors in the Panel.  TESTING OF PANEL :- (i) Connect 8kg/cm. sq. air pressure to air pipeline and check the air leakage with soap water. (ii) Check cable continuity from SB end to other and give 110V DC Supply to LTSB and Check Operation manually. (iii) Check RS element value with micro ohm. Meter and also IR value with megger. (iv) Offer for inspection and attend booking, if any. (v) Record all test result in the check sheet. (vi) Write name plate, apparatus number and LOCO number with Paint. (vii) Hand Over ready BA2/ BA2+3 Panels to shop no.-11.  WORK INSTRUCTION FOR OVERHAULING OF EP CONDUCTOR :  INCOMING CHECKING AND DISMANTLING : (i) Visual Check of defects, deficiency of components/ Parts, if any. (ii) Visual Check of damage & deformation, if any. (iii) Put EP Conductor (Line, C 145 and Shunting) on the work bench manually. (iv) Do dusting of EP conductor with soft nylon brush, duster or clean dry compressed air. (v) Open the fixation screws of the servomotor assembly and moving contact assembly from the conductor. (vi) Dismantle of side plates, blowout coil assembly servo assembly, moving contact assembly and both fixed & moving contacts.  CLEANING, OVERHAULING AND ASSEMBLING :- (i) Clean the dismantled side plates by K. Oil and then Petrol. Remove any frames of metallization with sand paper. Replace them if found split or scratched. (ii) Check the blowout coil with brush or dry comp. air. (iii) Check the condition of asbestos thread provided to avoid its inter turn short circuit. (iv) Change it on condition basis. (v) Clean the contact portion of blow out coil by Polish paper and with petrol if any overhauling works. (vi) Varnish the coil with red insulating varnish. (vii) Remove the EP valve by unscrewing bolts fitted on Servomotor. (viii)Clean the exciting grease of piston, piston cap, cylinder and spring with duster. Wash them with petrol. (ix) After drying, replace new piston bucket, lubrication felt and all gaskets. (x) Reassemble the servomotor assembly with cylinder & new EP valve and then lubricate with mobile oil. (xi) Remove the knuckle spring from moving contact assembly and check roller, roller arm, brush, roller pin, axl pin and spring etc. for any defect change if required. (xii) Clean roller arm, brass plate and moving contact lever.
  13. 13. 12 | P a g e (xiii)Check the condition of all flexible shunt. If found any abnormality such as breakage of shunts then replace by new moving contact assemble/ new contactor. (xiv)Lubricate the roller & brush. Open moving contact and clean the contact portion of assembly by polish paper and then refit by new one. (xv) Refit the knuckling spring. (xvi)Refit the fixed contact by new on fixed contact/ blow out coil assembly in the fitment of both the contactors; air gap between contacts and contact holder is not permissible. (xvii) Finally, assemble the EP contactor fitted with side plates, blow out coil assembly moving contact assembly and servomotor assembly along with new insulating sleeves/ components including distance piece especially damage in case of line/ C 145 contactors. (xviii) Lubricate all moving parts.  TESTING OF EP CONTACTOR :- (i) Mount the overhauled contactor on the test bench manually; Connect its nipple with compressed air supply ( maintain from 5 to 9 kg/cm sq.) (ii) Check the coil resistance, min. operating air pressure, min. working voltage, pick up and voltage, air tightness test, IR value between coil & Body of EP ( NC4 ) Value. (iii) Check air tightness test of contactor in coil energize and de-energize Condition. (iv) Ensure that there is a no gap between fixed and moving contact while closing. (v) Ensure that contact bedding between fixed and moving contact is more than 80%, Check and adjust main contact gap with “ GO – NOT GO ” gauge in open condition. (vi) Check main contact pressure with the help of spring balance. (vii) Check continuity and discontinuity of aux. interlock. (viii)Check Mechanical endurance test for 20 times continuous operation in order to maintain air pressure range of 5 kg to 9 kg/cm sq and voltage range of 68 volts to 136 volts/cm sq. (ix) Check the locking condition of arc Chutes. (x) Check IR value with meggar (a) Between power terminal & earth with arc Chute. (b) Between power contact to contact with arc chute fitted and contact in open condition. (xi) Record all results of Test Parameters in the Check sheet.  WORK INSTRUCTION FOR OVERHAULTING OF RESERVER (J) AND TRACTION BREAKING SWITCH (CTF)  INCOMING CHECKING & DISMANTLING:- (i) Visual Check of defect, deficiency of components/Parts of frame & base of Switch, if any. (ii) Visual check of damage & deformation, if any. (iii) Put reverser/CTF on the work bench manually. (iv) Remove finger contact assembly, servomotor, auxiliary switch assembly, pressure setting nut & spring, Aux. interlock cover etc. from reverser/CTF. (v) Remove mobile drum contacts from drum assembly by unscrewing allen screw, NC – 4 EP valve from servomotor, finger contact from foundation base and cylinder cap of servo motor with piston.  CLEANING, OVERHAULTING AND ASSEMBLING:-
  14. 14. 13 | P a g e (i) Clean, dismantled parts/ components such as frames, finger contact assembly, dram contact, insulated dram etc. with blowing of compressor air and then with K/Oil and finally with petrol. (ii) Remove the EP valve by unscrewing bolts fitted on servomotor; clean the existing grease of servomotor assembly.(Piston, Piston Cap, Cylinder and Spring ) with duster, wash them with K.Oil and then Petrol. (iii) Reassemble the servomotor assembly. With new replacement of EP valve, lubricant the servomotor with mobile oil. (iv) wash the drum including bearing with petrol. Apply a coat of red varnish on the insulated parts of the drum and finger contact fixing bar ( insulated carrier ). (v) Check “ U ” for the roller and replace the roller if worn out. (vi) Adjust the driving cam so that the interlocking lever should rest in cam group, when the servomotor piston reaches its max. limit. (vii) Remove any groove and scratch mark form both drum segment contact finger contact by an extra smooth file and fine sand paper after unscrewing both the contacts. (viii)Replace both the contact when these wear by 1 mm. from the original thickness ( approx 2 mm. ) of silver lining and any breakage of flexible shunt in case of finger contacts assly. (ix) Check the dip ( Clearance between finger contact & contacts holder of finger contact assly., which should be 2 + 0.5 mm). (x) Replace all aux. contacts by new. (xi) After painting of frame assemble the reverser/CTF with ensuring double doewel pins at all places.  TESTING OF REVERSER & CTF :- (i) Mount the overhauled reverser/CTF on the test bench and connect its nipple with compressed air supply ( maintain from 5 to 9 kg/cm sq. ) (ii) Check the coil resistance, minimum operating air pressure, min. working voltage, pick up & drop out voltage, air tightness test, IR value between coil and body of EP ( NC 4 ) valve (iii) Check air lightness test of reverser/ & CTF in coil energized and de- energised condition. (iv) Ensure that there is no gap between fixed and moving contact. Check the dip clearance of finger contact. Also Check main contact pressure. (v) Check the continuity & discontinuity of aux. interlock. (vi) Check the mechanical endurance for 20 times no load conditions operation by energizing electro valve from 68V to 100V DC supply and maintaining air pressure from 5 kg/cm sq. to 9 kg/ cm sq. The switch should not shown any sluggishness or abnormality. (vii) Check the minimum air pressure, which should be 3kg/cm sq. (viii)Check the IR value with meggar. (ix) Between power terminal and earth. (x) Between two terminals of finger contacts as well as drum contacts also. Record all test parameters in the check sheet.  In EMU the BA Panel is know as switch group(1,2) and consists of the following parts:-  SWITCH GROUP 1 :- 1. Electro-pneumatic motor Contractor(M1,M2) 2. Electro-pneumatic Reverser(1) 3. Negative Electro-pneumatic Contractors(NC1,NC2) 4. Overload Relay(1,2) 5. Current Limiting Relay Board(CLR,2 relays)
  15. 15. 14 | P a g e 6. Notch Repeater Relay(NR,1,2) 7. Auxiliary Over voltage Relay(AOVR)  Switch Group 2:- 1. Electro-pneumatic motor Contractor (M3, M4) 2. Electro-pneumatic Reverser(1) 3. Negative Electro-pneumatic Contractors(NC3,NC4) 4. Overload Relay(1,2) 5. Current Limiting Relay Board(CLR,2 relays) 6. Auxiliary Over voltage Relay(AOVR)  CHECKING & TESTING AFTER OVERHAULING :- TESTING DATA M/CONTACTOR [M₁-M₄, NC₁-NC₄] 5022 PC6 1500V , 375A NR₁ NR₂ REVERSER (K₁, K₂) 29RPS 1500V, 600A Lc CONTACTOR, 8EC4,150V 12A(LH), 100 (RH) Vc CONTACTOR 8EC5,1500V 12A(LH), 12A(RH) Cc, CONTACTOR 19EC, 150V 200A Cc2 CONTACTOR SEC, 120V, 10A WORKING AIR PRESSURE (kg/cm²) 4.9 - - - - - MAIN CONTACT GAP (mm) 20.6 TO 23.8 (M₁ - M₄/ NC₁ - NC₄ ) 19.05 ± 1.6 10.3(MINᴹ) 10.3(MINᴹ) 10.3(MINᴹ) 6.15 TO 7.35 AUX. CONTACT GAP (mm) 2.4 TO 3.2 28.6 (MIN) - - - - MAIN CONT. PRESSURE (kg) 1.8 TO 3.0 (M₁ - M₄/NC₁ - NC₄ ) 1.59 (NR₁ - NR₂) 2.3 – 3.6 kg (O/C) 2.49 – 4.1 kg (I/C) 0.9 TO 1.8 0.9 TO 1.8 2.3 TO 3.2 0.10 TO 0.15 AUX. CONTACT PRESSURE (kg) 0.11 TO 01.17 0.34 - - - - VALVE FERRULE BORE (mm) 2.38 (M₁ - M₄/NC₁ - NC₄ ) 1.59 (NR₁ - NR₂) 6.35 - - - - AIR BOLT BORE (mm) 6.35 (M₁ - M₄/NC₁ - NC₄ ) 130 (NR₁) 2.38 ( NR₂) - - - - - COIL RESISTANCE AT 20˚C 957 ± 8% dc 919 ± 8% 102 + 8% (SET COIL) 105 +8% (TRIP COIL) 102 +8% (SET COIL) 105+8% (SET COIL) 468 +8% 1122+8% COIL PICK UP VOLTAGE 55V (min) 55V DC (MIN) 55Vdc min 55Vdc min 55Vdc min 55Vdc min
  16. 16. 15 | P a g e COIL DROP OUT VOLTAGE CAM TO ROLLER GAP (min) 10V dc 10v dc(min) Megger Value :- (i) Body To Magnet Coil O/C – OUT SIDE CONTACT (ii) Body To Fixed Contact 5MΩ I/C – IN SIDE CONTACT (iii) Body To Mobile Contact (iv) Body To Terminal Board  BLOCK DIAGRAM OF SWITCH GROUP FOR EMU :
  17. 17. 16 | P a g e  Motor Contactor = 4 Nos.  Magnetic Contactor = 4 Nos.  Reverser = 2 Nos.  NR₁ Notching Relay =1 Nos.  NR₂ Notching Relay = 1 Nos.  O/L Over Load = 4 Nos.  Current Balancing Relay = 2 Nos.  Over Voltage Relay = 1 Nos.  Aux. Voltage Relay = 1 Nos. TK PANEL TK Panel is the another main part of LOCO. TK Panel also call AC2 Panel. Its play vital role in Panel, All cable and connection go through in this section. In this section divided into many parts, like (i) Relays, (ii) Resistance, (iii) Diodes, (iv) Electro Pneumatic Contactor (3 Phase), (v) Switch board, (vi) BD, (vii) Microprocessor, (viii) Capacitor for MCP and ARNO, (ix) LTBA  Checking & Testing after overhauling/ EM Section : During Overhauling and RC all contactors are maintain the following chart. Test C101, C102, C103, C105, C106, C107, C111, C121, CPR C118 1.Main Contact Gap 8.5 ± 1 mm 17 ± 1 mm 2.Aux. Contact Gap 6 ± 1 mm 6 ± 1 mm 3.Main Contact Pressure 850gm – 1050gm 5 – 6.7 kg 4.Aux. Contact Pressure 80gm ± 10% 80gm ± 10% 5.Crussing 3.3 – 4.3 mm 4.45 – 4.55 mm 6.Magnet Coil Resistance Value 585 ± 5% Ω 95Ω ± 5% 7.Min Pick Up Voltage 68 V 68 v 8.Drop Out Voltage 10 – 20v 10 – 20 V 9.Dist. b/w Pole to Pole(3 Phase) 40mm - 10.Dist b/w Yoke & Armature 12mm 12mm 11.Allowable Slackness (a) Diameterically (b) Laterally 0.5mm 0.2 to 0.5mm 0.5mm 0.2 to 0.5mm 12.Phase Sequence 13.Megger Valve with 500v Meggar (a) B/w pole to pole (b) B/w Pole to Body (c) B/w Coil to Body 5MΩ 5MΩ 1MΩ 5MΩ 5MΩ 1MΩ 14. Verify the Alignment of Main Moving Contacts with respect of fixed contacts  RELAY :-
  18. 18. 17 | P a g e Relay is an electrical device and also an electrically operated switch placed in between the main electrical power circuit and the circuit breaker in such a manner that any fault in the circuit actuates the relay which in turn energises the trip circuit and causes circuit breaker to open and turns protects the circuit from any severe damage. When an electric current is passed through the coil it generates a magnetic field that activates the armature, and the consequent movement of the movable contact(s) either makes or breaks (depending upon construction) a connection with a fixed contact. If the set of contacts was closed when the relay was de-energized, then the movement opens the contacts and breaks the connection. When the current to the coil is switched off, the armature is returned by a force, approximately half as strong as the magnetic force, to its relaxed position. Usually this force is provided by a spring. In a low-voltage application this reduces noise; in a high voltage or current application it reduces arcing. When the coil is energized with direct current, a diode is often placed across the coil to dissipate the energy from the collapsing magnetic field at deactivation. Alternatively, a contact protection network consisting of a capacitor and resistor in series may absorb the surge.  Notching Relay : A DC motor power circuit relay which detects the rise and fall of current in the circuit and inhibits the operation of the resistance contactors during the acceleration sequence of automatically controlled motors. The relay operates a contactor stepping circuit so that, during acceleration of the motor, when the current falls, the relay detects the fall and calls for the next step of resistance to be switched out of the circuit. See DC Resistance Control and Camshaft.  No-Volt Relay : A power circuit relay which detected if power was lost for any reason and made sure that the control sequence was returned to the starting point before power could be re-applied. See Motor Protection.  Overload Relay : A power circuit relay which detected excessive current in the circuit and switched off the power to avoid damage to the motors. See Motor Protection above.  RELAY POSITION FRONT SIDE FOR CONVENSATIONAL LOCO : TK Panel having the following Relay : QOP – 1 & QOP – 2 = Earth Fault Relay for Circuit for Power circuit to Earth Protection QOA = Earth fault relay for auxiliary circuit. QE = Overload Relay For Breaking Excitation. QRS - 1.1 & QRS - 1.2 = Overload relay for rectifier protection. Q – 30 = No Voltage relay. QLM = Overload relay for main Transformer. QLA = For tripping purpose in Auxiliary. Microprocessor Relay With SIV  RESISTANCE : The electrical resistance of an electrical conductor is the opposition to the passage of an electric current through that conductor. The inverse quantity is electrical conductance, the ease with which an electric current passes. Electrical resistance shares some conceptual parallels with the mechanical notion of friction. The SI unit of electrical resistance is the ohm (Ω).
  19. 19. 18 | P a g e In TK Panel there are seven (7) nos. resistance, there are as follows – RQOA1 RQOA2 RHOBA RPQOA RPQOP1 RPQOP2 RQ3O (680Ω) (680Ω) (210Ω) (150Ω) (150Ω) (150Ω) (Value Variable) In RQOA1, RQOA2, RHOBA and RPQOA No Need For SIV. RQ3O No Need For Microprocessor.  DIODES USE IN TK PANEL ( Microprocessor With SIV) :  CT & SIGNAL CONDITIONING UNIT:  Electromagnetic Contactor each parts consist of the following main parts :
  20. 20. 19 | P a g e 1. Yoke 2. Armature 3. Coil 4. Fixed Contact 5. Auxiliary Contacts 6. Arc Chutes 7. Pressure Adjusting Springs 8. Copper Shunts 9. Bearing 10. Bolts, Nuts, Screws, Washers  CONSTRUCTION : These Contactors have a U – Shaped fixed part (yoke), a fixed core and a U- Shaped moving armature. The armature is attracted inside fixed yoke. The auxiliary contacts are fitted below the magnetic circuit. Dimensions of contactor type CBC – 45 – A – 320Z are shown.  MAGNETIC COIL CHARACTERISTICS: (a) RESISTANCE : Coil resistance should be 580 ± 8% ohms at 20˚c. (b) OPERATING (PICK UP) VOLTAGE: The minimum operating voltage should not be more than 57 V at ambient temperature when the contactor picks up. (c) RELEASING ( DROP OUT) VOLTAGE : The voltage at which the contactor electrically opens out should be more than 10 V and less than 20 V at ambient temperature.  IMPORTANT PARAMETERS OF ELECTRO MAGNETIC CONTACTOR TYPE I EMC/ 1 : 1968 : 64A : 3P Main Circuit rated voltage : 500 V AC, 50HZ Main Circuit rated current : 80 A, AC 95 A, AC for high Capacity Contactor Minimum Pick up voltage : 57 V D.C. Rating of operating coil Resistance at 20˚c : 580 ± 8 % ohms Nominal Voltage : 110V D.C. Operating Voltage : Between 68V to 136 V DC Number of Auxiliary Contacts : 2 N/C and 2 N/O Rated Voltage of auxiliary contacts :136 V D.C. Rated current of auxiliary contacts : 5 A D.C. Rupturing capacity of auxiliary contacts : 2A, 136V DC at L/R Ratio of 25/1000  ELECTRO MAGNETIC CONTACTOR :- This is a 3Phase,380V, AC, 50 Hz contactor with 3 Poles and is used for operating auxiliary machines in the locomotives, Operating Coil is Connected to 110V DC by switching “ON” the lever of BL key from driver desk. When coil get energised its armature is attracted then the fixed and moving contacts get closed. According the auxiliary machines starts with their respective time delay.  THE FOLLOWING CONTACTORS ARE USED IN THE LOCOMOTIVE :-
  21. 21. 20 | P a g e SL. NO. Description Abbreviations 1. Contactors for Traction Motor Blower Motors C105, C106, MVMT₁, MVMT₂ 2. Contactors For Main Compressor Motor C101, C102, C103 3. Contactors for Transformer Oil Cooler Blower Motors C107 HVRH  Switch Board :  LECC ( Lamp/ Fuse Tester)  ZUBA ( Voltmeter Relaxation Switch)  HSIV (Static Inverter)  HBA ( Battery On Off Switch)  HPH ( Oil Pump Rotary Switch)  HVRH ( HVRH Motor)  HCP( Compressor Motor Snt. MCP)  HVSL 2 ( Silicon Rectifier Motor)  HAD ( Air drier switch)  HPAR ( Head Light Fault)  HVSL1 ( Silicon Rectifier)  HRAVT ( Cab Fan/ Cab Heater)  UBA ( Voltmeter Switch)  HMCS2 ( Switch For Motor Cut Out)  HVMT1( Blower Motor 1)  HVMT2 ( Blower Motor 2)  HMCS1 ( Switch For Motor Cut Out)  “D” Type HRC Fuse: CCBA(35 A), CCLC/6 A), CCRA2(16 A), CCRA1(16 A), CCLF1(6 A), CCPT(16 A), CCVT(6 A), CCLF2(6 A), CC1VT(6 A)  Fixed Coupler (19 no. Pin)  WORK INSTRUCTION FOR OVERHAULING OF TK PANEL + SWITCH BOARD ( POH/ POH + RC )  INCOMING CHECKING AND TESTING :- (i) Visual Check of defect and deficiency of materials/ Components. (ii) Visual Check of damage & deformation of panel frame.  STRIPPING OF MATERIALS :- (i) Open all the chute separator and arc chutes of EM contactors( EMC ) and open their coil connection as well as interlock connection. Open fixation/ foundation bolts of the entire EM fixation bar and dismount them from the panel. (ii) Open all the electrical connection of SB 1+2, SBTR & TKBD terminals in TK panel and SB3 terminal in switch board and then dismount these terminals after unscrewing of fixation bolts in case of POH Work. (iii) In case of Re-cabling, strip out all the cables by cutting of both end connection after removing/ Cutting the existing bunching tapes. (iv) Open electrical connection of all the VS Diode, economy resistance, Push bottom switches ( BP, DJ, BP 2 DJ etc.), LTBA, Aux. capacitor Boxes, if available, TFS if any ZLE switches, LE 3 + 4 Lamp fitting etc. of TK Panel & all fuses, LECC, ECC, HOBA Knife Switch etc. from switch board.
  22. 22. 21 | P a g e (v) After unscrewing all the above equipment, dismount them from front/ back side (TK – 1/TK-2) Panel and switch board. Other equipment such as rotary switches from switch board are to be stripped by Rotary switch section and relays are to be stripped by relay section. (vi) Remove the power circuit bus bars from inside the TK Panel in R/C LOCO.  CLEANING, OVERHAULING AND ASSEMBLING :- (i) Necessary mechanical repairing of TK Panel frame and switch board frame in LOCO, if required is to be made including stiffeners, relay base, capacitor base etc. in case of POH. In case of re cabling, do any mechanical alteration/ addition of panel frame, if required. (ii) Clean the Panel frame both inside and outside as well as switch board frame with K.Oil and then petrol, soft nylon brush, duster and cotton waste. Clean all the LT control cables with petrol in case of POH work only. (iii) Paint inside and outside of TK Panel as well as switch board, apply anti track varnish on all stiffeners of TK Panel and switch board. (iv) Clean copper bus bar ends with steel wool/ emery paper and then do necessary tinning. Apply anti track varnish on bus bar except tinning portion. Shop No. – 9A is Traction Motor shop of Kanchrapara Railway Workshop, Where Periodic Overhauling (POH) of Traction Motor, Traction Motor Frame, Auxiliary Motor, Transformer of LOCO & EMU are done. This Shop Has a Four Section : (iv) Traction Motor (v) Traction Motor Frame (vi) Auxiliary Motor (vii) Transformer Mr. Debdas Goswami SSE is the incharge of Shop No.-9A and Others SSE and JE are as follows:
  23. 23. 22 | P a g e  Mr. A.K. Samaddar ( SSE/ Traction Motor)  Mr. Debabrata Mukhopadhye (SSE/ TMF)  Mr. T.K. Biswas (SSE/ Auxilary Motor)  Mr. A.K. Mitra (SSE/ TFP[LOCO])  Mr. B.N. Bera ( SSE/ TFP [EMU]) Auxiliary Motors Auxiliary Motors can be run AC or DC. It is not use for Traction Purpose but it helps to cooling of Transformer, Traction Motor, Compressor etc.  Various Type Of Auxiliary Motors are as follows:  MPH (Transformer Oil Circulating Pump) : The transformer tank is filled with oil and it absorbs the heat generated in the transformer and takes it away to the transformer oil cooling Radiator. The circulation of the oil is carried out by MPH. A flow valve with an electrical contact is provided in the oil circulating pipe. As long as the oil is circulating properly the contact on the relay remain closed. However in case of MPH fails or stop the relay contact open which in terns trips QPH relay. This strip the main circuit breaker(DJ) of the LOCO. Thus transformer is protected. Work : For Circulating of Oil Pump.  Specification: It is used in both EMU and LOCOs. Phase : 3 Phase Frequency : 50 HZ Voltage : 290V to 500 Volt Model : 1143L Size : 100 x 100 Discharge : 750 LPM/400LPM LOCO&EMU Speed : 2850 rpm HP : 4.3 Current : 7 Amp Insulation Class : H Winding Connection : Star Connection Manufacture : 23/12/2013 Makers: Flow well pumps & Meter, Bangalore, India
  24. 24.  MVRH (Transformer Oil Cooling Radiator blower) : The MPH circulates the transformer oil through a radiator array on top of the transformer. Air is blown over the radiator by the MVRH. This discharged the heat from the radiator into the atmosphere. A detecting relay is provided in the air stream of the MVRH. The flow detector is a diaphragm type device. The flow of air presses the diaphragm which closes the electrical contact. This relay is known as QVRH. In case the MVRH blower fails the Q trips the DJ through the relay Q-118. Work : For Oil Cooling through Radiator.  Specification: It is used in LOCOs. Phase : 3 Phase Voltage : 415V (290V – 500V) Speed : 1470rpm Current : 40 Amp Winding Connection : Star Connection Make: Crompton Greaves Ltd.  MVSI 1 and 2( Rectifier cooling blower): One blower is provided for each of the rectifier blocks. As rectifiers are semiconductors, they are very sensitive to heat and hence must be cooled continually. The switching sequence of the MVSI blowers is set up in such a way that unless the blower is r be achieved. A detection relay of diaphragm type is also provided in the air stream of the Fig: MPH Motor MVRH (Transformer Oil Cooling Radiator blower) : The MPH circulates the transformer oil through a radiator array on top of the transformer. Air is blown over the radiator by the MVRH. This discharged the heat from the radiator into the mosphere. A detecting relay is provided in the air stream of the MVRH. The flow detector is a diaphragm type device. The flow of air presses the diaphragm which closes the electrical contact. This relay is known as QVRH. In case the MVRH blower fails the Q 118. Work : For Oil Cooling through Radiator. It is used in LOCOs. Frequency : 50±3 % 500V) AMB : 65˚C KW/HP : 22.0/30.00 Insulation Class: H Winding Connection : Star Connection Manufacture : June 2014 Make: Crompton Greaves Ltd. Fig: MVRH Motor MVSI 1 and 2( Rectifier cooling blower): One blower is provided for each of the rectifier blocks. As rectifiers are semiconductors, they are very sensitive to heat and hence must be cooled continually. The switching sequence of the MVSI blowers is set up in such a way that unless the blower is running, traction can not be achieved. A detection relay of diaphragm type is also provided in the air stream of the 23 | P a g e The MPH circulates the transformer oil through a radiator array on top of the transformer. Air is blown over the radiator by the MVRH. This discharged the heat from the radiator into the mosphere. A detecting relay is provided in the air stream of the MVRH. The flow detector is a diaphragm type device. The flow of air presses the diaphragm which closes the electrical contact. This relay is known as QVRH. In case the MVRH blower fails the QVRH releases and One blower is provided for each of the rectifier blocks. As rectifiers are semiconductors, they are very sensitive to heat and hence must be cooled continually. The switching sequence unning, traction can not be achieved. A detection relay of diaphragm type is also provided in the air stream of the
  25. 25. blowers. However the detection relay (QVSI 1 & 2) are interlocked with different relay known as Q45. This is a much faster acting relay with blower would trip the DJ in less than 1 sec. Work: For Ventilation of Silicon Panel.  Specification: It is used in both EMU and LOCOs. Frequency : 50 HZ HP : 4.3 Motor No.-05669 Manufacture : September 1991  MVSL (Auxiliary of the Smoothing reactor) : In WAM4 LOCOs only MVSL blower is provided for the cooling of Work : Its Helps to Smoothing reactor. When current convert from DC to AC, a smooth curve is needed, hence it required.  Specification: It is used in LOCOs. Voltage : 415V (290V – 500V) Type: AB-50 Speed : 2880 rpm Manufacture : January 2005 Make: Ranjan Axle Blower, India blowers. However the detection relay (QVSI 1 & 2) are interlocked with different relay known as Q45. This is a much faster acting relay with a time delay of only 0.67. Hence the failure of MVSI blower would trip the DJ in less than 1 sec. Work: For Ventilation of Silicon Panel. It is used in both EMU and LOCOs. Type: AX 28-400 Speed : 2860 rpm Current : 4.7 Amp Manufacture : September 1991 Make: Blower Sahal Haram Motor, India Fig: MVSI Motor MVSL (Auxiliary of the Smoothing reactor) : In WAM4 LOCOs only MVSL blower is provided for the cooling of smoothing reactors SL 1 & 2. Work : Its Helps to Smoothing reactor. When current convert from DC to AC, a smooth curve is It is used in LOCOs. 500V) Phase: 3 Phase Wattage : 1850 Current : 4.6 Amps Connection : Star Make: Ranjan Axle Blower, India 24 | P a g e blowers. However the detection relay (QVSI 1 & 2) are interlocked with different relay known as a time delay of only 0.67. Hence the failure of MVSI Make: Blower Sahal Haram Motor, India smoothing reactors SL 1 & 2. Work : Its Helps to Smoothing reactor. When current convert from DC to AC, a smooth curve is
  26. 26. Fig: MVSL Motor  MVMT 1 and 2 (Traction Motors Cooling blower) : In normal operation of traction motor generates a lot of Heat. This heat is dissipated by two blowers namely MVMT 1 and 2. Which force air through a duct into the traction motors of bogie 1 namely TM1, TM2, TM3 and bogie 2 namely TM4, TM5, TM6 respectively motor cooling blowers required a large quantity of air which is taken from vents in the side walls of the LOCO. Work : For traction Motor Cooling Purpose.  Specification: It is used in LOCOs. Phase : 3 Phase Voltage : 290V to 500 Volt Frame : C200M Speed : 2955 rpm Current : 46 Amp Winding Connection : Star Connection Makers: Crompton greaves Ltd, India  MCP 1,2 & 3 (Air Compressors) : Electric LOCOs need compressed air at a pressure ranging from 6kg/cm² to 10kg/cm². Compressed air is used for the LOCOs won air brake system as also for the train brakes for raising the Pantograph, Operating the power switch gear in contactors, Change over Switch, Windscreen wipers, Senders the compressed air is obtained by providing 3 air compressors, each having capacity to pump 100 Lt. of air per minute. Work : For main compressor ( Air pressure build u  Specification : It is used in LOCOs. Phase : 3 Phase Voltage : 415Volt Speed : 970 rpm Current : 24 Amp Winding Connection : Star Connection Makers: Crompton greaves Ltd, India  MPV 1 & 2 ( Vacuum Pumps): Fig: MVMT Motor MVMT 1 and 2 (Traction Motors Cooling blower) : In normal operation of traction motor generates a lot of Heat. This heat is dissipated by two blowers namely MVMT 1 and 2. Which force air through a duct into the traction motors of bogie 1 namely TM1, TM2, TM3 and bogie 2 namely TM4, TM5, TM6 respectively motor cooling blowers required a large quantity of air which is taken from vents in the side Work : For traction Motor Cooling Purpose. It is used in LOCOs. Frequency : 50 HZ Motor No.: 26 KD2-MVMT AMB: 65˚C KW/HP : 26/35 Insulation Class : H Winding Connection : Star Connection Manufacture : July 2014 Makers: Crompton greaves Ltd, India & 3 (Air Compressors) : Electric LOCOs need compressed air at a pressure ranging from 6kg/cm² to 10kg/cm². Compressed air is used for the LOCOs won air brake system as also for the train brakes for raising the Pantograph, Operating the power switch gear inside the LOCO such as power contactors, Change over Switch, Windscreen wipers, Senders the compressed air is obtained by providing 3 air compressors, each having capacity to pump 100 Lt. of air per minute. Work : For main compressor ( Air pressure build up purpose) It is used in LOCOs. Frequency : 50 HZ Model : M0409415 KW:10.4 Insulation Class : H Winding Connection : Star Connection Manufacture : 23/12/2013 Makers: Crompton greaves Ltd, India MPV 1 & 2 ( Vacuum Pumps): 25 | P a g e In normal operation of traction motor generates a lot of Heat. This heat is dissipated by two blowers namely MVMT 1 and 2. Which force air through a duct into the traction motors of bogie 1 namely TM1, TM2, TM3 and bogie 2 namely TM4, TM5, TM6 respectively. The traction motor cooling blowers required a large quantity of air which is taken from vents in the side MVMT Electric LOCOs need compressed air at a pressure ranging from 6kg/cm² to 10kg/cm². Compressed air is used for the LOCOs won air brake system as also for the train brakes for side the LOCO such as power contactors, Change over Switch, Windscreen wipers, Senders the compressed air is obtained by providing 3 air compressors, each having capacity to pump 100 Lt. of air per minute. 23/12/2013
  27. 27. In LOCOs equipped to haul vacuum braked trains, two vacuum pumps are also provided of which at least 1 is running in normal service and sometimes both may have to be run if train breaks are required to be released in a hurry  MVRF / MVRB ( Dynamic braking resistance cooling blower) : In LOCOs equipped with internal dynamic braking resistances, MVRF blower are provided for cooling the resistance during braking. While all the auxili supply provided by the ARNO Converter / SIV / Motor alternator Set, The MVRF blower runs of the supply derived from the output of the traction motor itself and is connected in parallel to the dynamic braking resistances.  Specification: It is DC series motor with blower used in LOCOs. Phase : 3 Phase Voltage : 450Volt AMB : 55˚C Speed : 2950 rpm Current : 75 Amp Make: Danlat Ram Industries, India  MCPA (BABY COMPRESSOR) : The foot mounted motor is series wound with four poles. A weak shunt field is provided to limit the no load speed to safe valve thus safe guarding the unit coupled to the motor. The motor front cover is designed to provide a spigot mounting for the crankcase. The radial box type brush holders are mounted on the insulated rocker arm and can be removed without disturbing the rare cover. The armature is dynamically balanced and is supporte duty ball bearings. The entire winding is dipped in varnished to get good insulation properties. A protection cover is provided to protect commutator and brush gear. An oil seal is provided to prevent crank case oil entering into the motor. For working of baby compressor (MCPA) to build up pneumatic Pressure. For raising of Pantograph. For closing of DJ (de jointer) Parts of Baby Compressor : (i) Crankcase, (ii) Cylinder, (iii) Piston, (iv) Silencer, (v) Terminal Casing, (vi) Rocker Ring In LOCOs equipped to haul vacuum braked trains, two vacuum pumps are also provided of which at least 1 is running in normal service and sometimes both may have to be run if train eaks are required to be released in a hurry MVRF / MVRB ( Dynamic braking resistance cooling blower) : In LOCOs equipped with internal dynamic braking resistances, MVRF blower are provided for cooling the resistance during braking. While all the auxiliary machine run on the power supply provided by the ARNO Converter / SIV / Motor alternator Set, The MVRF blower runs of the supply derived from the output of the traction motor itself and is connected in parallel to the dynamic braking resistances. It is DC series motor with blower used in LOCOs. Frequency : 50 HZ Cooling – Air Closed KW : 30 HP : 40 Insulation Class : H Ram Industries, India Fig: MVRF/MVRB Motor MCPA (BABY COMPRESSOR) : The foot mounted motor is series wound with four poles. A weak shunt field is provided to limit the no load speed to safe valve thus safe guarding the unit coupled to the motor. The tor front cover is designed to provide a spigot mounting for the crankcase. The radial box type brush holders are mounted on the insulated rocker arm and can be removed without disturbing the rare cover. The armature is dynamically balanced and is supporte duty ball bearings. The entire winding is dipped in varnished to get good insulation properties. A protection cover is provided to protect commutator and brush gear. An oil seal is provided to prevent crank case oil entering into the motor. For working of baby compressor (MCPA) to build up pneumatic Pressure. For raising of Pantograph. For closing of DJ (de jointer) : (i) Crankcase, (ii) Cylinder, (iii) Piston, (iv) Silencer, (v) Terminal 26 | P a g e In LOCOs equipped to haul vacuum braked trains, two vacuum pumps are also provided of which at least 1 is running in normal service and sometimes both may have to be run if train In LOCOs equipped with internal dynamic braking resistances, MVRF blower are provided ary machine run on the power supply provided by the ARNO Converter / SIV / Motor alternator Set, The MVRF blower runs of the supply derived from the output of the traction motor itself and is connected in parallel to The foot mounted motor is series wound with four poles. A weak shunt field is provided to limit the no load speed to safe valve thus safe guarding the unit coupled to the motor. The tor front cover is designed to provide a spigot mounting for the crankcase. The radial box type brush holders are mounted on the insulated rocker arm and can be removed without disturbing the rare cover. The armature is dynamically balanced and is supported by two heavy duty ball bearings. The entire winding is dipped in varnished to get good insulation properties. A protection cover is provided to protect commutator and brush gear. An oil seal is provided to For working of baby compressor (MCPA) to build up pneumatic Pressure. For raising of : (i) Crankcase, (ii) Cylinder, (iii) Piston, (iv) Silencer, (v) Terminal
  28. 28. Fig: MCPA Motor for LOCO  ARNO Converter : This is a rotary converter which has a combined set of winding & is used to convert the single phase supply from tertiary winding various auxiliary machines in the LOCO. ARNO is basically a split stator for the generating phase. In a induction motor, the rotating field of stator creates a corresponding field in the rotor squirrel cage too which cause the rotor to slip speed which is slightly less than synchronous speed. However this rotating field of the rotor is additionally utilized in the ARNO to create power in the generating phase winding which gives the three phase output of the ARNO conve motoring phases carry the load as well supply currents of the ARNO in opposite direction which cause a net reduction in the actual current carried by the winding in the stator but the generating phase carries only the load current which cause a voltage drop in the generating phase.  Specification: S.R. No.: 2531 Single Phase Input : 150 KVA 380 Volts 395 Amps Frame – VA 330 Cycle - 50˚c Make : Jyoti Ltd., Varoda, India Fig : Circuit Diagram of Arno Converter Fig: MCPA Motor for LOCO Fig: MCPA Motor for EMU This is a rotary converter which has a combined set of winding & is used to convert the single phase supply from tertiary winding of the LOCO transformer to 3ɸ AC which is fit for use by the various auxiliary machines in the LOCO. ARNO is basically a split – phase induction motor with an additional winding on the stator for the generating phase. In a induction motor, the rotating field of stator creates a corresponding field in the rotor squirrel cage too which cause the rotor to slip speed which is slightly less than synchronous speed. However this rotating field of the rotor is additionally utilized in the ARNO to create power in the generating phase winding which gives the three phase output of the ARNO convertor. In the stator winding of the ARNO, the motoring phases carry the load as well supply currents of the ARNO in opposite direction which cause a net reduction in the actual current carried by the winding in the stator but the ly the load current which cause a voltage drop in the generating : S.R. No.: 2531 Three Phase Output : 120 KVA 380 Volts 190 Amps RPM : 1495 Connect to Star Make : Jyoti Ltd., Varoda, India Fig : Circuit Diagram of Arno Converter 27 | P a g e Fig: MCPA Motor for EMU This is a rotary converter which has a combined set of winding & is used to convert the single AC which is fit for use by the phase induction motor with an additional winding on the stator for the generating phase. In a induction motor, the rotating field of stator creates a corresponding field in the rotor squirrel cage too which cause the rotor to start rotating at a slip speed which is slightly less than synchronous speed. However this rotating field of the rotor is additionally utilized in the ARNO to create power in the generating phase winding which gives rtor. In the stator winding of the ARNO, the motoring phases carry the load as well supply currents of the ARNO in opposite direction which cause a net reduction in the actual current carried by the winding in the stator but the ly the load current which cause a voltage drop in the generating Three Phase Output : 380 Volts
  29. 29.  Work instruction of auxiliary Motor Section :  Scope : Overhauling of Auxiliary motors of LOCOMOTIVE & EMU motor coaches  Procedure :  Incoming Testing, Dismantaling & Overhauling (i) Check the motor visually and its insulation by 500V magger. (ii) Carry on SCT test on the stator. (iii) Remove the air duct and impeller with suitable puller . (iv) Run the motor at rated voltage on load and check the sound. (v) remove the end cover slowly with the help of snappers and wooden mallet. (vi) Take out the rotor and remove the bearing from it with the help of puller. (vii) Clean the stator and rotor well whi (viii) Check the rotor bar of any crack, flash marks damages/Cracks of cooling fan, impeller locking threads, keyway. (ix) Check the condition of winding and cleanliness of rotor. (x) Measure the bearing Seat of the shaft wi (xi) Clean the end cover with Kerosene and cloth. (xii) Measure the bearing housing with dial bore gauge.  Assembly & Final Testing: (i) Bake the stator and rotor at 120 ± 10 degree centre grate for 8 to 12 hours (ii) Apply one lout of insulating varnish on winding over hang portion and allow it cool to room temperature. (iii) Fit new bearing on the rotor shaft for LOCO aux. motor & aux. motor by heating the bearing at induction RR-3 grease. (iv) Insert the rotor into the stator. (v) Assemble the end shields on both sides of the motor by tightening the bolts. (vi) Rotate the shaft by hand and check its rotation is free from an obstruction if so, take out the rotor & repeat the procedure again. (vii) Run the motor at rated voltage on no load and check sound. (viii) Insert the key on shaft and mount the fan. (viii) Tighten the fan mount bolt and ensure that the fan position and paint it fit the duct wherever necessary. Fig : ARNO Converter Work instruction of auxiliary Motor Section :- Overhauling of Auxiliary motors of LOCOMOTIVE & EMU motor coaches Incoming Testing, Dismantaling & Overhauling (i) Check the motor visually and its insulation by 500V magger. (ii) Carry on SCT test on the stator. (iii) Remove the air duct and impeller with suitable puller . the motor at rated voltage on load and check the sound. (v) remove the end cover slowly with the help of snappers and wooden mallet. (vi) Take out the rotor and remove the bearing from it with the help of puller. (vii) Clean the stator and rotor well which compressed air and orion 77. (viii) Check the rotor bar of any crack, flash marks damages/Cracks of cooling fan, impeller locking threads, keyway. (ix) Check the condition of winding and cleanliness of rotor. (x) Measure the bearing Seat of the shaft with the help of outside micrometer. (xi) Clean the end cover with Kerosene and cloth. (xii) Measure the bearing housing with dial bore gauge. (i) Bake the stator and rotor at 120 ± 10 degree centre grate for 8 to 12 hours ii) Apply one lout of insulating varnish on winding over hang portion and allow it cool to (iii) Fit new bearing on the rotor shaft for LOCO aux. motor & on condition basis in EMU motor by heating the bearing at induction heater, cool the bearing & apply servo gen (iv) Insert the rotor into the stator. (v) Assemble the end shields on both sides of the motor by tightening the bolts. (vi) Rotate the shaft by hand and check its rotation is free from an so, take out the rotor & repeat the procedure again. (vii) Run the motor at rated voltage on no load and check sound. (viii) Insert the key on shaft and mount the fan. Tighten the fan mount bolt and ensure that the fan properly sealed on its paint it fit the duct wherever necessary. 28 | P a g e Overhauling of Auxiliary motors of LOCOMOTIVE & EMU motor coaches (v) remove the end cover slowly with the help of snappers and wooden mallet. (vi) Take out the rotor and remove the bearing from it with the help of puller. (viii) Check the rotor bar of any crack, flash marks damages/Cracks of cooling fan, impeller th the help of outside micrometer. (i) Bake the stator and rotor at 120 ± 10 degree centre grate for 8 to 12 hours ii) Apply one lout of insulating varnish on winding over hang portion and allow it cool to on condition basis in EMU heater, cool the bearing & apply servo gen (v) Assemble the end shields on both sides of the motor by tightening the bolts. (vi) Rotate the shaft by hand and check its rotation is free from any mechanical properly sealed on its
  30. 30. 29 | P a g e (x) Keep the assembled motor on test bench and tighten the foundation. (xi) Connect the 3Phase 415 ± 22.5% volt ac supply to the motor terminal for LOCO Auxilary motors. For EMU motor coaches connect the capacitor in series with the starting winding and the phase and neutral of 220 volt AC the motor terminal. (xii)Switch on the motor by switching “ ON ” the MCB. (xiii) Ensure the motor is rotating in proper direction and record the current. (xiv) Measure the insulation resistance, the value should not be less than 10 M Ω. (xv) Paint the motor with brush externally and dry it.  Different Type Of Test For Auxiliary Motors : (i) Winding to Winding Test, 3ɸ Motor, For 1ɸ a Identical motor is needed. (ii)Earth fault Test (iii)SCT Test (a) Inter Turn Short test (b) Open circuit Test (c) Coil to Coil Short in same phase (d) Phase to phase short
  31. 31. 30 | P a g e Traction Motor Traction motor is one of the most important equipment of electric locomotives. Traction motor type HS-15250 A was specially dev99eloped by M/s Hitachi for Indian Railways. This traction motor is being used in AC locomotives type WAG-5, WAG-7, WAP-4 and AC/DC locomotives type WCAM-3. Mainly DC Series Motor is used as traction motor as its starting torque is high enough to provide tractive effort.  Different Parts of Traction Motor:  FRAME:- This is a magnetic steel cast member, on the commutator side. Opening have been provided for upper air inlets & lower inspection covers. The terminal box is situated above the axle side.  POLE:- The mail pole are built up of magnetic laminations 1m tick, held together by drown steel retaining pins welded to the end plates the assembly is fixed to the frame by 3 screws the commutating pole are also built up from 0.5mm thick magnetic sheets with class it varnish insulation. The four inter segment stacks are supported by 3 intermediate supports & two end supports & assembled by two drown steel rivets. The stack assembly is fixed to the frame by three screws. On the main pole s every second lamination is insulated with h-class varnish.  FIELD COIL:- The conductor is of high conductivity electrolyte copper, ground insulation is by kepton tape followed by glass mica, glass silicon tape & F,G tape in turn insulation is nomex silicone impregnated paper.  ARMATURE STACK:- These are composed of magnetic steel laminations of 0.5 mm thick insulated by class H varnish. The punching are keyed to the armature shaft. Assembled hot in a process, the laminations are maintained by a cast steel armature head at one end and the other end by the cast steel armature sleeve retained on the shaft by set ring and rotating ring.  COMMUTATOR:- The segment are in silver-copper alloy separated by micanite. The segment are assembled on the collector ring and maintained by a mobile cone with insulting micanite cones. Each complete assembly is secured by 20 screws.  ARMATURE WINDING:- It is composed of high conductivity electrolytic copper conductor with 2/3 lap kapton, bunch insulation Is made by – (1) Glass-mica silicon tape on the involute portion (2) Nomex –silicon mica upper in the slot portion The coil are maintained in the slot by moulded directs slot wedges or laminated fibre slot wedges and by polyglass tape.  BRUSH HOLDER:- The 6 brush holders are carried on a rotery brush holder ring whose positioning & locking is obtained by means a special screw inverse threaded. Inspection of the brush holders are
  32. 32. 31 | P a g e carried out through inspection door. The connection between stator and brush holder is assured by flexible connector.  ARMATURE BEARING:- The armature is supported on two roller bearing mounted on cast steel end shields. An inspection panel on the commutator side end shield allows access to the brush holder insulated supports. Cooling air is evacuated through the armature head & expended metal at the pinion en shield. Parallel roller are fitted  TERMINAL BOX:- This is situated on the upper part of the motor frame axle side a removable cover gives access to the connection.  Rating:- Continuous 535V 340A 1260 R.P.M Insulation (Armature) H Insulation Clean (Field) F Insulation Level 1000V  Construction:- The armature core is built up from electrical quality varnished sheet steel lamination assembled on the shaft with interference fit and consolidated under pressure. The armature has a forty percent equalization. The armature coils are capton covered. The armature and equalizer coil leads are TIG welded to commutator riser. The armature coil are held down in the core slots by Epoxy glass wedges and the end winding are squired by Res-i- glass bands. The wound armature s finally vacuum pressure impregnated by insulating varnish. The commutator is of arch bound construction built up with hard drawn silver bearing copper segment which are insulated with micanite segment and are assembled with mounded mica insulation between steel V-ring. After assembly, the commutator is statically and dynamically seasoned to ensure stability. The complete armature is dynamically balanced. The commutator outer mica V-ring is protected with anti-creepage tape/ring. The high permeability cast steel or fabricate magnate frame is machined to ensure aliganment of the end shield, pole bores and alxe-way bores. The main pole are built from steel lamination rivetted together Main pole and interpole coil are epoxy insulated and bonded to pole bodies using epoxy resin. This improve heat dissipation. There are four brush holder per motor is carrying to split carbon brushes. The brush holder is and integral casting having a single adjustable spring for each brush to provide the correct brush pressure. The brush holder is secured to the magnet frame by FRP moulded insulated pins. The rubber top carbon brushes are split type to ensure better contact the commutator. Arching horns are provided near the brush holders to minimize the damage in an event of a flashover. The armature is supported on two grease lubricated rollers bearing. Bearing assemblies are sealded type, thereby necessitating lubrication in about two years. The armature is located axially by the commutator end bearing, while the pinion end bearing is capable of taking are any axial play between armature and frame. The axle suspension bearing is highly leaded bronze shell type one half of the bearing is keyed to the axle cap to prevent rotation and to align the oiling window. The oil lubrication is provided by spring loaded wick assembly of the axle lubricator. The pinion which is shrunk on the armature shaft, drives the loco axle through a spur gear wheel which is pressed on to the axle. The gearcase is of welded steel construction and is
  33. 33. 32 | P a g e in two halves, which are bolted together. The complete gearcase is supported on the motor frame and endshield PE. The joint between the gearcase halves are baffled and grooved to carry felt sealing rings so as to prevent ingress of dust and any other foreign materials and the escape of the gear lubricant. The motor Is self ventilated and the fan is mounted on CE. Shaft extension. Air enters the motor through a duct system connected to an opening provided in fan chamber and assembled on the motor frame at the commutator end. The cooling air then sucked by fan flows in two parallel paths, one under the commutator through the armature core ducts and the other along the outside of the armature and between the field coil and is discharged through the opening provided at the penion end of the fream.  No Load Testing Procedure Of BHEL, Hitachi, Tao Traction Motors : Parameters Checked Standard Value For BHEL Standard value For HITACHI Standard Value For TAO Starting Voltage / Current 2 – 4Volts/ 25 – 40 Amps 4 – 6 Volts/45 – 65 Amps 3 – 4 Volts/ 40 – 60 Amps 2 Hr No – Load run test at rated RPM 1500 895 1095 Voltage/ Current on rated RPM 84 – 86 Volt/ 35 – 40 Amps 70 – 72 Volt/ 45 – 48 Amps 68 – 72 Volt/ 45 – 50 Amps Maximum Temperature rise Note maximum temperature Note maximum temperature Note Maximum Temperature Decrease Stable Temperature Note Minimum Temperature Note Maximum Temperature Note Maximum Temperature Ambient Temperature Note Ambient Temperature Note Maximum Temperature Note Maximum Temperature Temperature Rise 35 – 40 35 – 45 35 – 45 Vibration(mm/sec) by vibration Pen 0 to 1.4 Green 1.5 to 3.5 Yellow 3.6 to above – Red a) 0 to 1.4 Green b) 1.5 to 3.5 Yellow 3.6 to above Red 0 to 1.4 Green 1.5 to 3.5 Yellow 3.6 to above Red  Assembly of traction Motor of type 4610AZ, HS – 15250A &TAO – 659 : (i) Keep the traction motor Yoke on assembly stand. (ii) Tilt the armature vertically and lift the armature assembly from wooden stand. (iii) Gradually insert the armature into the magnet frame carefully then fix the CE and shield on the magnet frame. (iv) Tight the PE and shield bolt crosswise with the help of torque wrench. (v) Fit the brush holder and check the gap between the brush holder and commutator permissible limit 1.6 to 3.2 mm. (vi) Check the ARC horn and ARC horn gap. Permissible limit 10 – 11 m. If the ARC horn defective change it. (vii) Check the clearance between commutator rise to brush holder face and check not rubber with raiser.
  34. 34. 33 | P a g e (viii) Insert the carbon brush in the brush holder and check face movement of the carbon brush connect the pig tail with brush holder. (ix) Fit the inspection cover and point back side lower from stand using crane on testing bay.  Work Instruction Of traction Motor Section:-  Scope : Overhauling of EMU/LOCO traction Motor  Procedure : 1.Incoming Checking of Traction Motor : (i) Inspect the traction motor for any external mechanical damage, defects and deficiencies, condition of pinion. (ii) Inspect the traction motor for any axle suspension area damage. (iii) Check the cable cleat, cable, E/brush, E/brush fixation hole etc. (iv) Check the IR value of field coil and armature to the respect to earth with 1000 volt megger. (v) Check the commutator visually for any spark or end flash mark. (vi) Check the condition of brush holder. (vii)Check the vibration or bearing noise by running the TM for five minute by run at 1500 rpm. 2. Striping of EMU Traction Motor(460IAZ) : (i) Dismantle of the air duct by removing the bolt size M – 16x 35 and remove the commentator inspection covers. (ii) Open the TM Fan chamber and check the condition of thread of the bolt and holes for any worn- out for any damage of threads. (iii) Remove the sealing wire from outer bearing cap ( PE Side) and adapter plate ( CE Side ). (iv) Remove the lock Nut 82.5 mm and lock plate. Remove the cooling fan with puller. (v) Check the fan blade for any damage or crack check the thread holes, key slot and hub dia. of the Fan for any deformation. (vi) Remove the pinion wiper PE wiper CE, With puller remove the adapter plate, Bearing cap PE by removing the Allen Bearing M12 x 40. Check all the fitting, pinion. (vii) Remove the PE and Shield bolt M-20 x 50 and remove PE end shield carefully so that the bearing not damage. Remove the arm with the help of eye bolt carefully. So that it does not rub with stator poles. (viii) Remove the bearing from the cartridge with the help of puller and check the condition of bearing End shield block. Bearing cap etc. for any damage / cracks or threads damage.  Overhauling Of Bearing : (i) At the time of dismantling the traction motor, Special case should be taken to collect and stored the bearing grouped as per their identification and also along with corresponding inner race and outer race to avoid incorrect assembly or mismatches. (ii) Wiped out the coagulated grease with soft cloth, then the bearing fully depend into ORION- 776 or Kerosene Oil for one day long. Coagulated greases and foreign materials if any is removed by blowing compressed, air with IRION – 77/ Kerosene Oil from the
  35. 35. 34 | P a g e inaccessible part of Bearing till bearing, till bearing cleaned up to the mark by checking visually. (iii) Finally the bearing are depend into a container which contains fresh IRION – 77 / Petrol and the rest particle of dust and grease are removed by rotating the rollers by hand, so as to residual unwanted materials come out from the inaccessible part of the bearing as well as remove traces of kerosene oil. At the time of final cleaning compressed air is not used to avoid the moisture contamination with the bearing part as the compressed air is not dry and free moisture. After completing the above procedure the bearing are taken out from the container and wiped off the solvent thoroughly with the help of new soft cloths. (iv)Examine all the rollers freely rolling or not. (v) Visual checking is done to check the stretch mark, pit mark and score mark, dis- colouring on the functional surfaces i.e. rolling elements and race ways. (vi) Clean the inner racer, out racer and roller and examine for any crack score, dislocation and closely observe for any air hair line cracks. (vii) If any inner race found crack then changed the bearing. (viii) Check the radial clearance as per recommended value of the PE & CE bearing and record it in the register. (ix) If the clearances are not within the limit replace it with a new bearing. Date of insulation should be marked on the new bearing by itching pen and record it in bearing resister. (x)Record the bearing insulation date in bearing register and itch the same on outer racer.  Stripping of LOCO Traction Motor ( HS – 15250A & TAO – 659 ) : (i) After incoming checking dismantle the bearing stopper, pinion stopper plate bolts & lock plate for dismantling of pinion and send to clearing area for clearing. (ii) Remove the outer bearing cover, outlet bearing stopper / retaining plate of PE side and send to clearing area for clearing. (iii) Stand the motor pinion side top position for remove pinion end Shield carefully to avoid any damage of the bearing and send to clearing area for clearing. (iv) Remove the Arm with the help of Eye bolt carefully so that it does not rub with starter poles. (v) Turn the CE end top position with the help of crane for removing the CE End shield brush holder and brush holder revolving ring after removing the BHRR locking bolt and send to clearing area for clearing. (vi) Remove the outer bearing cover, outer bearing stopper of CE side and send to clearing area for cleaning.  Overhauling of Traction motor end component :- (i) Scrap the sludge, coagulated grease with the help of a meta scrapper and steel wire brush from the end components and fan chamber, air duct, impeller, adopter plate and all the inspection covers, earth return brush holder. (ii) To moist all the spare parts by Kerosene oil applied with a brush and wipe out with jute or cloth afterwards.
  36. 36. 35 | P a g e (iii) Clean thoroughly using moistened jute or cloth by Kerosene oil and ensure that there is no dirt or sludge inside the bearing components and other metal parts. (iv) Check the condition of the end shield block, DPT test should be done in the welded portion of the end shield block. (v)Check the end Shield fixation hole is elongated or not. If elongated, then replace it with new one. (vi) Measure the bearing housing dia. and bore of the end shield by Go, Not Go gauge or inside micrometer. (vii)Examine all threaded hole of end components to be checked, if found worn out then replace it with new one. (viii)Visually checked the condition of bearing housing of end component and bore, which is related with armature shaft for smooth surface damage etc.  Overhauling of Brush Holder assembly during POH : (i) Clean the brush holder with petrol thoroughly to remove dust and carbon particle from brush holder. (ii) Check the brush holder assembly visually for any flashing / damage. (iii) Check the condition of arcing stud for any damage melt if found damage replace with new one. (iv) Check the condition of the brush holder insulator in case of EMU traction Motor if found damage replace with new. (v) Check the condition brush holder, pocket if any flashing mark or Pilting mark rectifies all and checking should be done with new carbon brush inserting in to the pocket. (vi) Check the slot of the brush holder fixation in case of LOCO brush holder if damage/ not matching replace with new one. (vii) Replace all the spring in case LOCO as must change and check the brush holder spring pressure with the spring balance or weighing machine if low than the recommended value adjust the spring. (viii) Check the megger value with 1 kV megger and finally do the HV test at 3 kV for 1 Minute  Rate Of Traction Motor and No Load Testing Schedule : EMU / LOCO Traction motor type 4601AZ/BZ/BY/BX continuously rating- 535 V, 350Amp, 167Kw, 1260 RPM one hour rating – 535v, 380 Amp. 187 kW, 1182 RPM Type of Bearing – PE NU 326 bearing , CE NUP 318 bearing  Testing Procedure : Run the Traction motor at rated speed 1500 RPM for 45 minutes in clockwise and 45 minutes in anticlockwise run the Traction Motor at 2000 RPM for 15 minutes and 2275 RPM period for high speed. Check all the parameter.  LOCO Type Traction Motor: Traction Motor type TAO – 659 Continuous Rating : 750 v, 840 Amp, 585 kW, 1095 RPM
  37. 37. 36 | P a g e One hour Ratting : 750V, 870 Amp, 650 kW, 1076 RPM Type of Bearing : PE NU 328 Bearing, CE NH 318 Bearing  Hitachi Type HS – 15250A : Continuous Rating : 750V, 900 Amp, 630Kw, 895 RPM One hour Rating: 750 V, 960 Amp, 670Kw Type Of Bearing :PE NU 330 Bearing CE NH 324 Bearing  Testing: Run the LOCO Traction motor at rated speed for 3 hrs. including high speed for a short period in case of high speed LOCO traction motor as bellows and check all the parameters testing. For high speed TAO-659 traction motor run the Traction motor and 2000 speed for a short period.For Hitachi Traction Motor run the Traction Motor for high speed LOCO at 2200 RPM FOR a short period.  Flow Chart of Work Schedule of Traction Motor (Shop No 9A)
  38. 38. 37 | P a g e Traction Motor Frame The high permeability cast steel or fabricated round magnet frame is machined to ensure alignment of the end shields, pole bores and axle way bores. Main pole and com pole coils are edge wound, curved epoxy insulated and bonded to pole bodies using epoxy resin. This improves heat dissipation and eliminates spring and support plates.
  39. 39. Fig: LOCO TM Frame Fig : EMU TM Fram  Frame has the following parts:  Yoke : Yoke is made of cast steel/cast iron. It serves double purposes (a)It provides mechanical support for the poles & acts as a protecting cover for the whole machine and (b)It carries the magnetic flux produced by the poles. The feet of the terminal box is welded to the frame afterwards.  Pole Core & Poe Shoe : The field magnets consist pole core & pole shoes. The pole spread out the flux in the air gap & also being of large cross section reduce the reluctance of the magnetic path. It is mainly made of cast iron or cast steel but the pole shoe is laminated and is fastened to the pole face by means of counter sunk screw. In modern design the complete pole core and pole shoe are build of thin lamination of annealed steel which are riveted together under hydraulic pressure. The laminated poles may be screwed to the yoke by means of screws bolte through the yoke and into the pole body or the holding screws are bolted into a steel bar which passes through the pole across the plane of the lamination.  Pole Coils : The field coil or pole coil is consist of cupper correct dimension then the former is removed and wound coil is put into place over the core when current is passed through this coil, they electromagnetism the poles which produces the necessary flux that is cut by revolving armature conductor  Rocker Assembly & Brush Holder: This motor is pole type motor and brush holders are mounted on the rocker ring that is fixed to the bearing bracket at commutator side by four bolts. The brush holders and car brushes can be inspected by rotating the rocker ring until each brush holder comes to the inspection windows. The brush holders are mounted on the rocker ring by one insulating rod. Brushes can be changed without dismantling the motor. Flame retard (fluonlex) cable is used for brush gear connections.  Interpole: Fig: LOCO TM Frame Fig : EMU TM Fram Frame has the following parts:- Yoke is made of cast steel/cast iron. It serves double purposes (a)It provides mechanical acts as a protecting cover for the whole machine and (b)It carries the magnetic flux produced by the poles. The feet of the terminal box is welded to the frame The field magnets consist pole core & pole shoes. The pole shoe serve two purposes (a)It spread out the flux in the air gap & also being of large cross section reduce the reluctance of It is mainly made of cast iron or cast steel but the pole shoe is laminated and is fastened to y means of counter sunk screw. In modern design the complete pole core and pole shoe are build of thin lamination of annealed steel which are riveted together under hydraulic pressure. The laminated poles may be screwed to the yoke by means of screws bolte through the yoke and into the pole body or the holding screws are bolted into a steel bar which passes through the pole across the plane of the lamination. The field coil or pole coil is consist of cupper wire or strip, are former correct dimension then the former is removed and wound coil is put into place over the core when current is passed through this coil, they electromagnetism the poles which produces the by revolving armature conductor Rocker Assembly & Brush Holder:- This motor is pole type motor and brush holders are mounted on the rocker ring that is fixed to the bearing bracket at commutator side by four bolts. The brush holders and car brushes can be inspected by rotating the rocker ring until each brush holder comes to the inspection windows. The brush holders are mounted on the rocker ring by one insulating rod. Brushes can be changed without dismantling the motor. Flame retardant modified ETFE (fluonlex) cable is used for brush gear connections. 38 | P a g e Fig: LOCO TM Frame Fig : EMU TM Frame Yoke is made of cast steel/cast iron. It serves double purposes (a)It provides mechanical acts as a protecting cover for the whole machine and (b)It carries the magnetic flux produced by the poles. The feet of the terminal box is welded to the frame shoe serve two purposes (a)It spread out the flux in the air gap & also being of large cross section reduce the reluctance of It is mainly made of cast iron or cast steel but the pole shoe is laminated and is fastened to y means of counter sunk screw. In modern design the complete pole core and pole shoe are build of thin lamination of annealed steel which are riveted together under hydraulic pressure. The laminated poles may be screwed to the yoke by means of screws bolted through the yoke and into the pole body or the holding screws are bolted into a steel bar which wire or strip, are former - wound fir the correct dimension then the former is removed and wound coil is put into place over the core when current is passed through this coil, they electromagnetism the poles which produces the This motor is pole type motor and brush holders are mounted on the rocker ring that is fixed to the bearing bracket at commutator side by four bolts. The brush holders and carbon brushes can be inspected by rotating the rocker ring until each brush holder comes to the inspection windows. The brush holders are mounted on the rocker ring by one insulating rod. ant modified ETFE
  40. 40. 39 | P a g e This are small poles fixes to the yoke and spaced in between the main pole. They are wound with comparatively few heavy gauge copper wire turns and reconnected in series with the armature so that they carry full armature current. As interpole carry armature current their commutating EMF is proportional to the armature current this ensures automatic neutralization of reactance voltage which is also due to armature current. The main function of interpole are (a) Reduce cross-magnetization effect of armature reaction (b) Reduce spark. (c) Help in commutation  HIGH CURRENT TEST OF BRAZED JOINTS AS PER RDSO /2011/EL/SMI/0271 Rev ‘0’  (For traction motor frames of HS15250A & Tao-659) The stators are first dismantled from the traction motor and cleaned properly so that high current injection test can be performed.  Main Field Coil Circuit:- The insulation resistance of the field circuit is measured with 1000 V Megger. If insulation resistance >30 MΩ, then 500 A current from DC high current set is injected to the field circuit and voltage drop at motor terminals are measured and recorded.  Compoles in Armature Circuit:- The positive & negative terminals for the rocker ring in armature circuit is shorted. The insulation resistance of the armature circuit is measured with 1000 V Megger. If insulation resistance >30 MΩ, then 500 A current from DC high current set is injected to the field circuit and voltage drop at motor terminals are measured and recorded.  CONNECTION ARRANGEMENT (AS PER DRG NO. SKEL-4867)  Equipment reqd: (i)1000V Megger; (ii)Voltmeter(Range->0V-15V), (iii)Ammeter(Range->0A-1000A) (iv)DC High Current Injection Set (Range->0A-1000A)  HIGH CURRENT TEST PARAMETERS If the recorded value found more than the specified value as mentioned in the above table, investigation is carried out thoroughly to detect faulty or bad brazed joints. VOLTAGE DROP AT 30°C MP CIRCUIT CP CIRCUIT HITACHI STATOR 4.48±0.2 V 4.00±0.2 V TAO/TAOCHI STATOR 3.70±0.2 V 2.70±0.2 V
  41. 41. 40 | P a g e  TESTING PARAMETERS OF TRACTION MOTOR FRAME :  Work Instruction of Traction Motor Frame Section:-  Scope: Overhauling of Traction Motor Stator Type 15250/TAO659.  Procedure: (i) Clean the stator with recommended cleaning agent or kerosene oil. (ii) Check and replace the nose wiring plate. (iii) Check and replace the gear case lug bush and attend any mechanical defect in the frame. (iv) Check the MP/IP Coil fixing bolts gor any looseness if found lose same to be tighten with recommended torque and locking to be done to avoid free movement of bolt and pole shoes for rubbing mark visually with armature. (v) Check the IR or MP and IP with megger, it should be recorded. (vi) Check visually the surface insulation of MP and IP coil for peel off/ damaged. For further checking and works like replacement of wear plates and both gear case lugs, strengthening of both bottom and top gear case lugs and modification of bottom inspection covers works as per SMI or TSO to be done by sending to mechanical shop.  Motor Type HS – 15250A/ TAO -659 or TAOCHI Stator : (i) Place the cleaned and good stator in baking oven and bake for 150˚C for 12 Hours . (ii) Varnish the baked stator by H class anti tracking finishing varnish. (iii) Place the varnished stator at test area for electrical testing. (iv) HV test at 2.5 KV and note leakage current. (v) Check IR by 1KV megger and note . (vi) Check coil resistance by MOM and Note. (vii) Check brazing joints by applying high current as per SMI. (viii) Check the polarity of the coils i.e. N pole / S pole. (ix) Check all threaded poles and re-tapped. (x) Check tightness of all MP and IP coil fixing bolts at specified torque. (xi) Replace all needle roller bearing for HS- 15250A stator.
  42. 42. 41 | P a g e (xii) Seal all coil fixing bolts with M-Seal and anabond- 685 or Similar only. (xiii) For Sealing of bolts at housing area use anabond – 685 or similar only. (xiv) Carry Out D.P test at welded part of nose supporting bracket For HS -152508 Stators. Note all relevant data regarding the stator and dispatch to TM section For further work.  No Load testing of Traction motor of EMU/ Loco:  Responsibility : SE of the TM Section, Shop No: 9A/ KPA  Procedure : (i) Place the assembled traction motor in test bench. (ii) Connect the terminals of traction motor to no load test machine. (iii) Connect the speed sensor properly. (iv) Switch on the supply and run the motor and observe Any unusual noise Excessive Chattering of carbon Brush. (v) If everything OK run the motor for 2 hrs at rated speed and high speed as mentioned below in case EMU/LOCO traction motor. Check the vibration by using vibration monitor( Bearing Echo Meter) and shall not be more the 35 db( Yellow Zone ). If exceeds run the motor again for 2 hrs. If no improvement dismantle and check again. (vi) Check the bearing temperature with thermometer shall not exceed ambient +25˚c. (vii) If exceeding chattering in carbon brush check the ovulate not more than 0.05 mm also check the bedding of carbon brush. (viii) If all parameters ok after the motor is ready for pinion fitment. Repair reclamation of potted IP field coil (BHEL) : TYPE:- 4601AZ WORKING PROCEDURE:- (i) Place the coil on the table and cleaned. (ii) Test the coil with the help of SCT machine. (iii) Place the coil on pressing zig under press M/C with the help of clean. (iv) Remove the shoe the from the coil with help of press machine. (v) After remove the pole shoe from the coil for any damage. (vi) Strip the lamination with the help of knife and mallet. (vii) Clean the coil with send paper. (viii) Ground insulation done on coil with the help of GUAT-CN & 4FTNA & EGT tape. (ix) Sacrifice tape done with the help of 4FT & polyester tape and baked. (x) VPI done with HEW-290 varnish with the help of VPI plant. (xi) Baked after VPI at 150°C. (xii) Pole shoe cleanest. (xiii) Pole shoe fitted in the coil & light with pressuring plate. (xiv) Resin 823(A+B) mixed with 1:1 & paint in between core & coil. (xv) Varnish 821(A+B+C+D) mixed with 5. (xvi) Apply varnish TVA1410 at 70°C - 80°C. (xvii) Test IR value, D,E test, SCT. (xviii) Dispatch. TRANSFORMER
  43. 43.  INTRODUCTION : The transformer is a static device, which transform power from one AC circuit to another AC circuit at same frequency. These circuits are conductively disjointed but magnetically coupled by a common time varying magnetic field. It can raise or lower the vo with a corresponding decrease or increase in current. In all the electric locomotives, limiting the value of current during starting, speed control is achieved by supply of variable voltage to the traction motors. This variation of applied voltage can be carried out easily by the use of transformer along with tap changer provided in the locomotive. Transformer is one of the most important traction equipment of AC EMU/MEMU/LOCO. It is double wound with primary and secon sandwich construction. Current at 25 kV is taken from OHE to its primary winding via the pantograph, the vacuum circuit breaker and the high tension main bushing. The return path for this current is via the earthing brushes mounted in the axle cap of each traction motor and the running rails. The secondary winding of the transformer is in two sections, one section having five tapped sections, other being untapped. This arrangement gives a total twenty various connections of transformer tappings and voltage dropping reactors. This voltage, which is controlled by the tap-changing switch group, is applied to the silicon rectifiers, the full wave output of which is fed to the traction motors via t Two tertiary windings, auxiliary I and II are provided. Auxiliary I, 266 V winding feeds the single phase a.c. auxiliary machines. Auxiliary II, 141 V winding supplies power to normal lights & fans, head lights stabilizer, the auxilia The transformer is a static device, which transform power from one AC circuit to another AC circuit at same frequency. These circuits are conductively disjointed but magnetically coupled by a common time varying magnetic field. It can raise or lower the vo with a corresponding decrease or increase in current. In all the electric locomotives, limiting the value of current during starting, speed control is achieved by supply of variable voltage to the traction motors. This variation of applied n be carried out easily by the use of transformer along with tap changer provided in the locomotive. Transformer is one of the most important traction equipment of AC EMU/MEMU/LOCO. It is double wound with primary and secondary windings interleaved together to give a Current at 25 kV is taken from OHE to its primary winding via the pantograph, the vacuum circuit breaker and the high tension main bushing. The return path for this current is hing brushes mounted in the axle cap of each traction motor and the running rails. The secondary winding of the transformer is in two sections, one section having five tapped sections, other being untapped. This arrangement gives a total twenty-two voltage various connections of transformer tappings and voltage dropping reactors. This voltage, which changing switch group, is applied to the silicon rectifiers, the full wave output of which is fed to the traction motors via the smoothing reactor. Two tertiary windings, auxiliary I and II are provided. Auxiliary I, 266 V winding feeds the single phase a.c. auxiliary machines. Auxiliary II, 141 V winding supplies power to normal lights & fans, head lights stabilizer, the auxiliary rectifier for main compressor motor Figure : LOCO Transformer Figure : EMU Transformer 42 | P a g e The transformer is a static device, which transform power from one AC circuit to another AC circuit at same frequency. These circuits are conductively disjointed but magnetically coupled by a common time varying magnetic field. It can raise or lower the voltage In all the electric locomotives, limiting the value of current during starting, speed control is achieved by supply of variable voltage to the traction motors. This variation of applied n be carried out easily by the use of transformer along with tap changer provided in Transformer is one of the most important traction equipment of AC EMU/MEMU/LOCO. dary windings interleaved together to give a Current at 25 kV is taken from OHE to its primary winding via the pantograph, the vacuum circuit breaker and the high tension main bushing. The return path for this current is hing brushes mounted in the axle cap of each traction motor and the running rails. The secondary winding of the transformer is in two sections, one section having five tapped two voltage steps by various connections of transformer tappings and voltage dropping reactors. This voltage, which changing switch group, is applied to the silicon rectifiers, the full wave Two tertiary windings, auxiliary I and II are provided. Auxiliary I, 266 V winding feeds the single phase a.c. auxiliary machines. Auxiliary II, 141 V winding supplies power to normal lights ry rectifier for main compressor motor

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