Coach alternator

Alternator
• Ratings in use (at dc output terminals)
– 3 kW for MG TL coaches
– 4.5 kW, 120 V, 38 A for TL coaches 12 kW, for
MG AC coaches and Jan shatabdi
– 18 kW, 130 V, 140 A for under slung AC coaches
– 22.75 kW (optimised) for RMPU coaches
– 25 kW, 130 V,193 A for RMPU coaches
• How capacity decided?
 Governing specifications
Specification no Equipment
RDSO/PE/SPEC/AC/0054- 3 & 4.5 kW, 110 V brushless
2004 Rev 0 Amdt 1 alternator with RRU
RDSO/PE/SPEC/AC/0056- 18 kW alternator
2004 Rev 0 Amdt 1
RDSO/PE/SPEC/AC/0056- 25 kW alternator with RRU
2004 Rev 0 Amdt 1
RDSO/PE/SPEC/AC/0015 ERRU for 4.5/18/25 kW
Rev 0 ,amdt 1&2 alternators
 Governing specifications/Drgs
Specification/Drg no Equipment
RDSO drg SKEL 4024 alt 1 Mounting arrgt and drive
RDSO drg SKEL 3645 alt 1 Alternator V grooved pulley
RDSO drg SKEL 3652 alt 2 Axle V grooved pulley
RDSO/ELPS/SPEC/TL/13 Alternator and Axle pulley
RDSO drg SKEL 3652 alt 2 Rubber pad for Axle pulley
RDSO/PE/SPEC/AC/0059-04 V Belt
RDSO drg SKEL 3940 Spring tensioning device
RDSO/PE/AC/SK/0077 2004 25 kW alternator outline
 Governing specifications/Drgs
Specification/Drg no Equipment
RDSO drg SKEL 3943 alt 4 Suspension hanger pin
RDSO drg SKEL 4022 alt 3 Safety chain for 18/25 kW
RDSO/PE/SK/AC/0047-2003 Terminal board for 4.5/25 kW
 Alternator
• Quantity
– TL coaches 1 set/coach
– All AC coaches except FAC 2 sets/coach
– FAC 1 set/coach (being increased to 2/coach)
• Used for charging battery set of 56 cells of
800/1100 LA at nominal 110 V and catering AC
and TL load of the coach
• RRU/ERRU used for
– Rectify ac output of alternator
– Regulate output of alternator
– Prevent reverse flow of current from battery
 Alternator: Approved vendors
Alternator Part I Part II
4.5 kW KEL Kundra Unilec
SIL PD Steel
HMTD Taloja Kapsons
Presstech
Best & Crompton
Stesalit
IC Electrical
25 kW KEL Kundra & Kasargod Best & Crompton
SIL
HMTD Taloja
Presstech
Stesalit
IC Electrical* * Not for RRU
MOUNTING ARRANGEMENT
 Alternator: General technical data
• Hetro polar, inductor and self exciting type having NO
windings on rotor
• Suitable for bi-directional generation
• Operating condition -5 to 55 0C and 100% RH
• Bogie transom mounted
• Universal applicability
• Able to operate without battery
• Rotor shaft made of EN 24 (hardened and tempered)
• Coach wheel Dia: New/fully worn -915/813 mm
• Rotor and Alternator pulleys dynamically balanced
• Finished shafts to be 100% ultra sonic tested
• I/P & O/P sockets terminated on separate terminal posts
 Alternator: General technical data
• RRU is magnetic amplifier type field excitation control.
• Insulated cleat provided on frame to support cables
• Dual coated enameled winding wires and VPI adopted
• Winding star connected (formed in stator overhung)
• RRU has un-controlled, 3 phase full wave rectifier
• RRU regulate O/P voltage at all speeds 800-2500 RPM
and at all loads from 10 A-Irated
• Universal RRU when used with other make Alternator
MFO permitted tolerance of +- 50 RPM
• Sr no of Alternator: Ist two digits-Yr of mfr, Next two
digits- month of mfr & No of m/c manufactured in month
 Alternator: Scope of supply
• Each alternator set comprises of
– 1 TL/AC alternator with 1/2 V grooved pulleys
– Safety chains 2(TL)/3 25 kW
– 1 RRU/ERRU
– Belt tensioning device complete
– Axle pulley complete with rubber pad and hardware
– Suspension pin complete with hardware
– Crimping type sockets for Alternator and RRU/ERRU
– Maintenance manual
• Items procured separately
– V belts 4 (TL), 6+6 (AC)
– Nylon suspension bushes 2/set
 Alternator terminology
• Cut-in speed: Alternator speed in RPM at which
rectified output is 110 V at no load.
• Min speed for full output (MFO): Min Alternator
speed in RPM at which it gives rated O/P I at rated V.
• Voltage and Current detector: Device to limit voltage
and current of alternator to pre-set values.
Voltage
Voltage vs Current characteristic

Current
Alternator suspension Bracket
 Coach Alternators

TL alternator AC coach alternator

25 kW alternator outline
Modified Nylon
bush
arrangement
issued vide
RDSO letter no
EL/1.6.9.15
Dt. 28.12.2012
Self Generating System- Alternator
 Self Generating System- Alternator
• Principle of working
– Both windings (AC & Field) accommodated in Stator
– AC windings distributed in small slots
– Field winding concentrated in two slots and each coil spans half
the total no of slots.
– Rotor consists of stacked stampings like cogged wheel having
teeth and slots uniformly distributed on surface skewing rotor axis.
– Core of stator (completely embraced by field coils) retain residual
magnetism, if excited once by battery.
– Flux produced by field coils find its path through rotor
– On rotation, rotor offers varying reluctance path for the field flux.
– Varying field flux induce alternating voltage in AC coils
– Frequency depend on speed and magnitude on speed and level of
excitation
25 kW Alternator Suspension pin
Self Generating System- RRU
Circuit diagram
 Self Generating System- RRU
• Functions
– Rectification of 3 phase AC output of Alternator
using full wave rectifier bridge
– Regulation of voltage at set value
– Regulating output current at set value
• Components
– 3 ph full wave rectifier (Diode D1 to D6) with heat
sinks
– 1 ph full wave rectifier (Diode D16 & D17) on heat
sink along with free wheeling diode D18
– Sensing diodes (D19 & D20) for current/voltage
setting with zener diode Z1
Full wave rectifier
 Alternator-Bearings
• 4.5 kW NU
– Drive end: NU-311 -
(cylindrical) 311
– Non drive end: 6309
(Deep groove ball)
• 25 kW
– Terminal end NU-312
(cylindrical)
– Other end 7312
(angular contact ball)
• L 10 life 16 million km at
1500 RPM
6309
• Make : SKF/FAG
 Alternators- Salient features
Feature 4.5 kW 25 kW
Rating 120 V, 37.5 Amp 130 V, 193 Amp

Factory set at (1500 RPM) 128.5V at 1/2 load 128 V at 1/2 load

Efficiency 70% at full load and 80 % at full load

1800 RPM and 1800 RPM
Min RPM for 2 V ac rms 300 NM

Field wdg resistance 4.5+/- 0.5 Ω 8.5+/-1.5 Ω

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

to phase)
Suspension pin dia 31.75+0/-0.10 mm 35.0 +0.2/-0.3 mm
Insulation class F H
 Alternators- Salient features
Ripple content (max) 5% 3%
Alt pulley width 110.5+/-1.5 mm 200+/- 1 mm
Axle pulley width 110.5+/-1.5 mm 210+/- 1 mm
Cut in speed (min)* 357 RPM 400 RPM
MFO (max)* 600 RPM 800 RPM
Alt pulley groove angle 34+/-0.5 0 36+/-0.5 0
Axle pulley groove angle 38+/-0.5 0 38 +/- 0.5 0
Tensioning device working 310 mm 295 mm
length
Distance of axle pulley from 140+-1 mm 228+/-0.5 mm
wheel hub
Weight (max) NM < 525 kg
* With new wheel dia (915 mm)
 Alternators- Salient features
Current limit set between 228 & 232 A
Voltage not to dip <120 V at 225 A
Mating of Alt pulley with shaft > 80 %
Free hanging clearance from RL 178 mm
O/P V tolerance (10 A to full load) +- 4%
I limiting by potentiometer 228-232 A
Voltage not to dip below 120 V at 225 A
Max Vset through potentiometer 140 V at 800 rpm
on 10 A load
Max Iset through potentiometer 232 A
Bearing L10 life > 16 million km
at 1500 RPM
 Alternators- Salient features
Bearing re-greasing interval >30 M or 6 lac km
OVR set at 145+- 1 V
Size of rotor (D * L)
No of teeth (slot) on rotor 8 12
 Alternator capacity
– Cl 3 of UIC 550 OR stipulates : battery to supply full coach
load for 3 hrs and lighting load for 5 hrs.
– Assumptions
– Conversion factors of 0.72 & 0.83 for 3 & 5 hrs discharge
(cl 5.5 & 5.6 of IS 6848)
– Condemning capacity of battery-80%
– 100% roof load (excldg NL) from 6-10 PM
– 50% Rdg lights from 6 -10 PM
– 20% light load (incldg NL) from 10 PM-4 AM
– 50 % roof light load from 4-6 AM
– 100 % fan load for 24 hrs
– Ah efficiency of battery-80%
– Avg Alternator current -90% 0f capacity
• Battery capacity (10 hr)=Total load *3/0.72*0.8=5.2*TL
– OR Lighting load*5/0.83*0.8=7.54*lighting load
• Alternator capacity
– To ensure that battery get fully charged in a night run of 12
hrs with generation to non generation ratio of 2
 Alternator capacity
• Alternator capacity
– Avg load-A
– Generation to non generation ratio-2
– Non generation period –n hrs
– Generation period -2n hrs
– Load Ah by direct generation=A*2n
– Load Ah through battery=A*n
– Battery input=A*n/0.8=1.3*A*n
– Total generation required- (2+1.3)*A*n=3.3 *A*n
– In case of externally regulated=3.3*A*n/(2*n*0.8)
= 2.06*A
Back
Dyna drive for testing Generation
/Load sharing of Alternators
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
1 AC/SMI/9 Instruction for re-assembly of EL/7.1.21/K
NH type bearing of 18 kW KEL Dt. 03.7.1991
make alternator during POH
2 RDSO/PE/SMI Fits and limits on bearings of EL/7.1.38/1
/AC/ALT/0002 alternators and motors used on Dt. 20.01.99
98(Rev.0) AC coaches.
3 RDSO/PE/SMI Procedure for measuring bearing EL/7.1.38/1
/AC/ALT/0003, clearance of a free bearing. Dt. 20.01.99
98(Rev.0)
4 RDSO/PE/SMI Condition monitoring of EL/7.1.38/1
/AC/ALT/0004 bearings. Dt. 20.01.99
–98(Rev.0)
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
5 RDSO/PE/SMI/ Fitment of outer race of bearings EL/7.1.38/1 Dt.
AC/ALT/0005– in the housing. 20.01.99
98(Rev.0)
6 RDSO/PE/SMI Testing and checking of new EL/7.1.38/1 Dt.
/AC/ALT/0006 bearings for alternators and 20.01.99
– 98(Rev.0) motors of AC coaches.
7 RDSO/PE/SMI Guidelines to identify genuine EL/7.1.38/1 Dt.
/AC/ALT/0007 and spurious/reconditioned 20.01.99
–98(Rev.0) bearings.
8 RDSO/PE/SMI Proper mounting ,maintenance April 1999
/TL/ /0003-99 and handling of power and field
(REV.`0’) diodes provided in RRU
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
9 RDSO/PE/SMI/ Proper load sharing in AC EL/7.1.38/1
AC/0018–99 coaches. 05.02.1999
(Rev.0)
10 RDSO/PE/SMI/ Testing procedure for proper EL/7.1.38/1
AC/0019 –2002 working of OV protection
(Rev. '0') provided in 25 kW alternator.
11 RDSO/PE/SMI/ SMI for checking shaft of TL Oct. 2003
TL/026 2003 alternator
(REV.`0’)
12 RDSO/PE/SMI/ Protection of Lead wire of TL & EL/1.6.9.15 dt.
AC/0033-2006 AC Alternator 20.06.2006
(Rev. 0)
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
13 RDSO/PE/SMI For 4.5/25 kW RRU/ERRU June-2012
/TL/0045- voltage setting on TL and AC
12(Rev-0) Coaches
14 RDSO/PE/SPE Guideline to use standby circuit Aug-2012
C/TL/0175- in ERRU
2012 (Rev-0)
15 RDSO/PE/MS/ Provision of modified terminal EL/1.6.9.15
TL/0020-2003 box cover for 4.5 kW 110 V TL 20.02.2003
(Rev. '0') Alternator
16 RDSO/PE/MS/ Provision of OV protection in EL/1.6.9.15
TL/0021-2004 RRU of alternator used in SG AC 19.08.2004
(Rev. '1') coaches.
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
17 RDSO/PE/MS/Provision of modified terminal EL/1.6.9.15
TL/0024-2003
board assembly in 4.5/18/25 kW 31.07.2003
(Rev. '0') alternators.
18 RDSO/PE/MS/Provision of filter circuit in RRU EL/1.6.9.15
of 4.5 kW alternators used in TL
TL/0033-2004 18.08.2004
(Rev. '0') coaches.
19 RDSO/AC/MS Modification to cable layout from EL/7.1.21/K dt.
/22 18 kW alternator terminals to 4.7.91
junction box of AC coaches.
20 RDSO/AC/MS Procedure for brazing winding EL/7.1.21/K
/24 wire with flexible lead wire on 17.12.91
alternators.
 Alternator RDSO SMI/MS’s
S SMI/MS N0 Description Reference
no
21 RDSO/PE/MS/ Arrangement for anchoring of EL/1.6.9.15
TL/ 0002 – 99 outgoing cables from alternator dt.15.02.1999
(REV.0) TB/box to RRU TB and UF TB
of TL alternators
22 RDSO/PE/G/0 Guideline for rewinding of EL/7.1.38/1
002-2005 TL/AC Alternator Aug. 2005
(Rev. 0)
23 RDSO/PE/MS/ For protection of lead wire in 4.5 EL/7.1.38/1
AC/ 0034- /25 kW Alternator 23.08.2005
2005 (Rev. 0)
 Alternator Tests
Test P T R A
Dimensional verification of all assemblies Y Y Y Y
Measurement of stator and field resistance Y Y Y Y
Temp rise test on Alternator and RRU Y Y N Y
IR test of Alternator and RRU Y Y Y Y
HV test Y Y Y Y
OC test Y N N N
Load test Y Y Y Y
Current limiting characteristic test Y Y Y Y
Mechanical over speed and induced voltage Y Y N Y
test
SC characteristic test Y N N N
Surge protection test Y Y N N
 Alternator Tests
Test P T R A
Efficiency test Y N N N
Environmental test Y N N N
Hose proof test Y Y Y N
OVP test Y Y Y Y
Special tests Y N N N
Parallel operation of Alternators Y Y N N
Checking dynamic balancing of rotor and pulley N Y Y N
Temp rise test at 2500 RPM N N N Y
 Alternator tests
• Measurement of winding resistances:
By suitable resistance measuring device at ambient temp.
R20 averaged for 5 m/cs. Not to vary by more than +-7% of
declared value.
• Temp rise test:
Alternator run at Irated and 2500 rpm and repeated at
MFO. Forced air-cooling 6 & 4 m/sec for alternator and
RRU respectively. Temp rise by resistance method above
ambient of 550 not to exceed 1150& ---- for AC & TL
alternator respectively. Locations temp measured by point
contact pyrometers. After test overload test at 222/--- A for
1 hr at MFO and 2500 rpm done
 Alternator tests
• IR test
Measured before and after HV test between all terminals
shorted together and body with 500 V dc megger. Value to
be > 20 Mῼ.
• HV test
Immediately after temp rise test 1500 ac rms 50 hz
(gradually increased from 500 V) applied all shorted external
terminals and frame for 1 min. For acceptance duration 5 sec
and without temp rise test. ILeakage < 30 mA
• Open circuit test
Alternator run at min 5 speeds 9500,900,1500,1800,2500)
with field separately excited. O/P voltage vs field excitation
curves plotted
 Alternator tests
• Load test : Conducted with resistance load and or with
battery. All characteristic tests done at 129 V, 96.5 A at
1500 rpm. Test consists of , No load test, speed vs O/P
and Current vs V test.
• No load test: Conducted at base load of 10 A. DC O/P
voltage recorded at MFO,1500,1800 and 2500 rpm and
variation not to exceed 4% of pre set voltage.
• Speed vs O/P voltage: Done at full rated and half rated
current at speeds from MFO to max speed. V not to vary
>+-4% of pre set value.
• Current vs voltage: Done at 1800 rpm. I varied from 10
to 193 a keeping speed constant. V not to vary > +-4%.
 Alternator tests
• Current limiting characteristic test: Done after I vs V
test. Point when , current doesn't increase even with load
increase. Not to exceed 230 A.
• Mechanical over speed and induced voltage test:
Done just after temp rise or load test. Alt run for 2 mts in
each direction with OC stator wdg anf separate excitation at
cut-in speed level at speed of 3035 rpm.
• Short circuit test: Done on cold m/c. O/P terminals short
circuited with an Ammeter and excitation adjusted to
achieve 25, 50, 75 and 100% full load. Curves plotted for
various speeds.
• Parallel operation: Done at 800,1800 and 2500 at 25,50
and 100% load. Difference not to exceed 30 A.
 Alternator tests
• OV protection: Time delay of 3 s. Set at 145+-1 V.
• Surge protection test: At 1800 rpm, full thrown off and
O/P voltage rise recorded. Again full load leaving 10 A
resistive load thrown off and V not to rise > 400 V and
should drop to normal in 5 S.
• Efficiency test : Efficiency at 1800 rpm to be >80%.
Speed vs efficiency curves at rated load.
• Environmental tests: Done on RRU only. Temp rise (dry
and damp heat), in corrosive atmosphere, combined dust
humidity and heat and vibration and shock test.
• Hose proof test: for RRU, IP 55S of IS 4691-85
 Alternator tests
• Special tests
– Ripple content not to exceed 3%. (Vmax-Vmin)/(Vmax-
Vmin)*100 %
– Mating of pulley with shaft: Done using plug and ring gauges
and prussian blue and media
– Shorting of power diode: At 1800 rpm and full load for 2”.
– OC power diode
– Junction temp of semi conductors
– Dynamic balancing of rotor and pulleys
– MFO at cold and hot condition
– MHO measurement
• Fire retardant test for terminal board