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CHAPTER 1

INTRODUCTION AND WORKING PRINCIPLE OF BRUSHLESS ALTERNATOR

1.1 INTRODUCTION

Alternators are axle driven, with ‘V’ belt drive, power generating machine mounted on the under frame of the coaches or on
bogies of the coaches. Alternators are of various power and capacity as per requirement of the coaches and are governed by
different RDSO specifications as per their ratings. The specification nos. are mentioned here :-

IRS:E52-88 with amdt. 4.5 KW, 150A, 30V DC

no. 1 & 2 3.0 KW, 100A, 30V DC

EL/TL/47 Rev ‘C’ 3.0 KW, 25A, 120V DC

May 1998 with 4.5KW110V, 37.5A, 120V.
amdt no.1,2,3 DC used on general coaches

EL/TL/54 Rev ‘A’ 18 KW 110V ,138.5A,130V Apr.1991 with amdt. DC, used on AC coaches.
no.1

ELPS/SPEC/TL/01 Optimised 22.75 KW/25KW with amdt no.1& 2 alternators used on AC

coaches of Self Generating
type with roof mounted
package unit.
1.2 BASIC CONSTRUCTION
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The alternator is totally enclosed, hetropolar induction type machine having no winding on the rotor. It has no sliding
contacts like brushes, slip ring commutators etc; offering robust construction suitable for severe shocks and vibrations
encountered in Railway services.
The alternator consists of two sets of windings viz. AC winding and field winding. Both accommodated on the stator. The
AC windings are distributed in the small slots and field windings are concentrated in two slots. Each field coil span is half of
the total number of stator slots.
The rotor consist of stacked stamping, resembles a clogged wheel and is screened. The field winding produces a steady
magnetic flux.
The stator shell is made of good quality steel plate rolled into a shell and joined by sound weld. Two suspension bracket
are secured welded to the shell. A machined steel tube is welded to the suspension brackets houses the cast nylon suspension
bushes. The cost nylon suspension bushes have

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been modified vide RDSO’s drg. No.SKEL 3942/A - Alt3. The suspension pin is to be hard chromium plated as per RDSO’s
drg. No. SKEL 3939 - Alt2, for detail same may be referred, to reduce wear and tear on the suspension bushes.
The bearings are grease lubricated. Leakage of grease from bearing housing is avoided by grooves in bearing cap bore. A
cylindrical roller bearing NU 311 is fitted at the drive end and a deep groove ball bearing 6309 at the non drive end (SKF make
bearing shall be provided) for 4.5 KW alternator and for AC alternators viz.18 KW, optimised, 25 KW the bearing no NU 312
ECJ/ECP roller bearing on terminal box side and a pair of angular contact ball bearing type 7312 BE CBJ/BE CPP on the other
end, of SKF/FAG make imported one, is provided.
The terminal box has a sliding arrangement to facilitate maintenance and provided with captive screws. Gasket is provided
with cover to prevent ingress of moisture and dust. Five holes are provided on the body of the alternator for each incoming
leads from the winding (3 for phase and two for field leads). To avoid lead failures cable glands are provided for taking out the
leads from terminal box preventing damage of the cable against the metal surface. The three phase AC leads (U.V.W.) and field
leads F+ and F- are terminated crimping type copper sockets and fixed to the respective terminal points provided on the
terminal board. The end shield are robust designed to withstand service loads and shocks.

A suitable belt tensioning arrangement is also provided to adjust belt tension as required. RDSO’s drg.no. SKEL 3940
sheet 1 & sheet 2 may be referred for details as shown in the fig 2.1 on page 57 of the tensioning device. The belt tension is
indicated by compressed length of the spring through an indicator plate for each rating of the alternator viz. 4.5 KW, 18 KW.

1.3 PRINCIPLE OF OPERATION

1.3.1 Alternator

The core of the stator which is completely embraced by the field coils, will retain a residual magnetism if excited by a
battery once. The flux produced by the filed coils find its path through the rotor. When the rotor is rotated the passage of rotor
teeth and slots, alternatively, under the field, offers a varying reluctance path for the flux produced by the field coils. The flux
which vary periodically links with AC coils and induces an alternating voltage in AC coil.
The frequency of the induced voltage depends on the speed of rotor, whereas the magnitude depends on the speed of the
rotor and the level of excitation. The field is controlled through regulator to attain desired output voltage by means of positive
feedback system.
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1.4 RECTIFIER/REGULATOR UNIT

The Regulator/Rectifier unit has mainly following function:

„ Rectifying the three phase AC output to DC. using full wave rectifier bridge.
„ Regulating the voltage generated by the alternator at set value.
„ Regulating the output current at the set value.

1.4.1 Basic Construction

Rectifier Cum Regulator is housed in fabric steel box with hinged covers. The silicon rubber gasket of adequate thickness
has been provided to prevent entry of water and dust. The box is zinc sprayed as per IS: 905 to prevent corrosion during
service.
The main rectifier consists of six silicon diodes adequately rated and mounted on aluminium blocks secured on main
aluminium heat sinks whose cooling surface is also adequately rated and exposed to air at the rear portion of the box. These
aluminium blocks are suitably insulated from the main heat sink electrically by means of Nomex/Kapton insulation paper of
adequate thickness. Nylon bushes/washers at the same time ensure proper conduction and transfer of heat generated during
operation.
The control circuit are comprises of following components :
„ Magnetic amplifier
„ Excitation transformer
„ Current transformer
„ Zener diodes
„ Auxiliary diodes
„ Potentiometer
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„ Inductors and Capacitors

1.4.2 Principle of Operation (4.5 KW)

The working principle of all make of rectifier and regulator is on similar line. The principle of operation of one make i.e. of
Stone India is given below for reference.
1.4.2.1 Working Principle of M/s Stone India make R.R.U.
The circuit diagram is shown in the fig 1.1on page no 7. The three phase out put from the alternator is fed to the 3 phase bridge
(D1 - D6) of the RRU. The current transformers (CT1, CT2, CT3) are used for securing the out put current.
The magnetic amplifier consists of two gate windings each with diode D7 & D8. A central winding is provided to link both
the cores. The gate winding are used to saturate the core to keep the operating point at the saturation region where
the inductance is negligible.

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Central winding is used to de-saturate the magnetic amplifier core to bring the operating region where the inductance is very
high.

A centre tapped excitation transformer fed from two phases is provided and it feeds two gate windings of the magnetic
amplifier. The centre tap of the transformer serves as the negative field.

Set the central winding of the magnetic amplifier in such a way to keep the out put voltage constant at a pre-set value.
When the load current increases beyond the set value, the out put voltage will decrease. The output voltage is sensed through
diode D10, D11, D2 at V+ and is fed into the voltage sensing chain R1, VR1, R2 and R3. Similarly the currents attained from
the secondary of the CT is fed into a three phase Bridge Rectifier (D13-D18) and then to the resistors R8, R9, VR2 and R6,
thus converting current signal into voltage signal.

The voltage and current sensing is done by comparing the voltage with the reference voltage of the Zener diode. As any
one of the voltage exceeds the Zener diode voltage setting control current flows in the central winding keeping the output
voltage and current within specified limit of the set values.

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Note : For full details of different make alternators, RRU refer the enclosed annexures, consisting of following documents.
i) 4.5 and 25 KW Alternators, assembly drawings indicating the fitment of each part.
ii) Circuit diagram of Rectifier Regulator.
iii) Data sheet of alternator and Rectifier Regulator.

Annexure I M/s KEL make 4.5 KW/25 KW

Annexure II M/s Stone India 4.5 KW/25 KW

make

Annexure III M/s HMTD Make 4.5 KW/25 KW

Annexure IV M/s CGL make 4.5 KW only

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ANNEXURE I
4.5 KW/25 KW KEL MAKE ALTERNATOR
1.1 4.5 KW ALTERNATOR
Design Data

I Alternator Particulars

a. Rated capacity 4.5 KW

b. Maker’s type KEL A 45135 D
c. No Load to full load voltage range 120 V to 124 V
d. Cut-in speed 300 rpm
e. MFO speed 550 rpm
f. Max. Permissible speed 2540 rpm
g. Drive/Mounting Belt/Transom
h. Overhaul length 690.25 ± 5 mm
i Overhaul dia 285 mm
j Weight of alternator without pulley 194.5 Kg
k. Weight of pulley Alternator 19.5 kg.
Weight of Axle pulley 153 kg.
l Both side bearing particulars NU-311 (DE)
6309 (NDE)
II Alternator shell particulars

a. Material of the shell M.S.

b. Length of the shell 468 mm
c. Outer dia of the shell 285 mm

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Sr.No. Description Qty. (Nos.)

1 Stator frame 1
2 Stator lamination 780
3 Stator lamination end plate 2
4 Stator circlip 2
5 Winding catcher 2
6 Allen screw 6
7 Spring washer 6
8 Rotor circlip 1
9 Shaft 1
10 Rotor End plate 2
11 Rotor lamination 648
12 Spacer 1
13 Inside bearing cover 1
14 Ball bearing 6309 1
15 Shoulder washer 1
16 Hex screw 1
17 Lock 1
18 Outside bearing cover 1
19 Screw 12
20 Spring washer 12
21 End shield 1
22 Screw 12
23 Spring washer 12
24 Spacer 1
25 Inside bearing cover 1
26 Roller bearing NU 311 1
27 End shield 1
28 Spacer 1
29 Out side bearing cover 1
30 Lock washer MB 11 1
31 Lock nut KM 11 1
32 Pulley 1
33 Shaft key 1
34 Shoulder washer 1
35 Castle nut 1
36 Split pin 1
37 Suspension bush 1
38 Cast nylon bush 1

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d. Inner dia of the shell 255 mm

e. Drawing of the shell with all tolerances Not Applicable
and manufacturing process (N.A.)

III Alternator Stator particulars

a. Inner dia of stamping 50 mm

b. Outer dia of stamping. 175 mm
c. Thickness of stamping N.A.
d. No. of stamping used N.A.
e. Weight of stator core N.A.
f. Grade of material used Hot Rolled
Dynamo grade
g. Supplier’s name M/s GKW and
M/s Radiant
h. Power loss per kg. N.A.
i. Material specification Hot Rolled dynamo
grade stampings
having max. loss of
6.3 W per kg at 1.5
Tesla.
j Details of locking arrangement of the Stator circlip
stator core of both side arrangement.
k Pressure used to install the lamination 0.225 Tons per
in position. square inch.
l Checking method adopted to ensure Mechanical
true-bore of stator measurement
m Total length of the stator lamination 280 mm
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IV Alternator Rotor particulars

a. Total length of rotor shaft 656 mm

b. Material of rotor shaft EN 24
c. Inner dia of stamping 50 mm
d. Outer dia of stamping 175 mm
e. Total length of stamping 280 mm
f. Thickness of stamping N.A.
g. No. of stamping used N.A.
h. Weight of Rotor core 48 kg (total)
i Grade of magnetic material used Hot Rolled dynamo
grade
j Supplier’s make M/s GKW and
M/s Radiant
k Power loss per kg N.A.
l Material specification Hot Rolled dynamo
grade stamping having
max. loss 6.3 W per
kg.
m Details of locking arrangement of the Rotor circlip
stator core of both side arrangement at one end
collar at other end.
n Pressure used to install the lamination 0.225 Tons per square
in position. inch.
o Checking method adopted to ensure Micrometer
true-bore of rotor

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p Finished shaft drawing clearly indicating N.A.

bearing sheet, dimension of shaft and
dimension of bearing with tolerances
q Both ends end-shield manufacturing N.A.
drawing
r Rotor skew angle. N.A.

V Windings of Alternator
a Size of copper wire (stator, with 1.25 mm (phase), IS:
specification ) 13730 Part 13.
b Size of copper wire (field, with 1.6 mm (field), IS: 13730
specification ) Part 13 (RDSO approved
supply)
c No. of turns per coil (stator) N.A.
d No. of turns per coil (field) N.A.
e Type of winding used N.A.
f Type of varnish used for impregnation Elwotheren F 50 Class `F’
g Method of impregnation used Vacuum pressure
h Types slot insulation used Nomex
i Type of wedge insulation used Fibre Glass Rod
j Type of insulation used on overhung Silicon sleeves
k Details of lead wires 16 mm2 for phase,
4 mm2 for field
l Method of lead and winding wire joints. Brazing the joints with
rod as per RDSO’s
recommendations.

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1.2 RECTIFIER/REGULATOR 22.75 KW (OPTIMISED)

A. Current Sensing N.A.

a. CT / Shunt Shunt
- Type Variable resistor
- Rating
- Type of insulation
- Busbar size
- Accuracy / Burden detail
b. Rectifier N.A.
- 3 phase full wave bridge
- No. Of diodes
- Current (I)
- PIV
- Type
- Make
- Heat Sink
- Temperature Rise
c. Current Detector N.A.
- Rating of all the fixed resistance
- Numbers
- Make
- Type
- Tolerance

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d. Zener Diode N.A.

- PIV
- Current (I)
- Make
- Type
- Rating (voltage wattage)
- Heat sink
B. Voltage Detector
a. Voltage Detector
- Rating of all the fixed resistors
- Make
- Type Epoxy encapsulated
- Tolerance ±5% component.
- Numbers
b. Zener Diode
- PIV
- Current (I) Epoxy encapsulated
- Make - Meltron component.
- Type - 1N 3005
- Rating (voltage/wattage)
- Heat Sink
c. Rectifier
- 3 Ph. Full wave Bridge
- No. of diodes -3
- Current (I) - 1 Amp.
- PIV - 1200 V
- Type - BY 127
- Make - M/s BEL

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- Heat Sink - Nil

- Temperature Rise - Not possible to measure since the current is of the order of mA.
C. Magnetic Amplifier
a. Main winding
- No. of windings Epoxy encapsulated
- Turns component.
- Size of winding wire
- Current paths
- Insulation (class of insulation)
- Temperature Rise
b. Control winding
- No. of windings Epoxy encapsulated
- Turns component.
- Size of winding wire
- Current paths
- Insulation (class of insulation)
- Temperature Rise (max)
D. Excitation Transformer
a. Auto Transformer Type - N.A.
- Current rating of primary & secondary
- Turns
- Size
- Current paths
- Insulation
- Temperature Rise (max)
b. Isolation Type

- Current rating of primary Epoxy

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& secondary
- Turns encapsulated
- Size component
- Current paths
- Insulation
- Temperature Rise (max)
E. Main Rectifier
- Full wave - Yes
- No. of diodes - 6 nos.
- Current Rating - 70 Amp.
- PIV - 1200 V
- Type - 12 KHN 70DS
- Make - M/s Keltron
- Temperature Rise (max) - 42
- Type of thread - M8
- Type of Polarity - Normal
F. Snubber Network
a. Details of condenser/Resistors
- Type Epoxy encapsulated
- Make
- Rating
- Type of insulation

1.3 25 KW ALTERNATOR
MAIN TECHNICAL DATA

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Type KEL A 25130 A

Rated capacity 25 KW
Full load voltage 130 V
Full load current 193 A
Cut in speed 400 rpm
Minimum speed for 800 rpm
full output
Maximum permissible speed 2500 rpm
Drive `V’ belt C-122
Mounting Transom Mounted
Class of insulation Class `H’
Type of bearing NU312 & 7312BECBJ
Weight of Alternator 525 kg

1.4 25 KW REGULATOR

Type KELC 25130

Voltage adjustment range 120 V-140 V
Current adjustment range 185 A - 230 A
Class of insulation Class `F’
Weight of regulator 60 kg

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Sr.No. Description Qty.

1 Stator frame 1 no.
2 Stator circlip 2 nos.
3 Fibre lamination 2 nos.
4 Stator lamination 754 nos.
5 Winding catcher 2 nos.
6 Cap screw of Hexagon socket type 8 nos.
7 Spring washer 8 nos.
8 Shaft 1 no.
9 Rotor end plate 2 nos.
10 Rotor lamination 686 nos.
11 Rotor circlip 2 nos.
12 Ball bearing 7312 BEG BJ 1 no.
13 Roller bearing NU 312 ECJ 1 no.
14 End shield 2 nos.
15 Internal bearing cover 2 nos.
16 External Bearing cover 2 nos.
17 Bearing cover fixing screw 12 nos
18 Spring washer 12 nos.
19 Spacer 1 no.
20 Spacer 1 no.
21 Lock washer MB-12 2 nos.
22 Lock nut - KM-12 2 nos.
23 Alternator pulley 200 PCD 2 nos.
24 Fan locating pin 2 nos.
25 Fan 2 nos.
26 Fan fixing screw 16 nos.
27 Spring washer 16 nos.
28 Key for pulley fixing 2 nos.
29 Shoulder washer 2 nos.
30 Castle nut 2 nos.
31 Split pin 2 nos.
32 Fan cover fixing screw 8 nos.
33. Spring washer 8 nos.
34 Fan cover 1 no.
35 Fan cover (terminal box side) 1 no.
36 Suspension bush 2 nos.

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Sr.No. DESCRIPTION SYMBOL QUANTITY

1 Stator Generator ALT 1 no.

2 Phase fuse F1 1 no.
3 Field fuse F2 1 no.
4 Current Transformer CT1, CT2 & CT3 3 no.
5 Power rectifier PR 1 no.
6 Field Diodes D1, D2, D3, D4 4 nos.
7 Blocking diodes D6, D7 2 nos.
8 Magnetic amplifier MA1, MA2 2 nos.
9 Voltage detector DT1, DT2 2 nos.
10 Rheostat Rh1, Rh2 2 nos.
11 Capacitor C1 6 nos.
12 Capacitor C2 1 no.
13 Capacitor C3 1 no.
14 Bridge rectifier for DT1 RT1 1 no.
15 Bridge rectifier for DT2 RT2 1 no.
16 Surge protection diode D5 1 no.
17 Zener diode for DT1 D8 1 no.
18 Zener diode for DT2 D9 1 no.
19 Resistance ballast Rb1, Rb2 1 no.
20 Capacitor C 1 no.
21 Wire wound resistor R 1 no.
22 Over voltage relay OVR 1 no.

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ANNEXURE II
4.5 KW/25 KW STONE INDIA MAKE ALTERNATOR

1.1 4.5 KW ALTERNATOR

Design Data
I Alternator particulars

a. Rated capacity 4.5 KW

b. Maker’s type A 175L
c. No Load to full load voltage range 120 V, 122 V ,124 V
d. Cut-in speed 357 rpm
e. MFO speed 600 rpm
f. Max. Permissible speed 2500 rpm
g. Drive/Mounting `V’ Belt
h. Overhaul length 700 mm (max)
i Overhaul dia 286 mm
j Weight of alternator without pulley 193 Kg
k. Weight of Alternator plley 19 kg.
Weight of Axle pulley 120 kg.
l Both side bearing particulars SKF NU311 (DE)
SKF 6309 (NDE)
II Alternator Shell particulars

a. Material of the shell M.S.

b. Length of the shell 468 mm
c. Outer dia of the shell 285 mm
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d. Inner dia of the shell 255 mm

III Alternator Stator particulars

a. Inner dia of stamping 175 mm

b. Outer dia of stamping. 255 mm
c. Thickness of stamping 0.5 mm
d. No. of stamping used 620
e. Weight of stator core 48 kg.
f. Grade of material used Hot Rolled
g. Supplier’s name M/s SAIL
h. Power loss per kg. 6.3 W per kg
i. Material specification 50 H 630 IS:648
j Details of locking arrangement of the Stop ring
stator core of both side
k Pressure used to install the lamination in 30 Ton
position.
l Checking method adopted to ensure GO-NOGO Gauges.
true-bore of stator
m Total length of the stator lamination 310 mm

IV Alternator Rotor particulars

a. Total length of rotor shaft 656 mm

b. Material of rotor shaft EN 8
c. Inner dia of stamping 60 mm
d. Outer dia of stamping 175 mm
e. Total length of stamping 310 mm
f. Thickness of stamping 0.5 mm
g. No. of stamping used 620
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h. Weight of Rotor core 38 kg

i Grade of magnetic material used Hot Rolled
j Supplier’s make M/s TISCO
k Power loss per kg 6.3 W per kg at 1.5 T
l Material specification 50 H 630 IS:648
m Details of locking arrangement of the Stop ring
stator core of both side
n Pressure used to install the lamination in 30 Ton
position.
o Checking method adopted to ensure Snap Gauge
outer dia of Rotor.
p. Rotor skew angle. 1 slot pitch

V Windings of Alternators
a. Size of copper wire (stator with 1.25 mm dia, IS:13730
specification ) Part 13.
b. Size of copper wire (field with 1.6 mm dia, IS: 13730
specification ) Part 13 (RDSO
approved supply)
c. No. of turns per coil (stator) 8
d. No. of turns per coil (field) 200
e. Type of winding used Wave
f. Type of varnish used for impregnation Class `F’
g. Method of impregnation used Vacuum pressure
h. Types slot insulation used Calanderised Nomex
i. Type of wedge insulation used Fibre Glass
j Type of insulation used on overhung Calanderised Nomex
& Glass Fibre tape
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k Details of lead wires Uninyvin-6 (13.3

2
mm )for stator,
Uninyvin-12 (3.22
mm2 ) for field
l Method of lead and winding wire joints. Brazed.

1.2 4.5 KW SIL MAKE RECTIFIER REGULATOR

Design Data
A. Current Sensing
a. CT / Shunt CT
- Type - Made of use of lamination E&I
- Rating -3 VA
- Type of insulation -Class `B’
- Busbar size -2x20 mm wide copper,
Electro-tinned
- Accuracy/Burden detail
b. Rectifier
- 3 phase full wave bridge - Yes
- No. of diodes - 6 nos. (D13 to D18)
- Current (I) - 1 Amp. at TC - 750C
- PIV - 1000 V
- Type - 1N4007
- Make - Ruttonsha International
Rectifier Ltd.
- Heat Sink - Not used
- Temperature Rise - About 1750C.
c. Current Detector
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- Rating of all the fixed - R8,R9-100/200 Ohms ±5%

Resistance 6W
- Numbers - 3 Nos.
- Make - PEC (Hyderabad)
- Type - P6 for R8, R9 & P2A for R10
- Tolerance - Specified above
d. Zener Diode
- PIV Please refer(b) in B as single - Current (I) reference for both voltage
- Make and current sensing.
- Type
- Rating (voltage/wattage)
- Heat sink
B. Voltage Sensing
a. Voltage Detector
- Rating of all the - R1-1500 Ohms ± 2%,50W
fixed resistor R2-75 Ohms ± 2%, 2.5 W
R3 -150 Ohms ± 2%, 6 W
R11-0 Ohms (link)
R12-6.8 Ohms ± 2%, 2.5 W
- Make PEC (Hyderabad)
- Type PPR50 for R1,P6 for R3 &
P2 A for R2 & R12.
- Tolerance ± 5 % - Specified as above.
- Numbers - 4
b. Zener Diode
- PIV (VZT, Continuos
reverse voltage of Zener) - 12 V
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- Current (I) - 1 A (in forward direction)

- Make - Meltron semi conductor
- Type - 1N 2976 BR
- Rating (voltage, wattage) - 12 V, 10 W
- Heat Sink - Mounted on Aluminium
block in main heat sink
c. Rectifier
- 3 Ph. Full wave Bridge - Yes
- No. of diodes - 6 nos.(D10,D11,D12 & -ve
half common with D4,D5&
D6 of main rectifier.
- Current (I) - 1 A (for D10,D11,D12)
at TC = 750C
*actual loading in ckt <0.1 A
- PIV - 1000 V
- Make - Ruttonsha International
Rectifier Ltd.
- Heat Sink - Not used.
- Temperature Rise - ≅ 150C (observe in testing)

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C. Magnetic Amplifier
a. Main winding
- No. of windings - 2 gate windings
- Turns - 250
- Size of winding wire - 18 SWG
- Current paths -1
- Insulation (class of insulation) - Class `B’
- Temperature Rise - ≅ 400C

b. Control winding

- No. of windings -1
- Turns - 1000
- Current paths -1
- Insulation (class of insulation) - Class `B’
- Temperature Rise (max) - ≅ 400C

D. Excitation Transformer
a. Auto Transformer Type - N.A.
- Current rating of primary
& secondary
- Turns
- Size
- Current paths
- Insulation
- Temperature Rise (max)
b. Isolation Type

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- Current rating of primary

& secondary - 3.5 A/6 A
- Turns - Primary: 180,
Secondary: 90-0-90
- Size - 19 SWG/18 SWG
- Current paths - As applicable for centre
tapped transformer,
Secondary rectified.
- Insulation - Class `B’
- Temperature Rise (max) - ≅ 500C
E. Main Rectifier
- Full wave - Yes
- No. of diodes - 6 nos.
- Current Rating - 55 A/70 A at 1800 Conduction.
- PIV - 1000 V
- Type - Normal polarity,
D55DMIOC
- Make - Usha India Ltd.
Alt.70HM100 of Ruttonsha
Alt S10BEN71 of Hind.
- Temperature Rise (max) -125 0 C at case with rated
current permitted.
- Type of thread - M8x1.25
- Type of Polarity - Normal

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F. Snubber Network Not used

a. Details of condenser/Resistors
- Type
- Make
- Rating
- Type of insulation
1.2.1 Principle of operation and Circuit Diagram with markings
Description : Already described in the Sub-Para 1.4.2.1 of Para 1.4.2 .
1.3 25 KW ALTERNATORS
Main Technical Data
Rated capacity 25 KW
Full load voltage 130 V DC
Full load current 193 Amps.
Cut in speed 400 rpm
Minimum speed for 800 rpm
full output
Maximum speed 2500 rpm
Field Resistance 9.72 Ω
Stator Resistance between phases 44.2 Milli Ω
Drive V-Belt
Mounting Bogie
Weight of Alternator with pulleys 510 Kgs approx.
Class of insulation Class ‘H’

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Item no. Description Qty. (nos.)

1 Wound stator assembly 1
2 Field coil assembly 2
3 Field coil clamp 2
4 Rotor & shaft assembly 1
5 Endshield roller bearing end 1
6 Outer bearing cap roller bearing end 1
7 Inner bearing cap roller bearing end 1
8 Roller bearing 1
9 Spacer 1
10 Bearing lock washer 2
11 Bearing lock nut 2
12 End shield - ball bearing end 2
13 Outer bearing cap - ball bearing end 1
14 Inner bearing cap - ball bearing end 1
15 Ball bearing - angular contact 2
16 Spacer 1
17 Fan 2
18 Pulley 2
19 Pulley key 2
20 Castle nut 2
21 Split cutter pin 2
22 Washer (for pulley fixing) 2
23 Cowl (R.H.) - T.B. side 1
24 Cowl (L.H.) 1
25 Suspension bush 2
26 Terminal board assembly 1
27 Terminal box cover 1
28 Gasket 1
29 Hinge pin 1
30 Captive screw 4
31 Gland & gland plate assembly. 1
32 Gasket 1
33 Cable cleat 2

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Make and type of bearing a)SKFNU312ECJ/ECP

b) SKF 7312 BECBJ/ BECBP (double)
Design Data
I Alternator particulars

a. Rated capacity 25 KW
b. Maker’s type A250 LX
c. No Load to full load voltage range 120 V to 140 V
d. Cut-in speed 400 rpm
e. MFO speed 800 rpm
f. Max. Permissible speed 2500 rpm
g. Drive/Mounting V-Belt/Transom
h. Overhaul length 1019 ± 5 mm
i Overhaul dia 470 mm
j Weight of alternator without pulley 510 Kg
k. Weight of Alternator pulley 30 kg.
Axle pulley 150 kg.
l Both side bearing particulars NU-312 ECJ/ECP
7312 of BECBJ/BE
SKF or FAC
II Alternator shell particulars

a. Material of the shell M.S.

b. Length of the shell 502 mm
c. Outer dia of the shell 400 mm
d. Inner dia of the shell 335 mm
e. Drawing of the shell with all tolerances and Not Applicable

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manufacturing process (N.A.)

III Alternator Stator particulars

a. Inner dia of stamping 250 mm

b. Outer dia of stamping. 335 mm
c. Thickness of stamping 0.5 mm
d. No. of stamping used 708.
e. Weight of stator core 82 Kg
f. Grade of magnetic material used M45
g. Supplier’s name SAIL
h. Power loss per kg. 2,3 W/Kg
i. Material specification SAIL
j Details of locking arrangement of the Stop rings
stator core of both side
k Pressure used to install the lamination 30 Tons -Total
in position press.
l Checking method adopted to ensure Go & No Go Plug
true-bore of stator Gauges
m Total length of the stator lamination 354 mm

IV Alternator Rotor particulars

a. Total length of rotor shaft 934 mm

b. Material of rotor shaft EN 24
c. Inner dia of stamping 85 mm
d. Outer dia of stamping 250 mm
e. Total length of stamping 354 mm
f. Thickness of stamping 0.5 mm
g. No. of stamping used 708
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h. Weight of Rotor core 88.5 kg (total)

i Grade of magnetic material used M 45
j Supplier’s make SAIL
k Power loss per kg 2.3 W/Kg
l Material specification CRNO M45
m Details of locking arrangement of the stator Stop ring
core of both side
n Pressure used to install the lamination in 30 Tons total
position. pressure.
o Checking method adopted to ensure true- Snap Gauge
bore of Rotor
p Finished shaft drawing clearly indicating N.A.
bearing sheet, dimension of shaft and
dimension of bearing with tolerances
q Both ends end-shield manufacturing N.A.
drawing
r Rotor skew angle. One slot pitch

V Windings of Alternator
a. Size of copper wire (stator
with 1.25 mm (phase),
specification ) IS: 13730 Part 13.
BIC BB
b. Size of copper wire (field with specification 1.5 mm (field), IS:
) 13730 Part 13 BIC
BB.
c. No. of turns per coil (stator) 5
d. No. of turns per coil (field) 290
e. Type of winding used Wave
f. Type of varnish used for impregnation Class `H’
g. Method of impregnation used Vacuum Imp.
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h. Types slot insulation used Nomex

i. Type of wedge insulation used Fibre Glass Rod
j Type of insulation used on overhung Nomex & Glass
Fibre.
k Details of lead wires 1) Stator-Uninyvin-
2-33.3 Sq.mm.
2) Field-Uninyvin-
12-3.22 Sq.mm.
l Method of lead and winding wire joints. Brazed.

1.4 25 KW SIL MAKE REGULATOR/RECTIFIER

Main Technical Data
Rated Capacity 25KW
Voltage Adjustment Range 120-140V
Current Adjustment Range 185-230A
Type of Control Magnetic Amplifier Weight 88 Kg. Approx.
Class of Insulation Class ‘F’
Design Data
A. Current Sensing
a. CT / Shunt CT
- Type Made of using lamination E&I type
- Rating 3.5 VA

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- Type of insulation Class ‘F’

- Busbar size 3 x 25 mm wide copper, Electro tinted
- Accuracy / Burden detail 39 Ohms ± 1% wire wound resistance 6 Watts, type P6
of PEC make (Hyderabad)
b. Rectifier
- 3 phase full wave bridge Yes
- No. Of diodes 6 Nos. (D13 to D18)
- Current (I) 1A at Tc=75 C
* actual loading in Circuit < 0.1A
- PIV 1000V
- Type 1N4007
- Make Ruttensha Int. Rect. Ltd.
- Heat Sink Not used
- Temperature Rise ≅ 15°C at junction
c. Current Detector

- Rating of all the R8, R9 - 100Ω ± 1%, 6W

fixed resistance R10 - 2Ω ± 2%, 2.5W
- Numbers 3 Nos.
- Make PEC Hyderabad.
- Type P6 for R8, R9 and P2A for R10
- Tolerance Specified above

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d. Zener Diode Please refer (b) in B as single

- PIV Zener diode has been used as - Current (I) reference for both voltage &
- Make current sensing through
- Type gating diodes D19 & D20
- Rating
(voltage wattage)
- Heat sink
B. Voltage Sensing
a. Voltage Detector
- Rating of all the fixed resistors R1-1500Ω ± 2%,50W R2-2.2KΩ ± 5%,2.5W
R3-180Ω ± 1%, 6W
- Make PEC Hyderabad
- Type PPR50 for R1, P-2A for R2 & P6 for R3
- Tolerance Specified above
- Numbers 3 Nos.
b. Zener Diode
- PIV(VZT, Continuous 12V
Reverse Voltage of Zener)
- Current (I) 1A in forward direction
- Make Meltron
- Type 1N 2976BR
- Rating (voltage/wattage) 12V, 10W
- Heat Sink Mounted on a L shaped aluminium bracket on PCB as dissipation is
limited within 100 W
c. Rectifier
- 3 Ph. Full wave Bridge Yes
- No. of diodes 6 Nos. (D10,D12 and Negative half common with D1,D2 &D3
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of Main Rectifier 3 Phase

full wave bridge)
- Current (I) 1 A(for D10,D11 & D12) at Tc=75°C.
- PIV 1000 V
- Make Ruttensha Int. Rect. Ltd.
- Heat Sink Not used
- Temperature Permissible ≅ 175°C at junction.
C. Magnetic Amplifier
a. Main winding
- No. of windings 2 gate windings, split into two housings
- Turns 270 per gate windings
- Size of winding wire 17 SWG
- Current paths Single
- Insulation (class of Class ‘F’
insulation)
- Temperature Rise ≅ 40°C (by resistance method observed in testing)

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b. Control winding
- No. of windings One, split into two housings
- Turns 650
- Size of winding wire 26 SWG
- Current paths Single
- Class of insulation Class ‘F’
- Temperature Rise (max) ≅ 37°C (By resistance method observed in testing)
D. Excitation Transformer Not used

a. Auto Transformer Type - N.A.

- Current rating of primary & secondary
- Turns
- Size
- Current paths
- Insulation
- Temperature Rise (max)
b. Isolation Type
- Current rating of primary & secondary
- Turns
- Size
- Current paths
- Insulation
- Temperature Rise (max)

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E. Main Rectifier
- Full wave - Yes
- No. of diodes - 6 nos.
- Current Rating - 320 A at 180°Conduction
- PIV - 1000 V
- Type - D320 Z M10C (SPL)
- Make - Usha (India) Ltd.
- Temperature Rise (max) - at rated current is 125°C
- Type of thread - M20 x 1.5
- Type of Polarity - Normal, Stud Cathode
F. Snubber Network Not used
a. Details of condenser/Resistors
- Type
- Make
- Rating
- Type of insulation

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ANNEXURE III

4.5 KW/25 KW HMTD MAKE ALTERNATOR

1.1 4.5 KW ALTERNATOR

Design Data

I Alternator particulars

a. Rated capacity 4.5 KW

b. Maker’s type A 45130
c. No Load to full load voltage range 120,122,124 ± 5%
d. Cut-in speed 350 rpm
e. MFO speed 550 rpm
f. Max. Permissible speed 2500 rpm
g. Drive/Mounting V Belt/Transom
h. Overhaul length 668 mm
i Overhaul dia 285 mm
j Weight of alternator without pulley 210 Kg
k. Weight of Alternator pulley 15 kg.
Axle pulley 150 kg.
l Both side bearing particulars NU-311 (DE)
6309 (NDE)
II Alternator shell particulars

a. Material of the shell St. 42S IS:226

b. Length of the shell 403 mm

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Item Description Qty. (nos.)

1 Stator frame 1
2 Field coil support 1
3 Rotor core 1
4 Rotor end plate 2
5 Hi ten hex head screw 8
6 Ball bearing SKF 6309 1
7 Circlip 1
8 Bearing ring 1
9 Shaft 1
10 Outer bearing cap NDE 1
11 Grease nipple NDE 1
12 Nut 1
13 Washer 1
14 Inner bearing cap NDE 1
15 Stator winding 1
16 Field coil assembly 1
17 17 Non drive end shield 1
18 Stator core retainer 2
19 Stator termination 1
20 Hanger plate 2
21 Suspension bush 2
22 Suspension bush holder 1
23 Suspension tube 1
24 Grease nipple De 1
25 Lock nut 1
26 Roller bearing 1
27 Inner bearing cap DE 1
28 Drive end shield 1
29 Lock washer 1
30 Outer bearing cap DE 1
31 `V’ ring seal 1
32 Pulley key 1
33 `V’ belt pulley 1
34 Washer 1
35 Castle nut 1
36 Split pin 1

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c. Outer dia of the shell 285 mm

d. Inner dia of the shell 255 mm
e. Drawing of the shell with all tolerances Not Available (N.A.)
and manufacturing process

III Alternator Stator particulars

a. Inner dia of stamping 175 mm

b. Outer dia of stamping. 255 mm
c. Thickness of stamping 0.5 mm.
d. No. of stamping used 550
e. Weight of stator core 332 Kg.
f. Grade of material used CRNGO
g. Supplier’s name Precision Stamping
h. Power loss per kg. 4.5 W
i. Material specification M45C3
j Details of locking arrangement of the Lamination retainer
stator core of both side
k Pressure used to install the lamination in 80 Tons (approx.)
position.
l Checking method adopted to ensure true- Bore Gauge
bore of stator
m Total length of the stator lamination 280 mm

IV Alternator Rotor particulars

a. Total length of rotor shaft N.A.

b. Material of rotor shaft EN 8
c. Inner dia of stamping 60 mm
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d. Outer dia of stamping 175 mm

e. Total length of stamping 280 mm
f. Thickness of stamping 0.5 mm.
g. No. of stamping used 550 nos.
h. Weight of Rotor core 34 kg
i Grade of magnetic material used CRNGO
j Supplier’s make Precession Stamping
k Power loss per kg 4.5 W
l Material specification M45C3
m Details of locking arrangement of the Lock nut with lock
stator core of both side washer
n Pressure used to install the lamination in 80 Ton (Approx.)
position.
o Checking method adopted to ensure true- Micrometer
bore of Rotor
p Finished shaft drawing clearly indicating N.A.
bearing sheet, dimension of shaft and
dimension of bearing with tolerances
q Both ends end-shield manufacturing N.A.
drawing
r Rotor skew angle. 4.250
V Windings of Alternator
a. Size of copper wire (stator with 18 SWG, BIC
specification ) IS:13730 Part 13
b. Size of copper wire (field with 16 SWG, BIC
specification ) IS:13730 Part 13
c. No. of turns per coil (stator) 54 nos.
d. No. of turns per coil (field) 170
e. Type of winding used Wave
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f. Type of varnish used for impregnation H 71

g. Method of impregnation used Vacuum pressure
h. Types slot insulation used Polyester Nomex
i. Type of wedge insulation used Fibre Glass (F.G.)
j Type of insulation used on overhung Unvarnished F.G.Rod
k Details of lead wires UNINYVIN, 18mm2
l Method of lead and winding wire joints. Silver brazing with
48% Silver.

1.1.1 Working Principle of Alternator

HMTD Brushless alternator is a totally enclosed three phase, hetropolar inductor alternator without any winding in the
rotor. Both the field winding (16) and AC winding (15) is concentrated into two slots and held by two aluminium support (2).
The rotor (3) resembles a cogged wheel and skewed. The field produces a steady magnetic flux.

The rotor when passing in-front of AC winding creates a variation in the air gap flux between maximum (near rotor tooth)
and minimum (near rotor slot). The flux variation induces a voltage in the AC winding and an alternator output is made
available in the alternator terminal.

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1.2 RECTIFIER REGULATOR

Design Data
A. Current Sensing
a. CT / Shunt CT
- Type EI
- Rating 25 VA
- Type of insulation Class `B’
- Busbar size 18 mm2 F.G.cable
- Accuracy/Burden detail ± 5%
b. Rectifier
- 3 phase full wave bridge - Yes
- No. of diodes - 6 nos.
- Current (I) - 0.2 Amp.
- PIV - 600 V
- Type - BY127
- Make - BEL
- Heat Sink - Not used
- Temperature Rise - About 150C.
c. Current Detector
- Rating of all the fixed
Resistance
- Numbers N.A.
- Make
- Type
- Tolerance

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d. Zener Diode
- PIV - 22 V
- Current (I) - 25 m A
- Make - ECIL/MELTRON
- Type - Stud type
- Rating (voltage/wattage) - 22 V 2 W
- Heat sink - Aluminium extrusion
B. Voltage Sensing
a. Voltage Detector
- Rating of all the - 12 W
fixed resistor
- Make - Sujit, Mumbai
- Type - Radial, End lead
- Tolerance - ±5%
- Numbers - 4 Nos.
b. Zener Diode
- PIV - 22 V
- Current (I) - 0.01 Amp.
- Make - ECIL/Meltron
- Type - Stud type
- Rating (voltage, wattage) - 22 V, 3 W
- Heat Sink - Aluminium extrusion
c. Rectifier
- 3 Ph. Full wave Bridge - Yes
- No. of diodes - 3 nos.
- Current (I) - 10 mA
- PIV - 600 V
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- Type - BY127
- Make - BEL
- Heat Sink - Not used.
- Temperature Rise - ≅ 150C
C. Magnetic Amplifier
a. Main winding
- No. of windings -2
- Turns - 260
- Size of winding wire - 19 SWG
- Current paths -2
- Insulation (class of insulation) - Class `F’
- Temperature Rise - ≅ 200C
b. Control winding
- No. of windings -1
- Turns - 490
- Current paths -1
- Size of winding wire - 29 SWG
- Insulation (class of insulation) - Class `F’
- Temperature Rise (max) - ≅ 200C
D. Excitation Transformer
a. Auto Transformer Type
- Current rating of primary
& secondary N.A
- Turns
- Size
- Current paths
- Insulation N.A.
- Temperature Rise (max)
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b. Isolation Type
- Current rating of primary
& secondary - 3 A/8 A
- Turns - Primary: 230, Secondary: 196
- Size - 19 SWG/18 SWG
- Current paths -2
- Insulation - Class `F’
- Temperature Rise (max) - ≅ 200C
E. Main Rectifier
- Full wave - Yes
- No. of diodes - 6 nos.
- Current Rating - 55 A.
- PIV - 1100 V
- Type - Stud type
- Make - Hind Rectifier/RIR
- Temperature Rise (max) - 45 0 C
- Type of thread - M8
- Type of Polarity - Stud cathode
F. Snubber Network Not used
a. Details of condenser/Resistors
- Type
- Make
- Rating
- Type of insulation
1.2.1 Working Principle of Regulator/Rectifier
The HMTD rectifier regulator is of magnetic amplifier type.
1.2.1.1 Magnetic Amplifier
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Magnetic amplifier has three types of winding namely two gate winding, a control winding and a compensating winding.
The magnetic amplifier gate windings are used to saturate the core to keep the operating point at the saturation region
where the inductance is very negligible. Control winding is used to de-saturate the magnetic amplifier core to bring the
operating region where the inductance is very high. Compensating winding is connecting to the field in series to give better
voltage characteristics when the alternator is loaded.
1.2.1.2 Description of Circuit
The output voltage of the alternator is rectified by main bridge rectifier (D1-D6) and fed to the battery (B+ and B-).An
isolated DC voltage derived through diodes (D7-D9) for voltage sensing and the load current is sensed through three Current
Transformer (CTs) and bridge (D10-D15). The voltage and current sensing is done by comparing the voltage obtained at the S1
and the middle point of P1 respectively with the reference voltage of the Zener diode (Z1). As any one of the voltage exceeds
the Zener voltage a control current flows in the control winding of the magnetic amplifier. This de-magnetised the magnetic
amplifier core and increases the reactance in the field circuit and the field current is controlled to have the pre-set voltage. The
current is also achieved in the same way. Thus a control of output voltage and current is maintained to give the pre-set voltage
and current.

2.1 25 KW HMTD MAKE ALTERNATOR

Main Technical Data
Type BA25130
Rated Capacity Contd. 25KW
One hour rating 28.86 KW
Full load Voltage 130 V
One hour rating 28.86 KW
Cut in speed 400 rpm

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Minimum speed for full output 800 rpm

Max. Permissible speed 2500 rpm
Field Resistance 9.72 Ω
Weight of Alternator with pulleys 495 Kgs approx.
Class of insulation Class ‘H’
Make and type of bearing (a)SKFNU312
(b) SKF 7312 BECB (PAIR)
Max. Test speed 3050 rpm

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Figure 1.10 File name: Figure 4.doc, Page No. 1

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CAMTECH/99/E/ALT/1.0 41

Item Description Quantity

1 Stator frame 01
2 End shield roller bearing 01
3 Can shield plate 01
4 Spring washer M10
5 Hex head screw M10 x 20 24
6 Stator core retainer 07
7 Stator lamination
8 Rotor lamination
9 End plate 02
10 Fan 02
11 Inner bearing cap 02
12 Outer bearing cap roller side 01
13 Grease nipple 3/2 TND 02
14 Cylindrical roller bearing 01
15 Outer bearing ring 02
16 Split pin 02
17 Castle nut 02
18 Shoulder washer 02
19 `V’ deep groove pulley 02
20 Lock nut 02
21 Shaft 01
22 Lock nut 02
23 Lock washer 01
24 Inner bearing 02
25 Lock nut 01
26 Lock washer 01
27 Field coil support 02
28 Hex head cap screw M6x60 01
29 Hex. Nut M6 01
30 Single row ...... 01
32 Felt seal 01
33 Slotted CSR screw M6x14 16
34 Outer bearing cap ball bearing side 01
35 Fan ....................... plate 01
36 End shield plate 01
37 Field coil assembly 01
38 Stator winding 01
39 Suspension bush 02
40 Hanger assembly 02
41 Gasket for safety chain 03

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2.2 25 KW HMTD MAKE REGULATOR/RECTIFIER

Type MA 25130
Weight 50 Kg.
Class of Insulation Class ‘F’
Setting on Regulator

Voltage setting 130 V DC at half load

(can be set between 124 to 136 V)
Current setting 193 A DC (can be set from
75% to 100% of the set value)

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Figure 1.11 File name: Figure 4.doc, Page No. 2

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ANNEXURE IV
4.5 KW CGL MAKE ALTERNATOR
REGULATORS COMPONENTS LIST AND MANUFACTURES

Components Ratings Make

R8 1 K, 12 W SURE/YESDEE
R7 400 E, 12 W SURE/YESDEE
R6 100 E, 12 W SURE/YESDEE
S1 6 A., 230V, 3 Way Cam Switch MECON
D19-D20 1000 V, 6 Amp. Hind Rectifier
FS2 6 Amp. Havell’s/RBCO
FS1 32 Amp. English Electric
P2 500 E, 7.5 W Pankaj
P1 250 E, 7.5 W Pankaj
R5 1 K4, 12 W SURE/YESDEE
R4 500 E, 12 W SURE/YESDEE
R3 200 E, 12 W SURE/YESDEE
R2 1 K5, 12W SURE/YESDEE
R1 1 K,12 W SURE/YESDEE
Z1 22 V, 5 W EC
D16-D18 1000 V, 12 Amp. Hind Rectifier
D7-D15 700 V, 1 Amp. BEL
D1-D6 1000 V, 55 Amp. Hind Rectifier

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Figure 1.12 File name: Figure 6.doc, Page No. 2

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CAMTECH/99/E/ALT/1.0 41

Figure 1.13 File name: Figure 4.doc, Page No. 3

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CHAPTER 2

INSTALLATION AND MOUNTING INSTRUCTIONS

Alternator is mounted on the bogie or suspended from under frame. Bogie mounting is called ‘Transom-mounting’ and
suspension from under frame is called ‘under-frame mounting’. While all new 110 V coaches have Transom mounted
alternators, the old under-frame mounted alternators are being replaced by transom mounted Alternators at the time of POH.
2.1 CHECKS TO BE EXERCISED DURING INSTALLATION
„ Check proper setting of out put voltage and current of the potentiometer.
„ Check the setting of the selector switch in case of 4.5 KW alternator.
„ Check proper generation of Alternator.
„ If the residual magnetism is lost due to reverse connection of field winding, flash the field winding (F+, F-) with 6 to 12
Volts DC with correct polarity.
„ Check for any wear & tear of the suspension bush and replace the same if necessary.
„ Check the suspension pin is chromium plated.
„ Check the proper fitment of the alternator pulley with a torque wrench with 30 Kg torque value.
„ Check the proper fitment of Axle pulley with a torque wrench of 30 Kg- m.
„ Check the wear and tear or any damage of the alternator and axle pulley with suitable NO & GO gauges, replace the same if
necessary.
„ The alternator and axle pulley should be in proper alignment.
„ Check that support is provided by mechanical device on coach bracket for belt tensioning device to prevent wear & tear of
the tensioning rod.
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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„ Check for any wear and tear of the tensioning device, if necessary.
„ Check and adjust proper belt tension.
„ Check the terminal board, it should be as per R.D.S.O.’s latest drawing No. SKEL 4011 Alt 2. The figure is shown in fig
3.1 of chapter 3.
„ Check that lid of terminal box is properly secured.
„ Check proper fitment of the safety chains.
„ Check proper load sharing of A.C. alternators.
„ Ensure smooth working of the bearings.
„ All parts of the machine should be rust free, if rusted, de-rust the same.
„ The rotor of the alternator should be rotated by hand and check the residual voltage with AC voltmeter of range 0-10 V
connected across the terminals should read about 3.5 V for 110 V alternator.
„ Ensure that suspension bush is introduced form correct side.
2.2 MOUNTING OF THE ALTERNATORS
2.2.1 Bogie Mounted or Transom Mounted Alternator
„ Mount the alternator on the bogie by inserting the suspension pin through suspension bush and bogie suspension bracket.
„ Lock the suspension pin in place by using split cotter pin.
„ Connect the free ends of the safety chain to the holes provided for this purposes on the bogie using nut, bolt and split pins.
„ Fix the tensioning arrangement by keeping the spring seat unit on the cavity provided on the bogie and locking the fork eye
with the tensioning bracket on the alternator by a lock pin, a washer and a split pin.
„ After placing the `V’ belts over the pulleys create correct belt tension by tightening the spring compression nut up to the
level of indicator plate and lock the nut with another lock nut.
Note : For detail of general arrangement of 4.5 KW and 25 KW Alternators refer RDSO’s Drg. No. SKEL 3942 A with
tensioning device.
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2.2.2 Under-frame Mounted Alternator

„ Mount the alternator below the frame by inserting the suspension pin through alternator suspension bush and frame
suspension bracket.
„ Introduce spring holder on suspension pin and lock it in place using cotter pin.
„ Connect free ends of the safety chains to the under-frame of the coach.
„ Slip one hook of spring onto spring holder. Slip the tension bolt onto the other hook of spring. Ensure that the tension bolt
carries one M 12 Hex nut.
„ Swing the alternator towards axle pulley and slip the belt over both the alternator and axle pulleys. Align the alternator
pulley with axle pulley.
„ Apply belt tension by operating the captive nut on bracket. Lock the captive nut against unfastening by using the hex nut on
tension belt. Note that for correct belt tension, the belt tension indicator has to be in green zone of the indicator plate.

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2.3 MOUNTING THE TENSION GEAR

The belt tension gear assembly consists of a threaded spindle, compression spring at one end, and passed through, spring
seats at both ends, sleeve lock nut etc.
The fork end of the spindle is assembled on to tensioning lugs provided on the alternator by means of lock pin. The free
end of the spindle are anchored to the coach bracket.
Belt tension is adjusted by screwing the special nut so that the spring get compressed. An indicator plate is attached to
ensure correct belt tension. Special nut is tightened to compress the spring upto indicator plate to provided correct belt tension
guided by indicator plate. The nuts provided on the free end side should never be disturbed from its original settings since these
are provided only to prevent the tension screw from falling. The clearance between the coach bracket and shunt provided at the
free end side shall be maintained as per RDSO’s Drg. SKEL 3940 sheet given in figure 2.1 for ready reference.
2.4 MOUNTING OF `V’ BELT
The following procedure should be followed after inserting the `V’ belt to the axle :
„ Ensure that alternator pulleys and axle pulleys are aligned.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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Figure 2.1 File name: Figure 5.doc, Page No. 2

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

Figure 2.2 File name: Figure 5.doc, Page No. 1

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

„ Move the alternator towards the axle pulleys and insert the belt in position.
„ Tension the spring assembly as described at “Mounting of tension gear”.
Note : For detail of Alternator pulley refer RDSO’s Drg. No. SKEL 3882 & is shown in figure 2.2 for ready reference.
2.5 MOUNTING OF FLAT BELT
4 ply flat belt conforming to IS 6583-1972 is used for driving the generator.
The mounting arrangement for the flat belt is shown in figure 2.3 as per RDSO drg. No. 3111 for ready reference.
2.6 MOUNTING OF REGULATOR/RECTIFIER
The rectifier/regulator unit should be installed on the coach under-frame in line with the length of the coach, such that
there is no restriction to the free flow of air over the main rectifier heat sink mounted at the back of the box with the hinged
cover facing outward and easily accessible. The three phase output from alternator shall be connected to the respective terminal
of the regulator. The field terminals of the alternator shall be connected from their respective terminal of regulator. And DC+
and DC- of rectifier shall be connected to positive and negative terminals of the batteries.

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Figure 2.3 File name: Figure 5.doc, Page No. 3

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CAMTECH/99/E/ALT/1.0 41

2.6.1 Single core unsheathed flexible copper cable conforming to IS 694-1990 shall be sued from Alternator terminal bolt to the
rectifier/regulator. The size of the cable/cable sockets shall be as per RDSO’s Drg. No. SKEL 4011 Alt-3.
2.6.2 The wiring from Alternator to rectifier regulator through junction box at the under frame shall be provided with PVC flexible
conduit with steel wire reinforced (finolex or equivalent make) of 50 mm dia to avoid damage of the cable insulation.
2.6.3 All cable connections of the rectifier regulator shall be check for proper tightness.
2.6.4 All cable leads shall be provided with cable sockets of proper size as recommended in RDSO’s Drg/ No. SKEL 4011.
2.6.5 The neoprene rubber gasket provided for regulator/terminal box cover shall be checked for any damage. The gasket shall be
properly fixed and cover shall be properly tightened to ensure no water entry during services.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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CHAPTER 3

MAINTENANCE PRACTICES

3.1 ROUTINE MAINTENANCE

„ Check the terminal connection and pulley fitment and check the proper fitment of split pin of castle nut for unfastening due
to vibrations.
„ Clean the dust, dirt etc., if any, accumulated in the terminal box.
„ Check belt tensioning arrangement for any damage and proper tightness.
„ Ensure that belt runs smoothly and is having correct tension as per RDSO’s Drg. No. SKEL 3940. Over tensioning in the
belt is to be avoided as it can damage to belt, bearings, shaft and pulley.
„ Check the alternator terminal box for proper fitment.
3.2 PERIODICAL OVERHAUL OF ALTERNATOR (POH)
3.2.1 Terminal Box
„ Loosen captive screw of cover and open the cover. Check if the terminal is provided as per RDSO’s Drg. No. SKEL 4011
Alt-3 and enclosed herewith for the ready reference as fig 3.1.

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„ Check for any damage of terminal board, replace if necessary.

„ Check the condition of incoming/outgoing leads if damage, replace the same or repair the damage leads.
„ Ensure proper tightness of the terminals.
„ Clean the terminal box thoroughly.
„ Check that no hardware has worked loose, replace the damage/rusted fasteners.
3.2.2 Pulley and Key Removal
„ Remove spit pin, castle nut and then plain washer.
„ Take out the pulley using a suitable pulley extractor or by using the to M 12 taped holes provided for the purpose.
„ Avoid damage of shaft in pulley extraction.
3.2.3 Drive End shield Removal
„ Remove the DE (Drive End) bearing cap fixing screws.
„ Remove the outer bearing cap.
„ Open out the lock washers on the DE end shield fixing screws. Remove the screws.
„ Take out the end shield using two M 8 taped holed provided in it or jacking. The outer race of the roller bearing will come
with the end shield.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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3.2.4 Non Drive End shield Removal

„ Remove the NDE (Non Drive End) bearing cap fixing screws.
„ Open out the lock washer on the NDE end shields fixing screws. Remove the screws.
„ Take out the end shields using two M 8 tapped holes provided in it for jacking.
3.2.5 Rotor Removal
„ Gently pull the rotor out of the stator taking care to see that the winding are not damage.

3.2.6 Drive End Bearing Removal

„ Unfold the lock washer teeth.
„ Unscrew the lock nut and remove lock nut first and then lock washer.
„ Using the bearing pullar, draw the bearing inner race out.
„ Remove the drive end (DE) internal bearing cap.

3.2.7 Non Drive End Bearing Removal

„ Remove circlip.
„ Pull the bearing out using a bearing pulled.
„ Remove Non Drive End internal bearing cap.
3.3 GREASING AND FITTING THE BEARINGS
„ Remove the old grease from all the grease pockets in the bearing caps.
„ Clean the bearings, shaft, and grease pockets with petrol (to which add a few drops of oil) and dry them thoroughly.
„ Check the bearing and shaft for any wear and tear.
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„ Heat the bearings to 80° C using a suitable bearing heater (induction heater or by oil tub) and fit them on the shaft.
Note: Only approved make of bearings shall be used.
„ After cooling change the bearing caps and bearing with correct quantity of grease. As recommended by bearing’s
manufacturer.
„ Over greasing of bearing shall be avoided as it causes overheating of the bearing.
„ CASTROL AP2 grease manufactured by M/s Indian oil corporation or equivalent as recommended by the manufacturer
shall be used. Castrol AP2 is a lithium soap base grease.
„ Mixing of grease of different grade should be avoided as the essential lubricating properties may be lost.
„ Thread the greased DE and NDE bearing caps on shaft.

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„ Lock the inner races of the bearing. Following reverse sequence adopted for unlocking.
3.4 CHECKS TO BE EXERCISED BEFORE ASSEMBLY

3.4.1 Terminal Board/Box

As discussed in sub para 3.2.1 of para 3.2.
3.4.2 Suspension Bushes
„ Check the suspension bush for any wear and tear. Generally the suspension bush shall be replaced during POH.
„ The Suspension bush have been modified as per RDSO’s Drg. No. SKEL 3943 Alt-3 and 3942/A Alt-3 for AC and 4.5 KW
Alternator respectively. For detail same drawing may be referred.
„ 4.5 KW Alternator supplied with amendment no. 3 to RDSO’s specification EL/TL/47(Rev.) after March 1998 are
provided with modified suspension bushes as per RDSO’s Drg. No. SKEL 3942/A-Alt-3. For detail same drawing may be
referred.
„ 25 KW Alternators are provided with modified suspension bushes as per RDSO’s Drg. No. SKEL 3943 Alt-3. For detail
same drawing may be referred.
„ The material and dimension of the suspension bushes shall be as per RDSO’s drawings indicated above.

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3.4.3 Suspension Pin

„ Check for any wear and tear on the suspension pin, replace if necessary.
„ The chromium pin shall be hard chromium plated as per IS 1337.
3.4.4 Tensioning Device assembly
Check the tensioning device for any wear and tear, replace the damage/rusted parts.
3.4.5 Insulation Resistance
Check the insulation resistance as per specification of Alternator/Rectifier regulator. Take remedial measures if, necessary.
3.4.6 Winding Resistance
Check the winding resistance of stator and field windings to detect inter turn short circuit.
3.5 ASSEMBLY OF THE ALTERNATOR
Assembly of the alternator can be proceeded on the reverse way with care on the following points.

„ The bearing shall be heated in a oil bath at 85° C and pressed in gently on seating of the bearing on the shaft.
„ Care shall be taken to avoid damage to the winding while fixing rotor.
„ The alternator pulley should be tighten with a torque wrench using 30 Kg. Meter torque.
„ The castle nut after tightening small amount should be provided with a split pin, so that it shall not get loose in service.
„ There shall be no wear and tear on the shaft and pulley key ways .
„ The shaft and pulleys shall have correct tolerances as specified in RDSO’s respective drawings.

„ There shall be no damage or wear and tear on the alternator and axle pulley.

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3.5.1 Procedure for fixing Alternator Pulley on Shaft

To prevent pulleys from slipping in service and causing damage to shaft key and keyway, the pulley shall have 80%
tapered surface of the contact with the bore of the pulley to ensure this the following procedure should be followed :
„ Thoroughly clean the pulley and fixing portion of shaft and bore of pulley with petrol. The matting surface shall be free of
any oil, foreign material or any contamination.
„ Remove any nicks, burns or scoring either on the pulley bore surface or on shaft surface. Use fine emery cloth for cleaning
and giving smooth surface. Please do not use file for this purpose.

„ Insert pulley forcibly on shaft by hand as hard as possible without twisting the pulley.
„ Mark relative angular position of pulley on shaft with chalk.
„ Remove pulley from shaft carefully. Do not twist pulley while removing.
„ Dress down the blue spots very lightly using fine emery cloth.
„ Lightly cover the bore of the pulley with bluing compound again.
„ Insert pulley forcibly on the shaft by hand as hard as possible without twisting the pulley by taking care to place it in the
same relative position as indicated by chalk mark showing previous fit position.
„ The fit generally will be improved but the operation have to be repeated several times until at least 80% fit is obtained.

„ After final fit is obtained make punch mark on the shaft and pulley for their relative position and punch serial no. of
alternator on pulley.

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„ Under no circumstances use a lapping compound since lapping will produce a shoulder at the large end of the tapered fit.
„ Remove pulley and clean thoroughly the shaft and pulley bore surface to remove all bluing oil or grease.
„ Fit back pulley in the same relative position as indicated by punch mark showing final fit position.
„ Alternator pulley shall not be changed during POH.
3.6 REWINDING
For rewinding of the alternator refer RDSO’s guide line for rewinding no. E-21/15/97 Dec.’97 circulated for the
Railways in Feb.’1998.
3.7 RECTIFIER/REGULATOR UNIT
„ Check the neoprene rubber gasket of the terminal box/regulator box cover, replace if necessary.

„ Check the mounting the power/field diode with a torque wrench using the specified torque.
„ Check proper tightness of all terminals.
„ Check fuses replace, if necessary with HRC fuse of correct value and rating.
„ Check for any dry solder, repair if necessary.
„ Check internal wiring, terminal block, components etc. Repair/replace if necessary.
„ Replace damage/rusted fasteners.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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CHAPTER 4

TROUBLE SHOOTING CHART

It is assumed that load circuit connections and load conditions in the coach are normal.

Sr. Type of Probable Check Remedy

No. defects cause

Alternator a) Incorrect Check the belt Correct the tension of belt

output is belt tension
less or no tension.
generation Check residual Flash the field winding
. b) Residual voltage. with 6 or 12 V DC with
magnetism correct polarities.
lost due to Note : Before doing this
reverse practice field connections
connection should be removed.
of field.

Check the fuse. Fix the fuse if loose

c) Stator fuse otherwise replace the
blown or same if blown out.
removed.
Check the field Replace the field fuse if
d) Field fuse fuse. defective.
Blown. Note : Use HRC fuse for
replacement. Never use
fuse wire
Sr. Type of Probable Check Remedy
No. defects cause

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e) A loose Remove the field If the connection between

connection connection from two fields is broken, join
in the field regulator. Check the two field leads by
circuit or the field brazing of the opened
open circuit connection in the leads. If the field coil is
of the field alternator in defective, remove the filed
winding or between the field coil carefully and replace
in terminal winding and it with the new field coil.
short circuit check the The resistance of the new
in the field continuity of field coil at 20° C is 7.5 +
winding/ alternator field 0.5 ohms for 18 KW and
earthed. winding with the 9 + 0.5 ohms for 22.75 &
field cables. If 25 KW. The megger value
the continuity is is less than 1 M ohm ,
OK check the send the alternator to shop
resistance of the for proper attention of
filed coil. Check field coil.
up the megger
value of the field
coil.

f) Phase Check the lead If the leads are open,

winding and continuity of braze the leads with the
open circuit the phase coil termination. If the
or short winding. Check phase winding is short
circuit or the insulation circuited or earthed send
earthed. resistance of the the alternator to the shop
stator winding. for re-winding.

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Sr. Type of Probable Check Remedy

No. defects cause
g) Defective/ Check the free Replace the free wheeling
leaking free wheeling diodes, if found defective.
wheeling diodes by using
diode or multimeter.
reverse
connection
of free
wheeling
diodes.

h) One or Check the Replace the power diode, if

more power power diodes found defective.
diode one by one by
open/short. multimeter.
After removing
the tail
connection
from the heat
shink /bus bar.
A healthy
diode will
conduct only in
one direction.

i) PCB Check the Change the PCB, if

assembly PCB. defective.
may be
defective.

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Sr. Type of Probable Check Remedy

No defects cause
j) Open/short Check the Replace the
circuit in the continuity of defective
excitation primary transformer
transformer, if winding (P1 &
exist. P2) and
secondary
winding.

02 No voltage Check the Check the Replace magnetic

regulation. control wiring continuity amplifier.
of magnetic between
amplifier. control
winding.

03 No current a)CT burden Check the Change the

limit resistor short value of defective resistor.
circuit. burden resistor
(1.4 K ohms).

b) Defective Check the Replace the

Printed PCB. defective PCB.
Circuit Board
(PCB).
c) Secondary Check the Replace defective
coil of CT resistance CT.
open/short. value (6± 5%)
for 110 V for
CT secondary
after removing
burden
resistance.

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ANNEXURE

PROBABLE REASON OF BLOWING OF THE FUSES PERSISTENTLY

If the field fuse blows consecutively after two or three replacements, it can be due to a fault in the regulator.
The following can be the probable reasons:
„ A defect in the transformer
„ A defective voltage detector
„ A defective control/load winding of magnetic amplifier.
„ An inter-turn short circuit in the field winding.
„ A short circuited free wheeling diode.

HOW TO TEST A DIODE

A diode conducts in only one direction and offer a very high resistance to the current in the reverse direction. This
phenomenon is used in the testing of diodes.
Use a multimeter in resistance range. The leads of the multimeter are connected to the diode after disconnecting the diode from
the associated circuit. One lead goes to the anode and second to the cathode . Observe the deflection to the multimeter.

Now reverse the connection to the diodes. Observe the deflection.

If the diode is good it shows infinite resistance (no deflection) on the multimeter in one direction and 500 ohms to 1000 ohms
in the other direction.
Note : A open diode will show infinite resistance in both directions, and a short diode will show full deflection in both directions.

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Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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CHAPTER 5

TESTS ON ASSEMBLED ALTERNATOR

5.1 INSULATION RESISTANCE TEST

5.1.1 Check the Insulation Resistance
Alternator Required Value
AC Coaches Conventional Coaches
Between stator. Above 20 M.Ω Above 1 M Ω
winding and earth
Between field Above 20 M.Ω Above 1 M Ω
winding and earth.
Between field Above 20 M.Ω Above 1 M Ω
winding and stator.
Regulator Required Value
AC Coaches Conventional Coaches
Short all terminal Above 10 M Ω Above 1 M Ω
(live parts) together
and check the
insulation resistance
between the live
parts and earth.
Note: The insulation resistance of all the above should be measured by 500 V megger.
5.2. NO LOAD TEST
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5.2.1 For AC Coaches

Connect the Alternator and Regulator with a resistance/battery load. Run the Alternator at base load (10 Amp) at various
speed from 400 RPM to 2500 RPM. The voltage should not exceed 130 + 5%. Set the voltage by setting potentiometer VR1 to
get the correct value. Cut in speed should be 400 RPM.
5.2.2 For Conventional Coaches
Connect the alternator and regulator with a resistance/battery load. Run the Alternator at base load (1 A) at various speed
from 357 rpm to 2500 rpm.
Thus voltage should not exceed ± 5% of set the voltage. The cut in speed should also be checked. It should not be more
than 357 rpm at 108 volts.
5.3 LOAD TEST
5.3.1 For AC Coaches
Connect the alternator and regulator with a resistance/battery load. Run the alternator at half load i.e. 97 Amps. and full
load at i.e. 193 Amps. respectively at various speed from 800 rom to 2500 rpm. The voltage should not exceed 130 V ± 4 % of
the set voltage at a speed of 1000 rpm, and 130 V ± 3 % at a speed above 1000 rpm to 2500 rpm at the set voltage. The set
voltage is 130 V, 97 Amp. at 1500 rpm and also check the MFO (minimum speed for full output). It should not be more than
800 rpm.
5.3.1 For Conventional Coaches
Connect the alternator and regulator with resistance/battery load. Run the alternator at half load i.e. 19 Amp. and full load
37.5 Amp. respectively at various speed from 600 rpm to 2500 rpm.
The voltage should not exceed ± 5 % of the set voltage at a speed from 600 rpm to 2500 rpm. The set voltage can be 120
V, 122 V, 124 V at 19 Amp., 1500 rpm. Check the MFO (minimum speed for full output) i.e. 37.5 Amp. for 4.5 KW alternator.
It should not be more than 600 rpm.
5.4 TEMPERATURE RISE TEST
5.4.1 For AC Coaches
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Run the alternator at 800 rpm and apply the load. The Alternator should be capable of giving a load of 138 Amp. in case of
18 KW, 175 Amp. in case of 22.75 KW and 193 Amp. in case of 25 KW Alternator at 130 V, and 37.5 Amp. At 120 V DC for
4.5 KW Alternators. Run the Alternator at 2500 RPM with full load for five hours with a fan cooling the body. Check the
temperature at different parts of the Alternator and should be as follows:
a) Power diode - Should not exceed 100 0C at
ambient of 500 C.

b) Alternator terminal - Should not exceed 100 0C at

ambient of 550 C.
c) Bearing temperature - Should not exceed 100 0C at
ambient of 500 C.
d) Magnetic amplifier - Should not exceed as per
manufacturer’s design value.
e) Stator and Field - Should not exceed 900C at load
winding of 193 Amps.
5.4.2 For Conventional Coaches
Run the alternator at 600 rpm and apply the load. The alternator should be capable of giving 37.5 Amps. load at 120 Volts.
Run the alternator at 2500 rpm with full load for five hours with a fan cooling the body. Check the temperature at different part
of the alternator and should be as follows :
a) Power diode - Should not exceed 100 0C at
ambient of 500 C.
b) Alternator terminal - Should not exceed 100 0C at
ambient of 500 C.
c) Bearing temperature - Should not exceed 35 0C at
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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ambient of 500 C.
d) Stator and Field - Should not exceed 900C at
winding load of 37.5 Amps.

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CHAPTER 6

DO’S AND DON’TS OF THE EQUIPMENT

6.1 ALTERNATOR
6.1.1 Do’s
„ Do ensure the correct polarity of field winding i.e. positive connected to F + while measuring the continuity of the field
winding, otherwise the alternator will not excite self.
„ Do check the belt tension after every round trip of the coach or at least once in every 1000 kms covered by the coach.
„ Do check the tension of the new V-belt fitted, after an initial run of approximately 200 Kms.

„ Do check the proper compression force on the tensioning spring with indicator plate by tightening the special nut.

Note: When belt are replaced, take care to see that they form a matched set.
„ Do keep the terminal box tightly closed.
„ The belt should run on the crown of the pulleys, in case of flat belt drive.

„ Do open the terminal box once in a week and clean the dust, if accumulated.

„ Do check tightness of the connection regularly, at least once in a week.

„ Do use the cable grommets or cable gland with correct size for reducing the vibration of terminal connections. It is
preferable to anchor the cables externally to avoid shocks and vibrations on the terminals.

„ If the alternator is not generating or low generationg then

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

„ Remove the connection of alternator from regulator terminals +F and -F and check the continuity of field leads.

„ Remove the belt and rotate the rotor, check the residual voltage develop across AC terminals with a low range
voltmeter.

6.1.2 Don’ts

„ Do not energise field from battery in case of failure of field circuit diode in regulator. Apart from non regulation, this may
damage the field windings.

„ Don’t use improper tools to handle the alternator, it may damage some parts of the alternator.
„ Don’t re-grease the bearing during run on track, it is not necessary before completion of one year service. Re-greasing
should be made after thoroughly cleaning the bearing with white spirit. It is preferable to re-grease the bearing only during
POH.
„ Don’t over-grease the bearing.
„ Don’t clip the belt by shearing of the belt edges in the case of flat belt drive.
„ Don’t keep the belts in over tension as this may reduce life of the belt.

6.2 REGULATOR
6.2.1 Do’s
„ Do check the regulator terminal box once in a month for loose connections and for cleaning the dust.
„ Do short all seven terminals of the terminal box before the measurement of insulation resistance.
„ Do ensure that DC+ and DC- are connected to battery positive and negative respectively. Wrong connection will damage
main diodes.
6.2.2 Don’ts

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

„ Don’t disturb the settings of the regulator shunt and potentiometer.

„ In no circumstances the burden resistance setting should be disturbed.
„ Don’t open the regulator box unless there is a defect.
„ Don’t use a megger to test the components . Use multimeter.
„ Don’t reverse the field terminals on regulator and alternator.
„ Never use a fuse wire for field fuse. Always use HRC fuse of required value. A rewirable fuse will damage the
regulator.

6.3 `V’ BELTS

6.3.1 Do’s
„ Use belt of the same length (i.e. grade) for a set.
„ Belts should be stacked in lots as per date of receipt and the used in the principle of first in first out to be adopted. The belts
shall be stored in a well ventilated room free from direct sunlight and moisture.
„ Ensure correct belt tension i.e. 330 Kg for 18 KW, 22.75 KW and 25 KW alternators and 105 kg for 4,5 KW alternators.
The tolerance of tension shall be ± 5 kg in both cases.
„ Re-tension newly fitted belts after first trip or 300 kms. Run whichever is convenient.
„ Maintain a gap of approx. 75 mm between supporting plate and fixing nut on the free end of tension rod or upto the split pin
for the 18 KW, 22.75 KW, 25 KW Alternators and 55 mm for 4.5 KW alternators.
„ Maintain proper alignment between axle pulley and alternator pulley.
„ Replace pulley with burn out grooves.
„ Form grades of the belts received from the stores/suppliers after checking on belt measurement gudgets. The grading of
belts should be between 48 and 52 only.
6.3.2 Don’ts
„ Do not allow loose belts.
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CAMTECH/99/E/ALT/1.0 41

„ Do not disturb the nut and checkout on free end of tension rod if proper gap is available between supporting plate and
fixing nut i.e. 75 mm for AC coach alternators and 55 mm for TL alternator.
„ Do not use repaired pulleys.
„ Do not use old and new mixed belts in sets.
„ Belt should not have any oil or grease traces ,if persist clean it by soap and water.
„ The matched set should have belts of one manufacturer only. Do not use belt of same grade of different manufacturer in a
set.
APPENDIX - A

REQUIRED TOOLS AND SPARES FOR THE MAINTENANCE

LIST OF TOOLS

„ Spanners - double end Screw driver

Size 8/9
Size 10/11
Size 12/13
Size 14/15
„ D.E. Spanner with suitable M3 screws for rheostat
„ Box Spanner with extension rod and ratchet of size 10 and 13
„ Box Spanner with extension rod and ratchet size for M24 castle nut
„ Torque wrench torque upto 6 lb-ft
„ Cutting pliers
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

„ Crimping tool a. Dowell’s BRD 95 R2 with dies 5,6 and 7

b. Dowell’s PSD 22 to 16

LIST OF SPARES REQUIRED FOR THE MAINTENANCE OF 10 SETS OF THE 18 KW ALTERNATOR

Item Quantity
1. Complete control box 2 no.

2. Regulator rack 4 no.

3. Field transformer 2 no.

4. Voltage detector DT1 2 no.

5. Voltage detector DT2 1 no.

6. Magnetic Amplifier 2 nos.

7. Set of field rectifier diode 2 sets

8. Lot of capacitors 1 set

9. Rheostat 4 nos.

10. Fuses NS6 10 nos.

11. HRC Fuses 2 nos.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

12. Axle Pulley of alternator 2 nos.

Pulley.

13. Stacked rotor 1 no.

14. Double ball bearing 2 nos.

of roller bearing

15. Alternator terminal board 2 nos.

16. Suspension nylon bush 6 nos.

17. Suspension pin 2 nos.

18. Crimping socket for 2 sets.

phase and field

19. Lead wire as per specification 10 meters.

20. Alternator pulley key & lock 4 nos.

Washer.

21. Castle nut 1 no.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

APPENDIX - B

TECHNICAL DATA OF ALTERNATORS

18 KW BRUSHLESS ALTERNATOR

As per RDSO specification no. EL/TL-54 Rev. (A) with amendment no.1

Dispatch setting 130 V at 70 A,1500 rpm.

of regulator

Voltage variation from ± 4% of dispatch setting.

10A to 138.5 A load.

Current limiting 158 Amps max. at DC side

Cut in speed 400 rpm for 110 V on load

Minimum speed for 750-800 rpm for 138.5 A at 130V

full output (MOF)

Maximum speed 2500 rpm

Class of insulation ‘F’

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CAMTECH/99/E/ALT/1.0 41

22.75 kW (OPTIMISED) BRUSHLESS ALTERNATOR

As per RDSO specification no. EL/PS/Spec./TL 01 with amendment no. 1.

Designated value 175 A , 130 V
Dispatch setting of regulator 130 V, 87,5 A, 1500 rpm
Voltage variation from ± 4% of dispatch settings.
10 A to 175 A load.
Current limiting 202 Amps max. at DC side.
Cut in speed 400 rpm
Minimum speed for 750-800 rpm for 175A,
full output (MOF) 130 V.
Maximum speed 2500 rpm
Maximum test speed 3050 rpm
Setting on Regulators
Voltage Setting:
130V setting for half load, 1500 rpm (can
be set between 124 to 136V)
Current setting:
-138 Amps DC for 18 KW.
-175 Amps DC for optimised 22.75 KW.
-193 Amps DC for 25 KW.
(Current can be set from 75% to 100% of the rated value.)

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

APPENDIX - C

COMPARISON BETWEEN 22.75 KW (OPTIMISED) AND 25 KW ALTERNATORS

Sr. Alternators 22.75 KW 25 KW

No particulars (Optimised)

01 Output power. 22.75 KW 25 KW

i) Continuos 25 KW 28.86 KW
ii) One hour rating

02. Output voltage 130 ± 4% 130 ± 3%

03. Output current rating 175 Amps. 193 Amps.

04. One hour rating 193 Amps. 222 Amps.

05. No. of grooves 6 6

06. Class of insulation ‘H’ `H’

Sr. Alternators 22.75 KW 25 KW
No particulars (Optimised)
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CAMTECH/99/E/ALT/1.0 41

07. Cut in speed (rpm) 400 400

08. MFO (rpm) 800 800

09. Weight of alternator 460 kg 495 kg

with pulleys

10. Mounting same same

arrangement

11. Bearing TB side NU312 NU 312

NTB side 7312 BECB 7312 BECBJ
12. Weight of regulator 50 kg 50 kg

13. Power diode 250 Amps. 1200 320 A, 1200

V V

14. Over voltage Not included Included

protection

15. Filter circuit Not included Included

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

DISTRIBUTION LIST
Railway Board, Rail Bhavan, New Delhi

1. Addl. Member (Elect.).

2. Officer on Special Duty (Elect.)
3. Executive Director (EE/G).
4. Executive Director (E&R).
5. Executive Director (Safety).

RDSO, Manak Nagar, Lucknow

6. Secretary to DG for kind information of DG/RDSO.

7. Executive Director (PS & EMU)
8. Director (PS & EMU)
9. Library

Zonal HQ

10. Chief Electrical Service Engineer,

Central Railway , Parcel Office Building, II - Floor,
CST, Mumbai - 400001.

11. Chief Electrical Service Engineer

Western Railway, Church Gate, Mumbai.

12. Chief Electrical Service Engineer

Southern Railway, Chennai.

13. Chief Electrical Service Engineer

S.C. Railway, Secunderabad.

14. Chief Electrical Service Engineer

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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Eastern Railway, Fairly Palace, Calcutta.

15. Chief Electrical Service Engineer

South Eastern Railway, Garden Reach, Calcutta - 43

16. Chief Electrical Service Engineer

Northern Railway, Baroda House New Delhi.

17. Chief Electrical Service Engineer

Northern East Railway, Gorakhpur - 273 012.

18. Chief Electrical Engineer

Northern East Frontier Railway,
Malegaon, Guwahati - 781 011.

Divisons

19. Sr. D.E.E.(G)

CENTRAL RAILWAY
DRM OFFICE
JHANSI U.P. 284 001

20. Sr. D.E.E.(G)

CENTRAL RAILWAY
DRM OFFICE
BHUSAVAL - MAHARASTRA - 425 201

21. Sr. D.E.E.(G)

CENTRAL RAILWAY
DRM OFFICE
JABALPUR M.P. - 482 001
22. Sr. D.E.E.(G)
EASTERN RAILWAY
DRM OFFICE
DANAPUR BIHAR -202 392
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23. Sr. D.E.E.(G)

EASTERN RAILWAY
DRM OFFICE
DHANBAD BIHAR 826 011

24. Sr. D.E.E.(G)

EASTERN RAILWAY
DRM OFFICE
DHANBAD BIHAR 826 011

25. Sr. D.E.E.(G)

EASTERN RAILWAY
DRM OFFICE
HOWRAH W.B

26. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
CHEMSFORD RD.
NEW DELHI 110 001

27. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
HAZRAT GANJ
LUCKNOW 226 001

28. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
AMBALA CANTT.
29. Sr. D.E.E.(G)
NORTHERN RAILWAY
DRM OFFICE
ALLAHABAD

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30. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
FEROZPUR - 152 002.

31. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
JODHPUR 342 001

32. Sr. D.E.E.(G)

NORTHERN RAILWAY
DRM OFFICE
BIKANER - 334 001

33. Sr. D.E.E.(G)

NORTH-EARSTERN RAILWAY
DRM OFFICE, HAZARAT GANJ
LUCKNOW - 226 001

34. Sr. D.E.E.(G)

NORTH-EAST FRONTIER RAILWAY
DRM OFFICE
LUMDING DIVISON
LUMDING

35. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
PARK TOWN
CHENNAI - 600 003

36. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
MADURAI

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
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37. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
TRIVENDRAM - 695 014

38. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
PALGHAT - 678 001

39. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
BANGLORE CITY - 560 023

40. Sr. D.E.E.(G)

SOUTHERN RAILWAY
DRM OFFICE
TIRUCHIRAPALLI - 620 001

41. Sr. D.E.E.(G)

SOUTH-CENTRAL RAILWAY
DRM OFFICE
SECUNDERABAD - 500 003

42. Sr. D.E.E.(G)

SOUTH-CENTRAL RAILWAY
DRM OFFICE
HUBLI - 580 020.
43. Sr. D.E.E.(G)
SOUTH-EASTERN RAILWAY
DRM OFFICE
KHARGPUR - 721 301

44. D.E.E.(G)
SOUTH-EASTERN RAILWAY

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CAMTECH/99/E/ALT/1.0 41

DRM OFFICE
ADRA - 723 121

45. D.E.E.(G)
SOUTH-EASTERN RAILWAY
DRM OFFICE
VISHAKAPATNAM A.P.

46. D.E.E.(G)
SOUTH-EASTERN RAILWAY
DRM OFFICE
BILASPUR M.P

47. Sr. D.E.E.(G)

SOUTH-EASTERN RAILWAY
DRM OFFICE
KHURDA ROAD
ORISSA

48. Sr. D.E.E.(P)

WESTERN RAILWAY
DRM OFFICE
MUMBAI - 400 008

49. Sr. D.E.E.(P)

WESTERN RAILWAY
DRM OFFICE
KOTA
50. Sr. D.E.E.(P)
WESTERN RAILWAY
DRM OFFICE
RAJKOT
GUJRAT

51. Sr. D.E.E.(P)

WESTERN RAILWAY
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

DRM OFFICE
VADODARA

52. D.E.E.(P)
WESTERN RAILWAY
DRM OFFICE
JAIPUR

53. Sr. D.E.E.(P)

WESTERN RAILWAY
DRM OFFICE
AJAMER

54. Sr. D.E.E.(G)

CENTRAL RAILWAY
DRM OFFICE
SHOLAPUR

55. Sr. D.E.E.(G)

CENTRAL RAILWAY
DRM OFFICE
NAGPUR - MAHARASTRA

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

Institutions

56 The Director,
IRIEEN, P.Box. No. 233,
Nasik Road - 422 101

57. Principal,
Railway Staff College, Vadodara - 390 004

58. Principal ,
C.E.T.I. Central Railway, Thakurli

59. Documentation Centre/CAMTECH.

60. Library/CAMTECH.

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 41

CIRCUIT DIAGRAM FOR 25 KW RECTIFIER REGULATOR UNIT OF SIL MAKE

Figure 1.7

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 48

ASSEMBLY DRAWING FOR 4.5 KW HMTD MAKE ALTERNATOR

Figure 1.8 (Details are given at page no. 49)

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 60

CIRCUIT DIAGRAM OF 4.5 D1 + D6 = S10HN55

or 61HM100
Figure 1.9 KW HMTD MAKE
RECTIFIER D7 - D15 = BY126
REGULATOR D16 - D18 = SIOHN14
or 12FM 100
Z1 = 3Z24
R1 = 1K12 W
R2 = 925E12 W
R3 & RT = 200 E12 W
R4 = 240E12 W
R5 = 280E12 W
R6 = 600E12 W
R8 = IK4E12 W
F1 = 32 Amps.
F2 = 2 Amps.
F3 = 6 Amps.
S1 = 3 way No Off
P1 = 500E7.5 W
PR1 = 200E 7.5 W

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 60

ASSEMBLY DRAWING FOR 25 KW HMTD MAKE ALTERNATOR

Figure 1.10 (Details are given on page no. 61)
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 63

D1-D6 - S12HNS320
Z1-Z3 - 3Z22A
F1 - 160 A HRC
F2 - 160 A HRC
F3 - 6 A HRC
RELAY - OEN 250
T1 - 2N3440
C1 - 2200 mfd 450 V
R1 -1K
R2 - 500 E
R3 - 400 E
R4 - 730 E
D7-D18 - BY 126
R6 - 10 K
R7 - 1 KJ
R8 & R9 -1K
R10 -1K
R11 - 10 K
D19-D20 & - S10HN20
D26
D21 & D22 - S10HR20
D23 & D24 - S10HN20
D25 - BY 126
Ckt. DIAGRAM FOR HMTD MAKE 25 KW RECTIFIER REGULATOR UNIT
Figure 1.11
Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0

Maint. Handbook for Brushless Alternator of `TL’ & `AC’ Coaches Sept.’1999
CAMTECH/99/E/ALT/1.0 115

CIRCUIT DIAGRAM FOR 4.5 KW CGL MAKE

RECTIFIER REGULATOR UNIT
F

Maint. Handbook for Brushless Alternator for `TL’ & `AC’ Coaches Sept.’1999