‘ssueosy ausen (sth R. Ziberna ENGINEERING DESIGN 498 (EC) D. Becker sy mono PERFORMANCE SPECIFICATION September 17, 1996 RW. Becker ELECTRO-MOTIVE DMSION sureneces ‘General Motors Corporation TCO TSeke— Laceange, ince cs “susvect Dynamic Brake Grid Resistors AFFECTS MODELS. GT46MAC Locomotive [esr omwnes| TED ORIGINATOR- N¢ IN NY _INF( 1 HICH 1S RESTI Dt INLY™. SUPPLIER- THE FOLLOWIN: MATION I Pi fF Mi Vist AND MUST BE TREATED AS PRIVILEGED COMMUNICATION BETWEEN SUPPLIER ANI CUSTOMER. 4.0 SCOPE 1.1 This specification outlines the requirements for a highly reliable box grid resistor to be used on AC diesel-electric locomotives. The supplier is responsible for insuring the grid resistors operate reliably in the system as configured. Based on this information, the supplier will be expected to determine the actual air flow, both stationary and dynamic. Modeling may be a necessary C cesign toot in order to predict the performance of the system, such that design iterations can be minimized. Validation testing of the overall system shall be performed by the supplier. The test results shall be documented in a report and provided to EMD. This documentation shall include the test plan, organized data, including temperature and air velocity profiles, analysis of the data, conclusions, justification for design iterations, etc, The design of these grid resistors shall include the definition of the motor tap grid which insures the correct fan speed. This implies the , Specified limits of the fan motor are not violated. ‘This document is # property fot DLW/INDIAN RAILWAYS AVD ANY Unsthorised USE af the document considered Wlagal 3d LW/t !OIAN Frilwoys will have right to initiate legal proceedings agsinat the defaullel§y 4 FeTRMIED cer == WE SAEED TED ca | - : Page 1 of 23EE EEE EE EE EEE ooo 2.0 24 2.2 7 3.0 34 mame tate Get Ron INTRODUCTION ‘These specifications were developed without consideration to possible involvement of patent rights. In all cases the supplier shall assume full patent liability. During dynamic brake operation, the kinetic energy of the train (load) is transformed into electrical energy in the traction motors. This energy is first converted to de power by the traction inverters and provided to the dc link. The DC link voltage is then applied to the resistor grids which dissipate the power in the form of heat. This action provides the braking effort Which slows down the locomotive. Onboard computers optimize the dc link voltage and control the braking effort. The resistor grids are forced cooled with air, discharging the heat through the top of the locomotive. Please refer to the following attachments : Brake Effort Curve (See Page 17) Schematic illustrating the application (See Page 18) Moisture resistance; EIA Std.RS-186C, Method 2 (See Pages 19,20, 21) ECD 52-165, EMD Vibration requirement curve (See Page 22) Fan Performance Curve (See Page 23) EDPS # 303 - Dynamic Brake Fan Motor Dynamic Brake Hatch Equipped Drawing # 10631909 Dynamic Brake Structure Drawing # 10630495 APPLICABLE DOCUMENTS The following documents shall form a part of this specification to extent specified herein. The latest revision of these documents shall be used. EMO P/N EMD Engineering Detail Part Drawing PPAP Supplier Submission Of Material For Production Approval Iso 9001 Quality Requirements ORDER OF DOCUMENT PRECEDENCE For the purpose of interpretation in case of any conflicts, the following order of precedence shall apply: A. Purchase Order B. The Detail Component Drawing NC. This Specification “D. Other Reference Documents pear rien 1 Unger’ SSEae EDPS 498 - Page 2 of 2344 42 43.4 43.2 43.3 444 442 mance ca Resin APPLICATION The supplier is required to review, when advised of the actual GMLG circuit application, ‘communicating to the component engineer any potential misapplications of their product wh could be detrimental to it's longevity. The mounting location will be GMLG's option, however, the supplier is responsible for insuring that this grid resistor will survive in the environment as specified herein, EXPECTED LIFE The expected life of these grid resistors is 20 years. No maintenance shall be required. MATERIALS Materials shall be inherently non-nutrient to fungus and shall not blister, crack, outgas, blow or exhibit other immediate or latent defects that adversely affect storage, operation or environmental capabilities of these grid resistors, The frame shall be either painted or plated to provide resistance to corrosion for the entire life of the product. If painted, it should be suede gray in color (Ref. Dupont $17-43094). If plated, a zinc plating with a dichromate conversion coating is suggested (typically gold in color). The grid ribbon is the current carrying element of the grid resistor assembly. The ritbon actually dissipates the electrical energy in the form of heat. Typically, this is special metal alloy. The selection of this material will be left to the discretion of the supplier, in order to insure the performance characteristics are met. The insulators electrically isolate the grid ribbon from the frame which is grounded, and mechanically supports the grid ribbons and terminals. The insulators must be capable of withstanding the dielectric strength and creepage distances as specified herein, The moisture absorption rate of this material shall not exceed 0.05 % per ASTM SPEC. # D570. NAMEPLATE DATA AND SERIAL NUMBER NAMEPLATE DATA ‘A. EMD part number B. Resistance value C. Manufacturer's name D. Serial number SERIAL NUMBER ‘The serial number is to include the month and year as 96A11 (Month A (January) thru M (December), eliminating the letter |), followed by a specific number for each grid. REAFFIRMED Baer RS - EDPS 498 SSE/BE Page 30f23rame Sate Gad Rest | 4.4.3. The nameplate shall be located in such a position that it will allow for easy visibility when viewed from the grid resistor's normal mounting position. 45 TERMINAL MARKING All terminals are to be legibly and permanently marked. The same marking shall also appear adjacent to the terminal on the case. These markings shall be located such that it can be read | after external connections are made. 4.5.1. The following number scheme shall be used for terminal identification: TERMINAL? = DESCRIPTION 1 One end of total grid resistance 2 Other end of total grid resistance 3 Motor Tap, Extended Range, or Control Connection © As aminimum, each grid segment will have at least two terminals; #1, and # 2.The terminal identification shall also appear on the case such that it will be legible after the connection is made, 46 SHIPPING Package identification - unless otherwise specified, containers shall be marked at a minimum with the following information: GMLG part number GMLG purchase order number Number of resistor grids in the container Manufacturer's name or identification ‘Shipping date or date code (warranty © The resistor grids shall be warranted by the manufacturer for six years from the date of application, 4.8 MAINTENANCE INSTRUCTIONS {Not applicable. This product is expected to be maintenance free. In the event of a failure where rebuild is a consideration, it should be rebuilt by the supplier. | Voce’ SSE/SE OPS 498 Page 4 of 23PT ym Bate ci Rein 5.0 TAL NTS 5.1, AMBIENT TEMPERATURE 5.1.1. The ambient temperature in which these grid resistors are required to operate is ~40°F to +117°F (40 C to +47 C). This ambient refers to the environment that surrounds the locomotive, ‘The effect of sunlight will increase the maximum surface temperature to 158 F (70 C) in the unpowered state 5.2 ALTITUDE 5.2.1, The resistor grid must be capable of operating continuously at altitudes from -300 to + 5,000 feet above sea level. ( MBRATION ‘€.3.1 These resistor grids shall be capable of meeting GMLG ECD 51-165 continuous vibration requirement curve. (copy attached - see page 22) 5.3.2. The resistor grid shall be mounted in i's normal position and vibrated in all three perpendicular planes to the EMD minimum curve. 5.3.3. After completion of the search of the vibration curve, the grid shall be vibrated for 8 hours continuously at the resonant point for each of the 3 vibration planes. 5.4 MECHANICAL SHOCK ‘These resistor grids shall be capable of withstanding a mechanical shock of 2g's. The acceleration pulse shall be a half-sine waveform with an allowable distortion not to exceed #20 %. The pulse duration shall be #10 milliseconds. The grid shall be mounted in it's normal orientation and receive a total of 10 shocks. At the conclusion of the test, the grid shall show no signs of mechanical damage, and be capable of dissipating full power. ‘DUST The dust test shall be conducted in accordance with the following specifications and constitute two subcycles of the moisture resistance test (Section 5.6). 5.5.1 |DUST CHAMBER A Shall be of sufficient size to house the grid under test, and allow distribution and scattering of dust from any direction surrounding the grid under test. B. Shall have a dust collection pan at the bottom of the chamber. C. Shall have an available high pressure air jet directed at the dust collection pan of such a nature to result in near dust saturation of the entire chamber. BEAIFIRMED a Bengt 0 SsEez EOFS 426 - = = Page 5 of 23TBEsTUED Fo OpyeinO Freon begTeno Tor 7 =F dang pue LOL eIpuy wo SaIGEIOMTET = TE) ware 15160Maa eeeeee enn ne nnn eeennneensnesnneeeneeeeneennnnnnnnnan 2 Dac Bae a Reon 5.6.7. Immediately after the fourth cycle, the grid resistors shall be removed from the chamber and meggered as described in section 5.5.5. If the grid resistor meets this requirement, it shall be subjected to a high pot test as described in section 6.3, 5.7. SALT ATMOSPHERE | 5.7.1 Locomotives come close to the sea where the atmosphere is humid and salt laden. | 5.8 CONTAMINANTS 5.8.1 The grids are located at the roof line of the locomotive, and are open to the outdoor environment. In the course of their lifetime, they will be exposed to: rain, snow, ice, salt, diesel exhaust, diesel fuel, oil, coal dust, brake shoe dust, sand and other contaminants. The locomotive has one DC link, and the electrical requirements are as follows, Non-Mtr, Tap | PARAMETER Segment Units Note Max. grid Power 367.5 kw | Short time (1 sec.) 3600 volts 7 | Max. Grid Current - Hot 553 amps | Max. DC volts across resistance 2700 volts Min, Grid Resistance - Cold 4.093, ‘ohms Max. Grid Resistance - Cold 4.425 ‘ohms Assumed R Hot/R Cold Ratio 4.40 max. 1 | Minimum Grid Resistance - Hot 1.202 ohms | Maximum Grid Resistance -Hot 1.238 ohms 2 (minimum current) Watt Den: 3 Motor Tap Section: Data from the system level testing will be required to finalize the definition of the motor tap section. Assistance from EMD will be provided to determine the first iteration. 1. The hot / cold ratio is an estimate. This ratio, along with the cold resistance values will | be adjusted when the information becomes available. | 2. This is the absolute maximum resistance, not to be exceeded under any circumstances. 3. The watt density should be kept to a minimum such that the maximum ribbon temperatures and thermal gradients have ar sdequate safety margin which will yield @ feliable design. The watt density shall be submitted with justification. REAFFIRMED Boagaee’ EDPS 492 Page 7 of 23 SSE/SEDre re Gases | 5.5.2 1 TION | ‘The dust used in this test shall vary in size from 1 to 650 microns in diameter and shall consist of approximately equal parts of the following substances. A. Calcium carbonate | B. Iron - Brake shoe dust or iron filings C. Silicon - Sand D. Aluminum E. Carbon black 5.5.3. The grid under test shall be mounted in it's normal orientation. 5.5.4 The total subcycle time shall be for a period of two hours, during which time the air jet will scatter dust three times per minute. 5.5.5 Following the subcycle, megger the grid resistor to determine it's resistance to ground with a 500 volt megger. The minimum acceptable resistance to ground is 1 megohm. Continue to the next step if the grid meets this requirement. 5.5.6. When the grid is removed from the test chamber and placed in the humidity chamber care must be taken so as not to unnaturally remove any of the dust that may adhere to the surfaces of the arid. 5.5.7 If more than 10% of the dust is removed by any unnatural shock(s), the grid shall be resubmitted for the entire dust test. NOTE: Upon completion of each of these tests, there shall be no evidence of physical damage such as cracks, broken welds, disengaged pins, etc. There shall be no electrical or mechanical failure 5.6 MOISTURE RESISTANCE 1 Grid shall the resistor be capable of meeting the requirements of EIA standard RS-186C, method 2 (copy attached - see pages 19, 20, & 21). 5.6.2. Prior to conducting this test, the grid resistor shall be tested to insure it meets all of the drawing requirements. | 5.6.3 , The grid resistors shall be in their normal mounting orientation, and subjected to this test under jino load, 5.6.4. The grid resistors shall be tested for 2 series of 4 cycles (96 hours). 5.6.5 Subcycling: twice during the test, the grid resistors shall be subjected to the dust test specified in section 4.5 5.6.6 Subcycle performed during any 2 of the first 3 cycles, humidity uncontrolled. REAI FIRMED Breen | DPS 498 -- SSEee Page 6 of 23ype tne Go Raines 644 Cl NEI ION See Page 18 6.1.1.1There are two circuits. Each circuit will consist of three non-motor tap grids, and one motor tap grid 62 DIELECTRIC 6.2.1. Air gap: 3500 volts / inch Creepage: 600 volts / inch Maximum voltage to ground : 1475 volts o Hence, . Minimum air gap to ground: 0.421 inches Minimum creepage to ground: 2.50 inches Minimum air gap, row to row: 0.421 inches Minimum creepage, row to row: 2.50 inches Exception: The distance between the top edge of the grid ribbon in the top row, and the underside of the screen should be a minimum of 3.85 inches. This may be achieved via the grid and hatch designs. 6.3 HIGH POT TEST The grid must be able to withstand a test potential of 4,000 volts AC for one minute between terminals and mounting frame. 64 DUTY CYCLE The resistor grids will be subjected to operation in the following manner: Overall % of time in operation - 15% }% of this time at >90 % of rated kw - 25%. % of this time at 50 to 90 % of rated kw - 50 % REAFFIRMED Bgot™® EDPS 498 Page 8 of 23,ye se Ren 7.0 MECHANICAI ENT: 7.1 MECHANICAL SUPPORT 7.1.1 The insulators must provide mechanical support for the terminals and the ribbon as follows : A. Support the terminals of the grid such that a 50 Ib. Force in any direction can be applied to the end of any terminal without causing detrimental damage to the terminal, support insulator, or ribbons. B. Support and space the ribbons of the grid such that the ribbons are not hindered in expanding when heated and are spaced properly to prevent adjacent ribbons from touching. 7.2 LIETING 7.2.1. Acrane will be required to lft both the entire grid system, and each grid section individually Hence, a method of lifing via a crane hook must be provided on the top side of the case. This hardware can not exceed TBD inches above the top flange of the grid case. 73 GEOMETRY 7.3.1 Box Type - Refer to drawing part number 8304193. 7.4 GUARD 7.4.1. The guard will be a separate component, which will be applied during the long hood equipped operation. 7.5 WEIGHT 7.5.1 The total weight of a single grid resistor shall not exceed 300 Lbs. RIBBON The temperature of the grid ribbon along with the worse case gradient shall be kept to a minimum, Its maximum value shall be justified as an integral part of the design, REAFFIRMED Rage EDPS 498 Page 9 of 238.0 84 82 83 mmc rae aa Reston AIR DELIVERY SYSTEM ; ‘Two 48 inch diameter fans, each with (10 ) 12 inch blades, powered by a 36 hp blower motor. The OD. of the fan hub is 24 inches. The requirements for the blower motor are defined in EDPS # 303, Fan performance characteristics can be found on page 23. Performance at other speeds and air densities can be calculated from fan laws. The fan is driven by a 4 pole DC motor. The source for the motor is a tap on one of the grid segments. The resistance of the tap determines motor voltage and fan speed. The air density into the fan will set the torque load of the fan on the motor and therefore motor current. Motor torque, speed, voltage, and current are all inter-related by the motor characteristics. Hence, grid systems operating at increased altitudes will have higher fan speeds. DRAWING REQUIREMENTS ‘The supplier will be responsible for furnishing GMLG a component drawing that includes the following information: Mechanical Outline (Three Views) - Dimensioned . Schematic with Terminals Labeled Resistance at 25°C (Ohms) Max. Grid Power . Short Time Power Rating (1 Sec.) Max. KW Max. Grid Current - Hot Max. DC Volts Across The Resistor Grid Tolerance Min. and Max. Grid Resistance - Cold and Hot Watt Density - Hot Grid Plate Width |. Grid Plate Thickness Grid Plate Length, Pin to Pin Grid Plate Length, Less Pins Grid Plate Effective Length |. Maximum Number of Grid Plates Grid Plate Embossment (include depth ) Spacing Between Adjacent Grid Plates Grid Plate Spacing Between Holes |. Weight . Design Must Conform to EDPS # 498. EOPS 498 Page 10 of 2340.0 RELIABILITY REQUIREMENTS (REQUIRE! ERIFIC, ANS) 10.1. Numerical reliability requirements for dynamic brake grids. 10.1.1 MTBF (mean time between failure) ‘The MTBF of a segment of the dynamic brake assembly shall not be less than 6,370,000 hours (corresponding to a failure rate of 0.1375 % per year (0.16 failures per million hours)). The failure rate of the system (consisting of 8 grid segments) shall not exceed 1.1 % per year. MTBF is defined as 8,760 hours times the number of units in the field during the year, divided by the total number of failures in the year. The system MTBF (mean time between failures) shall be guaranteed to EMD for the same number of years as the warranty period. Ghz Reliability Model ‘The series model in which the failure rate of individual components add (no redundancy considerations) shall be used to estimate the reliability of this product. For MTBF predictions, the total failure rate is the sum of the failure rates of all active parts 10.1.3 Precontract Estimate and Guarantee The vendor shail estimate the numerical reliability values specified in paragraphs 4,2 and 10.1.2 using actual field failure data or the data in NPRD-95. Use of field failure data will not be considered for approval unless accompanied by a listing that includes product configuration, list of railroads, type of service, years of service, and miles of service. The vendor shall supply information along with the values that are guaranteed to EMD with the proposal BAFO (best and final offer) 10.1.4 Postcontract Prediction the vendor shall prepare estimates of the numerical eliabilty requirements of paragraphs 4.2 and 10.1.2 and the derivation and rationale utilized in these estimates. The vendor shall update pre-contract data (paragraph 10. %.3), review and revise guarantees, if necessary, and supply this information to EMD at least 3 manths prior ta the start of manufacture. 10.1.5 Reliability of Deiivered Products | After the devices are received by EMD, the TR (test incidence reporting) program (paragraph 10.8), in which all vendors participate, will compare reliability achieved in the field with reliability ranted, on a regular basis, using vendor-supplied data BEAT FIRMED ' Wr Go? ssijee EDPS 498 Page 11 of 23EEE EEE EE EY, Dene batches 40.2 Operating Conditions 10.2.1 Environment ‘The product shall operate properly and achieve its specified reliability, even when exposed to | temperature (ambient, storage, thermal shock, heatffe) altitude, vibration, mechanical shock, \ humidity and moisture resistance, dust infiltration, and salt atmosphere exposure in accordance | with paragraph 4.7 of this specification. 10.2.2 Operational Profile 10.2.2.1 Locomotive Operation (typical) Idling, 7 hours/day Moving, 7 hours/day Off, 10 hours/day | Average annual operation: 330 days CG Average Distance: 200 Miles perday 66,000 Miles per year 10.222 Operational details and duty cycles The utilization values below are relative to the diesel engine operating time of 14 hours per day: Brakes: Brakes and actuator: 30,600 cycles/year, | Brake control circuits: 100% | Auxiliary systems 100% Diesel engine (hrs/day): moving train, 7; iding, 7; off, 10 | Alternator: 60% Propulsion system: 60% 10.3. Parts Control Program ‘The vendor shall have a documented parts control plan that inciuees the requirements of (paragraph 10.3, material identification, segregation, age control, end other normal requirements 288 applicable to this procurement. The parts control program and its effectiveness will be reviewed at all design reviews and auxiits. 10.3.1 Maximum Permissibte Failure Rate For Any Single Component , No component shall have a failure rete exceeding 1.14 failures per million hour assuming } operation in accordance with paragraphs 10.2.2.2 and 6.4, REAFFIRMED ger’ SSESE EDFS 4268 Page 12 of 2:‘ pane eG Rese, 10.3.2 Reliability Critical Parts, Assemblies, And Processes ‘Then vendor shall prepare a list of reliability critical parts, materials, and processes. These items are identified for attention because: 1. The failure of any one of them will cause the product to fail 2. They are crucial to system operational reliability. 3. Their failure rates or endurance characteristics are not known with sufficient certainty. ‘The documented measures to control the effectiveness and quality of these items will be assessed at vendor audits and design reviews. 10.4 General Requirements Yo Locomotive systems, sub-systems, assemblies, components and parts (products) shall be selected to ensure optimum reliability through application of the following criteria: + Use of products that are “service proven” in commuter rail applications + Use of the simplest possible product to perform the desired functionsconsideration of appropriate service and safety factors in design and manufacture Products shall utilize vandal-resistant design features and materials to the extent possible. Products shall be designed and installed in a manner which facilitates replacement, service, and repair. Products shell be designed and installed in a manner which will not require routine maintenance at intervals of less than 92 days Products shall be standard products, currently produced by reputable manufacturers, Non- standard, prototype, obsolete, or discontinued products shall not be used. Products shall be fully interchengezble between each locomotive without requiring adjustment. Design Reviews At least two formal design reviews will be conducted to determine the compliance of this product with the requirement of this specification (PRR, product review requirements, CDR, concept design review, DDR, detailed design review, PIR, product information review, MFR, manufacturing feedback review, and the VOR, validation design review), which occurs just prior ,{o production startup. Supplier is responsible for mesting all specified requirements, whether or not they are checked in one of the design reviews. The reliability portion of the design review data package shall show the status of reliability activities such as conformance to the component derating requirements, the latest estimates of MTBF, etc., and shall indicate the status of corrective actions. REAFFIRMED Bgerel EDPS 498 ~ Page 13 of 23,i Dye ea ton 40.6 TIR (Test Incidence Reporting System) This is the EMD equivalent of the widely accepted approach adopted by the transportation industry, as well as the military called FRACAS (failure reporting and corrective action system). The vendor shall have a closed loop system for recording failure data (including in process, final test and from the field), exercising corrective action on observed failures, and making such activity (especially current field failure rates) visible internally and at EMD. Within 10 days of receipt of failed product, this system shall provide failure analysis data for use in the EMD FRACAS system. A monthly failure summary by EMD part number and serial number shall be provided to EMD within 5 days of the end of each month. The supporting data that accompanies this surnmary shall be recorded in the format used in the TIR system, referenced in the applicable documents list. *9.7 Reliability Development / Growth Testing CG (Demonstration Of Achieved Reliability) The vendor shall demonstrate that the products delivered meet the specified, numerical reliability requirements of paragraphs 10.1.1 and 10.1.2 The actual field reliability shall be monitored, beginning with the first unit delivered, and the results plotted monthly and projected forward one yea ‘nts tho future. If the actual failure rate is less than the guaranteed maximum failure rate and remains so for one yeer ster the order quantity has been delivered, this requirement will be satisfied. If, at any time, legitimate projections of the actual field failure data show that the guaranteed maximum failure rate will be exceeded, EMD will assist the vendor in setting up a reliability development / growth test. This will include a closely monitored and well defined test, analyze, and fix activity to correct the problem(s). EMD reserves the right not to proceed with production based on the field test, results. 10.8 Design Guidelines For Maintenance And Serviceability © The product shall be built in accordance with the EMD design guidelines for maintenance and serviceability with specific emphasis on the items below. 10.8.1 Soliatility Centered Maintenance, Design Practice Fice: > design standpoint, RCM is a decision process jin which the maintenance strategy for each con22nent ANS system is determined as pert of its development, It considers the effect j of various p:cciuct failure modes on locomotive operation, and, after determining the severity ¥, consequencas of such failures, decides to proceed at that point or to proceed with a ‘Tris product shall require 10 regi veduled maintenance. iended maintenance strategy is to replace in ite event it fails (run to failure) ‘REA! FIRMED Bego0 EDPS 498 : Page 14 of 23mac Bate i Ron 10.9 Reliability Growth Testing (RGT) All validation testing, including conformance to all environmental requirements, in addition to section 10.9.1. constitutes the RGT. The supplier will be responsible for conducting a stress. test. Below is a suggested stress (warpage) test. It does not guarantee the desired reliability of the product, but will help identify areas for design improvements. Itis the supplier's, responsibilty to insure this product meets it's reliability goal. 10.9.1 Warpage Test 10.9.1.1 Purpose The purpose of this test is to determine the ribbons ability to withstand loading without warping to the point where it would lead to failure. The test is performed with a sample size of 10 grid sections made with production tooling. This test is to be performed at an YU altitude not to exceed 1000 ft. It is not required that this test be conducted at a specific temperature or range in temperature. 10.9.1.2 Procedure: ‘A. Mount two test grids, one on each side of the hatch relative to the inlet screens for loading purposes. This test hatch must be the same hatch part number used on production locomotives utilizing this grid design. Fill he remaining two positions in the test hatch with grids that were never previously loaded. These grids will not be loaded during this test. Connect s power source to the two test grids. Connect the test hatch fan to a separate power source such that the fan speed can be controlledindependently of the grid load. B. Set the fan speed to thd % of the fan's nominal value (based on ribbon temperatures slightly lower than 1600 degrees f) at full rated grid current. Once the fan speed is set, the fan will continue to run throughout the test program, YU C. Load the test grids to their full rated current level. With the reduced fan speed this will cause the grid ribbons to operate at an elevated temperature. Maintain this load on the grids for 3 minutes, then immediately remove the load and allow the grids to cool for 2 minutes (the fan is stifrunring). During this § minute cycle an observer should be watching the grids looking for signs of excessive ribbon warpage. Immediately repeat this loading straess (3 minutes on, 2 minutes off) : until either a failure occurs or the test grids have survived 8 pre-toading cycles. Immediately following these & cycles, continue the test by lowering the fan speed to td % of the fan's nominal value (based on a maximum ribbon temperature of 1600 degrees fj for an aciditional 8 cycles or until a failure occurs. Do not alter the load. REA: FIRMED Bogor SSE EDPS 498 Page 15 of 2310.9.1.21 Failure : A failure of the ribbon during this test is defined as a warpage of any of the ribbons that : 1. Is severe enough to cause that ribbon to contact an adjacent ribbon, thus initiating a ribbon burning process. Just prior to adjacent ribbons contacting, the area around the warpage will begin to become very red (increased temperature due to a lack of airflow). When actual contact occurs, the failed area of the grid will start sparking, which will lead to melting of the ribbons. At that point the load should be removed from the grid to prevent any harm to the observer. 2. Any two ribbons that are 1/16 inch apart, or less, after the test has been completed; and the grids have been allowed to cool down Co 4.2.2. Interpretation of Test Results : A high degree of confidence can be gained if at least 8 of the 10 samples tested survive the 16 cycles AS DEFINED ABOVE. ty Verification Testing 10.104 Following the reliability growth testing, will be reliability verification testing which will consist of equipping 25 locomotives, or the first production order, whichever is less, with grids produced from production tooling. These locomotives must be in service for 1 year with no failures allowed. If ene or more failures does occur, the following is requires ; 1. A design review must be held with EMD to discuss the failure mode(s), 2. Develop a corrective action plan, that includes further testing 3. Make a risk assessment prior to releasing any future orders, 10.11 Other Requirements: ‘To the extent possible, this product shall not require the use of special tools. EDPS 498 Page 16 of 23BRAKING EFFORT ~ KILOGRAMS 28000 24000 20000 46000 12000 6000 3 8 GENERAL MOTORS LOCOMOTIVE GROUP ELECTRO-MOTIVE DIVISION LA GRANGE, ILLINOIS, U.S.A DYNAMIC BRAKING EFFORT - SPEED CUAVE GTASMAC LOCOMOTIVE 85:16 G.A. - 4054.4 mm HH. | ANY ONIUNG GanuOsuaE a DADENS “ICz) a31419345 al 2YOATANE WHOLLGO yoy | Cer ql I wa 130 SAGA Hyak 53 OL Nawal V av 3 TVS UW DNINOLLIONOD 40 NOW INDE tasce19. (aod Lr een oats soaesev'sanan [P| tt -sunsvan :319A9 WNis 30. 0N3: sass DNINOILIGNOD USONVHD WOUs ONLV 3H OL a31337uNS 3U. LON TIVHS Sh 3¥I93u5 U3AIMOH 0314103u5NN 5 Sunzvuauna1 30 3NVHO JO LVI v: vu 2pmiowknda ON Hm inna xse00 x36.06 5600 xs600 ty BOVUOLLN3 $33493G WI SuniVEsEnaL OPS 438 Page 21 of 23 Bacere! SSE/SE .S3HONI - LN: 0c" Sie gi" vie He Ollie 380° 90° vo" Zo" REAFFIRMED Boe. SSE/SE Page 22 of 23 lal EDPS 498 G91-1S 003 4 BAMND LNSNSYTAOSY NOTLVYSIA \__L33HS 2 AAI LOW-C LFS 3 -G91-1G 0049Op ne Ress Wao‘ ‘2uinjon ooosy 0000» ooose o000¢ cose 000% ooos cooot 9008 ors ogg 09 099 ore ose ‘Aaysuop aye JH/“Gl OZ0" ‘Wes 0081 ownjon “sa osnssosd 2Ne1S ey oyerg ojueuhG oP Bago! SSE/SE caps 498 Page 23 of 23 “d “ainssaid ones OHM