Battery Capacity - Load Calculations

Preliminary Design Review (PDR)

CDRL 09-04, Rev NR
Date: April 15, 2021

Battery Capacity - Load Calculations

Preliminary Design Review (PDR)

CDRL TS- Section

09-04 9.2.5.1.d

Revision Prepared By Revision Description Approved by Date

NR Mouloud Belaid New Released version For Review April 15, 2021

NYCT – CAD Contract No. R-34257 – Conversion and Upgrade of R77E Locomotives Page 1 of 9
 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

Table of Content

1. Document Objective ............................................................................................................................................. 3

2. Technical Specification Requirements ................................................................................................................. 3
3. Design Criterias:.................................................................................................................................................... 3
4. Design Proposal: ................................................................................................................................................... 4
4.1. Operating modes: .......................................................................................................................................... 4
4.2. Load calculation: ............................................................................................................................................ 7
4.3. Battery sizing: ................................................................................................................................................ 8
4.4. Battery charger sizing: ................................................................................................................................... 9

Table of Tables
Table 1 – Load calculation ............................................................................................................................................ 7
Table 2 –Battery Capacity calculation .......................................................................................................................... 8

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

1. Document Objective

This preliminary document presents the considered loads to be supplied by the locomotive. Most loads are
identified. Some data remains to be refined or completed.
2. Technical Specification Requirements
TS-Section 9.2.5.1.d - The Contractor shall provide the load calculations used to size the battery to meet the
above requirements under all operating conditions for NYCT review. The Contractor will coordinate the
battery’s capacity and charging characteristics to minimize the amount of engine operation needed during
extended stays in the tunnels.

3. Design Criterias:
According to the following technical specification:

9.2.5.1.a The battery shall have sufficient capacity to supply all auxiliary power loads with adequate current
(measured at the load) while the engine is not running for a three-hour period. During the three-hour period,
the following loads, as a minimum, shall remain energized:

• Lights, including cab interior, headlights/ditch lights, marker lights, engine room lights and any other
exterior lights
• Brake and Propulsion Control
• Event Recorder
• Buzzer Signal System
• Monitoring and Diagnostics
9.2.5.1.b After the three-(3) hour period, the battery shall also be capable of six (6) consecutive cranking
starts of thirty (30) seconds each, with 60 seconds open-circuit between each attempted start. A battery
disconnect switch shall be mounted at an NYCT-Approved location in the cab. The battery disconnect switch
shall function as described in Section 6.4.12.

9.2.5.1.c The Contractor shall provide the load calculations used to size the battery to meet the above
requirements under all operating conditions for NYCT review. The Contractor will coordinate the battery’s
capacity and charging characteristics to minimize the amount of engine operation needed during extended
stays in the tunnels.

9.2.1.c Regardless of the configuration or topologies selected, the DC low voltage power system shall meet
the following steady-state requirements:

i) Maximum Output Voltage: 42.5 Vdc

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

ii) Nominal Output Voltage: 37.5 Vdc

iii) Minimum Output Voltage: 27.0 Vdc
iv) Steady-State Output Power capability of 120% of the calculated maximum steady-state DC low
voltage power requirement. Current capability at Maximum power will be based on Minimal output
voltage.
v) The battery must be able to provide the calculated maximum steady-state DC low voltage power
requirement for a duration of at least three hours with no assistance from the
LVPS. The battery voltage must meet or exceed 27 Vdc for this entire time period to provide adequate
trainline power to coupled vehicles.
9.2.4.1.d Capacity: The LVPS capacity shall be capable of supplying 120 percent of the full load requirements
of the Locomotive, including battery charging. Battery charging capacity shall be capable of fully charging the
batteries in four (4) hours when at 50% discharge and while also supplying full DC auxiliary power.

4. Design Proposal:

4.1. Operating modes:

Four operating modes are considered. This section lists the loads considered on the 32VDC/24VDC/AC from
inverter for each mode. These loads are summarized at table 1 and used to calculate the battery capacity
and the corresponding AESS/ battery charger power required.

4.1.1. Standby mode:

In this mode, the engine is not running, all active DC loads are powered from battery for up to 3 hours
minimum. After these 3 hours of depletion, the battery shall supply the six (6) consecutive diesel engine
cranking starts of thirty (30) seconds each, considering a 60 seconds open-circuit rest between each
attempted start. The following load are powered:
➢ 32 Vdc loads :
o Inverter 32 Vdc / 120 Vac : The inverter is powered to ensure the power supply of:
▪ Compressor Soft-start relay
▪ Cab fan
▪ Radio battery charger
o All audio and digital display in control stand
o For air brake system, the following components are powered:
▪ Drain valve heater for air compressor
▪ Air filter dryer
▪ Horn magnet valves

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

o Drain valve heaters for air reservoirs: both are powered in this mode.
o Compressor soft-start heater: it is energized to heat the soft start relay at low temperature
and is ready to be actuated.
o Electronic Bell: is available
o Lighting: most are available in this mode.
o Four points trainline communication system is on
o Locomotives Control Relays: Relays associated with locomotive traction are not energized
at the exception of what is required for operation.
o Traction Engine Control Unit (ECU) : is energized in standby mode, it also includes suppling
he following modules, managed by the TECU:
▪ Automatic engine start / stop system (AESS)
▪ Event recorder
➢ 24 Vdc Loads :
o Monitoring and diagnostic system (MDS)
o Train operator display (TOD)
o Engine control unit
o Closed Circuit Television System (CCTV)
o Automatic Fire Suppression System (AFSS).
4.1.2. Low-power mode:
The engine is running at 900 rpm (stationary), the battery charger supplies all connected loads and charges
the battery. In addition to DC loads mentioned above, the following ones are energized:
➢ 37.5 Vdc loads :
• Duplex receptacle 120 Vac – 20 amps by inverter.
• Cab windows heater: there are four heaters for windows which incorporate:
o Windshield
o Rear-facing windows
o Two (02) front windows
• Windscreen wipers motors
• Magnet valves of Air brake system.
➢ 24 Vdc Loads :
• Windshield washer pump

NYCT – CAD Contract No. R-34257 – Conversion and Upgrade of R77E Locomotives Page 5 of 9
 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

4.1.3. Propulsion mode:

The engine runs from 1350 to 1800 rpm, all DC loads mentioned above plus the following additional 37.5 Vdc
loads are supplied:
• Propulsion system control :
o One (01) AC three-phase power contactor control
o Two (02) DC power contactors control for propulsion system
o One (01) of two (02) DC power reverser control for propulsion system
• Sanding system control :
o Two (02) of Four (04) Magnet valves
4.1.4. Momentary mode:

This mode includes all intermittent loads such as engine start and cover maximum charges as per circuit
breakers protecting equipment. The following DC loads require short power surges, provided by battery:

• Locomotive starter: An important inrush current is required to start the genset, we assume that is
around 375 A under 32 Vdc battery voltage supply.

• Locomotives Control Relays: relays that could be powered in the Trainline when other locomotives
in train consist are connected.

• Air brake system: The drain valves and twin tower air dryer heaters could be actuated in this mode
depending on the climatic conditions.

• Drain valve heater for fuel tank: It may be actuated depending on the climatic conditions.

• Engine control unit: this unit shall be powered to start the engine.

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

4.2. Load calculation:

Table 1 – Load calculation
Operation Modes
Power
unit / load Propulsion
Duty cycle Low-Power
DC Loads Qty Input power Momentary Standby (1350 to
(900 rpm)
Current 1800 rpm)

(W , A) (W) (%) (W) (W) (W) (W)

37.5 Vdc Loads
INVERTER 37 Vdc/ 120Vac.
Compressor Soft-Start relay 1 150 W 150 W 100% 150 W 150 W 150 W
Cab fan 1 150 W 150 W 100% 150 W 150 W 150 W
Radio battery charger 1 7W 7W 100% 7 W 7 W 7 W
Oultet 120 Vac - 20 A 1 2,500 W 2,500 W 4% 100 W 100 W
TOTAL OPERATOR DISPLAY (AUDIO AND
1 10 W 10 W 100% 10 W 10 W 10 W
DIGITAL DISPLAY IN CONTROL STAND )
ALTERNATOR EXCITER 1 20 W 20 W 100% 20 W 20 W 20 W
AIR BRAKE SYSTEM
Drain valve heater for air reservoirs 2 35 W 70 W 50% 105 W 35 W 35 W 35 W
Twin tower air filter dryer 1 225 W 225 W 50% 338 W 113 W 113 W 113 W
Magnet valve Horn 2 13 W 26 W 50% 13 W 13 W 13 W
Magnet valve Engine/Safety 1 13 W 13 W 100% 5 W 5 W
SANDING SYSTEM
Valves for sanding system 4 18 W 36 W 10% 4 W
POWER CONTACTOR-3Ph AC CONTROL 1 100 W 100 W 100% 100 W
POWER CONTACTOR-DC CONTROL for TM 2 44 W 88 W 100% 88 W
POWER REVERSERS-DC CONTROL for TM 2 55 W 55 W 100% 55 W
COMPRESSOR SOFT-START HEATER 1 40 W 40 W 100% 40 W 40 W 40 W
STARTER 1 375 A 12,000 W 100% 12,000 W
ELECTRONIC BELL 1 17 W 17 W 100% 17 W 17 W 17 W
CAB WINDOWS HEATER 1
Windshield 1 645 W 645 W 100% 645 W
Rear-facing windows 1 225 W 225 W 100% 225 W
Front windows 2 135 W 270 W 100% 270 W
TECU including: 1 35 W 35 W 100% 35 W 35 W 35 W
Automatic engine start/stop (AESS)
system
Event Recorder
Deadman
LIGHTING
Cab Lights 4 6W 24 W 100% 24 W 24 W 24 W
Cab Red Reading light 1 5W 5W 50% 3 W 3 W 3 W
Cabinet lighting 2 10 W 20 W 100% 20 W 20 W 20 W
Marker lights 4 7.5 W 30 W 100% 30 W 30 W 30 W
Engine room lights (4 for
6 14 W 83 W 100% 83 W 83 W 83 W
Moteur/Alternator - 2 for compressor)
Strobe Light 1 12 W 12 W 100% 12 W 12 W 12 W
Walkway Lights 4 6W 24 W 100% 24 W 24 W 24 W
Step Lights 4 4W 16 W 100% 16 W 16 W 16 W
Headlights lights 4 55 W 110 W 100% 110 W 110 W 110 W
Ditch lights 4 75 W 150 W 100% 150 W 150 W 150 W
COMMUNICATION
Four point trainline communication
1 10 W 10 W 100% 10 W 10 W 10 W
system
LOCOMOTIVES CONTROL RELAYS 1 130 W 130 W 100% 195 W 20 W 50 W 130 W
WINDSCREEN WIPERS MOTOR 4 80 W 320 W 100% 320 W 320 W
24 Vdc Loads
MONITORING & DIAGNOSTIC SYSTEM 1 40 W 40 W 100% 40 W 40 W 40 W
WINDSHIELD WASHER PUMP 2 67 W 134 W 10% 13 W 13 W
TRAIN OPERATOR'S DISPLAY 1 20 W 20 W 100% 20 W 20 W 20 W
ENGINE CONTROL UNIT 1 173 W 173 W 100% 173 W 173 W 173 W 173 W
CAB CONTROL CIRCUIT 1 10 W 10 W 100% 10 W 10 W 10 W 10 W
CCTV 1 35 W 35 W 100% 35 W 35 W 35 W
AFSS 1 5W 5W 100% 5 W 5 W 5 W
Total Power Loads 1,374 W 1,843 W 3,310 W

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

4.3. Battery sizing:

The battery is sized on charges supplied in stand-by mode when the engine does not run, all listed DC load
including inverter demand to supply AC loads are covered. The following criteria are used:

➢ The battery should provide the calculated maximum steady-state DC low voltage requirement for a
duration of at least (03) three hours with no assistance from the LVPS.

➢ The battery shall also be capable of six (6) consecutive cranking starts of thirty (30) seconds each, with
60 seconds open-circuit between each attempted start, which means 6x30sec = 0.05 hour.

➢ The minimum operating voltage for the battery voltage will be determined from battery technology
used to not drop under the 27VDC requested. Note that capacity in Ah is calculated at 27.9V average
for all discharge cycle as worst case.

➢ To avoid deep discharge, the battery is sized with a safety factor (35%) exceeding the 20% (1/5)
requested.

Table 2 –Battery Capacity calculation

Duration Power Consumption
(hour) (W) (Wh)
Standby Mode 3.00 1,374 4,123
cranking start 0.05 12,000 600
Total Consumption 4,723 Wh

Minimum operating battery voltage

TBD
based on battery technology

Total Battery capacity under nominal

147.59 Ah
voltage (32 Vdc)
Safety factor (minimum 20 %) 35%
Total Battery capacity with safety factor 199.25 Ah

Minimally a 200 Ah Battery will be installed

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 Battery Capacity - Load Calculations
Preliminary Design Review (PDR)
CDRL 09-04, Rev NR
Date: April 15, 2021

4.4. Battery charger sizing:

The battery charger should be sized to recharge the battery at 50 % discharge in four (04) hour while supplying
full DC loads, having 200 Ah as total battery capacity.

Battery manufacturers recommend charging current not to exceed C/5 (recharge full capacity in 5 hours) to
minimize heating and degradation.

Charge current = 200Ah / 5h ≤ 40 A

Per R-257 TS: 50 % of the battery capacity (100 Ah) shall be recharged in 4 hours.

100 Ah / 4h = 25 A

As shown in table 1, DC bus loads in propulsion mode represents 3310 W.

Considering 20% of capacity overload:

3310 W * 1.2 = 3972 W

The power required to charge the battery in four hours is:

25 A * 37.5 Vdc = 937.5 W

The battery charger is sized to provide the total maximum DC loads and the full recharge power to recharge
50% of battery capacity in 4 hours:

3972 W + 937.5 W  4910 W

Note that 50% of battery capacity can be recharged in 2.5 hours in low power mode.

The LVPS/Battery Charger is sized to provide 5000 W

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