Coach alternator

Coach Alternators
TL alternator AC coach alternator

4.5 kW 25 kW
120 V 37.5 Amp 130 V 193 Amp
Cut in: 19 Km/h Cut in: 30 Km/h
MFO: 31 Km/h MFO: 51 Km/h
 BRUSHLESS ALTERNATOR
PURPOSE
 Charging the coach batteries
 Operation of lights, fans, AC…

DESIGN
• No Moving Contacts OR Windings on Rotor
• AC Windings and Field Windings BOTH accommodated
on Stator

CUT IN SPEED
Minimum speed at which alternator can pick up
generation
MFO (Minimum speed for Full load output)
Although generation picks up at cut in speed, full load
output is achieved from MFO speed onwards.
 Alternator assembly
Axle pulley Brackets for
safety chains
Rubber pad for
axle pulley
Brackets for
alternator
Bogie Transom suspension

Split pin

Suspension pin
Alternator pulley

Terminal Box
 Alternator
• Ratings in use (at dc output terminals)
– 3 kW for MG TL coaches
– 4.5 kW, 120 V, 38 A for TL coaches
– 12 kW, for MG AC coaches and Jan shatabdi
– 18 kW, 130 V, 140 A for under slung AC coaches
– 22.75 kW (optimised) for RMPU coaches
– 25 kW, 130 V,193 A for RMPU coaches
 Governing specifications
Specification no Equipment

RDSO/PE/SPEC/AC/0056- 4.5 kW alternator

2004 Rev 0 Amdt 1
RDSO/PE/SPEC/AC/0056- 18 kW alternator
2004 Rev 0 Amdt 1
RDSO/PE/SPEC/AC/0056- 25 kW alternator with
2004 Rev 0 Amdt 1 RRU
RDSO/PE/SPEC/AC/0015 ERRU for 4.5/18/25 kW
Rev 0 ,amdt 1&2 alternators
 Governing specifications/Drgs
Specification/Drg no Equipment
RDSO drg SKEL 4024 alt 1 Mounting arrgt and drive
RDSO drg SKEL 3645 alt 1 Alternator V grooved pulley
RDSO drg SKEL 3652 alt 2 Axle V grooved pulley
RDSO/ELPS/SPEC/TL/13 Alternator and Axle pulley
RDSO drg SKEL 3652 alt 2 Rubber pad for Axle pulley
RDSO/PE/SPEC/TL/04 1994 V Belt
RDSO drg SKEL 3940 Spring tensioning device
RDSO/PE/AC/SK/0077 2004 25 kW alternator outline
 Governing specifications/Drgs
Specification/Drg no Equipment
RDSO drg SKEL 3943 alt 4 Suspension hanger pin
RDSO drg SKEL 4022 alt 3 Safety chain for 18/25 kW
RDSO/PE/SK/AC/0047-2003 Terminal board for 4.5/25 kW
RDSO/PE/SK/AC/0076-2004 25 kW RRU drg
ELPS/SPEC/SI/0015-2001 Reliability assurance apec for
electronic components
 Alternator
• Quantity
– TL coaches 1 per coach
– All AC coaches except FAC 2 per coach
– FAC 1 per coach (being increased to 2 per coach)
• Used for charging battery set of 56 cells of
800/1100 LA at nominal 110 V and catering AC
and TL load of the coach
• RRU/ERRU used for
– Rectify ac output of alternator
– Regulate output of alternator
– Prevent reverse flow of current from battery
MOUNTING ARRANGEMENT
 Alternator: General technical data
• No windings on rotor
• Suitable for bi-directional generation
• Operating condition -5 to 55 0C and 100% RH
• Bogie transom mounted
• Able to operate without battery
• Self exciting type
• Rotor shaft made of EN 24 (hardened and
tempered)
 Alternator: General technical data
• Clearance from rail level when Alternator hanging free
to be > 178 mm
• Epoxy glass terminal board for cables connection
• Lead wire silver brazed with winding wire
• DMC cleat provided on frame to support cables
• Dual coated enameled wire (base coat with
polyesterimide enamel MT533.39A and top coat with
Allothem 602.35 of Dr Beck & Co
• Vacuum pressure impregnated winding
 Alternator: General technical data
• Air clearance between un-insulated live part and
alternator body > 10 mm and between un-insulated parts
> 4 mm
• RRU has epoxy filled MA, ET with separate primary and
secondary windings and Diode based 3 phase full wave
rectifier.
• Alternator and RRU of different makes fully
interchangeable
 Alternator: Scope of supply
• Each alternator set comprises of
– 4.5kW- 1no & 25kW-2 nos. V grooved pulleys
– Safety chains: 4.5kW- 2no & 25kW-3 nos
– 1 RRU/ERRU
– Belt tensioning device complete
– Axle pulley complete with rubber pad and hardware
– Suspension pin complete with hardware
– Crimping type sockets for Alternator and RRU/ERRU
– Maintenance manual
• Items procured separately
– V belts 4 (3/4.5 kW), 6+6 (25 kW)
– Nylon suspension bushes 2 per set
Voltage
Voltage vs Current characteristic

Current
Alternator Terminal Board

Old Design Modified Design

Alternator suspension Bracket
 Brushless Alternator
• Principle of working
– Both windings (AC & Field) accommodated in Stator
– AC windings distributed in small slots
– Field winding concentrated in two slots and each coil spans half
the total no of slots.
– Rotor consists of stacked stampings like cogged wheel having
teeth and slots uniformly distributed on surface skewing rotor axis.
– Core of stator (completely embraced by field coils) retain residual
magnetism, if excited once by battery.
– Flux produced by field coils find its path through rotor
– On rotation, rotor offers varying reluctance path for the field flux.
– Varying field flux induce alternating voltage in AC coils
– EMF: Frequency depends on speed and magnitude on speed and
level of excitation
Alternator cross section
Tensioning Device Assembly
Tensioning Device Assembly
 Alternator-Bearings
• 4.5 kW NU
– Drive end: NU-311 -
(cylindrical) 311
– Non drive end: 6309
(Deep groove ball)
• 25 kW
– Terminal end NU-312
(cylindrical)
– Other end 7312
(angular contact ball)

6309
 Alternators- Salient features
Feature 4.5 kW 25 kW
Rating 120 V, 37.5 Amp 130 V, 193 Amp

Factory Setting 128.5+/-0.5 V at 128+/-0.5 V at 97A,

19A, 1500 rpm 1500 rpm
Efficiency 70% at full load 80 % at full load and
and 1800 RPM 1800 RPM
Field wdg resistance 4.5+/- 0.5 Ω 8.5+/-1.5 Ω

Stator wdg resistance 0.4+/- 0.05 Ω 0.045+/-0.01 Ω

(phase to phase)
Suspension pin dia 31.75+0/-0.10 mm 35.0 +0.2/-0.3 mm

Insulation class F H
 Alternators- Salient features
Ripple content (max) 5% 3%
Alt pulley width 110.5+/-1.5 mm 200+/- 1 mm
Axle pulley width 110.5+/-1.5 mm 210+/- 1 mm
Cut in speed (min)* 350rpm (19Km/h) 550rpm (30Km/h)

MFO (max)* 600rpm (31Km/h) 930rpm (51Km/h)

Alt pulley groove angle 34+/-0.5 0 36+/-0.5 0

Axle pulley groove angle 38+/-0.5 0 38 +/- 0.5 0
Tensioning device working 310 mm 295 mm
length
Distance of axle pulley from 141±0.5mm 228±0.5 mm
wheel hub
Weight (max) NM 525 kg
* With new wheel dia (915 mm)
 RRU (Rectifier cum regulator unit)
• Functions
– Rectification of 3 phase AC output of Alternator
using full wave rectifier bridge
– Regulation of voltage at set value
– Regulating output current at set value
• Components
– 3 ph full wave rectifier (Diode D1 to D6) with
heat sinks
– 1 ph full wave rectifier (Diode D16 & D17) on
heat sink along with free wheeling diode D18
– Sensing diodes (D19 & D20) for current/voltage
setting with zener diode Z1
RRU circuit diagram
 RRU (Contd.)

– Current Transformer (CT)

– Main PCB with control circuit and voltage setting
potentiometer (P1) and current setting
potentiometer (P2)
– Field transformer (FT)
– Magnetic amplifier (MA)
Block diagram of RRU
Working principle
•Main rectifier converts AC into DC
•CTs sense all 3 phases and secondary current get
converted into voltage through burden resistance
•Rectified AC O/P of bridge (D11-D15) fed to voltage
divider P2-R2
•Rectified voltage O/P (D7 to D9) fed to R1-R2-P1-R4
•Two sensed voltages compared with reference
voltage of Z1 and fed to control winding of magnetic
amplifier
•MA acts as ON/OFF switch for controlling field current
•MA works on principle of saturation of magnetic core
 Safety feature in RRU
OVER VOLTAGE PROTECTION UNIT
 The over voltage protection unit is fitted in the Regulator.
 The over voltage relay (OVR) is set at 150 Volt DC.
 In the even of output voltage exceeding 150 Volt DC, the relay
energizes and the field circuit gets open, stopping generation.
 LED in the OVR will glow when the over voltage relay is
energized and as long as the battery is in the circuit.
 In case the OVR trips, proceed as follows:
Rectify the fault that caused over voltage generation. The
relay will continue to cut the field supply as long as over
voltage condition persists.
After rectifying the faults, the field circuit may be re-
energised by resetting the relay through push button switch
provided on the OVR.
RRU (Rectifier cum regulator unit)
ERRU – Open View
 Alternator capacity
– Battery to supply full coach load for 3 hrs or lighting
load for 5 hrs.
– Assumptions
– Conversion factors of 0.72 & 0.83 for 3 & 5 hrs discharge (cl
5.5 & 5.6 of IS 6848)
– Condemning capacity of battery-80%
– 100% roof load (excldg NL) from 6-10 PM
– 50% Rdg lights from 6 -10 PM
– 20% light load (incldg NL) from 10 PM-4 AM
– 50 % roof light load from 4-6 AM
– 100 % fan load for 24 hrs
– Ah efficiency of battery-80%
– Avg Alternator current -90% of capacity
• Battery capacity (10 hr)=Total load *3/0.72*0.8=5.2*TL
– OR Lighting load*5/0.83*0.8=7.54*lighting load
• Alternator capacity
– To ensure that battery get fully charged in a night run of 12 hrs with
generation to non generation ratio of 2
 Alternator capacity
• Alternator capacity
– Avg load-A
– Generation to non generation ratio-2
– Non generation period –n hrs
– Generation period -2n hrs
– Load Ah by direct generation=A*2n
– Load Ah through battery=A*n
– Battery input=A*n/0.8=1.3*A*n
– Total generation required- (2+1.3)*A*n=3.3 *A*n
– In case of externally regulated=3.3*A*n/(2*n*0.8)
= 2.06*A
 Alternator Load Sharing
 At times load sharing between the two 25KW alternators
provided on self-generating air-conditioned coaches is
not proper.

 Difference between currents supplied by two alternators

is very high during service.

 Occurs due to difference in voltage settings of alternators

 After proper checking/setting of the regulator, a test

should be conducted to determine the load sharing

 Parallel operation test carried out by means of Dynodrive

Dynodrive for testing Generation
/Load sharing of Alternators
 Parallel Operation Test
• Check voltage settings of both alternators individually and
set them to 128.0±0.5 V at half load at 1500 rpm.
• Parallel and drive alternators at 1500 rpm and record
current sharing for varying load conditions
1. Lighting load only
2. Lighting load + Battery charging load.
3. Lighting load + Battery charging load + one air-
conditioning plant
4. Lighting load + Battery charging load + both the air
conditioning plants
5. Lighting load + Battery charging + one heater 'on'
6. Lighting .load + Battery charging + both heaters' on '
• Difference in load current should not exceed 30A
• Before start of testing , polarity of DC outputs of both the
alternators should be confirmed for proper connections

Agencies of Implementation
All AC depots
POH Workshops
Production Units