Tesveo ey ENGINEERING DESIGN woNBER
R.K. Albright; 332 mR)
‘S.M. Bednarz
APPROVED FIRST 188UED
KES, f PERFORMANCE SPECIFICATION
.R. Smith May 13, 1986
SUPERSIDIS
Electro-Motive Division
# General Motors Corporation
u La Grange, 111ineis
subset AXIAL FLOW COOLING FANS FOR EMD LOCOMOTIVES
ile document Ie @ property fet
AFFicTs MODELS All Locometives DLPVIINDIAN RAILWAYS AND ANY
Unsthorisad Use
‘ensidered illegal end OLW/INDIAN.
RIP. DRAWINGS Hallways will havo right to initiate legal
~
ORIGINATOR - DO NOT AN
SUPPLIER +
A. SCOPE:
This specification applies to all axial flow cooling fans
an dynamic brake fans While this specification covers
the fan as an assembly, separate EDPS documents apply to
motors and drives as follows:
Item EDES
YU AC Motor Design - Cooling Fan EDPS #96, #308, #323
DC Motor Design - Dynamic Brake Fan EDPS #303
V-Belt Drives - Mechanically Driven Fan EDPS #146
Gast Aluninun Fan Blaces EDPS #175
2. EUNCTION:
2.1. The function of the cooling fan on a locomotive is to
r provide sufficient cooling air flow in order that the
we diese] engine can be safely operated over a wide variety of
ambients. The ultimate criteria is to meet the Equirment
Group standard of 210 deg. F. water out of the engine at.
118 deg. F. ambient and full rated engine load
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EDPS 332 Page 1 Of 53.1.
7 3.2.2.
3.1.2
3.2.
"9.2.4.
Y
c
3.2.2.
3.3.
3.3.1.
3.3.2.
The function of the dynamic brake fan is to provide
sufficient cooling air to the resister grids while in full
rated dynamic brake current under varying ambient and
altitude conditions.
REQUIREMENTS:
Fan Air Temperature:
Engine Cooling Fans
The design anbient air temperature range is -40 deg. F. to
150 deg. F. If the fan is mounted on the hot air side of
the radiators, the design fan air temperature is -40 deg.
F. to 220 deg. F. Also brief excursions to 250 deg. F. are
possible within tunnels.
Dynamic Brake Fans
Design dynamic brake fan air temperature is -40 deg. F. to
150 deg. F. if the fan is mounted on the cold air side of
the grids. If the fan is mounted on the hot air side, the
temperature range is -40 deg. F. to 450 deg. F. The
nominal grid air temperature rise is 250 deg. F. above
ambient.
Altitude Operation, Barometer and Air Density:
Fans may be operated on locomotives from sea-level to
10,000 ft. with barometer readings from 20 in. Hg. to 30
in. Bg.
3 3
The air density may be between 0.056 1b/ft to 0.096 1b/ft.
3
Nominal design air density is 0.070 lb/ft.
Fan drive system is expected to operate at both density
extremes without driveline failure, motor overspeed, etc.
Fan Daty Cycle:
All locomotives are expected to operate at 96% availability
or 8410 hours per year.
The fan is expected to be a life of the locomotive item or
20 years with provision for overhaul of the drive system at
4 year intervals.
Locomotive cooling fan speeds are proportional to engine
speed. Engine speed schedules are available from the
Engine Design group on a model basis.
Dynamic brake fan speeds are determined by braking current
level, applied motor voltage and motor design. Dynamic
brake speed schedules are specified by EMD engineering on
an application basis. ‘s aS.
REAP HIRMED opps 332 Page 2
let313.2.
3.3.3.
3.4.
3.4.1.
3.4.2.
3.5.
3.5.1
3.5.2.
3.5.2.1.
3.5.2.2.
Typical Duty Cycle for Domestic Road Loconetives:
(Percentage time in each throttle notch)
Throttle Of Rated Time Hours Per Year
Idle 48% 3869
1 4% 336
2 4% 336
3 4% 336
4 4% 336
5 4% 336
6 4% 336
1 4% 336
8 11% 1430
Dyn, Brake 9% 157
A maximun of 10 starts per hour can be expected for
locomotive cooling fans. A maximum of 25 starts per hour
can expected for dynamic brake fans
Shock Loads and Vibration:
The following loading mst be sustained by all fans
without causing permanent damage which would impair fan
operation:
Longitudinal Shock---3g (along locomotive centerline)
“Li/2¢
Fans must withstand normal 3g locomotive vibration per
attached curve at full (Sth throttle) fan speed per the
attached curve.
Structural Design and Overspeed Capsbilities:
The blades, hub and supporting structure must be designed
to withstand indefinite operation throughout the entire
fan speed range.
Structural testing is the responsibility of the supplier.
The supplier must submit mean and alternating strain data
for the blades, hub and support structure along with
fatigue-life calculations which indicate that the lite
goals given below in items #3.7.2 and #3.7.3 can be met.
The supplier is responsible for determining the fan blade
critical speeds of each new application of his fan to
ensure that such speeds are not within the fan operating
= REAFFIRMED
Le gael
SSE.
EDPS 332. Page 38.6.1.1.
3.6.2.
3.6.2.1.
3.6.2.2.
3.6.2.3.
3.7.
3.7.1.
3.7.2.
3.7.2.1.
The fan must be capable of the following overspeed
operation without sustaining damage:
AC Locomotive Cooling Fans-15% over 8th throttle speed
DC Dynamic Brake Fans-15% over full dynamic brake load
fan speed.
Fan Application:
Fans are to be mounted to the cooling or dynamic brake
hatch by means of eight 1/2" studs welded to the hatch
and equally spaced around the fan opening cutout. Fan
frame must provide eight clearance holes with bolt-circle
to be determined by EMD engineering.
Overall fan height affects the locomotive clearance
diagram. The maximum fan height on hood-mounted hot air
side fans must not exceed 10 1/4". The fan height is
jeasured from the mounting surface to the topmost point
f the fan assembly.
Guards:
Unless an exception is granted by EMD engineering, fan
assembly must be guarded per NEMA Standard #9-7-1977,
Bec. MG 1-1.25 D.1. 5
The guard on locomotive roof-mounted fans must be of
sufficient strength to withstand the weight of a 300 1b.
man. The guard must also meet items# 3.4.1 and 3.4.2 of
this specification.
On electrically driven fans, the guard must be oither
xenovable or have a latching access door to allow
electrical connection of the fan motor to the receptacles
provided on the locomotive. If the guard is removable, a
positive means of retaining the guard must be provided to
prevent the guard from falling into the fan during fan
operation.
Quality, Reliability and Durability:
Quality and reliability of blade or hub castings, motors,
support structure, belts, bearings and sheaves, guards
and any other subassembly parts of the fan are the
responsibility of the supplier.
The reliability goal of all fans is 0.8% failure rate
over two years of service. This shall include all
failures with the exception of those failures which would
constitute a safety hazard.
Fixing reliability or quality problems is the responsibility
of the supplier. REAFFIRMED
“geen |
papers
EDPS 332 Page 4 gps+ 3.7.3. (/ The fan durability goal is 1.6% failure rate by the time of
drive system overhaul (4 years for electrically driven
* fans) The mechanical parts of the fan -. blades, hub and
‘ support structure - must be life of the locomotive items
(20 years).
3.8. Performance:
3.8.1. Flow performance shall be specified by EMD engineering as
required for each application of the supplier’s fan.
3.8.2. Performance characteristics are as follows:
Flow - OM
Static Pressure IN. W.G.
3
Air Density = lb/ft
Fan Speed - RPM
7 3.8.3. Supplier is required to submit fan test data and
performance curves generated using approved fan test
chamber layouts and practices per AMCA standard #210 -
current standard / ASHRAE standard #51-current standard.
3.8.3.1. Supplier must provide test data for at least three fans
xepresentative of normal production practice. The
difference between the highest and lowest flow at the
system resistance given in item #3.6.2 must not exceed
2.5% of the specified flow rate.
3.9. Noise:
3.9.1. Noise qualification of cooling fans for locomotive
application consists of running fans on a locomotive to
determine wayside noise levels at 100 ft. from the
locomotive centerline. The total locomotive wayside
noise level shall not exceed 87 dBA for any reason. ‘The
uv fans alone running at full speed shall not exceed 80 dBA.
9.9.2, As a laboratory qualification of a fan design, a supplier
may run comparative tests with EMD fan assembly 9522997
run at 1860 RPM. Fan sound pressure level “A-scale” must
not exceed the level of the standard fan 9522987.
3.9.2:1. Supplier must submit test data and description of
. comparative noise tests per item #3.9.2. :
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EDPS 332 Page 5