Operating Manual For TL & AC Coaches-Eng PDF

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(For Official Use Only)
Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS
OPERATING MANUAL
FOR
TL & AC COACHES
CAMTECH/E/10-11/OM-Coaches/1.0
October 2011
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Maharajpur, GWALIOR - 474005
2 Camtech/E/10-11/OM-Coaches/1.0
OPERATING MANUAL
FOR
TL & AC COACHES
2
Camtech/E/10-11/OM-Coaches/1.0 3
FOREWORD
With the growing demand of passenger comfort and expectations it is essential to have
trouble free operation of TL & AC coaches enroute. CAMTECH has prepared this manual to
cover all aspects of operation of TL & AC coaches to ensure reliability.
The duties and instructions for escorting staff prescribed in this manual are to ensure safe
and comfortable journey. This manual also describes different checks and operating procedure
for AC coaches. A very useful compilation of common defects and their remedial, Do’s &
Don’ts and disaster management is also included in this manual.
I compliment CAMTECH for bringing out this manual, which will be of immense help to
the escorting staff of Indian Railways.
RDSO, Lucknow
Date : 10.10.2011 Executive Director/ PS & EMU
PREFACE
The perfect operation of TL & AC coaches is necessary to ensure reliability and

availability of coaches. Railway Board and RDSO have issued various operating and
maintenance instructions from time to time. CAMTECH has prepared this operating manual for
TL & AC coaches on the basis of information collected from Railways in consultation with
RDSO.
The objective of this manual is to disseminate knowledge among escorting staff and to
make them aware of operating and trouble shooting techniques to be followed on line.
This manual includes brief description of control panel as well as ratings of MCBs and
fuses, duties and instructions for escorting staff. This manual also includes pre-departure
preparation and operating procedure for AC coaches apart from trouble shooting and disaster
management.
It is clarified that this manual does not supersede any existing provisions laid down by
RDSO or Railway Board/Zonal Railways. This manual is for guidance only and it is not a
statutory document.
I am sincerely thankful to Sh. Prafull Chandra, Director, RDSO/ Lucknow and also all
field personnel who helped us in preparing this manual.
Technological up-gradation & learning is a continuous process. Please feel free to write
to us for any addition/modification in this manual.
CAMTECH, Gwalior Peeyoosh Gupta

Date: 10.10.2011 Jt. Director Electrical
4
CONTENTS
Chapter No. Description Page No.
Foreword iii
Preface iv
Contents v
Correction slip vii
Abbreviations viii
1. GENERAL 01
1.1 DUTIES OF AC ESCORTING STAFF BEFORE DEPARTURE 01
1.1.1 DUTIES OF AC COACH ATTENDANT 01
1.1.2 DUTIES OF AC COACH MECHANIC 01
1.2 DUTIES OF AC ESCORTING STAFF DURING RUN 02
1.3 INSTRUCTIONS FOR AC ESCORTING STAFF 02
1.4 LIST OF SPARES REQUIRED FOR AC ESCORTING STAFF 02
1.5 CABLES TO BE AVAILABLE IN AC COACHES 03
1.6 FUSES IN SG CONVENTIONAL (U/S) TYPE AC COACHES 03
1.7 MCBs & FUSEs IN SG RMPU TYPE AC COACHES 04
1.8 RSWs IN SG AC COACHES 04
1.9 COMPONENTS OF AC CONTROL PANEL 05
1.10 SAFETY PRECAUTIONS 05
1.11 SAFETY TIPS FOR PREVENTION OF FIRE 06
2. OPERATION 07
2.1 PREPARATION OF COACH 07
2.1.1 GENERAL CHECKS IN AIR CONDITIONED COACH 07
2.1.2 OPERATING PROCEDURE FOR AC COACHES 07
2.2 PRECOOLING PROCEDURE 08
2.3 TEMPORARY CONNECTION 09
2.3.1 DCV-DC FEED EXTENSION PROCEDURE 09
2.3.2 THROUGH FEEDING PROCEDURE (NON-AC COACHES) 10
2.3.3 THROUGH FEEDING WHEN AC COACH IS IN BETWEEN TWO
TL COACHES 11
2.4 WORK TO BE CARRIED OUT ON REACHING THE DESTINATION 11
2.5 PROFORMA FOR AC COACHES LOG BOOK 12
3. DISASTER MANAGEMENT 18
3.0 DUTIES OF ELECTRICAL ESCORTING STAFF IN CASE OF
EMERGENCY 18
3.1 DERAILMENT/ COLLISION (INCLUDING LEVEL CROSSING ACCIDENTS) 18
3.2 FIRE IN TRAIN 18
3.3 CYCLONE/ STORM/ FLOOD 18
Chapter No. Description Page No.

3.4 REPORTED BOMB IN TRAIN 18
3.5 EXPLOSION OF BOMB IN A TRAIN 19
3.6 EXPLOSION OF BOMB IS REPORTED IN A FIXED INSTALLATION 19
3.7 OPERATION OF FIRE EXTINGUISHERS 19
3.8 ELECTRIC SHOCK 20
4. TROUBLE SHOOTING 21
4.0 TROUBLE SHOOTING INSTRUCTIONS FOR RMPU AC COACHES 21
4.1 NO GENERATION 21
4.1.1 AT POWER PANEL 21
4.1.2 AT ALTERNATOR 21
4.1.3 AT RRU/ ERRU 22
4.2 110 V DC LOW VOLTAGE 22
4.2.1 AT RRU/ ERRU 22
4.2.2 AT BATTERY 22
4.3 INVERTER NOT WORKING 23
4.3.1 AT POWER PANEL 23
4.3.2 AT INVERTER 23
4.4 INVERTER TRIPPING ON “ON LOAD” 24
4.5 INVERTER TRIPPED ON “OFF LOAD” 24
4.6 INVERTER TRIPPING ON STABLLNG 24
4.7 AC PLANT NOT WORKING 25
4.7.1 POWER INDICATION LED NOT GLOWING 25
4.7.2 BLOWER MOTOR NOT WORKING 26
4.7.3 CONDENSER MOTORS NOT WORKING 28
4.7.4 COMPRESSORS NOT WORKING 29
4.8 ALL EQUIPMENT ARE NOT WORKING IN STATIONARY CONDITION 30
4.9 WRA/ MONOBLOCK MOTORS NOT WORKING 30
4.10 ALTERNATOR SEPARATE EXCITATION PROCEDURE 31
4.11 TROUBLE SHOOTING INSTRUCTIONS FOR NON AC COACHES 32
5. DOS AND DON’TS 33
5.1 GENERAL 33
5.2 IN CASE OF BURN 34
5.3 IN CASE OF HEAD INJURY/ BLEEDING NOSE 34
5.4 IN CASE OF TRAUMA 34
5.5 IN CASE OF INJURIES 35
5.6 IN CASE OF 25 KW ERRUs 35
5.7 IN CASE OF 4.5 KW ERRUs 36
APPENDIX – A TECHNICAL KNOW-HOW 37
APPENDIX – B ELECTRICAL CIRCUITS 42
REFERENCES 50
6
ISSUE OF CORRECTION SLIPS
The correction slips to be issued in future for this handbook will be numbered as follows:
CAMTECH/E/2010-11/OM-Coaches/C.S. # XX date---------
Where “XX” is the serial number of the concerned correction slip (starting from 01
onwards).
CORRECTION SLIPS ISSUED
Sr. No. Date of issue Page no. and Item Remarks

no. modified
ABBREVIATIONS
ACCA AC Coach Attendant ACCI AC Coach Mechanic

Ah Ampere hour Alt Alternator
Amp Ampere CD1 Condenser Motor1
CD2 Condenser Motor2 CP1 Compressor motor1
CP2 Compressor motor2 DP Double pole
EFT Emergency Feeding Terminal ELD Earth Leakage Detector
ERRU Electronic rectifier cum regulator FDB Fuse distribution board
unit
HP High pressure HRC High rupturing capacity
INV Inverter IR Insulation resistance
LED Light Emitting Diode LP Low pressure
MCB Miniature circuit breaker MCCB Moulded case circuit breaker
–VE Negative NPP Non Power panel
OHP Over heat protection OP Oil pressure
OVP Over voltage protection OVR Over Voltage Relay
+VE Positive PP Power panel
PVC Poly Vinyl chloride RMPU Roof mounted package unit
RRU Rectifier cum Regulator unit RSW Rotary Switch Way
SG Self generating SMF Sealed Maintenance Free
SMI Special Maintenance Instructions TC Temporary connection
TDR Time delay relay TP Triple pole
VR Vane Relay VRLA Valve Regulated Lead Acid
battery
WRA Water Raising Apparatus.
8
CHAPTER 1
GENERAL
1.1 DUTIES OF AC ESCORTING STAFF BEFORE DEPARTURE
1.1.1 DUTIES OF AC COACH ATTENDANT

1. To appear in prescribed uniform and have his badge fixed on it so as to easily
identify by the passengers.
2. To be present one hour before the schedule departure of the train.
3. To check that all internal electrical fittings in the coach provided for the comfort
and safety of passengers are intact and in working order.
4. To monitor electrical/ mechanical defects developing in the coach and call
maintenance staff for attending whenever necessary.
5. To assist the AC coach mechanic in pre-cooling of the coach well before
commencement of the journey.
6. Assist AC coach mechanic to take reading of pressure at panel board, discharge
pressure of refrigerant and oil pressure of compressor and voltage, current of the
alternators and battery etc., from time to time and make entries in the log book
and inform AC coach mechanic incase of any abnormalities in the readings.
7. To assist the AC coach mechanic in the rectification of minor faults in the AC
coach equipment enroute.
8. Keep doors closed during run & open at station when train is stopped.
1.1.2 DUTIES OF AC COACH MECHANIC
1. Should be available in the coach one hour before schedule departure of the train.
2. Check logbook of the coach for any entry by the maintenance staff and act
accordingly.
3. Check the condition of V-belts in stable condition. It should be 6+6 from the
primary depot.
4. Check OFF load battery voltage. It should be 118V.
5. Record all parameters of the equipment in the logbook.
6. Check whether the coach is pre-cooled or not. If not, pre-cooling should be done
after placement of the train and pre-cooling should be removed 10 minutes before
departure of the train.
7. Switch OFF one of the AC plant before removing pre-cooling cable from external
supply.
8. Check all the grills inside the coach. These should be in open condition.
9. Check all lights, emergency lights, fans, night lamps, reading lamps & mobile
charging sockets.
10. Attend complaint of passengers, if any.
11. Should do temporary connection in TL coach also, if required.
Operating Manual for TL & AC Coaches October 2011

1.2 DUTIES OF AC ESCORTING STAFF DURING RUN

1. As the coach picks up speed after its commencement of journey, observe the
reading of the voltmeter and ammeters of alternators, to ensure that they are
working and write down the parameters in the logbook for every two hours.
2. Observe the function of AC plants by noting the load currents on the inverters and
also cooling effect inside the coach.
3. Record temperature in the logbook for every 2 hours.
4. If any abnormality is observed, first note down the same in the logbook and try to
solve the problem to the extent possible.
5. Frequently check the AC control panel indicators for any faults.
6. Change the working of WRAs/ monoblock pump for every 6 hours if AUTO
mode is not in service.
1.3 INSTRUCTIONS FOR AC ESCORTING STAFF
1. Be cautious about un-claimed baggage /luggage.

2. Check working of AC plant/light/fans & reading lights etc.
3. Check cleanliness of compartment.
4. Keep panel shutter closed with latches already provided.
5. Ensure following in the coach:
a) Pre-cooling cable
b) Emergency feed cable.
Carry standard tool kit box.
6. Use fire extinguisher in case of fire.
7. Open emergency window in case of emergency.
8. Troubles shoot line failure immediately.
9. Communicate line failures & Non-AC certification, if any. Inform to base
depot & destination depot immediately.
10. Fill logbook details properly.
1.4 LIST OF SPARES REQUIRED FOR AC ESCORTING STAFF
S. No. Description Qty

1. 4 sq mm PVC copper wire in two pieces for manual operation of 15m
the ERRU/RRU
2. . Inter cell connection leads along with nut and bolts. 2+2
3. Carbon brushes for blower, condenser & compressor motor for 1 set
under slung coaches.
4. HRC fuses 400A, 250A, 160A, 125A, 63A, 40A, 20A, 10A & 6A 2 set
5. CFL & choke 2
6. Cotton cloth for cleaning 1m
October 2011 Operating Manual for TL & AC Coaches

1.5 CABLES TO BE AVAILABLE IN AC COACHES
S. No. SIZE OF E-BEAM COPPER CABLE QUANTITY
1 3 core 70 mm² cables as per RDSO’s 25 meter length with pre-cooling

specification No. ELRS/ SPEC/ ELC/ socket as per RDSO’s drawing No.
0019 (Rev-1) issued in July 2010. RDSO/ PE/ MS/ AC/ 0044-2008
(Rev-1) issued vide letter no.EL/
7.1.83 dated 28.05.2010.
2 2- Core 25 mm² cables as per RDSO’s 25 meter with proper crimping

specification No. ELRS/ SPEC/ ELC/ lugs on both ends for DC-DC feed
0019 (Rev-1) issued in July 2010. extension.
3 Single Core 50 mm² cable as per RDSO 0.5 meter with proper crimping
specification No. ELRS/ SPEC/ ELC/ lugs on both ends for bypassing
0019 (Rev-1) issued in July 2010. the cells.
Note: Only 3 cells can be bypassed.
4. Single Core 16 mm² PVC/2.5 mm² 1.5 meter with proper crimping
elastomeric /2.5 mm² e-beam cable for lugs for feed extension in TL
Feed extension in TL coaches as per Coaches.
RDSO’s Technical circular
No.RDSO/PE/TL/TC/0002-(Rev-0)
1.6 FUSES IN SG CONVENTIONAL (U/S) TYPE AC COACHES
S. No TYPE CAPACITY LOCATION
1 HRC 315A Negative and Positive terminal of cell bank
2 HRC 250A Both plant negative and positive supply
3 HRC 160A Incoming supply from alternator regulator
4 HRC 100A Positive supply of control panel for cooling

plants
5 HRC 60A For positive supply of heating control panel
6 HRC 2A For negative control supply
7 Bottle type 10A, 20A Blower and condenser motor supply

Cartridge

1.7 MCBs & FUSES IN SG RMPU TYPE AC COACHES
S. No TYPE & No CAPACITY LOCATION

1 Main MCB TP 63A Power input to RMPU equipment
2 MCB TP 1,2,3 6A Blower motor & Condenser motor
3 MCB TP 4,5 32A Compressor motor
4 MCB TP 6,7 16A Heater
5 MCB DP 8 2A In coming of Control transformer
6 MCB DP 9 4A Out going of Control transformer
7 MCB TP 16A For WRA
8 HRC-F3 10A ERRU field fuse
9 HRC-F1, F2 160A ERRU main fuse
10 HRC 400A Positive and negative of battery
11 MCB DP 0.6A Inverter cooling fan
12 MCCB DP 250A Inverter input
13 MCCB DP 300A Inverter input
( Siemens make)
14 HRC fuse 20A In ERRU/ RRU before capacitor
1.8 RSWs IN SGAC COACHES (As per RCF drawing no.CC70401, CC72405)
S. No. RSW No. CAPACITY LOCATION

1 RSW1 500A For alt1,alt2 and battery at power panel
2 RSW2 300A For Inv-1 & Inv-2 at power panel
3 RSW3 16A For inverter selector of WRA/ mono block pump
at power panel
4 RSW4 16A For Fans circuit at power panel
5 RSW5 10A L1 & L2 circuits at power panel
6 RSW6 2A Night lamps at power panel
7 RSW7 10A For WRA selection at power panel
8 RSW1 63A Power ON RSW at AC control Panel
9 RSW2 16A For blower ON at AC control Panel
10 RSW3 16A For auto/manual mode selector RSW at AC
control panel
11 RSW5 6A For compressor selector, bypass RSW at AC
control panel
12 COS-1&COS-2 63A Change over switch for selection of power supply
RSW1,RSW2, Change over control box
RSW3,RSW4

1.9 COMPONENTS OF AC CONTROL PANEL
1. Overload relay (O/L)

O/L – 1 - For evaporator blower motor.
O/L – 2 & 3 - For condenser motor 1 & 2.
O/L – 4 & 5 - For compressor motor 1 & 2.
2. Timer Delay Relay
T.D.R. – 1 & 2 - For compressor motor 1 & 2.
3. Contactors
C-1 - For blower motor.
C-2 & 3 - For condenser motor 1 & 2.
C-4 & 5 - For compressor motor 1 & 2.
C-6 - For heater bank 1 & 2.
AC-1 - For auxiliary contactor.
4. Rotary switch
R.S.W. – 1 - For 3 AC, main supply ‘ON/OFF’.
R.S.W. – 2 - For control supply ‘ON/OFF’.
R.S.W. – 3 - For VENT/ AUTO/ MANUAL COOLING/
MANUAL HEATING.
R.S.W. – 5 - For compressor by pass mode selection.
5. O.H.P. – 1 & 2 - For over heat protection of heater 1 and 2.
6. Electronic thermostat - For controlling heating/ cooling.
7. V.R. – 1 and V.R. 2 - Vane relay for check air loss in the air supply to
both side blower.
8. Transformer - 415V/ 110V, step down transformer for control
circuit.
1.10 SAFETY PRECAUTIONS

The following precautions should be observed to reduce risk of injury or death.
1. Keep all covers in place and doors closed during normal operation.
2. Ensure that the test equipment is in good and safe operating condition.
3. When working on the connected motor or motor supply cable, ensure that the
input MCCB of the converter is in ‘OFF’ position.
4. If smoke /fire observed anywhere in the coach then switch ‘OFF’ power supply
immediately.

1.11 SAFETY TIPS FOR PREVENTION OF FIRE
1. Ensure provision of two numbers of dry powder type fire extinguishers in A.C.
coaches.
2. Ensure that no protection is by-passed.
3. Proper rating of MCBs / fuses shall be used.
4. Look for any overheating sign after putting on all loads.
5. Loose or temporary connection, hanging wires/ exposed joints etc. should not be
allowed.
6. Check condition of PVC bushes/ glands provided in junction-boxes. Replace

worn-out bushes/ glands during schedules.
7. Check condition of insulation especially in junction-boxes. Don’t permit

damaged/ broken/ cracked insulation.
8. Rubbing of cables shall not be permitted.
9. Check physical condition of wire/ cables for external damage and overheating
marks, discoloration of lugs due to excessive flow of current/ overheating.

CHAPTER 2
OPERATION
2.1 PREPARATION OF COACH
2.1.1 GENERAL CHECKS IN AIR CONDITIONED COACH
Before placing the AC coach at starting station, this should be pre-cooled. The
AC coach attendant should check the followings:
1. Visually inspect, both upper and under frame and ensure all fittings are intact at
their places.
2. In under frame check alternator, axle pulley, ‘V’ belts of alternators, compressor
& condensers (in case of under slung), battery etc. if any abnormality found
rectify or inform the concerned supervisor/ mechanic, for rectification.
3. In upper frame check control & power panels, fan and light fittings etc..
4. Check the battery voltage. It should be above 118V at ‘OFF’ load & 115V on
‘ON’ load.
5. Check the position of ‘RSW I’ & ‘RSW II’ is normal and ensure that the mains
and LVR indication (U/S) is glowing in control panel.
Start the control panel and observe the reading of ‘LP’ HP, OP gauges (U/S).
I. Suction pressure gauge reading should be 2.6 – 2.8 kg/cm2.
II. Discharge pressure gauge reading should 12.6 - 15.5 kg/cm2.
III. Oil pressure gauge reading should be 5.6 - 6.3 kg/cm2.
IV. Feel the temperature suction side cold, delivery side hot and liquid line should be
warm.
2.1.2 OPERATING PROCEDURE FOR AC COACHES
1. Ensure coach voltage by pressing voltmeter switch (118V off load).

2. Keep 400A RSW1 in ALT 1, 2 position.
3. Keep the 300A, RSW2 in power panel on Inverter 1&2 position.
4. Latch ON the MCCB in the inverter and keep the inverter switch in ON position
and observe input DC voltage in the voltmeter (110 V D.C) and AC output
voltage 415V.
5. Put ON the main supply by putting rotary switch RSW1 in ON position. This will
cause the RED, YELLOW & GREEN (Power supply) indications to glow. This
rotary switch should be switched OFF only in case of repairs/servicing of the unit
or control panel. This is necessary to ensure healthy power supply to crank case
heaters even the unit is OFF. Normal ON/OFF operation of the unit is achieved
using RSW2.
6. Check that all the MCBs are ON and the ‘POWER ON’ (RED) LED is ON.
Ensure that RSW5 is at position Comp.1 & 2 ON.

7. Place RSW3 on AUTO position and ensure the contacts of CD1 & CD2 close
immediately and CP1 & CP2 contactors close after a time delay of 120 sec &150
sec respectively.
8. Observe and ensure that there is no trip indication in the LED indication panel of
AC control panel.
9. After closing of CP1 & CP2 contacts check the load current in the inverter output
side ammeters (21-23 Amps).
10. Follow the same procedure for the other side AC plant.
11. Ensure working of plant on AUTO mode.
12. Switch ON the WRA/ Monoblock pump motor and check for availability of water
in the toilets and wash basins.
13. Record the temperature of each unit (PP and NPP side) at Electronic thermostat
display unit. If Electronic thermostat is not there, the temperature may be
measured by portable thermometer near the return air grill.
14. Do not operate the alternator rotary switches (300 amps capacity) on load. This
can cause damage to the switch, electronic components and the V-belts.
15. For failure noticed enroute, if any assistance is required at the enroute station,
message should be given to the SE/JE of the station concerned in advance with a
copy to the primary and secondary maintenance depots concerned.
The following interlocks have been provided in the control panel to
ensure sequence of plant operation:
a. If blower motor is not ON, other equipment cannot get switched ON.
b. If Vane Relay is not ON, “AIRLOSS” LED will glow and no other
equipment except the blower can get switched ON.
c. One condenser fan is ON, the compressors can get switched ON.
d. However, if either condenser fan is defective, one of the compressors
operation should be disabled by using RSW5.
e. If Heater is ON, compressor cannot be switched ON.
f. Heaters can be switched ON only if both condenser fans are OFF.
2.2 PRECOOLING PROCEDURE

1. Place 63A change over switch in the AC control panel on external position.
2. Switch ‘ON’ one of the AC plant preferably NPP side when the external power
supply is not extended to battery charger.
3. Connect Female socket end to the coach and male socket end to the pre-cooling
socket.
4. Switch ‘ON’ the MCCB at Pre-cooling male socket.
5. Ensure the 3-Ph supply in the AC control panel and switch ON the other AC plant
through inverter only.
6. Ensure that centre zero ammeter reads charging Amperes depending upon battery
condition.

2.3 TEMPORARY CONNECTION
2.3.1 DC-DC Feed Extension Procedure

A. From Power Panel to Power Panel (RMPU)
1. Switch OFF AC plants before extending TC from DC Power Panel to DC
Power Panel.
2. Remove 250A inverter +VE, -VE fuses in the power panel for one of the
inverter supply.
3. Extend the DC supply from (2514 or 2513) terminals of power panel of
healthy coach to terminals of (2514 or 2513) power panel of defective coach
with 2 core 35 sq. mm copper cable as shown in the figures.
4. Remove the battery fuse of the defective coach.
5. After ensuring through feeding connections, re-insert the 250A fuses of the
inverters in both the healthy and defective coaches.
6. Switch on AC plant by balancing the load on both coaches to avoid over
loading of healthy coach alternators and batteries.
Healthy RMPU Coach Failed RMPU coach
B. Power Panel to/from AC Control Panel (U/S Type)

1. Switch OFF AC plants before extending TC from DC Control Panel to DC
Power Panel.
2. Remove 250A Inverter +VE, -VE fuses in the power panel for one of the
inverter supply.
3. Extend the DC supply from (2514 or 2513) terminals of power panel of
healthy/defective coach to terminals (B +VE, B -VE) of control panel of
defective/healthy coach with 2 core 35 sq. mm copper cable as shown in the
figures.

Healthy RMPUCoach Failed U/S coach
4. Remove the battery fuse of the defective coach.

5. After ensuring through feeding connections, ensure no switch is in ON
condition then re-insert the 250A fuses of the inverters in both the healthy and
defective coaches.
6. Switch on AC plant by balancing the load on both coaches to avoid over
loading of healthy coach alternators and batteries.
2.3.2 Through Feeding Procedure (Non-Ac Coaches)
Actions to be take in healthy coach ROOF JUNCTION BOX
1. The availability of power supply in the L1 RSW L2 RSW Fan RSW SPM RSW
emergency fed terminal should be ensured.
2. Only one dark coach should be extended
feed supply from one healthy coach.
3. Before connecting, the polarity of healthy
coach as well as dark coach should be
checked.
4. L-II circuit of the healthy coach shall be
switched off before connecting supply to the
dark coach. 16A Fan 16A SPM 35A -VE
16A L1 16A L2
HRC HRC HRC
5. The rotary switch (socket parreling main) HRC HRC
SPM I & II shall be kept in ON position.
Actions to be take in defective coach and feed extension

1. The earth fault shall be checked with the help
of test lamp. If earth fault is there then feed
extension should not be done.
2. The rotary switch (socket parrelling main)
SPM I&II shall be kept in ON position.
3. Remove (+ve) fuse from battery box and (-ve)
fuse from main junction box to disconnect the
power supply of battery.
4. L-II & fan circuits of the dark coach shall be
switched off before connecting supply from +VE, -VE EFT Terminals
healthy coach.
5. The feeding shall be given to L-I circuit only of the dark coach from healthy coach.

6. The defective coach shall be attended and feed cable should be removed at the first
available opportunity by TL staff.
7. The size of cables for feed extension shall be of 16 mm2 PVC aluminum/ 2.5 mm2
elastomeric cable/ 2.5 mm2 e-beam copper cable.
8. The length of the wire for feed extension shall be 2 x 1.5 meter (for both terminals).
9. Both ends of the cable shall be provided with suitable size of lug.
10. The cables shall be secured tightly by screws or bolts, nuts and plain washer. The
proper tightness of the connections should be ensured.
2.3.3 Through Feeding when AC Coach is in Between Two TL Coaches
1. Switch off the SPM RSW in healthy coach.

2. Remove –VE fuse in failed TL coach and switch off Lights and fans.
3. Extend the TC from healthy coach EFT to AC coach EFT.
4. Ensure the connectivity of the EFT cables on both ends of the AC coach.
5. Extend TC from the other end of the AC coach EFT to failed TL coach EFT.
6. Before switching on the SPM RSW, Switch off L2 circuit in the healthy coach.
7. Switch on SPM RSW and ensure the availability of supply in Roof Junction box of
failed TL coach.
8. Switch ‘ON’ L1 circuit and Fan circuit in the failed TL coach.
9. Always remember that when extending TC from one coach to other coach, switch
off L2 circuit in both the coaches to avoid over loading of alternator of the healthy
coach.
AC COACH Defective TL
Healthy TL Coach Coach.
TC TC
2.4 WORK TO BE CARRIED OUT ON REACHING THE DESTINATION
1. The failures which occurred during the outward journey should be reported at the
destination to the officials in charge in a written statement and obtain
acknowledgement from them. Also ensure that the failures have been attended.
2. Ensure that arrangements are made for charging the coach during stabling at the
destination station.
3. On return to the headquarters, escorting staff will handover the coach to the
platform electrical staff in all respects along with the logbook. In case of any
equipment failure or unusual occurrence, it should be reported to the SE/JE in
person and submit a detailed report of the problems and explain them besides
making entry in the logbook before breaking off duty.

2.5 PREFORMA FOR A.C. COACHES LOG BOOK

(As per RDSO TC No. RDSO/PE/AC/TC/0004-2010(Rev.0) dt 24.06.2010 issued vide RDSO
letter No. El/7.2.1 dt. 19.07.2010)
COACH HISTORY SHEET

Railways:
A. COACH PARTICULARS
Coach Coach Year of POH done POH due Coach type Remark
Sr No manufacturer manufacture date and place date SG/EOG/LHB/underslung
B. EQUIPMENT DETAILS (EX- POH)
S.No. Equipments Make and Sr no. of equipment

PP Side NPP
1 AC plant-
RMPU/under-slung
2 Compressor
3 Blower motor
4 Cond. motor
5 Control panel RMPU/
under-slung
Power panel
6 Thermostat
7 Alternator
8 Pre-cooling Socket
9 I.V. coupler
10 25 KVA inverter
11 ERRU/RRU
12 V-belts
13 60/50 KVA transformer
14 3 KVA transformer
15 Battery(make/lug date)
16 Pre-cooling transformer
17 Fire extinguishers
18 Emergency Light
C. EQUIPMENT REPLACED/REPAIRED IN BETWEEN POH TO POH
Date of replacement Equipment replaced Make and Sr no. of equipment Reason for
provided replacement
PP side NPP side
D. TELEPHONE/CUG MOBILE NO. OF IMPORTANT AC/TL DEPOT
Depot CUG No. BSNL Land line Railways Auto Phone number

E. INSTRUCTION TO ESCORTING STAFF
Sr No Instruction
1. Appear in uniform & name badge
2. Join duty one hour in advance from train departure
3. Be cautious about un-claimed/Baggage /Luggage
4. Check working of AC plant/light/fans & reading lights etc.
5. Check cleanliness of compartment
6. Keep doors closed during run & open at station when train is stopped
7. Keep panel shutter closed with latches already provided
8. Carry following
a) Standard tool kit box
b) Pre-cooling cable
c) Emergency feed cable
9. Use fire extinguisher in case of fire
10. Open emergency window in case of emergency.
11. Trouble shoot line failure immediately
12. Communicate line failures & Non-AC etc to base depot immediately
13. Communicate line failures, non-AC etc to destination depot immediately
14 Fill log book details properly
F. 16 POINT ACTION PLAN ON MAINTENANCE OF AC COACHES.

(Railway Board letter No. 97/Elec.(G)/180/7 dated 2.9.1999)
1. CESEs of Railways to interact with their counterparts in other Railways to advise the
unusual occurrences and obtain feed back.
2. All the Ac coaches to be pre-cooled before placement of rakes on platform. This is the
time when passengers require maximum and immediate comfort level. Pre-cooling cum
emergency leads should be provided in all SG AC coaches (1 in each coach) and power
cars (2 in each power car).
3. No train to leave the Primary Depot with EFTs or equipments in isolated condition.
4. Defects in the coaches to be noticed immediately after arrival of train and remedial action
taken accordingly. Escorting staff should report at secondary maintenance depot and
advise the status of coach and should sign the register with Depot and Depot staff to sign
the Log Book with Escorting Staff.
5. All AC coaches from Primary depot should go with both Alternators working. If an
Alternator cannot be replaced/repaired at the secondary maintenance depot, decision to
send coach with one Alternator to be taken at officer’s level. Second Alternator to be fully
functional with full generation and the coach/rake to be properly pre-cooled.
6. Ac coaches should go from Primary Depot with 6+6 belts on the Alternators and
minimum 5+5 from Secondary Depot. Adequate facilities to be built up for changing the
belt on rake itself.
7. The knowledge of all the ACCIs & ACCAs should be checked regularly regarding
operation of the AC coach equipment as well as handling of the situation in case of
failure of the equipment. ACCIs /ACCAs MUST maintain the log book and enter all the
unusual occurrences. Training of AC staff of one week duration to be standardized by the
Railways.
8. Drive system for generation testing and Regulator setting to be introduced for alternators
at all Primary Depots.
9. Unit Exchange Spares (UES) should be available in all despots. Each depot should have
authorized holding of UES. Register should be available for each major UES at all the
depots.
10. All the major depots should carry out failure analysis of major equipments and the
information should be sent to RDSO periodically.

11. The power supply system for pre-cooling to be augmented in view the increasing number
of AC coaches in the depots. Railways to examine and take corrective action.
12. Railways to revise their EACs (Estimated Annual Consumption) of the material because
of increasing AC Coach holding.
13. Cleating of alternator field and phase wires to be properly checked at primary depot.
14. Full load and no load voltage of each cell of SMF batteries to be recorded (weeded out
weak cell) every month for subsequent 3 months and if there is no abnormal variation in
voltage, it should thereafter be recorded once in 3 months.
15. Working of thermostat should be monitored and recorded in log book. If thermostat is not
found in working condition, the same should be attended/ replaced by primary depot.
16. Working of WRA/ Monoblock pump should be checked on arrival of train at
primary/secondary depot and its working should be ensured before placement of rake at
the platform.
G. LIST OF TOOLS IN STANDARD TOOL KIT FOR AC ESCORTING STAFF

(Circulated vide RDSO letter No. EL/7.2.2 dated 17.01.2006)
S.No. Description Qty

1. Tool box of size 325x440x120 mm (Approx.) with fixing arrangement for 1 set
tools and locking arrangement with 2 no. keys
2. Screw driver set with 8 nos of blade similar to Jhalani P. No. 830 or 1 set
equivalent
3. Combination plier insulated with thick CA sleeve with joint cutter length 1
205 mm
4. Digital multimeter 1
5. T spanner of sizes 10, 13, 15, 17 1
6. Panel key square type ¼ size suitable for opening of control panel of AC 1
coaches
7. Key for opening fittings of AC coaches 1
8. Test lamp holder (brass) fitted with two mtrs. of 2 core flexible copper wire 1
9. Torch, cells (+2 cell spare) 1

10. DE spanner set 8 pcs of sizes 6/7. 8/9, 10/11, 12/13, 14/15, 16/17, 18/19, 1 set
20/22
11. Allen key size 4 mm, 3/16, 7/32 1
12. Heavy duty cable cutting knife adjustable in aluminium casing over all 1
size 140 mm
13. Adjustable spanner length 255 mm 1
14. Thermometer digital 1
15. Nose plier 6” 1

16. Tongue tester A.C. (0-100 A) 1
17. Hammer ½ kg 1
18. Hacksaw frame with blade (+ 1 spare blade) 1

19. Insulating tap 1
20. Wire fuse 1

H. COACH MONITORING LOG SHEET FOR AC COACHES (TO BE FILLED BY ESCORTING STAFF)
RMPU type coach
Date------------ Originating/Destination Station------------- Train No. -------------------

AC coach Mechanic (Name /Design) ………….Attendant (Name/Designation) ------ No load voltage ---
1) Every two hour following details are to be filled

a) Status of battery, alternator , inverter and Temperature
Time Battery Alternator Battery Inverter-1 Inverter-2 Temp at return air

Voltage Current(A) current grill/Electronic
(ON Load) (A)(+ /-) thermostat display
Alt.1 Alt.2 A V I V I PP NPP
b) WRA Switching (Use WRAs alternately)
Time 0600- 1200- 1800- 0000- 0600- 1200- 1800-

1200 1800 2400 0600 1200 1800 2400
WRA-1
WRA-2
2) Record all line failures and unusual as under
S.No. Date Time Section Clearing Brief details of unusual

Time
Signature of escorting staff

with date & time

I. COACH MONITORING LOG SHEET FOR AC COACHES (TO BE FILLED BY ESCORTING STAFF)
Under-slung AC coaches
Date------------ Originating/Destination Station------------- Train No. -------------------

AC coach Mechanic (Name /Design) …………. Attendant (Name/Designation) ------ No load voltage –
1. Every two hour following details are to be filled Status of battery, alternator ,inverter,
Temperature
Time Battery Alternator Battery Pressure (PP) Pressure (NPP) Temp at

Voltage Current(A) current return air
(ON (A)(+ /-) grill/Electronic
Load) thermostat
display
Alt.1 Alt.2 LP HP OP LP HP OP PP NPP
2. Record all line failures and unusual/public complaint on TL&AC system as under
S.No. Date Time Section Clearing Time Brief details of

unusual
Signature of escorting staff

with date & time

J. FORMAT FOR MAINTENANCE LOG SHEET FOR AC COACHES (Primary/Secondary Maintenance)
Date ----------- Originating/Destination station --------------- Train No. ------------- From ------------ To -----------
Following checks to be done:
Sr Item to be checked Arrival condition of Departure condition of

No coach coach
PP side NPP side PP side NPP side
1 Temperature (to be taken at
Return air grill)
2 Working of RMPU in Auto mode
3 Condition of AC control panel of
RMPU
4 Current of compressors
5 Current of condenser motor
6 Current of Blower motor
7 Condition of inverter
8 WRA working
9 Refrigerant pressures (for under
slung AC caches
10 Alternator suspension bush /pin
11 Nos. of V-Belts
V-Belt Tension (Tight/loose)
Vane Relay
Lap top/mobile charger Available working Available working
12 Earth leakage Yes/No Yes/No

13 Test working of emergency light 1 2 3 4 1 2 3 4
14 Battery box Box-1 Box 2 Box-1 Box 2
condition/welding/tightening of
fastners
15 Battery No load Full load No load Full load
voltage voltage voltage voltage
16 SPG of pilot cells 2nd 55th 2nd 55th
17 Availability of cable Pre-cooling Emergency Pre-cooling Emergency

feed feed
Note : Depot mechanic shall ensure the implementation of all the SMIs and modifications issued by RDSO
during primary maintenance. No coach should be given in service until all SMIs & modification
sheets are complied for the coach.
BRIEF DESCRIPTION OF MAINTENANCE CARRIED OUT
1.
2.
3.
4.
Name/Designation & Signature of supervisor with date & time

CHAPTER 3
DISASTER MANAGEMENT
3.0 DUTIES OF ELECTRICAL ESCORTING STAFF IN CASE OF EMERGENCY
In the event of accident/ disaster, escorting staff shall contact train

conductor/guard and shall be ready for any type of help and same should be informed to
electrical controller.
3.1 DERAILMENT/ COLLISION (INCLUDING LEVEL CROSSING ACCIDENTS)

 Immediately check lights in the coaches and provide light in dark coaches.
 Provide light at accident site.
 Take necessary actions as a man of common prudence will take not only to help the
stranded passengers but also to arrange such helps as would be demanded by the
circumstances.
 Help in extricating the trapped passengers/bodies.
3.2 FIRE IN TRAIN

 Immediately isolate the affected coach/coaches electrically.
 Use fire extinguisher to extinguish fire to the extent possible.
 Immediately check lights in the coaches and provide light in dark coaches.
circumstances.
3.3 CYCLONE/STORM/ FLOOD

 Immediately isolate the affected coach/coaches electrically.
 Shall immediately check lights in the coaches and provide light in dark coaches.
circumstances.
3.4 REPORTED BOMB IN TRAIN
 Immediately isolate the coach in which the bomb has been reported with assistance
from C&W staff/Division.
 Immediately check lights in all the coaches including non-AC coaches and provide
light in dark coaches.
 Immediately isolate the power cars in case of Rajdhani/ Shatabdi trains.

 Help the passengers in moving out from the coach.

 Open/ break the emergency window of affected coach.
circumstances.
3.5 EXPLOSION OF BOMB IN A TRAIN
 Immediately isolate the coach/ coaches electrically.
 Use fire extinguisher to extinguish fire.
 Immediately check lights in all the coaches and provide light in dark coaches.
 Help in extricating the trapped passengers / bodies.
 Open emergency / break the window of affected coach.
 Inform the passenger of other coaches to evacuate to avoid the possibility of casualty
due to bomb explosion in other coaches.
 Take such necessary actions as a man of common prudence will take not only to help
the stranded passengers but also to arrange such helps as would be demanded by the
circumstances.
3.6 EXPLOSION OF BOMB IS REPORTED IN A FIXED INSTALLATION
 Shall immediately inform the Electrical control/TPC/PPIO through Walkie Talkie or
Telephone about the presence of bomb to arrange assistance.
 While communicating the incidence to ASM/Control definitely indicate the
requirement of fire brigade.
 Use fire extinguisher to extinguish fire to the extent possible.
 Isolate the electrical equipment/ fitting in the vicinity of affected area immediately to
avoid spread of fire before the main supply gets affected and get switched off.
 Help in extricating the trapped occupants/ dead bodies if any.
 Provide adequate lighting at accident site.
 Take such necessary actions as a man of common prudence will take not only to help
the stranded passengers but also to arrange such helps as would be demanded by the
circumstances.
3.7. OPERATION OF FIRE EXTINGUISHERS Clamp
1. Update knowledge on fire extinguisher types and operating

them.
2. Do not become panic when coach catches fire.
3. Remove the seal & clamp of the fire extinguishers.
4. Find out the base of the fire.
5. Hold the nozzle and aim towards near to the base of the
fire.
6. Hit the operating knob and ensure that the powder is
sprayed properly.
7. Ensure the fire is totally extinguished and it is cooled.
8. After extinguishing fire, isolate the fired equipment from the circuit.

3.8 ELECTRIC SHOCK
Electric shock occurs when an electric current flows through the body. The
human body is made up of 60% to 70% water. This makes it a good conductor of
electricity. Burns, damage to internal organs, heart rhythm problems, and death can result
from electric shock.
What to do when a person received an electric shock:
1. Switch off the current, if possible, by removing the fuse or switching off the
circuit breaker
2. Do not touch/ remove the victim from the electric source until the power source
has been shut off.
3. Separate the person from the source of electric current using a dry broom handle
or other type of non-conducting material such as wood or rubber.
4. Do not touch the victim with your bare hands, as electric current will pass through
you as well.
5. Let his head be slightly lower than the rest of the body, and raise his legs.
6. Inform TTE/conductor and call any Doctor, if available in the coach/train to
attend the injured person. Inform this incidence to electrical control.

CHAPTER 4
TROUBLE SHOOTING
4.0 TROUBLE SHOOTING INSTRUCTIONS FOR RMPU AC COACHES
4.1 NO GENERATION
4.1.1 At Power Panel
1. RSW 1 in Power panel should be on Alternator1, 2 &

battery position.
RSW1 in power panel
2. Check the incoming and out going supply at

RSW1. If RSW1 defective/ burnt, by pass it and
incoming +VE’s of alt1, alt2 & battery to be
connected to incoming of RSW2.
Alt1 incoming Battery +VE

+VE
4.1.2 At Alternator Alt2 incoming +VE
1. Ensure the availability of V-belts.

2. Check the continuity of field & phase windings at alternator terminals for open/
short circuit fault with multimeter and earth fault with megger of suitable range.
Axle pulley V-belts Tention

devise device
25 KW
V-belts alternator
3. If the coach was in ideal condition for a long time, to gain the residual magnetism,
check the field winding of alternator with 110V DC in series with test lamp of
25W/ 40W.
Phase wires Field wires

4.1.3 At RRU/ ERRU
1. Check the condition of OVP. If it is in tripped

condition, reset it.
2. Check and ensure the availability of 110V DC in
RRU/ ERRU at DC +VE, -VE terminals.
3. Check the condition of field fuse and its tightness.
Capacitor OVP Reset button

Universal Voltage controller
4. Check the condition of HRC field fuses (6 Amps) &

main fuse (160 Amps) in the RRU/ ERRU. Replace
them, if blown out.
HRC Main HRC Field

Fuse 160A Fuse 6,10A
5. Check the continuity of field & phase windings for
open circuit with multimeter.
6. Excite the field separately. If not succeeded, give external excitation to alternator.
4.2 110 V DC LOW VOLTAGE
4.2.1 At RRU/ ERRU
1. Check continuity of field after disconnecting from ERRU field terminals

2. Check for any loose connections at field terminals. If loose, tighten them.
3. Check the condition of field fuse and its tightness.
4.2.2 At Battery
1. Check for loose connection at inter-cell connections and battery end connections. If
loose, tighten them by torque wrench only at recommended torque.
2. Record OFF load/ ON load voltages of each cell. If any cell found reverse/dead,
bypass them.
3. Even though if the voltage is not improved, provide TC from the adjacent coach
DC-DC supply.

4.3 INVERTER NOT WORKING
4.3.1 At Power Panel
1. Check for availability of supply at incoming and outgoing terminals of RSW2 in

power panel and check the position, it should be in INV 1&2 position.
2. Check the condition of RSW2. If found defective,

bypass it.
3. Check the 400A, 250A HRC fuses in power panel. If

blown out, replace them.
HRC Fuses in power
4.3.2 At Inverter
1. Check and ensure the availability of input 110 V DC

supply at the inverter MCCB.
2. Check 350A HRC fuses and replace if blown out.
350A HRC Input to Inverter

Fuse MCCB
3. Check 4A glass fuses in 24V control circuit of

inverter. Replace it, if blown out.
4A Glass Fuse
4. Check the condition of Earth Leakage Detector (ELD).

If it is in tripped condition, reset it. If ELD is not
holding, check for earth leakage in the coach. If ELD is
found defective, bypass it by connecting wire on
terminal 18 to terminal 20 of ELD (On board type
Siemens). 20
18

4.4 INVERTER TRIPPING ON “ON LOAD”
4.4.1 At AC Control Panel
1. Switch off all MCBs of blower, condensers, compressors, heaters in the control panel
(MCB-1 to MCB-6).
2. Switch ‘ON’ the inverter again. If the inverter is
working on OFF load, switch ‘ON’ the AC plant
equipment MCB’s one after other as following:
a. Switch ‘ON’ blower MCB-1. If inverter not
tripped, switch ‘ON’ condenser motor-1 MCB-2.
Over load-1
b. If inverter not tripped, switch ‘ON’ condenser
motor-2 MCB-3.
c. If inverter not tripped, switch ‘ON’ compressor-1 MCB-7
MCB-1
MCB-4.
RSW-5
d. If inverter not tripped, switch ‘ON’ compressor -2
MCB-5.
3. Switch ‘OFF’ faulty equipment MCB on which the
inverter trips. Electronic 415/110 T/F
thermostat RSW1
Main MCB
4.5 INVERTER TRIPPED ON “OFF LOAD”
1. Check for fault indication in the inverter panel.

2. Check for short circuit/ earthing of power cables between Inverter output
and AC control panel terminals.
3. If no fault is found, then give message to next major station for necessary
attention.
4. Set on emergency mode and use three compressors only.
4.6 INVERTER TRIPPING ON STABLING
1. Check the individual cell condition. Isolate/ bypass the

defective cells.
2. Check the input DC voltage at inverter. It should not be

less than 90V to avoid input under voltage fault.
-VE terminal +VE terminal
3. Even though the voltage is not improved, provide TC from the adjacent coach as per
para 2.3.

4.7 AC PLANT NOT WORKING
4.7.1 Power Indication LED Not Glowing
Check the following at control panel:
1. Check the position of 63A changeover switch. It should be

in Inverter position and ensure the availability of three
phase supply at incoming and outgoing terminals of
Change over. If found defective, bypass it.
63 A CHANGE OVER
SWITCH
2. Check the healthy condition and availability of 3-phase supply at incoming and
outgoing terminals (361,362,363) of 63A RSW1 and 63A Main MCB
(358,359,360). If found defective, bypass it.
I/P MCB-8 for T/F
O/P MCB -9 for T/F
Control T/F
RSW1
Main MCB 63A
3. Check the working condition and availability of control supply at incoming

(358,359) and outgoing (370,371) terminals of MCB-8 of 415/110V AC control
transformer. If supply is not available, extend the supply from bus bar to the
control transformer bypassing MCB-8 and record in the logbook for further
rectification.
4. Check control transformer, if found defective extend the control supply either
from 110V AC fans or adjacent coach AC control panel temporarily.
5. Check working condition of MCB-9 at incoming (36,100) and out going terminals
(10,100).
6. Ensure availability of control supply on RSW2 at terminal (10, 12). If found

defective, bypass it.
Note: In case of SG AC coaches, control supply to MCB-8 shall be given from two
phases directly from inverter to TC-1 & 2 instead of bus bar.

4.7.2 Blower Motor Not Working

(a) Red light of over load ‘ON’
Check the following at control panel:
1. Check MCB-1 and ensure supply voltage of 415V

AC, 3- Ph at outgoing terminals of MCB-1
(343,344,345). If found defective, bypass it. MCB-1
MCB-1
2. Check Over load relay (OL-1)

a. If it is in tripped condition, check the over load setting (2.1 to 3.1A) and
reset it.
b. Check the supply from RSW2 to Blower OLP

NC point wire No.12 and out going wire No.13.
If supply not available at wire No.13, short 12 &
13 wires.
Note: Before bypassing OL-1, ensure the 3-ph supply

is available at T1, T2, T3 terminals of blower
motor to avoid single phasing.
12 13
OVER LOAD RELAY
3. Check the incoming (322, 323, 324) and out going 18

(301, 302, 303) terminals of blower contactor C1. If
found defective, bypass it.
4. Check ‘NO’ interlock of Auxiliary contactor (AC-1).

If found defective, bypass by shorting 18, 19
terminals. 19
AUXILARY
CONTACTOR (AC-1)
Check the following at blower:
1. Check availability of the supply at T1, T2, T3 power terminals of blower.
2. Rotate the blower by hand to check for any jammed bearing or loose blower
runners on the shaft.
Note: If blower motor is still not working and it seems to be defective, give
message to next major station for necessary attention.

(b) Air loss indication red LED glowing
1. If blower is ON but indication LED not glowing, check as per para (a).
2. Check the direction of rotation of blower motor, if it is rotating in reverse
direction, inter change any two phases of T1, T2, T3 (301, 302, 303) power
terminals.
3. Check Vane Relay flapper/ switch contact/ connection. If
found defective, bypass Vane Relay by shorting 44, 46
control terminals.
Note: Before shorting Vane Relay terminals, ensure that
blower is rotating in right direction. Put off MCBs
of Heater circuit.
Short 44, 46 terminals

Control Terminal block in
AC PANEL
4. Check whether the fresh and return air filters are

Air sucking
not clogged. If clogged, clean the filters.
position
Note: Put a handkerchief or paper at return air
grill inside the coach. If it is sucked, it
means that the blower is running in
correct direction. RETURN AIR GRILL
(c) Auto/ Manual Indication LED not glowing if mode selector RSW-3 is put to their
respective position
RSW3
1. If air loss indication LED is glowing, check the cause of air
loss as per para (b). RSW2
2. Check the condition of RSW-3 incoming supply at wire
No.19 and out going wire No. 23 for cooling mode and wire
No. 24 for heating mode. If supply not available at 23, 24
wires, short 19, 23 for cooling and 19, 24 for heating.
INDICATION PANEL
(d) Cooling Indication LED not glowing in Manual/ Auto mode.
If air loss indication RED LED is glowing when RSW-3 is in manual/ Auto mode,
check causes of air loss and take remedial action as per para (b) above.

4.7.3 Condenser Motors Not Working
CD1 or CD2 over load indication RED LED glowing when RSW3 is on
cooling mode
1. When cooling indication LED is not glowing in manual/ auto mode, then take
remedial action as per para 4.7.2 (b).
2. Check mode selections switch RSW3 as per para 4.7.2 (c).
3. Check over load relay (OL-2, OL-3).
a. Check the incoming supply from wire
No.23 and 40 at heater contactor (C6). If
found defective, bypass it (by shorting
23 & 40).
Note: Heater MCBs should not be kept ‘ON’
while bypassing.
b. If OL-2 and OL-3 are in tripped
condition, check the over load setting
(1.7 to 2.1A) and reset it. C6 Contactor
OL-2 OL-3
c. If OL-2 and OL-3 are found defective, AC CONTROL PANEL
bypass them by shorting 40 with 41 and
40 with 43.
Note: Before bypassing OL-2 and OL-3, ensure 3-ph supply is available at T4,
T5, T6 for CD1 and T7, T8, T9 for CD2 terminals of condenser motors to
avoid single phasing and measure the load current taken by the condenser
motor in each phase.
4. Check MCB-2 & MCB-3 and

ensure supply voltage of 415V AC,
3- ph at outgoing terminals of
MCB-2 (346, 347, 348) of CD-1
and MCB3 (349, 350, 351) of CD- C3 Contactor
2. If found defective, bypass it.
C2 Contactor
MCB-3
AC CONTROL PANEL MCB-2

5. Check supply at the incoming
terminals of contactor (C2) (325, 326, 327) of CD-1, contactor (C3) (328, 329,
330) of CD-2 and out going terminals of contactor (C2) (304, 305, 306) of CD-1,
contactor (C3) (307, 308, 309) of CD2 respectively. If found defective, bypass
them.

4.7.4 Compressors Not Working
a Compressor-1/ 2 over load red indication LED glowing
1. Ensure both the condenser motors are working. If not,

refer para 4.7.3.
2. Check output at TDR 1 &TDR2
3. Check the working condition of RSW5. If it is
RSW5
defective, bypass it. If supply not available, check the
continuity of wire No. 48 at outgoing terminal of
RSW5 from C2, C3 contactors.
4. Check over load relays (OL-4, OL-5). If

i. They are in tripped condition, check the over load setting (7A -12.5 A)
and reset it.
ii. OL-4 and OL-5 are found defective; bypass them by shorting 52 with
54 and 63 with 65.
C5Contactor
C4 Contactor
OL-5
OL-4
AC CONTROL PANEL
Note: Before bypassing OL-4 and OL-5, ensure 3-ph supply is available
at T10, T11, T12 for CP1 and T13, T14, T15 for CP2 terminals of
compressors to avoid single phasing and measure the load taken by
the compressors in each phase.
5. Check MCB-4 & MCB-5 and ensure supply voltage of 415V AC, 3- ph at
outgoing terminals of MCB-4 (352, 353, 354) of CP-1 and MCB-5 (355,
356, 357) of CP-2. If found defective, bypass it.
C5Contactor
C4 Contactor
MCB-5
MCB-4
AC CONTROL PANEL
6. Check the incoming terminals of contactor (C4) (331, 332, 333) of CP-1,
contactor (C5) (334, 335, 336) of CP-2 and out going terminals of
contactor (C4) (310,311,312) of CP-1, contactor (C5) (313, 314, 315) of
CP2 respectively. If found defective, bypass the contactors.

(b) HP1 or HP2 red LED glowing
1. Check the working condition of the condenser motors as per para 4. 7.3.
2. Check the condition of HP1/ HP2 cutout switches. If tripped, reset it
manually.(Setting 415 PSI)
(c) LP1 or LP2 red LED glowing
1. Check and clean wire mesh

2. Check the load of respective compressors with clip on meter. If current drawn
is less than 6.5 Amps, replenish gas where ever possible.
3. Ensure that return air filters are clean.
4. Check and ensure that all the grills are in open condition.
5. Check the direction of rotation of blower as per para 4.7.2 (b).
6. Check LP1 or LP2. If defective, bypass by shorting 29, 31 for LP1 and 35, 37
for LP2.
4.8 ALL EQUIPMENT ARE NOT WORKING IN STATIONARY CONDITION
1. Ensure the position of RSW1 in Alternator-I/ Alternator-II/

battery position. If it is found defective, bypass it by looping B,
Y, R phases to cable 361, 362, and 363 respectively.
2. Check the battery fuses. If blown out, replace it.
3. Check the inter-cell connectors of battery for open circuit.

400 A Battery fuse
4. Check the battery fuse bases for tightness.
5. Check the continuity of Battery +VE, -VE cables in

the power panel extending from the under-gear Inter cell
junction box. connector
AT BATTERY
4.9 WRA/ MONOBLOCK MOTORS NOT WORKING
4.9.1 AC WRA/ Monoblock Motor
1. Check for availability of 3-ph supply at RSW for

inverter selector RSW3. If supply not WRA
available on output side of RSW3, Selection
bypass it.
RSW for WRA Selection

2. Check the incoming (4151, 4152, 4153) and outgoing (4157, 4158, 4159)
terminals of MCCB and ensure availability of 3-ph supply. If found defective,
bypass it.
OFF button
WRA Overload contactor

cum MCB
ON button
POWER PANEL
3. Check for availability of 3-ph supply at inverter

selector RSW7. If supply not available on output
side, bypass it.
4. If MCB trips again due to internal fault of the motor,
change the position of RSW7 to the another motor.
Note: WRA motors are working but water not Flushout

coming in the toilets, release the air lock by Valve
pressing flush-out valve in the toilets. Ensure
proper tightness of the water filling pipe caps.
4.10 ALTERNATOR SEPARATE EXCITATION PROCEDURE

1. Remove the existing field wires
Field +VE
(F +VE, F -VE) at RRU/ ERRU
terminal block before extending the
separate excitation.
Field -VE
2. Ensure continuity of the alternator
field wires with millimeter and
healthiness of power diode.
3. Extend 6 cell connections (12V RRU/ERRU
supply) from battery as follows:
a. Connect the wire from first +VE of first
cell positive terminal to cell
alternator field +VE terminal
duly providing switch control
in between at main door -VE Cell of
handle, for switching OFF the 9th cell
separate excitation while
stabling. 1100 AH BATTERY
b. Connect 9th cell –VE terminal
to alternator field -VE terminal.
c. Incoming supply to extension terminal from RRU/ERRU shall be
disconnected.

4.11 TROUBLE SHOOTING INSTRUCTIONS FOR NON AC COACHES
S.N. Failure Cause Action to be taken

1. Coach is dark Loose contact in rotary Check and attend the defective
(Lights and switches rotary switch.
fans not
working) HRC Fuses of 16Amps (for Replace fuses with 16 & 35
L1, L2 & Fans) and Amps fuse wires.
35Amps negative may be
blown in main junction
box.
40 Amps battery fuses may Check battery fuses. If found

be blown near battery box. blown replace with 40Amps fuse
wire.
No generation / belts Measure the voltage if found

missing. below 90V then remove the
main –ve fuse from main
junction box and then connect
TC from the adjacent coach.
Cells defective ( Cells low Check the voltage if found

voltage or/and reverse below 90 volts then connect TC
polarity) from the adjacent coach.
2. Coach lights Over generation due to Cut the regulator field +ve & -ve
and fans in defective regulator. wires which are coming from
burnt/ smoke alternator or remove negative
condition & main fuse link and battery fuse
coach is in dark and then connect TC from
condition. adjacent coach.
3. Smoke in Burning of fans winding or Disconnect supply wires to

individual inverter in FTL. fans/lights.
Fan/ Light
4. Spark in Loose fitment of HRC/ Tightened or replace the fuses.

junction rewirable fuses in main/
boxes. distribution junction boxes.
5. Smoke from Cells sulphation. First extinguish smoke/ fire if

battery box. found then remove battery +ve
Low water level or Dry cell or –ve fuses and connect TC
from adjacent coach.
Cell container breakage
Loose connection
6. Belts smoke Alternator pulley jam Cut the belts and connect TC
from Adjacent coach.

CHAPTER 5
DO’S AND DON’TS
5.1 GENERAL
5.1.1 Do’s
 Do keep all the tools, gauges & instruments in working condition.
 Do tighten nuts & bolts fully by applying proper torque.
 Do keep all commonly used tools and gauges in a handy tool box.
 Do ensure that in 3 phase supply system the neutral is available.
 Do check continuity only by using series lights bulb of 100 W or higher rating and
not with ohm-meter.
 Do work with full confidence.
5.1.2 Don’ts
 Don’t climb on roof of coach in electrified sections.
 Don’t bypass safety devices.
 Don’t wear loose clothes and chappals.
 Don’t use defective tools, gauges and instruments.
 Don’t use oversize/ improper tools.
 Don’t apply unsafe method of working.
 Don’t leave tools gauges & instruments at work place after completion of work.
 Don’t leave nuts & screw/bolts half tighten.
 Don’t use nuts & bolts having different pitches together.
 Don’t apply excessive pressure for tightening the nuts, bolts & screws.
 Don’t use Fork lift, lift package unit from top through hooks only.
 Under no circumstances the plant should be run in manual mode for prolonged
period of time and without supervision of a qualified technician.
 Don’t allow the refrigerant gas to escape to the atmosphere.
 Don’t use refrigeration compressor for pulling a vacuum.

5.2 IN CASE OF BURNS

5.2.1 Do’s
 Do pour cold water immediately on the burn till the burning sensation stops.
 Do keep an ice or cold water pack on the burn.
 Do make the person roll on the floor, if his clothes catch fire.
 Do protect burn from dust, dirt, flies, etc. Cover it with a thin and light cotton
cloth.
 Do immediately get the help of doctor, if the burn is severe.
5.2.2 Don’ts
 Don’t apply any ointment on the burn.
 Don’t cover the burn with thick cloth.
 Don’t wrap a blanket around a person whose clothes have caught fire.
 Don’t tie a cloth tightly. Don’t use a dirty cloth.
 Don’t get the help from an unqualified person.
5.3 IN CASE OF HEAD INJURY/ BLEEDING NOSE
5.3.1 Do’s
 Do Make the victim lie down with his head in a lower position than the body
 Do pour cold water on the victim’s head.
 Do put a cold pack on the nose.
5.3.2 Don’ts
 Don’t put a pillow under the victim’s head.
 Don’t allow victim to put finger in his nose.
 Don’t allow victim to blow his nose too often.
5.4 IN CASE OF TRAUMA
5.4.1 Do’s
 Do make the victim lie down in a cool place
 Do keep an ice or cold water pack on the head of victim
 Do Give water or juice to drink to the victim.
5.4.2 Don’ts
 Don’t crowd around the victim.
 Don’t cover the victim with any cloth, especially woolen cloth.
 Don’t give hot tea or coffee to the victim.

5.5. IN CASE OF INJURIES

5.5.1 Do’s
 Do make the victim lie down in a cool place
 Do wash the wounds with clean water & then clean the wounds with an antiseptic
solution.
 Do give sufficient support to the affected area in case of sprains or tear in muscles.
5.5.2 Don’ts
 Don’t crowd around the victim
 Don’t apply any oily or greasy ointments
 Don’t massage the affected area
 Don’t get the help from an unqualified person
5.6 IN CASE OF 25 KW ERRUs
5.6.1 Do’s
 Do always connect same make of ERRU with same make CIP (Coach Indication
Panel)
 Do keep rotary switch on CIP, in normal position i.e. both ERRUs working.
 Do changes switch position in case ERRU-1/ ERRU-2 fails, accordingly for
emergency mode i.e. control circuit of healthy ERRU will drive both ERRUs. This
can be done when train is stationary.
 Do check ERRU status before changing the switch position, if OVP is tripped, then
reset it.
 Do reset CIP and old data cleared, if ERRU is fitted first time in coach. Do ensure
the correct parameter set.
 Do use only correct rating of HRC fuse i.e. 6A, 10A, 16A and 160A.
 Do use controlled supply with maximum output limited to 130V while charging the
coach battery with external charger.
 Do check connection polarity after attention or replacement; ensure correct setting
through the display panel.
5.6.2 Don’ts
 Don’t change the rotary switch position while alternators are running.
 Don’t reset ERRU, if OVP is tripping repeatedly.
 Don’t by-pass the OVP and fuse.
 Don’t disturb the setting of ERRUs.
 Don’t test the ERRU without connecting battery after installing in coach.
 Don’t touch control IGBT with naked hands.

5.7 IN CASE OF 4.5 KW ERRUs

5.7.1 Do’s
 Do make separate connection for DC+, BC+ and DC-, BC- in case of 4.5 kW
ERRU whereas 25kW ERRU, BC+ shall be used in power panel.
 Do reset display unit and old data cleared, if ERRU is fitted first time in coach.
 Do use only correct rating of HRC fuses i.e. 6A, 10A and 32A.
 Do use controlled supply with maximum output limited to 130V while charging the
coach battery with external charger.
 Do check connection polarity after attention or replacement.
5.7.2 Don’ts
 Don’t connect/ short DC+ and BC+ in 4.5 kW ERRU
 Don’t reset, if OVP is tripping repeatedly.
 Don’t by-pass the OVP and fuse.
 Don’t disturb the setting of ERRUs.
 Don’t touch control IGBT with naked hands.

APPENDIX-A
TECHNICAL KNOW-HOW
1.0 BRIEF DESCRIPTION OF ELECTRICAL COACHING
Based on the type of generation, there are two systems adopted over IR. These are
Self Generating System (SG) & End On Generation System (EOG). However, efforts are
being done for adoption of more efficient, more economical and more reliable Head On
Generation System (HOG).
1.1 SELF GENERATING SYSTEM
In this system, power supply is generated in individual coach through alternators

propelled by axles. Power generated during run supplies coach supply and also charges
the battery bank provided in each coach, which in turn supplies power to the coach while
the coach is stationary. The alternators are fitted in the under frame driven by the axle
through V-belts. These alternators generate 110V, AC, 3Ø, which is rectified and
regulated by Rectifier cum Regulator Units (RRU). The RRU further passes 110V DC for
coach supply and battery charging. This system is used for Air Conditioned coaches and
Non AC coaches of Mail/Express/Passenger trains.
ALT.
FIELD + TO COACH
WINDING - LOAD
RRU/ ERRU
BATTERY
BOX
1.2 END ON GENERATING SYSTEM
End on generation system envisages equipping of luggage cum brake vans in front
and rear end of rake & coaches in between them. Presently on IR three types of coaches
are being in use as per voltage i.e. 415 V, 750 V & dual Volt 415 V coaches are available
in low capacity rakes, these coaches are not equipped with 50 kVA step down
transformer & rating of Inter vehicular coupler of these coaches is lower therefore in
future all coaches will be converted into 750 V, 3 Φ AC by equipping 50 kVA step down
transformer. Dual volt & 750 V coaches are equipped with 50 kVA step down
transformers for stepping down 750 V, 3 Φ AC, 4 wire, 50 Hz supply to 415 V, 3 Φ AC,
4 wire, 50 Hz supply. Supply to entire rake is fed through two feeders running on both
sides of coaches along length of rake. Generator cars take entire load of rake, which
includes air conditioning unit, light/fan circuit, emergency battery charger circuit and
pantry equipments. This system is used for Air Conditioned coaches of Rajdhani/
Shatabdi/ Duronto/ Garib Rath trains.

FEEDER - I
ALT. ALT. ALT. ALT.
COACHES COACHES
FEEDER - II
GENERATOR GENERATOR
CAR CAR
COACH SUPPLY
750 V, 3 Ø AC
FEEDER LOAD
415 V, 3 Ø
50/60kVA TRANSFO RM ER 415 V, 3 Ø
LIGHTING TRANSFORM ER
110 V, 3 Ø
LIGHTING LO AD
1.3 TYPES OF COACHES WORKING WITH SG SYSTEM
 Under slung type AC coaches

 Roof Mounted Package Unit type AC coaches
 Non AC coaches
1.3.1 Under slung type SGAC coaches
These coaches are also called conventional type SGAC coaches. These coaches
are equipped with following equipment:
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Alternator 130 V DC, 18/22.75 kW 1 2
2 RRU 130 V DC, 18/22.75 kW 1 2
3 Battery 800 Ah Low maintenance Lead Acid 56 cells #
4 V-belt C-122 1x(6+6) 2x(6+6)
5 Compressor ACCEL/ Carrier 1 2
6 Compressor Motor 8.5/10 HP, 110 VDC 1 2
7 Condenser Motor 1.5 HP, 110V DC 2 4
8 Blower Motor 1 HP, 110V DC 1 2
9 Condenser Coil Under slung 1 2
10 Cooling Coil Over the corridor 1 2
11 Heater Unit 110V DC, 6 kW 1 2
12 WRA 1 HP DC motor 2
# Now for better reliability 1100 Ah VRLA batteries are being retrofitted.

1.3.2 Roof Mounted Package Unit type SGAC coaches
These coaches are also called RMPU type SGAC coaches. These coaches are
equipped with following equipment:
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Alternator 130V, 193A DC, 25kW 1 2
2 RRU/ERRU 130V,193A DC, 25 kW 1 2
3 Battery 1100 Ah, VRLA 56 cells
4 V-belt C-122 1x(6+6) 2x(6+6)
5 Sealed Compressor 3 Ø, 415 V AC 2 4
6 Condenser Motor 1 HP, 3 Ø, 415 V AC 2 4
7 Blower Motor 1 HP, 3 Ø, 415 V AC 1 2
8 Condenser Coil Roof Mounted 2 4
10 Heater Unit 3 Ø, 415 V AC, 3 kW 2 4
WRA/ Monoblock
11 3 Ø, 415 V AC, 1 HP 2
Pump
Input: 110V DC, 25 kW
12 Inverter 1 2
Output: 3 Ø, 415 V AC
1.3.3 Non AC coaches
These coaches are equipped with following equipment:
SN Equipment Rating Qty/ Coach

1 Alternator 120 V, 37.5A DC, 4.5 kW 1
RRU/ 120 V, 37.5 A DC, 4.5 kW
2 1
ERRU
57 cells or 19 Mono blocks,
120 Ah, 6V VRLA or 120 Ah,
3 Battery VRLA/ 54 cells or 18
6 V Monoblock
monoblock LMLA
4 V-belt C-122 4

1.4 TYPES OF COACHES WORKING WITH EOG SYSTEM

 Under slung type AC coaches
 Roof Mounted Package Unit type AC coaches
 LHB type AC coaches
 Generator Cars
 AC Pantry Cars
1.4.1 Under slung type EOG AC Coaches
These coaches are also called conventional type EOG AC coaches. These coaches
are equipped with following equipment:
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Step down Transformer 3 Ø, 750 V AC/ 415V AC, 50kVA 1
2 Battery 120 Ah, 6V Monoblock, Lead Acid 4 Monoblocks
3 Compressor ACCEL 1 2
4 Compressor Motor 15 HP, 415V, 3 Ø, AC 1 2
5 Condenser Motor 1.5 HP, 415V, 3 Ø, AC 2 4
6 Blower Motor 1 HP, 415V, 3 Ø, AC 1 2
7 Condenser Coil Under slung 1 2
9 Heater Unit 415V, 3 Ø, AC, 6 kW 1 2
WRA/ Monoblock
10 1 HP, 415V, 3 Ø, AC 2
Pump
Emergency Battery Input: 415V, 3 Ø, AC
11 1
Charger Output: 24 V DC
Input: 415V, 3 Ø, AC
12 Lighting Transformer 1
Output: 110 V, 3 Ø, AC
1.4.2 Roof Mounted Package Unit type EOG AC Coaches
These coaches are also called RMPU type EOG AC coaches. These coaches are
equipped with following equipment:
Qty/ Coach
SN Equipment Rating
1st AC Others
1 Step down Transformer 3 Ø, 750 V AC/ 415V AC, 50kVA 1
2 Battery 120 Ah, 6V Monoblock, Lead Acid 4 Mono blocks
3 Sealed Compressor 3 Ø, 415 V AC 2 4

Qty/ Coach
SN Equipment Rating
1st AC Others
4 Condenser Motor 1 HP, 3 Ø, 415 V AC 2 4
5 Blower Motor 1 HP, 3 Ø, 415 V AC 1 2
6 Condenser Coil Roof Mounted 1 2
8 Heater Unit 3 Ø, 415 V AC, 3 kW 2 4
WRA/ Monoblock
9 3 Ø, 415 V AC, 1 HP 2
Pump
Emergency Battery Input: 415V, 3 Ø, AC
10 1
Charger Output: 24 V DC
Input: 415V, 3 Ø, AC
11 Lighting Transformer 1
Output: 110 V, 3 Ø, AC

APPENDIX-B
ELECTRICAL CIRCUITS
1. AC POWER CIRCUIT
Description of Power Circuit
The 3- phase, 415 VAC, 50Hz power supply is used to operate two hermetically
sealed compressors, one double shaft blower motor, two condenser motors and one set of
heaters through six contactors. All the equipment are protected by over load relays and
MCBs.
FIR ST FER RU LE N o. 301

LAST FERR ULE No. 371 2A
359 371
FER RULE Nos. NOT USED TO CO NTROL
358 370 TRAN SFO RM ER
340,341,342,364 TO 369.
M CB-8
R Y B
2A
360 321 C C-HTR 1
359 320
TC2 358 319
TO C ONTR OL CIRCU IT C C-HTR 2
M CB-8 M CB-7
TC1
16A 16A
360 339 318
H EA TER-1
359 338 317 &
358 337 316 H EA TER-2
M CB-6 C6
32A 32A
360 357 336 315
359 356 335 314 COM P-2
358 355 334 313 M O TOR
R SW -1 M CB M CB-5 O L-5 C5
50 Hz IN COMING
63A 63A
415 V AC 3 Ph.
361 358
BO
362 359
YO
363 360
RO
32A 32A
360 354 333 312
R 359 353 332 311 COM P-1
358 352 331 310 M O TOR
Y
M CB-4 O L-4 C4
B
6A 6A
360 351 330 309
359 350 329 308 CON D-2
BUS BAR
358 349 328 307 M O TOR

CABLE SPECIFICATION
M CB-3 O L-3 C3
S.N o. SIZE (SQ.M M ) SYM BOL USED
1. 1.5 6A 6A
2. 2.5 360 348 327 306
359 347 326 305 CON D-1
3. 6.0 358 346 325 304 M O TOR
4. 16.0 M CB-2 O L-2 C2
R Y B
6A 6A
360 345 324 303
1. IF SEPARATE FILTERED CONTR OL SUPPLY OF
359 344 323 302 BLO W ER
415V AC FR OM IN VER TER IS AVAILABLE THE 358 343 322 301 M O TOR
C ON TR OL C IR CUIT (M C B-8) W ILL BE C ONNECTED
TO TC 1 & TC2 INSTEAD OF BUS BAR. M CB-1 O L-1 C1
2. M ULTI STRA ND ELA STOM ERIC C AB LES CO NFIR M ING
TO R D SO SPEC . N O. E-14/1 PART-1 (REV.II)
FEB. 1993 SHA LL B E USED FOR POW ER C IR CUIT.
PO W ER W IRING DIAGRAM
FLC-RLY-000101/CP/DATED: 04/08/98 (REV 1)

2.
RSW - 3
24
2 3 TO
1. VENT
2. AUTO 1 4 SHEET No. 4
23
3. MANUAL COOLING
4. MANUAL HEATING 2 3 2 3
1 4 1 4
MCB 4 23a 24a
370 36 20 RSW-2 C-1 18 AC-1 19
Camtech/E/10-11/OM-Coaches/1.0
10 11
12 12 12 44
Operating Manual for TL & AC Coaches

21 22 23b 24b 25 HR
415 V AC
110 V AC
O/L-1 C-1
operate at this control voltage.
CR
FROM SHEET NO.2

Description of Control Circuit
VR-2 VR-1
POWER
46 45 SUPPLY
371 100
13 14 15 16 17
ELECTRONIC
TO ELECTRONIC THERMOSTAT
TIMEDELAY RELAY
AC CONTROL WIRING CIRCUIT
(ETDR)
1 2 3 4 5 6 7 8
SENSOR TO BE LOCATED
A1 B1
AT RETURN AIR PATH IN RMPU
PCB
PCB
PCB
R R G R G G G G
C1 AC1 TO
100 100 100 100 100 AUTO 100 SHEET No. 4
FIRST FERRULE No. ...10
O/L TRIP
MANUAL
BLOWER
HEATING
COOLING
AIR LOSS
AUXILARY
LAST FERRULE No. .....100
POWER ON
BLOWER ON
CONTACTOR
CONTACTOR
FERRULE No. 11, 20, 37 TO 99
NOT USED
BLOWER MOTOR
NOTE:-
1. ALL CABLES FOR INDICATION LIGHTS SHALL BE PTFE OF 1.0 SQ. MM SIZE.
2. ALL CABLES FOR CONTROL CIRCUIT SHALL BE PTFE OF 1.5 SQ. MM SIZE.
October 2011
43
to control circuit. The thermostats, PCBs, OLPs, HP cut out, LP cut out, timers, etc
A step down transformer of 415V/110V is used to provide 110V AC, single phase
44
1. BOTH COMPRESSOR ON.

2. COMPRESSOR-1 BYPASS
24 C2 C3
3. COMPRESSOR-2 BYPASS
82 82
RSW-5
October 2011
C3 82
2
23 C6 2
C2 48 48
1 3 1 3 70 T38 C6
40 40 40 40 48 48
T40
49 a b 84
FROM SHEET NO. 3

61
OHP-1
O/L-3 T26
O/L-2 C-2 C-3 T28 60 T32 T34 T39
59 71 C4 C5
HP1
HP2 83 85
41 42 43 44 45 46
T27
T33 72 73 T41
51 62 T43
T29 T30 T35
58 T36 21 22 OHP-1
LP1 69
57 LP2 T42
87
T31 52 63
PCB
T37 68
86
9 10 11 12 O/L-4 13 14 15 16 O/L-5 17 18 19 20 23 24 25
G G
65
PCB
PCB
PCB
PCB
PCB
54 65
54
R G G R R R R 66 R R R R R R G
R
55 66
C2 N C3 N N1 Ph1 N N1 Ph1 N N N
C4 C5 C6
FROM FROM
SHEET Ph SHEET
{ N ETDR { ETDR
NO.3 NO.3
100 100 100 100
OHP 1 TRIP
COND.1
CONTACTOR
COND.1 O/L
COND.2
CONTACTOR
COND.2 O/L
COND.1 ON
COND.2 ON
COMP.1
CONTACTOR
COMP.1 O/L
COMP.1
COMP.2
CONTACTOR
COMP.2 O/L
COMP.2
COMP.1 ON
COMP.2 ON
CONTACTOR
OHP 2 TRIP
LP 1
BYPASS
LP 2
BYPASS
HP 1
HP 2
HEATER
HEATER ON
NOTE :
1. FIRST FERRULE No. 40 & LAST FERRULE No. 100.
2. FERRULE No. NOT USED - 47, 50, 53, 56, 64, 67, 74 TO 81, 85, 88 TO 99.
3. R-RED LED INDICATOR & G-GREEN LED INDICATOR
4. CABLE SIZE FOR ALL INDICATION LIGHTS SHALL BE PTFE OF 1 SQ.MM.
5. CABLE SIZE FOR CONTROL CIRCUIT SHALL BE PTFE OF SIZE 1.5 SQ.MM.
Camtech/E/10-11/OM-Coaches/1.0
Operating Manual for TL & AC Coaches

Control & Power Terminal Block Diagram of AC Panel
C O N T R O L T E R M IN A L S
C IR C U L A R S H E L L C O N N EC TO R CONTROL
H A R N ESS
26
FRO M H P1 CO M M ON 26 (A ) (A ) T -2 6 49
27
N .C . 27 (B ) (B ) T -2 7 51
28
N .O . 28 (C ) (C ) T -2 8 59
29
FRO M LP1 CO M M O N 29 (D ) (D ) T -2 9
30
N .C . 30 (E) (E ) T -3 0 58
31
N .O . 31 ( F) (F ) T -3 1 52
32
FRO M H P2 CO M M ON 32 (G ) (G ) T -3 2 61
33
N .C . 33 (H ) (H ) T -3 3 62
34
N .O . 34 (J) (J) T -3 4 71
35
FRO M LP2 CO M M O N 35 (K ) (K ) T -3 5
36
N .C . 36 (L) (L ) T -3 6 69
37
N .O . 37 (M ) (M ) T -3 7 63
38
FRO M O H P1 C O M M O N 38 (N ) (N ) T -3 8 82
39
N .C . 39 ( P) (P ) T -3 9 83
40
N .O . 40 (R ) (R ) T -4 0 84
41
FRO M O H P2 C O M M O N 41 ( S) (S ) T -4 1 82
42
N .C . 42 (T) (T ) T -4 2 86
43
N .O . 43 (U ) (U ) T -4 3 87
44
FRO M V R C O M M ON 44 (V ) (V ) T -4 4 12
45
N .C . 45 (W ) (W ) T -4 5 17
46
N .O . 46 (X ) (X ) T -4 6 16
47
F R O M C O O L IN G C O M M O N 47 (Z) (Z ) T -4 7 31
48
TH E R M O STA T LOW 48 (g ) (g ) T -4 8 27
49
M ED 49 (h ) (h ) T -4 9 28
50
H IG H 50 ( j) (j) T -5 0 29
51
F R O M H E A T L IN G C O M M O N 51 (k ) (k ) T -5 1 35
52
TH E R M O STA T LOW 52 (m ) (m ) T -5 2 32
53
M ED 53 (n ) (n ) T -5 3 33
54
H IG H 54 (p ) (p ) T -5 4 34
C IR C U L A R SH E L L C O N N EC TO R
ON PACKAGE
C IR C U L A R S H E L L C O N N E C T O R T E R M I N A L B L O C K S IN
O N C O N T R O L PA N EL C O N T R O L PA N EL
P O W E R T E R M IN A L S
PO W ER N O TE:
H A R N ESS
T E R M IN A L B L O C K S N O .
V A N E R E L A Y B Y PA SS : SH O RT 44 , 46.
1
1 1 T -1 301 H P1 B Y PA SS : SH O RT 26, 27.
FRO M BLO W ER 2
2 2 T -2 302
M OTOR 3 H P2 B Y PA SS : SH O RT 32, 33.
3 3 T -3 303
4
4 4 T -4 304 L P1 B Y PA SS : SH O RT 29, 31.
FRO M CO ND . 1 5
5 5 T -5 305
M OTOR 6 L P2 B Y PA SS : SH O RT 35, 37.
6 6 T -6 306
7
7 7 T -7 307
FRO M CO ND . 2 8
8 8 T -8 308
M OTOR 9
9 9 T -9 309
10
10 10 T -1 0 310
11
FR O M C O M P. 1 11 11 T -1 1 311
M OTOR 12
12 12 T -1 2 312
13
13 13 T -1 3 313
14
FR O M C O M P. 2 14 14 T -1 4 314
M OTOR 15
15 15 T -1 5 315
16
16 16 T -1 6 316
17
F R O M H E A T E R -1 17 17 T -1 7 317
18
18 18 T -1 8 318
19
19 19 T -1 9 319
20
F R O M H E A T E R -2 20 20 T -2 0 320
21
21 21 T -2 1 321
22
F R O M C P -1 C R A N K 22 22 T -2 2 364
23
C A SE H EA TER 23 23 T -2 3 366
24
F R O M C P -2 C R A N K 24 24 T -2 4 365
25
C A SE H EA TER 25 25 T -2 5
T E R M IN A L B L O C K S IN T E R M IN A L B L O C K S IN
A .C P A C K A G E U N IT S C O N T R O L PA N EL

3. SCHEMATIC DIAGRAM OF POWER PANEL
SCHEMATIC DIAGRAM FOR POWER PANEL

PUMP1 17
M U,V,W 2611
R TO 117 RSW-1 26 261 RSW-2 TO
P 4157,4158
C S TB 8 500A 300A 2612 OVR 6A MCB
4159 W7 PUMP2 19
B
4151, 4152 U1,V1,W1
R1, Y1, B1
300
330
FROM 4153
TB 7 R2, Y2, B2 RS W3 TB2
RSW-6
262, 1814 3,4,4a,5

ALT-1 (FL)
221,222
223
M 4154,4155 X TO
C R 400A 250A 250A 26
4156 TB 1 FROM 40A
B 191,192 250A 250A 250A
16
17
26 2614 2613 MCB
193,N 181 181 18
TO INV2 +(DP)
TO INV1 +(DP)
TO INV2 +(DP)
TO INV1 +(DP)
TO
TB4 TO MCB (+10A)
ALT-2
500
700
116
117
TO 40A MCB
FR1
MCB
RSW-6
FROM M R 17 117 19 (IC, L)
191,192 194,195 197,198 FY1
TB 1 C S MCB TO FROM TB6
193, N 196 199
B W4 TB 1
19 26
N FB1 N
MCB 17 16,17,116,117
- Ve FROM SHUNT
T
TO ALT-1
FROM U/F
TO ALT-2 TO
AMMETR TB 5
AMMETR
18 0 2.5A 1814 / VM
16
VOLT 2.5A 70
TO 201
METER TB 4
5A SP
FROM U/F 201

FROM U/F 16
FROM U/F 19
FROM U/F 116
1814 263 262 TO CL2 5A 1811
FROM FROM
706
707
701
702
TB 3 TB 4
TB 3
TO
5A 1182
BATT 10A 1803

RCL1
RCL2
1&3
2&4
FSL
FSL
AMMETER
10A 1804
700
201
19
18 40A 18
FROM
FROM 500A SHUNT TB 4 FROM TB 4
TO RSW 5
40A 26
IC2 10A 700
FROM
RSW 6
IC1 10A 500
TO TB 4
L2 5A 330
FROM
5A 300
RSW 5
L1
SP 5A SP
PAIL 2.5A 7
VM 262 2.5A FROM TB 4

TO TB 4
4. SPECIFICATIONS OF EQUIPMENT ( SG )
ALTERNATOR
Capacity : 25 kW
Voltage : 130 V +/- 5% on DC side (97V, 3phase AC)
193 A Max on DC side.
Cut in Speed : 380 RPM (30 Kmph )
MFO : 700 RPM (51 kmph approx for 135 A at
135V)
Max. Speed : 2500 RPM (156 Kmph approx)
Mounting : Transom mounting
Belts : V-belts (C-122)
Insulation : H- class
Resistance between field terminals : 7.3 ohms
Resistance between phase terminals : 0.08 ohms
Alternator Pulley : 200 mm PCD 6 groove pulley

RRU/ERRU
Capacity : 18/25kW
Voltage : 130V+/-5 % V DC
Current : 18 kW – 140A DC Max
25kW – 193A DC Max
BATTERY
Voltage : 2V
Capacity : 1100 Ah
Type : VRLA
BATTERY CHARGER
Input Voltage : 3-Ph 415 Volts, 50 Hz.
Input current : 45Amps
Output Voltage : 130V DC
Output current : 200 Amp.
AC WRA/ MONOBLOCK
Voltage : 3-Ph, 415V, 50Hz.
Capacity : 0.5 HP
INVERTER
Capacity : 25kVA
DC Input : 90V- 140V DC with 15% ripple
Rated input current : 250A
AC Output : 3- Ph. 3-wire, 415V+/- 5% PWM sine wave
Output frequency : 50 Hz+/- 3%
Output power factor : 0.8
Rated Output current : 35A
POWER PANEL EQUIPMENT

Voltmeter : 0-200V DC
Center-Zero-Ammeter : 500-0-500 DC
Ammeter for Alternator-I & II : 0-300A DC
RSW1 (Alternator supply selector rotary switch) : 400/500Amps
RSW2 (Inverter supply selector rotary switch) : 300Amps
Capacity of HRC Fuse between RSW1 & RSW2 : 400Amps
Capacity of HRC Fuse for inverter supply (RMPU) : 250Amps
Capacity of HRC Fuse for AC plant 1&2 supply (U/S) : 160Amps
Transformer for fans, mobile/laptop charging : 2 kVA, 415V/ 110V
AC.

RSW3 for Inverter Selector : 16Amps

Input side MCCB for 440/110V transformer : 16Amps
Contactor cum MCCB for WRA : 16Amps
RSW4 for fans : 16Amps
RSW5 for Lights : 16Amps
RSW6 for night lights : 16Amps
RSW7 for WRA selector : 16Amps
MCBs for +ve, -ve circuits of FTLs/ CFL Night : 6Amps
Lamps, fans, Mobile charging inverter.
AC CONTROL PANEL EQUIPMENT (RMPU)

RSW1 : 63Amps
MCB TP : 63 Amps.
MCB TP for blower, condensers : 6 Amps
MCB TP for compressors : 32 Amps.
MCB TP for heaters : 16 Amps
MCB DP for Control T/F : 4Amps
Contactors for blower, condensers : 6 Amps
Contactors for compressors : 32Amps
Contactor for heater : 16Amps.
Control Transformer : 415/110V AC
5. SPECIFICATIONS OF RMPU EQUIPMENT
Compressor
Make : Maneurop/Compelend scroll Maneurop/Compelend
scroll
Power consumption : 5250 W +/- 20 % depending 5250 W +/- 20 %
on ambient temperature depending on ambient
temperature
Current : 8.5A+/- 25% at 415VAC 3- 8.5A+/- 25% at 415VAC
phase 50Hz depending on 3-phase 50Hz depending
Ambient temperature on Ambient temperature
Power factor : 0.85 0.85
C.F.M.(Displacement) : 12.033 C.F.M, R-22 Vapour 12.033 C.F.M, R-22
Vapour
Volume : 117.65 CC/Revolution 117.65 CC/Revolution
Evaporator Motor
Type : Centrifugal type Centrifugal type
Diameter : 10” (250mm) 11” (280mm)

Air flow (CFM) : 4200 Cu.Mtr/Hr+/-10% at 20 4000 Cu.Mtr/Hr at 20 mm

mm water guage water guage
Pressure (External : 25 mm Minimum water guage 25 mm Minimum water
Static) guage
Speed : 1415+/- 10% RPM 1400+/- 10% RPM
Capacity : 1.5 HP 1.5 HP
Current : 2.6A +/-10% at 415 VAC 2.6A +/-10% at 415 VAC
3-Ph, 50Hz. 3-Ph, 50Hz.
Condenser Fans
Diameter : 24” 21”
Air flow : 4000 x 2 (6800 Cu.Mtr/Hr x 3825 x 2 (13000
2) at 7mm static. Cu.Mtr/Hr minimum)
Speed : 910 +/- 10% RPM. 1400 +/- 10% RPM
Motor capacity : 1 HP x 2 1 HP x 2
Current : 2.1A+/- 10% x2 at 415V.AC 2.2A+/- 10% x2 at
3 Ph 50Hz. 415V.AC 3 phase 50Hz
Evaporator Coil
Face area : 0.254 sq.mtr x 2 0.265 sq.mtr x 2
Material of Tube : Copper Copper
Tube O.D. : 9.525 mm(3/8”) 9.62 mm(3/8”)
Fin material : Copper Copper
Fin thickness : 0.127 mm 0.14 mm
No. of fins/25mm : 15 12+/-1
Condenser Coil
Face area : 0.7376 sq.mtr x 2 0.67 sq.mtr x 2
Material of Tube : Copper Copper
Tube O.D. : 9.525 mm(3/8”) 9.62 mm(3/8”)
Fin material : Copper Copper
Fin thickness : 0.127mm 0.14 mm
No. of fins/25mm : 15 12+/-1
Refrigerant : R-22 less than 2.5 kg each R-22 less than 3.0 kg each
circuit circuit
LP Cutout Range : 35+/- 2 PSI 35+/- 2 PSI
HP Cutout Range : 415+/- 2 PSI 415+/- 2 PSI

REFERENCES
1. Technical circular for standardization of logbook for AC coaches.

No. RDSO/ PE/ AC/ TC/ 0004-2010 (Rev.0) dt 24.06.2010 issued vide RDSO letter
No. El/7.2.1 dt. 19.07.2010
2. 16 Point action plan on maintenance of AC coaches.
Railway Board letter No. 97/Elec.(G)/180/7 dated 2.9.1999.
3. Trouble shooting directories received from East Coast Railway vide letter no.
ECoR/ EL/G/460/05/3554 dt. 18.11.2009.
4. Operating instructions to AC coach accompanying technicians received from
Southern Railway vide letter no. E.227/XX/20 dt. 27.10.2009.
5. Installation, operation, trouble shooting and maintenance manual of M/s Sidwal for
RMPU AC coaches.
6. Comments received from Sr. DEE/ P/ Ratlam vide letter no. EL 254/ 123/ 3 dt.
19.07.2010.
7. Comments received from Southern Railway HQ vide letter no. E.227/XX/20 dt.
07.09.2010.
8. Comments received from Sr. DEE/ G/ Mughalsarai, ECR vide letter no. MGS/
EL/G/197/ACC dt. 23.06.2010.
9. Comments received from Northern Railway HQ vide letter no. 3-Elect/1/ TL/
CAMTECH/ Pt-I dt. 14.09.2010.
10. Presentations given by participants from various Railways during seminar
conducted on 09-Sep 2010 at CAMTECH.

OUR OBJECTIVE
To upgrade maintenance technologies

and methodologies and achieve improvement
in productivity, performance of all Railway
assets and manpower which inter-alia would
cover reliability, availability, utilisation and
efficiency.
If you have any suggestions and any specific Comments

please write to us.
Contact person : Director (Elect.)
Postal Address : Indian railways

Centre for Advanced
Maintenance technology,
Maharajpur, Gwalior.
Pin code – 474 005
Phone : 0751 – 2470740

0751 – 2470803
Fax : 0751 – 2470841
E- mail : direlcamtech@gmail.com

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The perfect operation of TL & AC coaches is necessary to ensure reliability and

CAMTECH, Gwalior Peeyoosh Gupta

Chapter No. Description Page No.

Chapter No. Description Page No.

ISSUE OF CORRECTION SLIPS

CORRECTION SLIPS ISSUED

Sr. No. Date of issue Page no. and Item Remarks

ACCA AC Coach Attendant ACCI AC Coach Mechanic

1.1 DUTIES OF AC ESCORTING STAFF BEFORE DEPARTURE

1.1.1 DUTIES OF AC COACH ATTENDANT

Operating Manual for TL & AC Coaches October 2011

1.2 DUTIES OF AC ESCORTING STAFF DURING RUN

1.3 INSTRUCTIONS FOR AC ESCORTING STAFF

1. Be cautious about un-claimed baggage /luggage.

1.4 LIST OF SPARES REQUIRED FOR AC ESCORTING STAFF

S. No. Description Qty

October 2011 Operating Manual for TL & AC Coaches

1.5 CABLES TO BE AVAILABLE IN AC COACHES

S. No. SIZE OF E-BEAM COPPER CABLE QUANTITY

1 3 core 70 mm² cables as per RDSO’s 25 meter length with pre-cooling

2 2- Core 25 mm² cables as per RDSO’s 25 meter with proper crimping

1.6 FUSES IN SG CONVENTIONAL (U/S) TYPE AC COACHES

S. No TYPE CAPACITY LOCATION

1 HRC 315A Negative and Positive terminal of cell bank

2 HRC 250A Both plant negative and positive supply

3 HRC 160A Incoming supply from alternator regulator

4 HRC 100A Positive supply of control panel for cooling

5 HRC 60A For positive supply of heating control panel

6 HRC 2A For negative control supply

7 Bottle type 10A, 20A Blower and condenser motor supply

Operating Manual for TL & AC Coaches October 2011

1.7 MCBs & FUSES IN SG RMPU TYPE AC COACHES

S. No TYPE & No CAPACITY LOCATION

S. No. RSW No. CAPACITY LOCATION

October 2011 Operating Manual for TL & AC Coaches

1.9 COMPONENTS OF AC CONTROL PANEL

1. Overload relay (O/L)

1.10 SAFETY PRECAUTIONS

Operating Manual for TL & AC Coaches October 2011

1.11 SAFETY TIPS FOR PREVENTION OF FIRE

2. Ensure that no protection is by-passed.

3. Proper rating of MCBs / fuses shall be used.

4. Look for any overheating sign after putting on all loads.

6. Check condition of PVC bushes/ glands provided in junction-boxes. Replace

7. Check condition of insulation especially in junction-boxes. Don’t permit

8. Rubbing of cables shall not be permitted.

October 2011 Operating Manual for TL & AC Coaches

2.1 PREPARATION OF COACH

2.1.1 GENERAL CHECKS IN AIR CONDITIONED COACH

2.1.2 OPERATING PROCEDURE FOR AC COACHES

1. Ensure coach voltage by pressing voltmeter switch (118V off load).

Operating Manual for TL & AC Coaches October 2011

2.2 PRECOOLING PROCEDURE

October 2011 Operating Manual for TL & AC Coaches

2.3 TEMPORARY CONNECTION

2.3.1 DC-DC Feed Extension Procedure

Healthy RMPU Coach Failed RMPU coach

B. Power Panel to/from AC Control Panel (U/S Type)

Operating Manual for TL & AC Coaches October 2011