DEMU types and systems

DEMU
1400 HP DEMU has been inducted in Indian railways
to replace the existing slow moving Loco hauled
passenger train in non-electrified mainline sections
and also for low traffic density branch line services.
The high acceleration potential of DEMU makes
them suitable to work as fast passenger
transportation services between cities.
One unit of DEMU consists of four coaches:
1. Driving power car (DPC),
2. Trailer car (TC)
3. Driving trailer car (DTC).
 DEMU
DPC: Driving power car is a coach that houses the
diesel electric power plant. Around 50% of the coach
space is occupied by the plant and balance is for the
passengers. It has one control station.
TC: Trailer car (TC) is a simple coach that is meant
only for passengers.
DTC: Driving trailer coach (DTC) is also a coach
meant only for the passengers. However, one end of
this coach has parallel operator control station.
 DEMU SYSTEM
Power Pack The driving power car has a single power
pack consisting of a diesel engine (KTA-50-L)
complete with brush less traction alternator.
Rectification Three phases AC output obtained from
the alternator is rectified by the three phase bridge
rectifier to get DC output.
Traction motor Four axle mounted, self-ventilated
traction motors are mounted on two bogies of the
DPC. The motors are permanently connected in four
parallel combinations utilizing the full capability of the
traction alternator.
 DEMU SYSTEM
Control System Excitation and load control Module
(ELCM) system is designed to operate in conjunction
with alternator and fuel actuators. It regulates the
excitation by regulating the current to the exciter
stator on any given notch in such a way that
constant HP is obtained from engine with varying
current to the traction motors.
Vehicular couplers There are four nineteen pin inter
vehicular couplers viz., A, B, C & D.
 DEMU SYSTEM
Auxiliary Supply An 18 KW auxiliary alternator, belt
driven from traction alternator shaft with its rectifier
and regulator is provided to supply 135/110 V DC.
Compressor A belt driven compressor at the non
traction alternator end of the engine is provided to
supply compressed air at a required rate at 8 kg/cm2
 Parameters of 700HP DEMU
 Track gauge : 1676mm
 Composition of a unit : 1 DPC + 1 TC + 1 DTC
 Estimated service weight : 188 Tones
 Maximum axle load : 17T (DPC) 15T (TC)
 Wheel arrangement of Power Car : Bo-Bo
 Wheel Diameter : 952mm (New)
 Effective traction power : 610 HP output of engine
 Power transmission : Electric AC/DC
 Maximum operating speed : 100 Km/h
 Gear Ratio : 20/91
 Parameters of 1400HP DEMU
• Track Gauge : 1676 mm
• Composition of a unit : 1 DPC + 2 TC + 1 DTC
• Estimated Service Weight : 188 T
• Maximum axle load : 20T (DPC)
• Wheel arrangement of power car : Bo-Bo
• Wheel diameter : 952 mm
• Effective traction power : 1317 BHP
• Power transmission : Electric AC/DC
• Maximum operating speed : 100 km/h
• Gear ratio : 20: 91
 Parameters of 1600HP DEMU
Train formation : (1DPC+4TC)Up to 4 Basic units(20 car).

Maximum Service Speed :110 km/h

Maximum Test Speed : 123 km/h

Engine Power : 1600 HP

Input to Traction Alternator : 1450 HP

Passenger capacity (10 car): 900 seating, 1800 standing

Acceleration : 0.47 m/s2

 layout of 1600HP DEMU

1. Driver console 2.Vehicle control panel 3. Traction Alternator

4. Rectifier 5. Diesel engine 6. Traction converter
7. Auxiliary converter 8. Traction motor 9. PIS
10. Vehicle remote monitoring
 FEATURES

• Increased Power from 1400 to 1600HP.

• Increases passenger capacity.
• Extensive fault diagnostics and Fault tolerances
where ever possible.
• Touch Screen Display for driver interface as
against LED indication panel.
• All analog meters and gauges are duplicated in the
display.
• Dual Display units for redundancy.
 FEATURES

• Inbuilt Speed time and distance recorder

• In built Event recorder
• Life time Statistical Data recorder
• Intelligent data logger
• Remote monitoring system
• Auxiliary Power Control in place of Aux.
Alternator, to provide Load sharing.
 FEATURES
TCN(Train Communication Network) and Wired
Train Bus(WTB) Communication with Remote DPC
• Lead DPC communicate traction commands to
remote DPC.
• Remote DPC transfer all performance data to Lead
DPC.
• Crew related messages from remote DPC are
transferred to lead DPC.
• Redundant Train Line communication to utilise full
power from rear DPC in case WTB failed.
 FEATURES

• Optical hot redundant communication between

Vehicle Control Computer and Traction Inverter.
For reliable and trouble free service.
• IGBT based inverters.
For better efficiency and reliability.
• Traction Motors:
3 phase AC Induction motor.
 DIESEL ENGINE

Diesel Engine:(Caterpillar)
•4 Stroke, 12 Cylinder, water
cooled, turbo charged. 1600HP
@ 1800 RPM
•electronic fuel injection
•Built in small alternator to
charge 24V battery
•Compact hydraulic cooling
system
 TRACTION ALTERNATOR

Traction Alternator:
3 phase brush less alternator coupled
to engine.
Two parts. 1. Exciter 2. Alternator
Exciter output coils, diodes and
alternator field coils are mounted on
the shaft.
Exciter field and alternator output
coils are assembled on the stator
body.
 RECTIFIER

Rectifier :
3 phase, full wave bridge
rectifier alternator mounted.
Max. Voltage : 2400V
 Max. Current : 750A
Protections:
Fuse for over current
Thermal switch for over
Temperature
 VEHICLE CONTROL COMPUTER VCC

Vehicle Control Computer

VCC
Microprocessor based control
system with plugin modules.
Equipped in CP.
Performs entire DEMU control
based on drivers commands.
Performs Multiple Unit control
through Wired Train Bus
(WTB) communication
between DPCs.
 COMPRESSOR

Compressor : (ELGI)
Motor driven
Reciprocating air cooled
compressor - RR15070
under slung mounted.
1200 LPM delivery
irrespective of notch
Motor runs on 3 phase
AC, 415V
Motor drive (cut-in / cut-
out) is done by VCC
 Trouble Shooting
Problem Cause
Engine not cranking. 24 V knife switch in OFF position.
Starting panel MCB in OFF position.
Selector switch knob not set in correct
position.
Engine cranking but not Any shutdown safety device in operative
starting position-
LCWL /OPS/Over speed
Engine cranking but Empty fuel tank/Obstruction in fuel supply
suddenly stopped or main cutout cock close.
Air lock/pipe crack/Actuator linkage/
Governor MCB-OFF
Any shutdown safety device operated
 Trouble Shooting
Problem Cause
Engine not responding Driver’s key not properly fitted.
according to throttle. ECS in OFF position.
Master controller not working properly.
Engine over speed during Actuator linkage at maximum level.
start.
Engine shut down and Any shut down safety device in operate
not starts again. position.
Over speed trip/LCWL operate/LHOL
operate.
Fuel tank empty/Restrict fuel supply
 Trouble Shooting
Engine Hunting Engine not notch up properly.
Restrict fuel supply
Any idling device in operate condition.
Alarming Hot Engine Water temperature above 960 C.
Water pump not working properly.
Radiator fan not working properly.
Hydraulic pressure less.
ETS defective.
Engine shutting down Low water level.
with LCWL signal. Water leakage from radiator.
Wheel skid / Wheel jam Brake jam/Traction motor Bearing seized.
Smoke coming form Traction motor.
Defective Axle box bearing.
DPC Traction motor pinion jam.
 Trouble Shooting
Air spring D- flat Air spring air hose cracked or
brushed.
Broken Air spring.
Brakes are not applying in A-9, C-2 Relay valve may be defective
train Brake pipe pressure not building up
DPC brakes are not applying. DV may be defective
Brake cylinder pipe/ diaphragm
defective
TC/DTC brakes are not DV may be defective
applying Brake cylinder pipe/ diaphragm
defective