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 ‘REA! FIRMED EDPS 332 Page 1 Of 53.1. 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 let313.2. 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 38.6.1.1. 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. : REAL FIRMED ee 22! SSE/SE EDPS 332 Page 5