TL and AC Coaches

Electrical Design Concepts

BY

Power Supply & EMU Directorate RDSO

 BLOCK DIAGRAM FOR NON AC COACH FOR POWER SUPPLY
AND PROTECTION
L-2
CIRCUIT Fan circuit
FTL
L-1
ESSENTIAL
Electronic rectifier LIGHT CKT
cum regulating REWIRABLE
unit FUSE IN BRANCH
4.5 KW CIRCUIT
ALTERNATOR R -VE Fuse
Y ERRU/RRU 16A 16A
B WITH OVER fuse
16A 40A
fuse fuse
VOLTAGE
F
PROTECTION
+VE

JUNCTION BOX WITH

ROTARY SWITCH
120Ah,110V +v
BATTERY e
40 A
FUSE
-ve
POWER SUPPLY ARRANGEMENT & PROTECTION
SCHEME FOR PASSENGER COACHES
• 110 V DC two wire insulated system with each
wire placed in a separate conduit
• It requires at least two earth faults, one on
positive and one on negative circuit, to cause a
short circuit
• All the circuits are protected by suitable sizes of
fuses
• Supply scheme has multi level protection system
in the event of short circuit & more than two
earth faults
• It does not cause shock to any person due to
floating system
MAIN FDB
NEGATIVE
WIRES
6 A FUSE

CFL
FANS

EFT
6 A FUSE
MAIN
POSITIVE
WIRES

L1 L2 F SPM NEG
FDB

COACH FLOOR

COACH UNDERGEAR

4.5
KW
RRU 40 A
BATTERY 120 Ah
110 Volt
 110 Volts DC Power Supply System
• Electric power is generated by Alternator mounted on under
frame. It is connected to voltage regulator and rectifier.
• Alternator charges the batteries, which is also mounted on the
under frame, and also supplies power to coach when the speed
of the train is above 19 kmph. Below 19 kmph, power is
supplied by Battery.

 Positive and negative main wires of DC

supply from battery are taken to rotary
junction panel in the coach through
separate conduits. 40 Amps fuse is
provided in the positive main wire as third
40 A Battery Fuse level of protection
 110 Volts DC Power Supply System
Rotary Junction Panel

 In the Rotary Junction Panel bifurcation of

positive mains into four circuits takes place.
L1 ands L2 for two light circuits, one fan
circuit and one circuit for Emergency feed to
adjacent coaches.
16 A +ve Fuse 40 A –ve Fuse
• Each circuit is protected by a 16 Amps fuse, which is second
level protection.
• Positive and negative wires are taken in separate conduits
along the side walls of the coach.
• 40 Amps fuse on negative side is also provided for additional
safety.
110 Volts DC Power Supply System
 Supply to each fan and light is provided from fuse distribution
boards provided on both positive and negative main wires in
each bay.
• Two 6 Amps copper wire fuses are provided
on both positive and negative wire for each
light and fan for protection against short
FDB circuit.

• All the material used in coach wiring

including conduit, rotary switches, fuses,
cables etc. have fire retardant properties

6 A Fuse
 Different levels of protection in Non AC coaches

Level 3 protection Level 2 protection Level 1 protection

Battery Fuse Rotary Junction Box FDB

 Protection schemes available in Non –AC coaches
• DC system is floating system which means a single earth fault
will not create any spark, short circuit or unhealthy condition
in coach.
• +ve and –ve cables are laid in separate conduits to eliminate
any chance of short circuit.
• Three level fuse protection:
 Level - 1
Each Light, fan and mobile charging socket circuit of every bay is
protected by wire fuse (6A) provided in Fuse Distribution Board
(FDB) in both +ve and –ve circuit.
 Level - 2
HRC fuse (16A) on a group of lights and fans in Rotary junction
Box (RJB).
 Protection schemes available in Non –AC coaches

 Level - 3
Battery fuse (40A) on positive and negative side

 Failure of Level - 1 fuse will cause blowing of fuse at Level - 2 and

subsequently Level - 3.

 Other protections:
• Over voltage protection in RRU/ERRU circuit of Alternator
• 32 A & 6 A HRC fuse in phase and field circuit respectively in
RRU/ERRU.
 Fire Prevention Measures in Non AC coaches
Prevention measures to arrest initiation and propogation of fire

• Use of fire retardant & Zero Halogen Low Smoke (ZHLS) e-

beam cables

• Use of polyamide cable conduits which are halogen free and

fire retardant.

• Modification of FDB Covers

Inflammable garbage in TL coaches
Inflammable garbage in TL coaches
 Fire Prevention Measures in Non AC coaches contd..

Use of the modified Fuse distribution boxes to

restrict entry of any foreign material.
Old FDB cover Modified FDB covers
Fire Prevention Measures in Non AC coaches contd..
Centralised FDB

Exiting Arrangement FDB Eliminated

Fire Prevention Measures in Non AC coaches contd..
Centralised FDB

Exiting arrangement Modified Arrangement

 PROVISION OF GLASS FUSE IN
LAPTOP/MOBILE CHARGING SOCKET
Block Diagram of SGAC Coach
 AC coach protection

AC control panel AC control panel Power panel

 Protection in SGAC coaches
• Four tier protection scheme:

 Level -1
• Fan, light and laptop charging circuits are protected by MCBs in
both +ve & -ve.

• Heater circuit is protected by thermostat, interlocking with

blower motor, Vane rely (mechanical interlocking) and Over
heat protection system in air conditioning.

• Each 3-phase equipment of air conditioning unit is protected by

MCB, contactor and overload relay .
 Protection in SGAC coaches contd..
 Level - 2
• 40 A HRC fuse in light, DC fan and mobile charging circuit at coach
level in both +ve & -ve.
• 25 kVA inverter which converts 110V DC to 3-phase 415V AC protects
load side from earth fault, overvoltage, over current, single phasing,
short circuit and under voltage

 Level – 3 for Air Conditioning

• 250 A HRC fuse at the input of 25 KVA inverter in both +ve & -ve.

 Level – 4 for Air Conditioning

• Battery DC supply is protected by HRC fuse (400A) in both +ve & -ve.
 Protection in SGAC coaches contd..
 Other protections:
• Rectifier cum Regulator unit (RRU/ ERRU) protects alternator
from generation of over voltage.
• Over Voltage Protection as independent unit is also provided
in RRU/ERRU
• 160 A & 10 A HRC fuse in phase and field circuit respectively
in RRU/ERRU.
• Refrigerant is of A 1 safety category used in AC system as per
ASHRAE norms.
• Electronic temperature controller for safe operation of Air
Conditioning within the prescribed range.
 Fire prevention measures in AC Coaches

• Use of fire retardant & Zero Halogen Low Smoke (ZHLS) e-beam
cables
• Use of polyamide cable conduits which are halogen free and fire
retardant.
 Protection against failure of heating system
• Regular monitoring of return air temperature by electronic
controller.
• Use of vane relay for protection against switching on of heater in
case of failure of flow of air due to failure of blower motor
• Over heat protection system directly monitors the temperature of
the heating element.
• Use of fire retardant cotton canvas duct for AC coaches
Mounting arrangement of Heater assembly of coach
ACCN WR 951115

Wooden piece
 Standard mounting arrangement

FRP mounting
Over heat protection
Inflammable garbage in AC Duct
 Cleaning of AC duct of Coaches

• Ducts are to be cleaned

in POH.
• Manual or mechanized
system may be used.
 Smoke from Inverter Change Over
Switch
• Material complying to
V0 grade as per UL 94
from approved to be
ensured.
• Proper counseling of
staff to operate OFF
LINE ONLY
• Designed modified to
contactor based system
for new production.
 Fire safety related development for coaches contd.
• Provision of push button for testing of OVP in-situ condition
• Flush type LED fitting for SLR in luggage compartment
• BLDC fan for better passenger comfort and spark less
commutation.
• Development of Induction heating based pantry.
• Reverse cycle heating system in air conditioned coaches to
provide heater less system for warm air
• Complete switch over to LED lights in coaches.
 Salient Features of Coach Wiring
Electrical power scheme of coach is different from
House wiring
Faults which may result in sparking/smoke in a
building, do not create any unsafe condition in
coaches
Specification of Cables used in coaches are very
stringent in fire & toxic parameters
Cables in coaches are run in insulated fire retardant
conduits which are covered by glass wool, another
fire retardant material
 Salient Features of Coach Wiring contd.
All type of coaches have multilayered redundancy
in protection system which is not the case in
house wiring
Failure of one protection level is taken care by
another level of protection without creating any
unsafe situation
Electrical protection system provided in IR
coaches is at par with the practices followed by
foreign railways
 Hence, Probability of initiation of fire due to
electrical cause is negligible in passenger area
of coach
Probability of initiation of fire
due to electrical Cause
Case Study of Fire on Golden Temple Mail

3 coaches, S3, S4 and S5, of Golden Temple Express caught

fire just after leaving Jalandhar station on 15/05/2003. Details
of these coaches is as under:
 Probability of Initiation of fire in Coaches due to
electrical cause

While investigating fire case in train no 2903 near

Ladhowal station on 15.05.03, CRS NE Circle directed
RDSO to simulate various scenarios to asses the
probability of fire due to failure of electrical equipment,
wiring and their safety devices and the same was
reflected in CRS enquiry report also.

Simulation test results of trials conducted by RDSO in

coach no. WGSCN 96204 are summarized:
 Possible Abnormalities
1. Sparking from fans with kerosene soaked jute
in the vicinity
2. Sparking from fuse distribution boards with
kerosene soaked jute in the vicinity
3. Dead earth fault in light/ fan circuit
4. Dead earth fault in light/ fan circuit with their
branch fuse by-passed
5. Dead earth fault in light/ fan circuit with their
branch fuse and rotary switch board fuses in
by-pass condition
6. Dead earth fault in light/ fan circuit with their
branch fuse, rotary switch board fuses and
battery fuses in by-pass condition
Test-1
Purpose Description Observation
This test was All the fans of bay–2 No sign of flash, spark
conducted to ascertain were kept in switched or smoke was noticed
the possibility of fire on condition. A bundle during the test.
due to presence of of rags dipped in
highly inflammable kerosene was brought
material in the vicinity near the fan guard and
of DC Railway Carriage body of the fan and
Fans due to spark/flash kept there for few
from its commutator. minutes.
Test 2
Test 2
Purpose
The purpose of the test
was to ascertain the
working of protection
system of individual
branch wiring against
short circuits in fan and
light circuits. It is also to
be seen whether blowing
OFF of branch wiring
fuse provided in the fuse
distribution board may
cause fire if highly
inflammable material
are available in the
vicinity of fuse
distribution board.
Description Observation
A dead short circuit was As soon as the power
created in the positive supply for the fan,
and negative supply of having short circuit, was
fan circuit of bay No.3. A switched ON both the
bundle of rags dipped in rewirable fuses of 6 amp.
kerosene was placed (35 SWG) provided on
around the fuse positive and negative
distribution board cover. circuits of the branch
wiring of the fan circuit
blew off. Although the
flash was observed while
the fuses were blown, no
sign of smoke or fire
from the rags placed on
the fuse distribution
board was observed.
Test-3
Test-3
Purpose Description Observation
To assess the possibility Fuse wire connection of As the fuse wire was
of fire due to fan circuit in the fuse loose it was causing a
spark/flash because of distribution board was small spark when light
loose connection in the kept in loose condition circuits was switched
fuse distribution board. and the cover for the ON but when the fuse
same was closed. A distribution board was
bundle of rags soaked closed and rags soaked
in kerosene was kept with kerosene were
around the fuse kept around the cover it
distribution board did not caused any
cover. smoke or fire when the
switch was put ON and
OFF repeatedly.
Test-4
Test-4
Purpose Description Observation

The purpose of the A dead short circuit As soon as the fan

test was to see the was created in fan supply was switched
effect of short circuit between on by rotary switch
circuits in fan or positive and in the rotary switch
light supply circuits common negative board, the HRC
either at junction supply at the output fuses of 16 amps at
box or in the of the rotary switch fan positive and 35
conduit wiring in board by using a amps at common
the side wall of the 35mm² cable. negative supply
coaches between blew off without
positive and causing any flash or
negative supplies. smoke in the rotary
switch board or
cables.
Test-5
Test-5
Purpose Description Observation
The purpose of the test Short circuit was As soon as the rotary
was to see the effect of created in fan circuit switch for fan circuit
short circuit between between positive and was switched ON, next
positive and negative common negative level of protection with
supply in fan circuit or output of the rotary rewirable fuse of 40
either of the light switch board. The fuses amps (20 SWG) in the
circuits with their fuses of fan positive and battery circuit, blew
at rotary switch board common negative OFF as the fan positive
in bypassed condition. circuit were bypassed in and common negative
the rotary switch board fuses were in bypassed
by using a 35 mm² condition.
cable.
Test-6
Test-6
Purpose Description
To see the effect of The rewirable fuses in positive
dead short circuit in and negative supply of night
the electrical wiring light were by passed in fuse
inside the coach distribution board by using
with all safety flexible cable strands of total
devices in bypassed size of approximately 10 mm²,
condition and in bay No. 9 . In rotary switch
continuously board HRC fuses in positive
feeding the short and common negative supply
circuit through the were bypassed by using 35
battery supply. mm² cable and battery fuse in
the under-frame was also
bypassed by using 35 mm²
cable. Dead short circuit was
created across the night light
of bay nine.
Observation
The night light switch of bay No. 9
was switched ON. The short circuit
current was allowed to flow through
night light circuit continuously as all
the fuses i.e. branch wire fuse, fuse
on the positive and negative circuit
in the rotary switch board and
battery fuse were bypassed. Due to
short circuit current, the wiring of
the night light circuit got over heated
and light grey smoke was observed.
Finally the branch circuit got open
circuited due to over heating and
smoke also stopped after some time.
On checking, insulation of the cable
was found over heated and burned
but no fire or flame was observed
during the test.
 Probability of fire due to electrical cause
Conclusions

a) The normal working conditions of electrical equipment in a coach

with all necessary safety devices intact, do not create any
situation resulting in fire even when highly inflammable material is
in the vicinity.
b) Even if one protection system is by passed, the next level of
protection system is able to protect the electrical equipment
without creating any unsafe condition or fire, with highly
inflammable material in the vicinity.
c) With all the safety devices bypassed, a fault with dead short circuit
results in over heating of cables and insulation with slight smoke
which finally leads to open circuit due to breakage of conductor.
Though, slight smoke is generated due to overheating of cable
insulation, but situation does not result in fire.
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